Hyundai Robot
HX300060301MME2
Manipulator Maintenance Manual
- HX200L , HX200L-2000,
- HX300 , HX300L,
- HX400
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Contents
1. Safety
.................................................. 1-1
1.1. Introduction............................................................................................1-2
1.2. Relevant Safety Regulations .................................................................1-4
1.3. Safety Training.......................................................................................1-4
1.4. Safety Related Nameplate.....................................................................1-5
1.4.1. Safety Marking....................................................................................1-5
1.4.2. Safety Nameplate ...............................................................................1-6
1.5. Definition of Safety Functions................................................................1-7
1.6. Installation .............................................................................................1-8
1.6.1. Safety Fence.......................................................................................1-8
1.6.2. Placement of Robot & Peripheral Equipment....................................1-10
1.6.3. Installing the Robot...........................................................................1-12
1.6.4. Space for Robot Installation..............................................................1-14
1.7. Safety Operation for Robot Handling...................................................1-15
1.7.1. Safety Precautions for Robot Handling.............................................1-15
1.7.2. Safety Precautions for Operating Test..............................................1-18
1.7.3. Safety Precautions for Automatic Operation.....................................1-19
1.8. Safety Precautions for Access to Safety Fence...................................1-20
1.9. Safety Precautions for Maintenance and Repair..................................1-21
1.9.1. Safety Precautions for Hi4a Controller Maintenance and Repair......1-21
1.9.2. Safety Precautions for Robot System & Manipulator Maintenanace.1-22
1.9.3. Necessary Actions after Maintenance and Repair............................1-23
1.10. Safety Functions................................................................................1-24
1.10.1. Operating a Safety Circuit...............................................................1-24
1.10.2. Emergency stop..............................................................................1-26
1.10.3. Operating Speed.............................................................................1-29
1.10.4. Connecting the Safety Devices.......................................................1-29
1.10.5. Restricting the working Envelope....................................................1-30
1.10.6. Monitoring Function ........................................................................1-30
1.11. Safety Related to End Effectors.........................................................1-31
1.11.1. Gripper............................................................................................1-31
1.11.2. Tool / Workpiece..............................................................................1-32
1.11.3. Pneumatic and Hydraulic Systems .................................................1-32
1.12. Liabilities............................................................................................1-33
2. Specifications
.................................................. 2-1
2.1. Robot Machinery Part............................................................................2-2
2.2. Location of Robot Identification Plate ....................................................2-3
2.3. Basic Specifications...............................................................................2-4
2.4. Robot Dimension and Working Envelope ..............................................2-6
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Contents
2.5. Axis Identification.................................................................................2-11
2.6. Details of Wrist Axis Attachment Surface ............................................2-12
2.7. Details of Upper 1st ARM Attachment Surface.....................................2-13
2.8. Application Wiring and Inspection Wiring Diagram ..............................2-14
2.8.1. Details of Customer Application Connectors.....................................2-15
2.9. Restricting the Working Envelope........................................................2-16
2.9.1. Axis 1(Axis S)....................................................................................2-16
3. Instructions
.................................................. 3-1
3.1. Robot Component Name.......................................................................3-2
3.2. Location of Safety Nameplate................................................................3-3
3.3. How to operate ......................................................................................3-4
3.3.1. Using Crane........................................................................................3-4
3.3.2. Using Forklift Truck.............................................................................3-6
3.4. How to Install .........................................................................................3-7
3.4.1. Operating Conditions..........................................................................3-7
3.4.2. Installating the Robot Manipulator ......................................................3-8
3.4.3. Dimension of Installation Surface .......................................................3-9
3.4.4. Accuracy of Installation Surface........................................................3-10
3.5. Allowable Load of Wrist Axis................................................................3-11
3.6. Recommended Standy Posture...........................................................3-16
4. Inspection
.................................................. 4-1
4.1. Inspection Item and Period....................................................................4-2
4.2. Inspection Item and Period....................................................................4-3
4.3. Inspection of Main External Bolts...........................................................4-5
4.4. Inspection of Wrist Backlash..................................................................4-7
4.5. Inspection Internal Wiring ......................................................................4-8
4.5.1. The Conditions of Safety Inspection ...................................................4-8
4.5.2. Inspection Part....................................................................................4-9
5. Maintenance
................................................... 5-1
5.1. Grease Replenishment/Replacement....................................................5-2
5.1.1. S-Axis Reduction Gear .......................................................................5-3
5.1.2. H-Axis Reduction Gear.......................................................................5-4
5.1.3. V-Axis Reduction Gear .......................................................................5-6
5.1.4. R2-Axis Reduction Gear.....................................................................5-8
5.1.5. B-Axis Reduction Gear .......................................................................5-9
5.1.6. R1-Axis Reduction Gear................................................................... 5-11
5.1.7. Bearing Joint Parts ...........................................................................5-13
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5.1.8. A1 Frame - Gear Box........................................................................5-14
5.1.9. Wrist - Gear Box ...............................................................................5-15
5.2. Battery Replacement ...........................................................................5-16
5.2.1. Instructions for Battery Storage.........................................................5-18
5.3. Internal Wiring......................................................................................5-19
5.3.1. Wiring Connection Diagram..............................................................5-20
6. Troubleshooting
................................................... 6-1
6.1. Troubleshooting Procedure ...................................................................6-2
6.2. Trouble Symptoms and Possible Causes..............................................6-3
6.3. Diagnostics and Resolutions for Major Parts Failure .............................6-4
6.3.1. Fulcrum Bearings................................................................................6-4
6.3.2. Reduction Gear...................................................................................6-5
6.3.3. Brakes ................................................................................................6-7
6.3.4. Motor ..................................................................................................6-8
6.3.5. Encoder ..............................................................................................6-9
6.4. Motor Replacement .............................................................................6-10
6.4.1. Necessary Tools and Parts ...............................................................6-12
6.4.2. How to Replace Motor ......................................................................6-13
6.5. Encoder Zero Setting...........................................................................6-15
6.5.1. Zero Setting......................................................................................6-16
6.5.2. Encoder Reset..................................................................................6-17
6.5.3. Confirming the Reset........................................................................6-19
6.5.4. Encoder Calibration(Data input) and Selection.................................6-20
7. Recommended Spare Parts
................................................... 7-1
8. Internal Wiring Diagram
.................................................. 8-1
8.1. Manipulator Configuration......................................................................8-2
8.2. Wiring Diagram......................................................................................8-3
9. Decommissioning
.................................................. 9-1
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Contents
List of Figures
Fig 1.1 Recommended Size for Fence and Gate Hole (Square Gate)......... 1-8
Fig 1.2 Recommended Size for Fence and Gate Hole (Slot Gate).............. 1-8
Fig 1.3 Placement of Peripheral Equipment and Operator ........................ 1-10
Fig 1.4 Space for robot installation............................................................. 1-14
Fig 1.5 Robot’s Safety Circuit .................................................................... 1-24
Fig 1.6 Emergency Stop ............................................................................ 1-27
Fig 1.7 Emergency Stop Connection of External System .......................... 1-28
FIg 2.1 Robot Machinery Part...................................................................... 2-2
Fig 2.2 The location of identification plate.................................................... 2-3
Fig 2.3 Robot Dimension and Working Envelope : [HX300] ........................ 2-6
Fig 2.4 Robot Dimension and Working Envelope : [HX400] ........................ 2-7
Fig 2.5 Robot Dimension and Working Envelope : [HX200L]....................... 2-8
Fig 2.6 Robot Dimension and Working Envelope : [HX200L-2000] ............. 2-9
Fig 2.7 Robot Dimension and Working Envelope : [HX300L]..................... 2-10
Fig 2.8 Robot Dimension and Axis [HX300/400/200L/200L-2000/300L].....2-11
Fig 2.9 Details of Wrist Axis Attachment Surface : [HX300/400/300L] ....... 2-12
Fig 2.10 Details of Wrist Axis Attachment Surface : [HX200L] ................... 2-12
FIg 2.11 Details of Upper 1st ARM Attachment Surface............................. 2-13
Fig 2.12 Application Wiring and Inspection Wiring Diagram ...................... 2-14
Fig 2.13 Details of Application Connector (Encoder) ................................. 2-15
Fig 2.14 Details of Application Connector (Power)..................................... 2-15
Fig 3.1 Identification of Robot Components................................................. 3-2
Fig 3.2 Location of Safety Nameplate.......................................................... 3-3
Fig 3.3 How to Transport: Using crane [HX300/400].................................... 3-4
Fig 3.4 How to Transport: Using crane [HX200L/300L]................................ 3-5
Fig 3.5 How to Transport : Using Forklift Truck
[HX300/400/200L/200L-2000/300L] .............................................. 3-6
Fig 3.6 Dimension of Robot Installation..................................................... 3-9
Fig 3.7 Accuracy of Installation surface ..................................................... 3-10
Fig 3.8 Wrist Axis Torque Mapping:[HX300/300L]...................................... 3-14
Fig 3.9 Wrist Axis Torque Mapping : [HX400]............................................. 3-14
Fig 3.10 Wrist Axis Torque Mapping : [HX200L]......................................... 3-15
Fig 3.11 Recommended Standby Posture ................................................. 3-16
Fig 4.1 Inspection Part for Main Bolts [HX300/400/300L] ............................ 4-6
Fig 4.2 Abnormal Backlash Inspecting Directions........................................ 4-7
Fig 4.3 Cable Inspection Parts : [HX300/400/200L/200L-2000/300L].......... 4-9
Fig 5.1 Explains of internal wiring.............................................................. 5-20
Fig 5.2 Wiring connection diagram : [HX300/400/200L/200L-2000/300L].. 5-21
Fig 6.1 How to prevent dropping of ARM Axis H & V..................................6-11
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Fig 6.2 Encoder Reset Connector.............................................................. 6-18
Fig 8.1 Manipulator Configuration................................................................ 8-2
Fig 8.2 Motor and Brake wiring connection No.1......................................... 8-3
Fig 8.3 Motor and Brake wiring connection No.2......................................... 8-4
Fig 8.4 Encoder wiring Connection No.1 ..................................................... 8-5
Fig 8.5 Encoder Wiring Connection No.2..................................................... 8-6
Fig 8.6 Encoder Wiring Connection No.3..................................................... 8-7
Fig 8.7 Application Wiring Connection No.1................................................. 8-8
Fig 8.8 Application Wiring Connection No.2................................................. 8-9
List of Tables
Table 1-1 Safety marking............................................................................. 1-5
Table 1-2 State of robot stop...................................................................... 1-17
Table 2-1 Basic Specifications for Models.................................................... 2-4
Table 2-2 Axis Motion..................................................................................2-11
Table 3-1 Components name....................................................................... 3-2
Table 3-2 Allowable load weight..................................................................3-11
Table 3-3 Allowable Load Torque................................................................3-11
Table 3-4 Allowable Moment of Inertia....................................................... 3-12
Table 4-1 Inspection Schedule..................................................................... 4-2
Table 4-2 Inspection Items and Periods....................................................... 4-3
Table 4-3 Inspection part for main bolts....................................................... 4-5
Table 6-1 Trouble phenomenon and cause.................................................. 6-3
Table 6-2 Motor Weight.............................................................................. 6-10
Table 6-3 Necessary Tools......................................................................... 6-12
Table 6-4 Necessary parts ......................................................................... 6-12
Table 6-5 Reset connectors corresponding to axes................................... 6-17
Table 6-6 Data range after resetting .......................................................... 6-20
Table 7-1 Spare Parts ListⅠ........................................................................ 7-2
Table 7-2 Spare Parts ListⅡ........................................................................ 7-4
Table 7-3 Spare Parts List Ⅲ...................................................................... 7-5
Table 7-4 Spare Parts List Ⅳ ...................................................................... 7-6
Table 7-5 Spare Parts List Ⅴ ...................................................................... 7-7
Table 9-1 Materials of each part................................................................... 9-2
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1
Safety
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HX200/HX200L-2000/HX300/HX300L/HX400
1. Safety
1.1. Introduction
The main purpose of this chapter is to describe the safety precautions for users and
operators who repair and manipulate the industrial robot.
This manual describes safety precautions for robot manipulator and controller, in
comply with the requirement of ANSI/RIA R15.06-1999, Standard for Safety,
Industrial Robots, and qualified with safety regulations. The technical description and
installation method of robot system is presented in detail at the specifications
regarding installation of robot manipulator and controller.
Every operator, who installs, replaces, adjusts, manipulates, maintains, and repairs,
must read thoroughly and fully understand the manipulation and maintenance
manual, in particular, the special attention must be paid to the WARNING symbol, the
most important marking related to the safety.
Installation, replacement, adjustment, manipulation, maintenance, and repair of robot
system must be performed by the personnel who was duly trained for these purposes,
following the indicated operating procedure.
This company is planning and carrying out the relevant training such as maintenance,
repair, and manipulation for the above operations, so robot users make sure that
robot operators should get the relevant training. And make sure that the robot
handling work should be carried out only by the operators who completed this
training course.
The Users of HR and HX industrial robots have a responsibility under the safety
relavant regulations valid in the country where the robot is installed, and a
responsibility to properly design, install, and operate the safety devices to protect
workers.
The dangerous zone of robot system, that is the working range in which the robot,
tool, and peripheral equipment are operated, must be safeguarded to prevent
workers or objects from entering the zone. If a person or object should nevertheless
enters the dangerous zone, make sure that the robot system is immediately shut
down by emergency stop system. The operators of robot system have a
responsibility to take all necessary steps to make correct installation, examination
and operation of the relevant safety devices.
This manual is provided for the utilization of HR and HX Series Manipulator models
and Hi4a controller.
Valid application and invalid environment of HR and HX Series robots are as follows.
Application
1-2
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1. Safety
It is applied to the 6-axis industrial robot used by installing on the surface of wall or
plane (axes addable). It is also appropriate for controlling operation in the dotted
section or consecutive section.
Major application is
ꢀ Spot welding
ꢀ Handling
ꢀ Assembly
ꢀ Application such as Sealing
ꢀ MIG/MAG welding
ꢀ Palletizing
ꢀ Grinding
For the other use than the above emergency application, make a contact with our
company to consult on the robot use and possible applications.
Invalid environment
Our robot must not be used in a highly explosive environment and the areas
contaminated by oil, flammable materials or chemical materials. (Prohibited to be
installed and manipulated.)
1-3
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HX200/HX200L-2000/HX300/HX300L/HX400
1.2. Relevant Safety Regulations
The robot is designed as per ISO10218.Jan. 1992 , safety standards for industrial
robots, and furthermore in comply with ANSI/RIA 15.06-1999 regulations.
1.3. Safety Training
All the personnel who intend to teach, operate or inspect the robot must be trained in
an approved robotic operation and safety training course before start-up. The safety
training course includes the following details:
ꢀ Purpose and functions of safety devices
ꢀ Safety procedure to handle the robot
ꢀ Performance of robot or the robot system and possible hazards
ꢀ Tasks associated with any specific robot applications
ꢀ Safety concepts, etc.
1-4
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1. Safety
1.4. Safety Related Nameplate
1.4.1. Safety Marking
For the purpose of effective safety instructions, the following safety symbols are used
in this manual.
Table 1-1 Safety marking
Symbols
Descrptions
Indicate a potentially hazardous situation which, if not
avoided, could result in death or serious injury to
personnel and damage to equipment. The special
attention must be paid to the operation and handling.
Warning
Indicate the compulsory measures that should be
performed.
Mandatory
Prohibited
Indicate the prohibited actions and/or operations that
should not be performed.
1-5
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HX200/HX200L-2000/HX300/HX300L/HX400
1.4.2. Safety Nameplate
Identification plates, warning label and safety symbols are attached to the robot and
to the inside and outside of control panel. The designation labels and cable Mark for
wire harness between the robot and control panel, and the cables inside/outside of
control panel are provided.
All of these plates, labels, symbols and marks constitute safety-relevant parts of the
robot and the control panel. They must remain attached to the robot manipulator and
control panel at their clearly visible positions all the time for the safety and their full
performance.
The painted markings on the floor and signs indicating dangerous zones must be
clearly distinguished in form, color, and style from other markings on the machine
near the robot system or inside the plant facilities where the robot system is installed.
It is forbidden to remove, cover, or paint over by way of spoiling the
clearly visible identification plates, warning labels, safety symbols,
designation labels and cable marks.
1-6
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1. Safety
1.5. Definition of Safety Functions
Emergency Stop Function - IEC 204-1,10,7
There is one emergency stop button on the controller and teaching pendant
respectively. If necessary, additional emergency buttons should be able to connected
to the robot's safety chain circuit. The emergency stop function, which overrides all
other robot controls, stops all moving parts by disconnecting power supply, and
removes drive power to prevent the use of other dangerous functions controlled by
the robot.
Safety Stop Function - ISO 10218(EN 775),6.4.3
When a safety stop circuit is provided, each robot must be delivered with the
necessary connections for the safeguards and interlocks associated with this circuit.
The robot should have a number of electrical input signals which can be used to
connect external safety devices, such as safety gates, safety pads, and safety lamps.
These signals allow the robot's safety functions to be activated by all equipment,
including peripheral equipment and the robot itself.
Speed Limiation Function - ISO 10218(EN 775),3.2.17
In a manual mode, the speed of robot is strictly limited to 250 mm per second as
maximum.
The speed limitation applies not only to the TCT(Tool Coordinate Time), but to all
parts of manual mode robot. The speed of equipment mounted on the robot should
be possibly monitored.
Restricting working Envelope - ANSI/RIA R15.06-1999
The working envelope of robot axes should be restricted using software limits.
Axis 1,2, and 3 can also be restricted by means of mechanical stopper.
Operation Mode Selection - ANSI/RIA R15.06-1999
The robot must be operated either manually or automatically. In a manual mode, the
robot must be operated only by using the teach pendant..
1-7
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HX200/HX200L-2000/HX300/HX300L/HX400
1.6. Installation
1.6.1. Safety Fence
Install safety fence against the possible collision between the robot and workers, so
that no worker may approach the robot .When operators or other personnel enter the
robot's working envelope by accident, it may cause an accident. Install the safety
fence to stop the robot when one, who intends to replace for TIP DRESSING or TIP
replacement, or to inspect welding equipment, opens the fence gate and approaches
the equipment during operation.
4.9cm(1.875") Max
4.9cm(1.875") Max
Fig 1.1 Recommended Size for Fence and Gate Hole (Square Gate)
4.9cm(1.875") Max
Fig 1.2 Recommended Size for Fence and Gate Hole (Slot Gate)
① Install the safety fence to cover the robot’s working envelope and to secure
enough space for teaching and maintenance working. The safety fence
should also be firmly installed so that it is hardly accessible and removable.
1-8
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1. Safety
② The safety fence should be a fixed type in principle, using harmless materials
that do not have any broken surface or projecting part.
③ Install the safety fence with an entrance gate, and register the safety plug at
the gate so that it does not open unless pulling the plug out. Interlock the
robot to be MOTORS OFF when the safety plug is pulled out., or wire the
robot to be MOTORS OFF when the safety fence is open. (Refer to “11.
Connecting the Other Signals”, Hi4a Controller Manual)
④ When intending to operate the robot with the safety plug pulled out, wire the
robot as a low-speed play mode. (Refer to “11. Connecting the Other Signals”,
Hi4a Controller Manual)
⑤ For immediate emergency stop, install emergency stop button wihin
operator’s easily accessible distance.
⑥ If the safety fence is not installed, install other devices substituting for the
safety plug in the whole place within the robot’s working envelope, such as
photoelectric switch and mat switch. These devices may stop the robot
automatically when a person enters the working envelope.
⑦ The robot’s working envelope(dangerous zone) should be distinguished from
other zones by painting its floor.
1-9
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HX200/HX200L-2000/HX300/HX300L/HX400
1.6.2. Placement of Robot & Peripheral Equipment
(1) Make sure that the power supply is off before operating, when connecting the
primary power of controller or peripheral equipment. There is a possible
danger of electric shock because the high voltage such as 220V and 440V is
used as its primary power.
(2) Post a sign [No enter during operation] up the safety fence gate, and inform
the operators of its purport.
110 cm(44") Min
Operator
Controller
Interlocked Barrier Guard
Restricted
space
Maximum
space
Safeguarded
space
Fig 1.3 Placement of Peripheral Equipment and Operator
(3) Arrange such devices as controller, interlock panel, and other manipulation
panels to be handled outside of the safety fence.
(4) When installing operation stand, install the emergency stop button on the
stand. Make sure that the stand stops in an emergency wherever the robot is
handled.
1-10
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1. Safety
(5) Make sure that the robot manipulator and the wiring and piping of controller,
interlock panel, and timer should not be placed in the way of operator's
working range so that they would not be directly stepped on by FORK and
LIFT. There is a possible danger of accident if the workers are affected by
electricity or the wiring is down.
(6) Place the controller, interlock panel, and handling stand within the sight of
robotic performance. It may cause a serious accident to operate the robot
while the operator is working, or the robot is malfunctioning in an invisible
sight.
(7) Restrict the robot's working envelope by using soft limits and mechanical
stopper if the necessary working envelope is narrower than the holding
workable envelope. It is possible to stop the robot in advance when it moves
beyond its normal working envelope due to an abnormal condition. (Refer to
the 『Robot Manipulator Maintenance Manual』.)
(8) Welding spatters directly on the operator or around him may cause burning or
fire. Install such devices as a glare shield or a cover in the full sight of
robot's working envelope.
(9) Make sure that the device indicating the robot's running condition whether
automatic or manual mode must be noticeable even in the far distance. In the
case of automatic start-up, warning with a buzzer or warning lamp is also
valid.
(10) Make sure that there is no projecting part in the robot's peripheral equipment.
Cover it, if necessary. It usually may cause an accident if the operator comes
in touch with it. And it may lead a serious accident if the operator is
astonished at the sudden movement of robot, and conducts it.
(11) Don't make the system designed to allow the workers to carry the Work in
and out using their hands through the safety fence. It could be a cause of
accident associated with compressing or amputating.
1-11
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HX200/HX200L-2000/HX300/HX300L/HX400
1.6.3. Installing the Robot
Install the robot as per the planning and layout which has been previously reviewed
and studied for its optimized performance and functionality. In case of poor
conditions for robot installation, the serious problems can take place, including error
of relative position between robot and workpiece during operation, bad performance
quality of robot caused by vibration, shortening lifetime, and cause of serious
accidents. Thus, pay attention to the following precautions when installing the robot.
General Safety Precautions
(1) Design and install the robot system properly in compliance with laws,
regulations, and safety requirements valid in the country where the robot
system is installed.
(2) All the workers for the robot system must have the complete knowledge on
the information specified in the application and supplementary manual, and
proficiently operate and handle the industrial robot.
(3) Installation workers of robot must follow the safety instructions and apply
them to the installation when they face any safety problems.
(4) System provider must ensure that all the circuits utilizing safety functions
perfectly perform in a safe way.
(5) Install main power supply to be disconnected from outside of the robot’s
working envelope.
(6) System provider must ensure that all the circuits utilizing emergency stop
function perfectly perform in a safe way.
(7) For the immediate emergency stop, install emergency stop button within the
accessible distance for the operator.
Technical Safety Precautions
(1) Eliminate any interference with peripheral equipment considering the
dimension and working envelope.
(2) Avoid such places for installing which is directly exposed to the sun,
extremely humid, contaminated by oil or chemicals, and containing a large
amount of metal powder and explosive gas.
1-12
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1. Safety
(3) Install at the ambient temperature ranged 0~45℃.
(4) Secure sufficient space for the easier disassembly and maintenance.
(5) Install safety fence with a gate, and prohibit any person from entering the
robot's working envelope.
(6) Remove any obstacles out of the robot’s working envelope.
(7) Take a special measure, considering thermodynamics of controller, if the
robot is installed near the heating elements or places exposed directly to the
sun.
(8) Take a special measure if the robot is installed in a place of abundant dust
such as metal powder in the air.
(9) Install the robot not to transmit welding electric current. (In other word,
insulate SPOT GUN with/from the robot’s wrist.)
(10) Grounding is very critical in preventing electric shock and malfunction caused
by noise, and thus install as following instructions.
① Install an exclusive grounding terminal using class 3 or higher. (For the
input voltage of 400V of higher, use special class 3 or higher.)
② Connect grounding line into the grounding bus-bar inside of the control
panel.
③ In case of direct grounding on the floor by anchoring, two-point grounding
both by robot manipulator and by controller can produce a “ground loop”
and contrariwise cause abnormal operation. In this case, connect the
grounding line to the base of robot manipulator and disconnect the
second grounding point to the controller. If the robot vibrates even after
stopping, double-check the grounding status because the possible main
causes could be an incomplete grounding or “ground loop” .
④ In the use of internal transgun(GUN), there is a possible danger of
dropping because the primary power cable is directly connected to the
spot gun. In this case, directly connect the grounding line to the base of
robot manipulator in order to prevent any electric shock and protect the
control panel, but do not connect it to the controller.
1-13
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HX200/HX200L-2000/HX300/HX300L/HX400
1.6.4. Space for Robot Installation
Install robot after securing sufficient space for maintaining the robot manipulator, Hi4a
controller, and other peripheral equipment. Install the robot manipulator and controller,
securing space for installation as per the guideline as described in the figure below.
Install Hi4a controller outside of the safety fence in order to monitor the robot
manipulator and to operate in a safe way.
Door
Minimum 110cm
Hi4a Controller
SafetyFence
Minimum110 cm
Working Envelope
Working Envelope with Tool and
Workpiece installed
Fig 1.4 Space for robot installation
When installing, be sure to make it easier to perform the maintenance when opening
the Hi4a Controller door. Secure the available space. The controller power in the
above Figure could change depending on the kind of controller.
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1. Safety
1.7. Safety Operation for Robot Handling
Follow the safety instructions to prevent any accidents. Don't modify nor ignore safety
devices or circuits at any time, and be careful of electric shock.
All the normal operations in an automatic mode must be performed outside of the
safety fence. Check the robot's working envelope if anyone is inside before
operating.
1.7.1. Safety Precautions for Robot Handling
(1) Do not handle the robot other than such personnel as operators handling the
robot and other possible operators and supervisors who were designated as
whom duly trained in an approved robotic training course and become familiar
enough with the proper operation of the safety and robotic functions.
(2) Be sure to wear helmets, goggles, and safety shoes.
(3) Perform the work in pairs. One person must be ready to press the emergency
stop button in an emergency while the other must perform his work quickly
but carefully within the robot’s working envelope. Always check the escape
route before working.
(4) Make sure that there is no one in the working envelope when the power
source is on.
(5) Operations such as teaching must be performed outside of the robot's
working envelope. However, if the operation is performed within the working
envelope after stopping the robot, enter the envelope with safety plug or key
switch for converting to automatic mode. Make sure that other operators do
not change it into automatic mode by accident. Also, pay close attention to the
specific direction of robotic movement in case of abnormal operation and
malfunction.
(6) Supervisors should follow the instructions below.
① Be located at a place where you could take an entire view of robot, and
commit yourself to monitoring.
② Press the emergency stop button immediately when abnormality is found.
③ Anyone is forbidden to be near the operating area other than those who
are engaged in the operation.
(7) In a manual mode, the speed of teaching is limited to 250mm/sec
(8) In teaching, post a sign [Under Teaching].
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(9) Operators must pull the safety plug out, and enter the safety fence with the
plug.
(10) Do not use any devices causing noise in and around the teaching area.
(11) Handle the teaching pendant button, while checking the teaching point with
your naked eyes, and do not handle it just relying on your sense.
(12) Do not work with your back against the robot, and always pay attention to the
robot's movement.
(13) In teaching, check and examine carefully under your feet. In particular, in
high teaching for more than 2M, secure a safe zone on which you may step
before teaching.
(14) Instructions for any abnormal operations.
① Press immediately the emergency stop button when any abnormal
operations are found.
② Be sure to check if the relevant equipment is stopped when checking the
abnormality in an emergency stop.
③ In case that the robot stops automatically due to power failure, investigate
possible causes and take actions after confirming that the robot
completely stops.
④ In case of malfunction of emergency stop devices, immediately
disconnect the main power and investigate possible causes to take
necessary actions.
⑤ Investigation of the failure must be conducted only by a designated
person. For the re-operation after emergency stop, operators must
clarify the cause of failure and take necessary actions, and then operate
the robot again following the proper procedure.
(15) Write out the operating rules proper to working details and installing location
regarding the operation and handling method for the robot, and the
necessary actions for robot's any failure. In addition, it is recommended to
operate the robot in accordance with the operating rules.
(16) Instructions when the robot stops
Make sure not to approach the robot even when it seems to be stopped. Most
accidents occur from a sudden movement of robot which seemed to be
stopped when one approaches it. The conditions that the robot stops is as
follows.
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1. Safety
Table 1-2 State of robot stop
No.
1
State of Robot
Drive Power Access
Pause
ON
OFF
ON
ON
ON
X
O
X
X
X
(Minor failure, Pause switch)
Emergency stop
(Major failure, Emergency stop switch, Safety gate)
2
Input signal standby of peripheral equipment
(START INTERLOCK)
3
4
Playback Completion
Standby
5
Even in the accessible state of robot, be watchful against any possible
sudden movement of robot. Make sure to avoid approaching the robot
without precautions for emergency under all circumstances.
ꢀ Though the access during a pause is shown in the table as『×』, allow
the access to robot with the same precautions as teaching work if the
entrance is open to take actions for minor failures(i.e. malfunction
caused by failure in arc, nozzle contact and weldment detection).
(17) Clean up any split oil, tools, and impurities in the safety fence after
completing robotic operation. Accidents such as conduction may occur in the
working envelope contaminated by oil, or scattered tools on its floor. Make a
habit of organizing and cleaning things up.
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1.7.2. Safety Precautions for Operating Test
In case of operating test, errors in design or teaching and inferiority in manufacturing
are possibly seen in the entire system such as teaching program, jig, and sequence.
Thus, be more careful and safe in case of operating test. Accidents may occur by
these combined causes.
(1) Before handling, check the stop buttons and signal functions to stop the robot
such as emergency stop button or stop button. And then, check the
abnormality - detective movements. Above all, it is the most critical to check
all the stop signals. It would be the most important to stop the robot when any
possible accidents are predicted.
(2) In case of operating test, start the robot at low speed(approximately
20%~30%) in the variable speed function, and repeat it more than one cycle
to check the movements. If any errors are found, immediately correct them.
After then, increase in speed (50% → 75% → 100%) gradually, and repeat
more than one cycle respectively to check the movements. Operating at high
speed from the very beginning may cause a serious accident.
(3) In case of operating test, it is hard to predict what problems would happen.
Do not enter the safety fence during operating test. Unexpected accidents are
likely to occur because of its low reliability.
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1. Safety
1.7.3. Safety Precautions for Automatic Operation
(1) While posting a sign [Do Not Enter During Operation] up the safety fence gate,
ask the operators not to enter during operation. If the robot stops, you may
enter the safety fence under your full understanding of the situation.
(2) Be sure to check if any operators are inside of the safety fence when starting
the automatic operation. Operating without checking the presence of
operators may cause a personal injury.
(3) Before starting the automatic operation, check and confirm that the program
number, step number, mode, and starting selection are in the possible state
for automatic operation. If starting with the other programs or steps selected,
the robot could move in an unpredicted way, and lead to an accident.
(4) Before starting the automatic operation, check if the robot is properly located
to get started. Check whether the program number or step number is identical
with the location of robot. Even if it's all identical, accidents are still possible to
occur due to an abnormal movement when the robot is differently located..
(5) Be prepared to immediately press the emergency stop button when starting
the automatic operation. Immediately press the emergency stop button in
case of robot's unexpected movements or emergency.
(6) Be sure to detect any abnormalities by checking the route, condition, or
sound of robot movement. Sometimes the robot may be abnormally operated
including a sudden break down. However, it will show(give) a certain
indication before the break down. Understand the robot's normal condition
well in order to catch the symptom in advance.
(7) When any abnormality is detected from the robot, immediately stop and take
proper actions on it. Using the robot before any proper actions taken may
cause an interruption of produce as well as serious failure leading to a very
serious personal injury.
(8) When checking the robot’s movement after the proper actions taken for the
abnormality, do not operate the robot with operators inside of the safety fence.
Unexpected accidents are possibly to occur because its low reliability may
cause another abnormality.
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1.8. Safety Precautions for Access to Safety Fence
Robots are very powerful and heavy even at its low speed. When entering the safety
fence, one must observe the relevant safety regulations of its pertinent country.
The operators always must be aware of the unexpected movements of robot. Robots
are able to move fast shortly after being stopped. The operators should know that the
robot is able to move in a different route, without any notice, by means of external
signals. Thus, when trying to stop the robot during teaching or operating test, one
should be able to stop the robot with a teaching pendant or control panel.
When entering the working envelope through the safety gate, take the teaching
pendant with you so that other people may not operate the robot. Make sure to post
up the control panel a sign indicating the state of robot handling.
Read carefully and be aware of the follows when entering the working envelope.
(1) Do not enter the working envelope other than teaching person.
(2) Be sure to set the ‘handling setting’ on teaching pendant to TEACHING
LOCK.
(3) Operation set-up mode of controller must be a manual mode in the control
panel.
(4) Always wear the approved working suite.(Do not wear a loose clothes as
you please)
(5) Do not wear gloves when handling Hi4a contoller.
(6) Do not leave innerwear such as underwear, shirts, or necktie out of the
working suite.
(7) Do not wear personal accessories such as big earrings, rings, or necklaces.
(8) Make sure to wear safety shoes, helmet, and goggles and if necessary, wear
other self-protective outfit such as safety gloves.
(9) Make sure that the emergency stop circuit is working correctly and in its
proper function, turns MOTORS OFF when pressing the emergency stop
button in the control panel and teaching pendant before handling the robot.
(10) Make your posture face-to-face with the robot manipulator when performing
your work.
(11) Follow the predetermined working procedure.
(12) Be prepared for emergency exit or safe place considering that the robot may
unexpectedly rush at you.
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1. Safety
1.9. Safety Precautions for Maintenance and Repair
1.9.1. Safety Precautions for Hi4a Controller Maintenance and
Repair
(1) Maintenance and repair of the robot must be performed by the personnel who
was duly trained in the special maintenance training course and has a good
knowledge of maintenance.
(2) Perform your work following the maintenance procedures for controller.
(3) Perform your maintenance and repair in a safe way by securing emergency
exit or safe place.
(4) Before the daily maintenance, repair, or changing parts, be sure to power
down. In addition, post a warning sign [Do Not Input Power] up the primary
power so that other operators may not input power by accident..
(5) When changing parts, be sure to use the specified ones.
(6) Be sure to power down when opening the Hi4a controller door.
(7) Before performing, wait for three minutes after power down.
(8) Do not touch the heat sink and regeneration resistor of servo amp because
they generate an intense heat.
(9) After completing maintenance, Be sure to close the door completely after
checking if tools or other things are still remained in the Hi4a controller.
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1.9.2. Safety Precautions for Robot System & Manipulator
Maintenanace
(1) Refer to the safety precautions for Hi4a controller maintenance and repair.
(2) Perform your maintenance and repair for the robot system and manipulator,
following the indicated procedures.
(3) Be sure to disconnect the primary power of controller. Post the warning sign
[Do not input power] up the primary power to prevent other workers from
connecting the power.
(4) Make sure that the Arm is fixed and immovable before maintenance and
repair since dropping or moving of the robot's Arm may cause a danger
during maintenance and repair. (Refer to the 『Robot manipulator
maintenance manual』.)
1-22
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1. Safety
1.9.3. Necessary Actions after Maintenance and Repair
(1) Check if the cables or parts of controller are properly connected.
(2) After maintenance is completed, carefully check that no tools are left around
or inside of the controller and manipulator. Make sure that the door is firmly
closed.
(3) Do not turn on the power if any problems or critical failures are detected.
(4) Be sure that there is no one within the working envelope, and that you are in
a safe place before turning on the power
(5) Turn on the main circuit breaker on the control panel.
(6) Check the current position and status of robot.
(7) Operate the manipulator at low speed.
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1.10. Safety Functions
1.10.1. Operating a Safety Circuit
Contactor MSHP1
Contactor MSHP2
Drive
M
Unit
Interlocking
&
Operating
mode selector
&
Operating
mode selector
Man1
+
Man2
+
Auto1
TP
Auto2
TP
EN1
EN2
LS
Limit switch
ASG
GSG
TP EN
EM
AUTO Mode Safeguard
General Safeguard
Enabling device in T/P
Emergency stop switch
Computer
Commands
Fig 1.5 Robot’s Safety Circuit
The robot's safety system is based on a two-channel safety circuit that is
continuously monitored. If an error is detected, the power supply to the motors is
disconnected and the motor brake is applied. To return the robot to MOTORS ON
mode, the switches of two-channel circuit must be connected. If one of the
two-channel circuit switches shorts, the contactor of motor will be disconnected
leading to the application of brake, and finally the robot will be stopped. Furthermore,
when safety circuit is disconnected, the interrupting call will be sent automatically to
the controller to find out the possible reason for the interruption.
The safety control circuit of operation is based on dual safety electric circuit in which
the controller and MOTORS ON mode are operated inteactively. In order to be in
MOTORS ON mode, the safety circuit consisted of several swtiches must be all
connected. MOTORS ON mode indicates that drive power is supplied to the motors.
If one of the contactors is disconnected, the robot will always return to MOTORS
OFF mode.
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1. Safety
MOTORS OFF mode indicates that drive power is removed from the robot's motors
and the brakes are applied. The status of the switches is displayed on the teach
pendant. (Refer to the I/O monitoring screen of "SERVICE" menu, 『Hi4a controller
operation manual』.)
Safety circuit
The emergency stop buttons on the controller panel and on the teaching pendant and
external emergency stop buttons are included in the safety circuit of operation. Users
may install the safety devices (safety plug, safety stop device for safe place) which
are operated in the AUTO mode. In a manual mode, the signals of these safety
devices are ignored. You can connect the general safety stop devices that is active in
all operating modes. No one can enter the working envelope in an automatic
operation mode due to the unconditional operation of the safety devices (door, safety
mat, safety plug etc.). These signals are also generated in a manual mode, but the
controller will keep the robot operating while ignoring the robot's teaching. In this
case, maximum speed of robot is restricted to 250mm/s. Thus, the purpose of this
safety stop function is to secure the safe area around the manipulator while one
approaches the robot for maintenance and teaching.
When the robot is stopped by a limit switch, it can be moved from the position by
jogging it with the operation key on the teaching pendant. (Refer to constant setting,
『Hi4a controller operation manual』.)
The safety circuits must never be by-passed, modified or changed in
any way.
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1.10.2. Emergency stop
An emergency stop should be activated when people or equipment is located at the
dangerous area. The emergency stop buttons are located both on the control panel
and on the teaching pendant.
All safety control devices such as emergency stop buttons on the control panel must
be located outside the working envelope and easily accessible at any time.
Status of Emergency stop
When the button is pressed, the robot will operate as follows.
Robot stops immediately in any cases.
ꢀ Disconnect the servo system power.
ꢀ Motor brake is activated
ꢀ Emergency stop message is displayed on screen.
For the emergency stop, the following two methods can operated simultaneously.
(Emergency stop for control panel and teach pendant is basic)
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1. Safety
(1) Emergency stop for control panel and teach pendant (Basic)
The emergency stop switch is on the control panel and teach pendant of the
controller.
Emergency
stop switch
Fig 1.6 Emergency Stop
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(2) Emergency stop of external system
External emergency stop device (button etc.) can be connected to the safety
electric circuit in accordance with applied standard for the emergency stop
circuit.
▶ Emergency stop connection of the external system
SEQUENCE BOARD(BD461)
Emergency Stop Channel 1 LED
OPERATIONAL PANEL
Emergency Stop Switch
CNOP
EM_STOP1
EMST1A
EMST1B
EMST2A
EMST2B
CNOP:17
CNOP:18
CNOP:19
CNOP:20
P1(24V)
EMST1A
EMST1B
EMST2A
EMST2B
Emergency Stop Channel 2 LED
TEACHING PENDANT
Emergency Stop Switch
EM_STOP2
M1(0V)
CNRTP
CNTPS
EMST1B
EMST1C
EMST2B
EMST2C
A1
B1
A2
B2
K
L
M
N
EXTERNAL SYSTEM
Emergency Stop Switch
※
JP1
EMST1C
EMST1C
TBEXT:1
TBEXT:2
TBEXT:3
TBEXT:4
M1(0V)
M1
EMST2C
EMST2C
P1(24V)
P1
JP2
ESOUT1
ESOUT2
TBEXT:5
TBEXT:6
RUN CHAIN
Fig 1.7 Emergency Stop Connection of External System
※ When using the emergency stop of the external system, connect the Terminal No.
1 (ES1) & No. 2 (M1,0V Common) or No. 3 (ES2) & No. 4 (P1,24V Common) of
the terminal block of BD461 to the external emergency stop line, and you must
open JP1 or JP2.
At this time, the emergency stop must be connected to be Normal On and it must
be check for proper operation during test run.
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1. Safety
1.10.3. Operating Speed
To teach the robot, the operating mode switch must be in a MANUAL mode. Then the
maximum speed of robot is limited to 250mm/s..
1.10.4. Connecting the Safety Devices
External safety devices such as light beams, light curtains, safety plug, and safety
mats which can be adapted by the system builder execute interlocking the controller
by way of connecting with safety circuit within the controller. These devices are used
for safety device during execution of normal program in an automatic mode.
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1.10.5. Restricting the working Envelope
When the robot is not necessary to reach certain area for specific applications,
working envelope of the robot can be limited to secure the sufficient safety working
area. This will reduce the damage or loss in case of robot's collision with external
safety devices such as safety fence, etc.. The movement of axes 1,2, and 3 of HR,
HX can be limited by means of mechanical stopper or electrical limit switches. In this
case, the corresponding software limitation parameters must be also changed. The
movement of the three wrist axes, if necessary, can be also limited by the Main CPU.
Limitation of working envelope for all the axes could be carried out by the user. The
robot is delivered to customer as the status of full working envelope setting.
Manual mode: Maximum speed is 250mm/s..
In a manual mode, by means of worker’s selection, workers may enter the
safeguared area.
Auto mode: The robot can be operated via remote controller.
All safety devices such as safety door, safety mats, etc. are activated.
No one may enter the safety device area of rotbot.
1.10.6. Monitoring Function
(1) Motor monitoring function
Motors are protected against overload by means of onboard sensors.
(2) Volatge Monitoring Function
For the protection of, the servo amp module turns off the power switch when
the voltage is too low or too high.
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1. Safety
1.11. Safety Related to End Effectors
1.11.1. Gripper
(1) When a gripper is used to grip a workpiece, there should be safety
precautions for unexpected dropping of the loaded workpiece.
(2) When any end effectors or devices are installed on the robot arm, use the
required size and piece of bolt, and securely fasten as per the required torque
using torque wrench. Do not use the bolt which has rust or dirt on its
surface..
(3) End effector must be designed and manufactured not to exceed the maximum
allowable load at the wrist of robot. Even though power or air supply stops,
the gripped workpiece must not be dropped from the gripper. In order to
remove any risks and problems which may cause personal injury and/or
physical damage, the sharp edge and projecting part of end effector must be
made dull and smooth.
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1.11.2. Tool / Workpiece
(1) It must be possible to replace tools such as milling cutters in a safe manner.
Make sure that safety devices are working correctly until the cutters stop
rotating.
(2) Grippers must be designed to keep in gripping workpiece securely even
though a power failure or a control failure takes place. It must be possible to
release workpiece from the gripper in a manual mode.
1.11.3. Pneumatic and Hydraulic Systems
(1) The special safety regulations will apply to pneumatic and hydraulic
systems. .
(2) Since residual energy of pneumatic and hydraulic systems can be still
remaining even after the robot stops, particular care and attention must be
paid by users. Internal pressure of equipment must be removed whenever
starting the repair work for pneumatic and hydraulic systems.
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1. Safety
1.12. Liabilities
The robot system has been built in accordance with the latest technical standards
and approved safety rules. Nevertheless, the serious accidents such as death or
personal injury still may take place due to the collision between the robot system and
peripheral equipment.
The robot system must be used by operator who has a full technical knowledge on its
designated use and also pay his close attention to the possible dangers and risks
involved in its operation. The use of robot system is subject to compliance with these
operating instructions and the operation and maintenance manual supplied together
with the robot system. The safety related functions of robot system must not be used
for any purposes other than safety.
When you use the robot system for any other or additional purposes than its
designated usage, you must review whether it is valid in accordance with design
criteria. The manufacturers cannot take any responsibility for any damage or loss
which resulted from such misuse or improper use. The users shall have the full
responsibility for the risks caused by such misuse or improper use. When you use
and operate the robot system for its designated use, you must have a good
command of all the information contained at these operating instructions as well as
the maintenance manual.
The robot system may not be put into operation until it is ensured that the functional
machine or plant) into which the robot system has been integrated conforms to the
specifications of the EC directives 89/392 EWG dated 14 June 1989 and 91/368
EWG dated 20 June 1991.
The following harmonized standards in particular were taken into account with regard
to the safety of the robot system.
ꢀ IEC 204-1,10.7
ꢀ ISO 11161,3.4
ꢀ ISO 10218(EN 775),6.4.3
ꢀ ISO 10218(EN 775),3.2.17
ꢀ ISO 10218(EN 775),3.2.8
ꢀ ISO 10218(EN 775),3.2.7
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Users must take the full responsibility for any accident caused by their negligence or
non-observance of these instructions. The manufacturer will not take any liabilities
and responsibilities for any damages or losses caused by the misuse or malfunction
of such equipment which is not included in the contract between manufacturer and
user and provided by user, or such equipment which is installed around the robot
system arbitrarily by the user. User must take the full liabilities and responsibilities for
any risks and damages caused by such equipment.
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2
Specifications
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2. Specifications
2.1. Robot Machinery Part
HX300 * - *
Specification No.
Robot TYPE
Rated Payload
Series Name
FIg 2.1 Robot Machinery Part
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2. Specifications
2.2. Location of Robot Identification Plate
The model name, serial number, and manufacturing date of robot are written down in
the name plate.
The name plate is located in the rear of axis H in the ARM.
Product Name
Model Name
Serial Number
: Robot Mnipulator
: HX165
:
Year of Manufacture :
Weight(Net)
Manufactured by
:
Kg
Hyundai Heavy Industries Co., Ltd.
1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel
:
82-52-230-7901
Home page : www.hhi.co.kr
Made in Korea
Fax : 82-52-230-7920
Fig 2.2 The location of identification plate
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2.3. Basic Specifications
Table 2-1 Basic Specifications for Models
Item
Specification
HX200L
Model
HX300
HX400
HX200L
HX300L
-2000
Construction
Degree of freedom
Drive system
Articulated
6
AC servo system
S
H
V
Swivel
±3.142 rad (±180°)
+1.31 ~ -1.31 rad (+75°~ -75°)
+0.52 ~ -2.18 rad (+30°~ -125°)
±6.283 rad (±360°)
For/
Backward
Arm
Wrist
Arm
Up/
downward
Max.
Working
envelope
R2 Rotation 2
Bending
R1 Rotation 1
B
±2.094 rad (±120°)
±6.283 rad (±360°)
1.57 rad/s
(90°/s)
S
H
V
Swivel
1.658 rad/s (95°/s)
For/
Backward
1.57 rad/s
(90°/s)
1.658 rad/s (95°/s)
Up/
downward
1.483rad/s
(85°/s)
1.658 rad/s(95°/s)
Max.
Speed
1.920rad/s 1.745 rad/s
1.920rad/s
(110°/s)
R2 Rotation2
2.09 rad/s(120°/s)
2.09 rad/s(120°/s)
3.14 rad/s(180°/s)
1962 N(200 kg)
(110°/s)
(100°/s)
1.920 rad/s1.745 rad/s
(110°/s) (100°/s)
1.920rad/s
(110°/s)
Wrist
B
Bending
R1 Rotation 1
Load Capacity
3.142 rad/s2.793 rad/s
2.704rad/s
(155°/s)
(180°/s)
(160°/s)
2943 N
3924 N
2943 N
(300 kg)
(300 kg) (400 kg)
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2. Specifications
Item
Specification
HX400 HX200L
HX200L
HX300L
-2000
Model
HX300
1668 N·m 1960 N·m
(170 kgf·m)
1290 N·m
(131.5 kgf·m)
1668N·m
((170kgf·m)
R2 Rotation 2
Bending
R1 Rotation 1
(200 kgf·m)
Wrist
Torque
1668 N·m 1960 N·m
1290 N·m
(131.5 kgf·m)
1668N·m
((170kgf·m)
B
(170 kgf·m)
(200 kgf·m)
687 N·m 823 N·m
(70 kgf·m) (84 kgf·m)
604.6 N·m
(61.6 kgf·m)
687N·m
(70 kgf·m)
Accuracy of position
repeatability
±0.5 mm
Ambient Temperature
Relative humidity
0 ~ 40 ℃ (273 ~ 313 K)
20 ∼ 85 %RH
Robot's Weight
2230 kg
2430 kg
2230 kg
2530 kg
6.18 m²
Index of working envelope
4.519 m² 4.519 m² 6.18 m²
6.85 m²
2-5
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2.4. Robot Dimension and Working Envelope
Fig 2.3 Robot Dimension and Working Envelope : [HX300]
2-6
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2. Specifications
Fig 2.4 Robot Dimension and Working Envelope : [HX400]
2-7
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HX200/HX200L-2000/HX300/HX300L/HX400
Fig 2.5 Robot Dimension and Working Envelope : [HX200L]
2-8
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2. Specifications
410
300
2000
236
150
1490.8
1186
3250.3
Fig 2.6 Robot Dimension and Working Envelope : [HX200L-2000]
2-9
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Fig 2.7 Robot Dimension and Working Envelope : [HX300L]
2-10
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2. Specifications
2.5. Axis Identification
Table 2-2 Axis Motion
Axis Name
Operation
Arm Swivel
Teaching Pendant Button
S
H
LFT(S+)
BWD(H+)
UP(V+)
RHT(S-)
FWD(H-)
DOWN(V-)
Rx-(R2-)
Ry-(B-)
Arm Forward and Backward
Arm Upward and Downward
Wrist Rotation2
V
R2
B
Rx+(R2+)
Ry+(B+)
Rz+(R1+)
Wrist Bend
R1
Wrist Rotation1
Rz-(R1-)
Ry-
Ry+
Rx- Rx+
RHT
LFT
UP
Rz- Rz+
DOWN
FWD
BWD
Fig 2.8 Robot Dimension and Axis [HX300/400/200L/200L-2000/300L]
2-11
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2.6. Details of Wrist Axis Attachment Surface
When attaching the operating tool to the mechanical interface of robot's wrist flange,
fasten it with a bolt at P.C.D. 125.
Fig 2.9 Details of Wrist Axis Attachment Surface : [HX300/400/300L]
12
Ø10H7 D.P.16
6-M10 TAP
D.P.13(PCD 125)
6-M10 TAP
D.P.14(PCD 160)
2-Ø10H7 D.P.16
Fig 2.10 Details of Wrist Axis Attachment Surface : [HX200L]
2-12
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2. Specifications
2.7. Details of Upper 1st ARM Attachment Surface
There is a Tap in upper 1st ARM to attach peripheral equipment.
Attach peripheral equipment within the range marked as ▦.
[Attention]
Attach peripheral equipment to the upper side of the 1st ARM, or to only one side of
upper axis V. When attaching, be sure to the center position of gravity should be
located within the range marked as ▦.
ꢀ Max weight on the A1 Frame : 80kg
ꢀ Max weight on the 1st ARM
: 80kg
FIg 2.11 Details of Upper 1st ARM Attachment Surface
2-13
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2.8. Application Wiring and Inspection Wiring Diagram
There are air unit and connector to connect the additional equipment to the robot
manipulator.
Application connectors are indicated as follows.
[Note] Max air pressure of air connection : 7bar (7.1 kgf/cm2 , 101 psi)
Fig 2.12 Application Wiring and Inspection Wiring Diagram
2-14
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2. Specifications
2.8.1. Details of Customer Application Connectors
[Encoder Connector]
CONNECTOR<1> CONNECTOR<2>
CONNECTOR<3>
Fig 2.13 Details of Application Connector (Encoder)
① CABLE SPECIFICATION : 0.3sq * 40pcs
② CONNECTOR TYPE(Receptacle)
<1> CA3102A32A10PX(CNR10)
<2> MS3102A24-28S(CNR10A)
<3> MS3102A24-28SX(CNR10B)
③ CONNECTOR TYPE(Plug)
<1> CA3106B32A10S(CNR10)
<2> MS3106B24-28P(CNR10A)
<3> MS3106B24-28PX(CNR10B)
[Power Connector]
CONNECTOR<4>
CONNECTOR<5>
Fig 2.14 Details of Application Connector (Power)
④ CABLE SPECIFICATION : 2.0sq * 11pcs
⑤ CONNECTOR TYPE(Receptacle)
<4> MS3102A20-18P(CNR20)
<5> MS3102A20-29S(CNR30)
⑥ CONNECTOR TYPE(Plug)
<4> MS3106B20-18S(CNR20)
<5> MS3106B20-29P(CNR30)
2-15
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2.9. Restricting the Working Envelope
When installing the robot, take into account that the working envelope can be
adjusted freely within the entire working envelope.
In case of possible collision between the robot and peripheral equipment, the working
envelope must be limited mechanically and by means of software.
Following instructions explain how to install switches or additional stoppers for setting
the working envelope of main axes. This is an optional part.
2.9.1. Axis 1(Axis S)
By adding one more mechanical stopper, the working envelope of the 1st axis can be
limited. (by 15˚).
If the 1st STOPPER BLOCK and STOPPER are deformed due to a great impact,
they must be replaced.
2-16
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3
Instructions
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HX200/HX200L-2000/HX300/HX300L/HX400
3. Instructions
3.1. Robot Component Name
The following [Fig 3.1] and [Fig 3.2] show and name each component of the robot.
Fig 3.1 Identification of Robot Components
Table 3-1 Components name
No.
1
Component Name
BASE BODY
A2 FRAME
2nd ARM
No.
9
Component Name
WRIST
2
10
11
12
13
14
15
16
R2 axis Motor
B axis Motor
R1 axis Motor
V axis Motor
H axis Motor
S axis Motor
S axis Limit Switch
3
4
HINGE
5
LINK
6
BALANCE SPRING
A1 FRAME
1st ARM
7
8
3-2
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3. Instructions
3.2. Location of Safety Nameplate
In order to prevent any accidents, safety marking plates such as [Fig 3.2] is attached
to the robot. Do not remove or replace it unneccessarily.
HYUNDAI
ALVANIA 0769 GREASE
5cc Every 12 months
HANDLING WIRES(4 pcs)
:
WARNING
Length
3.5m
HOSE FOR PROTECTION
Length 50cm
:
4-M24 EYE BOLT
경 고
주 의
Moly White RE00 GREASE
30cc Every 12 months
서보모터 분해시
ARM 낙하 주의
Fig 3.2 Location of Safety Nameplate
3-3
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3.3. How to operate
3.3.1. Using Crane
4 Handling Wires
Length : 3.5 M
4 Handling Wires
Length : 3.5 M
Hose for
Hose for
protection
protection
4-M24
4-M24
EYE BOLT
EYE BOLT
Fig 3.3 How to Transport: Using crane [HX300/400]
3-4
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3. Instructions
Fig 3.4 How to Transport: Using crane [HX200L/300L]
The following lifting instructions are valid for a "naked" robot. If additional equipment
is put on the robot, the center of gravity may change and make lifting dangerous.
ꢀ Never walk under the robot.
ꢀ Pose the robot as shown in the Figure.
ꢀ Mount four pieces of EYE BOLTS at the four parts of Base Body.
ꢀ Hook 4 piece of wire hooks up with EYE BOLTS.
ꢀ Use 4 piece of protective hose(four parts/ 50cm) to prevent damage.
ꢀ Keep the safety regulations during Lifting process..
ꢀ Weight of manipulator : 2230kg(HX300/200L), 2430kg(HX400)
ꢀ Minimum crane capacity: 3 tons
※ Use wire rope in its length of 3.5m(2EA) and 3.3m(2EA). Insert a protective hose
to prevent damage of painting at the parts contacted with robot body. Refer to Figures
for the proper location of protective hose..
3-5
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3.3.2. Using Forklift Truck
Loading Capacity
minimum 3ton
Fig 3.5 How to Transport : Using Forklift Truck [HX300/400/200L/200L-2000/300L]
Forklift may be used for transporting the robot manipulator. The bracket for the forklift
transporting, as an option, is provided.
Follow the instruction for safety.
ꢁ Make each model taken a basic posture, referring to the Figure.
ꢁ Before forking, fasten each bracket for forklift to the left and right side of A2
Frame with 4 pieces of M12 bolts and flat washer.
ꢁ Transport at low speed.
ꢁ Follow the safety regulations.
Attention
ꢁ Do not lean against the robot manipulator during transporting.
ꢁ Check the robot manipulator not to collide against the ground while getting on
and off.
ꢁ Follow the safety regulations during forklifting and transporting.
3-6
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3. Instructions
3.4. How to Install
NOTE:
Before starting to unpack and install the robot, read the safety regulations and other
instructions very carefully..
Warning:
The installation shall be made by qualified installation personnel and should conform
to all national and local codes.
When unpacking the robot, check if it has been damaged during transporting or
unpacking. In addition, strictly keep the following installation instructions because
installation method and foundation are very important to maintain a good robot
performance.
3.4.1. Operating Conditions
(1) Ambient temperature should range from 0℃ to 45℃.
(2) Ambient humidity should range from 20% to 85% RH, without dew
condensation.
(3) Less dust, oil, or moisture.
(4) No flammable, corrosive liquid or GAS.
(5) No impact and shacking.
(6) No electrical noise generator near the robot.
(7) If the robot is not immediately installed, keep it in a dry area at an ambient
temperature between -15℃∼ and 40℃.
3-7
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3.4.2. Installating the Robot Manipulator
The manipulator must be firmly fixed with eight M20 bolts. Note that all eight bolts
must be used.
ꢁ Bolts
ꢁ Washer
ꢁ Tightening Torque
: M20*65 of higher(12.9) SOCKET HEAD BOLT
: OD = 44mm, ID = 25mm, T = 4mm
: 314Nm
The stiffness of the foundation must be designed to minimize the influence of the
dynamic behavior of the robot.
In case of installing the robot on the floor, where the concrete thickness is more than
200mm, remove unevenness and cracks on the floor, and then fix the mounting plate
with M20 Anchor Bolts. If the thickness of concrete is less than 200mm, the
foundation work is required. Thus, inspect the foundation before robot installation.
※ Allowable load of bolts
The repeated tensile load per bolt : Approximately 8820 N ( 900 Kgf )
3-8
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3. Instructions
3.4.3. Dimension of Installation Surface
Fix the swivel base for robot's installation.
Refer to [Fig 3.6] for the dimension.
[HX130/165,HX130S/165S]
[HX300/400/200L/300L]
Fig 3.6 Dimension of Robot Installation
3-9
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3.4.4. Accuracy of Installation Surface
The degree of flatness for the four attachment plate surfaces should safisty the
specification. Use a shim, if necessary. The rest of the surface must be flat within
±2mm.
■ Cautions
(1) The flatness of mounting plate must be within 1.0 mm.
(2) The flatness of attachment plate surface for the 4 points must be within 1.0
mm (±0.5 mm).
Fig 3.7 Accuracy of Installation surface
3-10
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3. Instructions
3.5. Allowable Load of Wrist Axis
The load, which will be applied to the mechanical interface of robot's wrist axis, is
restricted by allowable weight, allowable load torque and allowable moment of inertia.
Allowable Maximum Pay Load Weight :
Table 3-2 Allowable load weight
Robot Model
HX300/300L
Allowable Laod Weight
Less than 300kg(300kgf)
Less than 400kg(400kgf)
Less than 200kg(200kgf)
HX400
HX200L/200L-2000
Allowable Load Torque
Table 3-3 Allowable Load Torque
Allowable Load Torque
Robot Model
R2 Axis
B Axis
Rotation
R1 Axis Rotation
Rotation
Less than 608 N·m(62
kgf·m)
HX300/300L
HX400
Less than 1668N·m (170kgf·m)
Less than 1960N·m(200kgf·m)
Less than 1290N·m(132kgf·m)
Less than 490 N·m(50
kgf·m)
Less than 392 N·m(40
kgf·m)
HX200L/200L-2000
3-11
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Allowable Moment of Inertia
Table 3-4 Allowable Moment of Inertia
Allowable Load Torque
Robot Model
R2 Axis
B Axis Rotation
R1 Axis Rotation
Rotation
HX300/300L
HX400
150kg·m²(15.3kgf·m·s²)
30 kg·m²(3.1 kgf·m·s²)
120 kg·m²(12.2 kgf·m·s²)
50 kg·m²(5.1 kgf·m·s²)
58.8 kg·m²(6.0
kgf·m·s²)
HX200L/200L-2000
117.6 kg·m²(12.0 kgf·m·s²)
Loads must be kept below maximum conditions shown in [Fig. 3.8~Fig 3.10].
[Fig 3.8] and [Fig 3.10] show the possible range in which a point load can be
positioned, assuming the attached load is a particle. However, as the actual load(End
Effector) is not a particle, calculate and evaluate the moment of inertia on each axis.
The following exmple shows moment of inertia calculation assuming the attached
load is a particle.
[Example〕An attached load weight is 200Kg with the 【 HX300 】Model
ꢀ Allowable position of the center of gravity from the center of R1 axis
① Allowable position of the center of gravity from the center of Axis R1
LR1 ≤ (Allowable Torque) / (Load Weight)
LR1 = 687 N·m / (200Kg×9.8 m/s2) = 0.35 m
② Allowable position of the center of gravity from the allowable moment of
inertia
LR1 ≤ (Allowable moment of inertia/ Load Weight)1/2
= (30 kg·m2 / 200 kg )1/2 = 0.387 m( > 0.35 m)
From the above result, the maximum distance from the center of R1 axis becomes
0.35 m, being restricted by the allowable moment of inertia.
3-12
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3. Instructions
ꢀ Allowable position of the center of gravity from the center of Axis B
(The center of B axis is on the same axis of this robot, and the value of the
allowable load torque and allowable moment of inertia of B and R2 axes are
the same. Therefore, if the allowable condition on the B axis is satisfied, it
guarantees to satisfy that on the R2 axis..)
① Allowable position of the center of gravity from the allowable torque
LB ≤ (Allowable Torque) / (Load Weight)
LB = 1668 N·m / (200Kg×9.8 m/s2) = 0.851 m
② Allowable position of the center of gravity from the allowable moment of
inertia
LB ≤ (Allowable moment of inertia / Load Weight)1/2
= (150 kg·m2 / 200 kg )1/2 = 0.866 m( > 0.851 m)
From above result, the maximum distance from the center of B axis becomes
0.851m, being restricted by the allowable moment of inertia.
3-13
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HX200/HX200L-2000/HX300/HX300L/HX400
■ Torque Map
Fig 3.8 Wrist Axis Torque Mapping:[HX300/300L]
Fig 3.9 Wrist Axis Torque Mapping : [HX400]
3-14
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3. Instructions
Fig 3.10 Wrist Axis Torque Mapping : [HX200L]
3-15
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HX200/HX200L-2000/HX300/HX300L/HX400
3.6. Recommended Standy Posture
Selecting a good standby posture can save energy and reduce motor temperature.
If the tool is positioned as the figure below, the load on H and V-axes may be
minimized.
In case that the posture shown below might not be attained due to the limited space
and time caused by peripheral equipment or cycle times, then contact our company.
Fig 3.11 Recommended Standby Posture
3-16
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4
Inspection
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4. Inspection
This chapter provides the instructions for regular inspection and overhaul necessary
for the prolonged lifetime of robot performance.
4.1. Inspection Item and Period
Inspection is positively necessary to continue and maintain the high performance of
robot for long-term operation.
There are daily inspection and regular inspection. [Table 4-1] shows basic periods for
regular inspections, so inspectors should make an inspection according to the
indicated periods.
And overhaul every 35,000 operating hours.
The inspection periods have been reviewed for SPOT Welding. In case of high
precision work such as handling, it is recommended to inspect at the half intervals of
that period as shown in [Table 4-1].
Table 4-1 Inspection Schedule
Yearly Inspection
Yearly Inspection
3 months 6 months 9 months 12 months 3 months 6 months 9 months 12 months
1 year & 1 year & 1 year &
3 months 6 months 9 months 1 year
2 years
3 months 6 months 9 months
Daily Inspection
4-2
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4. Inspection
4.2. Inspection Item and Period
Table 4-2 Inspection Items and Periods
Inspection Intervals
Inspection
Inspection
method
No.
Standards
Remark
Items
3
1
year
Daily
mothns
Robot Manipulator and Axes common
Examine dirt and
1
2
○
Cleaning
dust with naked
eyes
Examine any cable
damages
Examine cable fixing
bracket tightening
bolts paint marking
with naked eyes
Examine any cable
cover damages with
naked eyes
Inspection
wiring
○
○
Examine paint
marking with naked
eyes
3
4
Main bolts
Check if the
emergency
stop lamp is on
when the limit
switch is ON.
Check the ON-OFF
function of limit
switch
Limit
Switch/ Dog
○
Check the abnormal
heating
Check the abnormal
sound
5
6
○
Motor
Brake
Check the ON/OFF
operation of brake
release switch
Note) Turn the
switch off in a
second because the
ARM of working axis
may be dropped
when the brake
When the
brake release
switch is OFF,
ARM of End
Effect will not
be dropped.
○
release switch is on
4-3
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Inspection Intervals
Inspection
Items
Inspection
method
No.
Standards
Remark
3
1
year
Daily
mothns
Axix S, H, V
Check the abnormal
sound
Reduction
gear
7
○
Check the
shaking(vibrating)
Axis R2, B, R1
Check the abnormal
sound
Check the vibrating
Reduction
gear
8
9
○
○
End Effect
tightening
bolts
Examine paint
marking with naked
eyes
there is any
diversion by rotating should not feel
10
○
Diversion
each axis to the right
and reverse
diversion by
touch
direction
ꢀ If the robot is utilized in adverse condition( such as spot welding, grinding,
etc.), perform the inspection more frequently to ensure proper reliability of the
robot system
ꢀ Inspect all visible cabling, and replace them if damaged.
ꢀ Check the mechanical bumper devices for deformation and damage. If the
bumper or Dog is bent, replace it immediately.
ꢀ Check the tightening torque of main bolts as shown in [Fig 4.1].
ꢀ Check the abnormal noise in an automatic or teaching mode in order to
ensure the condition of power transmission(such as motor, reduction gear,
etc).
4-4
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4. Inspection
4.3. Inspection of Main External Bolts
The recommended bolt torque is shown in [Fig 4.1].
Apply the appropriate torque, where required, using the torque wrench and place the
paint marking where the check-up is completed
Table 4-3 Inspection part for main bolts
No.
1
Inspection parts
No.
10
11
Inspection parts
H & V axis reduction gear case
attachment
R2 axis reduction gear
attachment
2
H & V axis motor attachment
Hinge and Link attachment
Balance spring attachment
R1 axis motor attachment
R2 axis motor attachment
B axis motor attachment
1st ARM attachment
Wrist attachment
B axis reduction gear attachment
Wrist CAP attachment
3
12
13
14
15
16
17
18
4
5
Wrist HOLDER attachment
Wrist HOLDER attachment
Wrist COVER attachment
6
7
R1 axis reduction gear
attachment
8
9
1st Link attachment
End-effector attachment
4-5
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Fig 4.1 Inspection Part for Main Bolts [HX300/400/300L]
4-6
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4. Inspection
4.4. Inspection of Wrist Backlash
Check a diversion by forcing the end-effector (End Effector : spot gun, hand device,
etc.), which is attached to the vertical hem of Wrist, in the direction of back and forth,
right and left, and up and down.
Fig 4.2 Abnormal Backlash Inspecting Directions
4-7
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4.5. Inspection Internal Wiring
Flexible cables are used for internal wiring of robot manipulator. However, when an
internal cable is broken or crushed, the robot may malfunction. Therefore, regular
inspection is required. When operating in the working envelope according to following
inspection conditions, inspection must be completed in advance.
4.5.1. The Conditions of Safety Inspection
When performing the operating work such as teaching (except shutting off driving
source of industrial robot) in the working envelope, check the following articles before
the work. If abnormality is found, correct the problem on the spot and then take
necessary actions.
ꢁ Check if the covered wire and sheathing are damaged or not.
ꢁ Check if the manipulator can be operated or not.
ꢁ Check emergency stop function
4-8
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4. Inspection
4.5.2. Inspection Part
Inspection part
Fig 4.3 Cable Inspection Parts : [HX300/400/200L/200L-2000/300L]
4-9
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5
Maintenance
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5. Maintenance
5.1. Grease Replenishment/Replacement
Attention
If greasing is performed incorrectly, the internal pressure of the grease bath
may suddenly increase, possibly causing damage to the seal, which would
in turn lead to grease leakage and abnormal operation. When performing
greasing, therefore, observe the following cautions.
① Before starting to grease, remove the plug from the grease outlet.
② Whenever possible, avoid using a compressed-air pump, powered by the
factory air supply. If the use of a compressed-air pump is unavoidable, restrict
the greasing pressure less than 7bar(7kgf/cm2)
③ Use grease only of the specified type. If not, may damage the reduction gear
or lead to other problems.
④ After greasing, confirm that no grease is leaking from the grease outlet and
that the grease bath is not pressurized, then re-attach the plug in the grease
outlet.
⑤ To prevent accidents caused by slipping, completely remove any excess
grease from the floor or robot.
⑥ When an ambient temperature is more than 40℃, be sure to shorten the
period of replenishment in half.
■ Periodic Replenishment / Replacement
Lubrication Cycle
ꢂ Grease Replenishment : 6,000 hours
ꢂ Grease Replacement : 12,000 hours
5-2
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5. Maintenance
5.1.1. S-Axis Reduction Gear
Attention
If grease is added without removing the outlet plug, the grease will go
inside the motor and may damage it. It is absolutely necessary to
remove the plug.
■ Grease Replenishment
① Remove the grease outlet plug.
② Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 500cc
③ Attach the outlet plug with seal tape.
■ Grease Replacement
① Remove the grease outlet plug.
② Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 3,650cc
③ The grease replacement is complete when new grease appears in the outlet
port. The new grease can be distinguished from the old one by color.
④ Move the S-Axis for a few minutes to eject the old grease and then add
grease until the new grease appears in the outlet port.
⑤ Wipe the outlet port with a cloth and attach the plug with seal tape.
5-3
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HX200/HX200L-2000/HX300/HX300L/HX400
5.1.2. H-Axis Reduction Gear
Attention
If grease is added without removing the outlet plug, it cause damage
to the seal of reduction gear and grease will go inside the motor and
may damage it. It is absolutely necessary to remove the plug.
■ Grease Replenishment
① Make the H-Axis Arm vertical for ground.(H:90°-Floor Type, H:0°-Shelf Type )
② Remove the grease outlet plug.
③ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 300cc
④ Wipe the outlet port with a cloth and attach the plug with seal tape.
5-4
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5. Maintenance
■ Grease Replacement
① Make the H-Axis Arm vertical for ground.(H:90°-Floor Type, H:0°-Shelf Type )
② Remove the grease outlet plug.
③ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 1,600cc
④ The grease replacement is complete when new grease appears in the outlet
port. The new grease can be distinguished from the old one by color.
⑤ Move the H-Axis for a few minutes to eject the old grease and then add
grease until the new grease appears in the outlet port.
⑥ Wipe the outlet port with a cloth and attach the plug with seal tape.
5-5
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HX200/HX200L-2000/HX300/HX300L/HX400
5.1.3. V-Axis Reduction Gear
Attention
If grease is added without removing the outlet plug, it cause damage
to the seal of reduction gear and grease will go inside the motor and
may damage it. It is absolutely necessary to remove the plug.
■ Grease Replenishment
① Make the V-Axis Arm horizontal for ground.(V:0°-Floor Type, V:-90°-Shelf
Type )
② Remove the grease outlet plug.
③ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 300cc
④ Wipe the outlet port with a cloth and attach the plug with seal tape.
5-6
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5. Maintenance
■ Grease Replacement
① Make the V-Axis Arm horizontall for ground. (V:0°-Floor Type, V:-90°-Shelf
Type )
② Remove the grease outlet plug.
③ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 1,600cc
④ The grease replacement is complete when new grease appears in the outlet
port. The new grease can be distinguished from the old one by color.
⑤ Move the V-Axis for a few minutes to eject the old grease and then add
grease until the new grease appears in the outlet port.
⑥ Wipe the outlet port with a cloth and attach the plug with seal tape.
5-7
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HX200/HX200L-2000/HX300/HX300L/HX400
5.1.4. R2-Axis Reduction Gear
Attention
Do not inject excessive grease. The excessive grease would cause
an abnormal operation.
■ Grease Replenishment
① Prepare a grease nipple A-PT1/4.
② Remove the grease outlet plug.
③ Remove the grease inlet plug and install grease nipple A-PT1/4.
④ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 250cc
⑤ Wipe the outlet port with a cloth and reinstall the inlet/outlet plugs with seal
tape
■ Grease Replacement
① Prepare a grease nipple A-PT1/4.
② Remove the grease outlet plug.
③ Remove the grease inlet plug and install grease nipple A-PT1/4.
④ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 1,100cc
⑤ The grease replacement is complete when new grease appears in the outlet
port. The new grease can be distinguished from the old one by color.
⑥ Wipe the outlet port with a cloth and reinstall the inlet/outlet plug with seal
tape.
5-8
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5. Maintenance
5.1.5. B-Axis Reduction Gear
Attention
Do not inject excessive grease. The excessive grease would cause
an abnormal operation.
■ Grease Replenishment
① Prepare a grease nipple A-PT1/8 and then Make the R2-Axis 0°degree.
② Remove the grease inlet plug and install grease nipple A-PT1/8.
③ Make the R2-Axis -90°degree and then Remove the grease outlet plug.
④ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 250cc
⑤ Wipe the outlet port with a cloth and reinstall the inlet/outlet plugs with seal
tape
5-9
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HX200/HX200L-2000/HX300/HX300L/HX400
■ Grease Replacement
① Prepare a grease nipple A-PT1/8 and then Make the R2-Axis 0°degree.
② Remove the grease inlet plug and install grease nipple A-PT1/8.
③ Make the R2-Axis -90°degree and then Remove the grease outlet plug.
④ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 950cc
⑤ The grease replacement is complete when new grease appears in the outlet
port. The new grease can be distinguished from the old one by color.
⑥ Wipe the outlet port with a cloth and reinstall the inlet/outletplug with seal
tape.
5-10
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5. Maintenance
5.1.6. R1-Axis Reduction Gear
Attention
Do not inject excessive grease. The excessive grease would
cause an abnormal operation.
■ Grease Replenishment
① Remove the grease outlet plug.
② Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 200cc
③ Wipe the outlet port with a cloth and attach the outlet plug with seal tape.
5-11
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HX200/HX200L-2000/HX300/HX300L/HX400
■ Grease Replacement
① Remove the grease outlet plug.
② Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Molywhite RE00
ꢂ Amount of grease : 435cc
③ The grease replacement is complete when new grease appears in the outlet
port. The new grease can be distinguished from the old one by color.
④ Wipe the outlet port with a cloth and attach the outlet plug with seal tape.
5-12
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5. Maintenance
5.1.7. Bearing Joint Parts
■ Grease Replenishment
① Prepare a grease nipple A-PT1/8.
② As necessary, remove grease inlet plug and install grease nipple A-PT1/8.
③ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Alvania0769
ꢂ Amount of grease : 3cc
④ Remove grease nipple A-PT1/8 from grease inlet port.
⑤ Reinstall the grease plugs with seal tape.
5-13
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HX200/HX200L-2000/HX300/HX300L/HX400
5.1.8. A1 Frame - Gear Box
■ Grease Replenishment
① Prepare a grease nipple A-PT1/8.
② Remove the grease outlet plug.
③ Remove the grease inlet plug and install grease nipple A-PT1/8.
④ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Alvania0769
ꢂ Amount of grease : 30cc
⑤ Remove grease nipple A-PT1/8 from grease inlet port.
⑥ Reinstall the grease plugs with seal tape.
5-14
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5. Maintenance
5.1.9. Wrist - Gear Box
■ Grease Replenishment
① Prepare a grease nipple A-PT1/8.
② Remove the grease inlet plug and install grease nipple A-PT1/8.
③ Inject the grease into the grease inlet using a grease gun.
ꢂ Grease type : Alvania0769
ꢂ Amount of grease : 30cc
④ Remove grease nipple A-PT1/8 from grease inlet port.
⑤ Reinstall the grease plugs with seal tape.
5-15
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HX200/HX200L-2000/HX300/HX300L/HX400
5.2. Battery Replacement
The position data of each axis is preserved by the backup batteries. The batteries
need to be replaced every two years. To replace batteries observe the following
procedure.
① Keep the power on. Press the Emergency Stop button to prohibit the robot
motion.
Attention
Replacing the batteries with the power supply turned off causes all current
position data to be lost. Therefore, zeroing will be required again.
② Dettach the battery bracket.
③ Take out the old batteries from the battery bracket.
④ Insert new batteries into it. Pay attention to the direction of batteries.
ꢂ Battery Spec. : ER6C(AA) 3.6V
ꢂ Manufacturer : Maxell
⑤ Reinstall the battery bracket.
5-16
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5. Maintenance
Attention
ꢂ Do not dipose the batteries. Dispose of the battery with industrial waste
acoording to the laws and other rules in the country where the controller
is installed.
ꢂ Do not recharge the batteries, otherwise batteries may result in exploding
or everheating.
ꢂ Do not use any batteries other than the recommended one.
ꢂ Change the batteries only with the specified one.
ꢂ Do not short positive and negative terminals of battery.
ꢂ Do not expose batteries to high temperature or flame
5-17
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HX200/HX200L-2000/HX300/HX300L/HX400
5.2.1. Instructions for Battery Storage
① Do not keep the batteries at a high temperature and humidity. Keep it in the
well-ventilating place without dew condensation.
② Keep it in a normal temperature, at relatively constant temperature(20±15℃)
and at relative humidity of less than 70%.
③ Check the battery storage every six months, and manage them with
first-in-first-out.
5-18
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5. Maintenance
5.3. Internal Wiring
Replacement cycle of internal wiring depends on follows.
ꢂ Continuous operation
ꢂ Operating speed
ꢂ Atmosphere/environment
Inspect on a regular basis,every three months and check any damage on the cables
or cable protect spring. If any damage, replace it.
Replace the cable every 16,000 operating hours regardless of working condition.
Attention
ꢂ As all the wires are flexible type, do not use any wires other than
specified one.
ꢂ Wiring replacement must be done by unit.
ꢂ Do not use any Cable, protective spring, and Hose that have external
damage as they may cause future problems.
ꢂ When purchasing robot cables, make inquiry of our service office about
wiring type.
ꢂ Specify the length of wiring for connecting the robot with the controller.
5-19
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HX200/HX200L-2000/HX300/HX300L/HX400
5.3.1. Wiring Connection Diagram
Refer to [Fig 5.1] for part symbols of the internal wiring.
JUNCTION BOX
CONNECTOR
CONNECTOR
BJ2
BJ1
CN
HX300-J2-MB1-A
S-Axis
MOTOR Brake
HX300 - J2 - MB1 - A
REVISION CODE(A, B, C... )
Axis No.(1: S-Axis, 2:H-Axis,3:V-Axis,4: R2-Axis, 5:B-Axis,6:R1-Axis)
For COMPONENT "H"(1: CNR10A, 2:CNR20A,3:CNR20B,4:CNR30A)
COMPONENT (MB:Motor/Brake, E:Encoder, L:Limit switch, H:Application Connector)
JUNCTION PART(J1:BJ1, J2:BJ2, J3:BJ3)
ROBOT TYPE
Fig 5.1 Explains of internal wiring
5-20
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5. Maintenance
Fig 5.2 Wiring connection diagram : [HX300/400/200L/200L-2000/300L]
5-21
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6
Trobleshooting
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6. Trobleshooting
HX200/HX200L-2000/HX300/HX300L/HX400
6.1. Troubleshooting Procedure
If a failure occurs during robot's operation, but it does not stem from the controller, it
must be caused by damage on machine parts. The way to troubleshoot as quick and
easy as possible should be to diagnose the problem. In addition, it is necessary to
determine which parts cause the problem.
(1) Step 1 : Which axis occurs the problem?
First of all, check which axis causes the malfunction. In case that it is hard to
detect the problem, check the following possible mechanical defaults.
ꢁ Is there any parts making noise?
ꢁ Is there any parts generating an overheating?
ꢁ Is there any parts have a play or backlash?
(2) Step 2 : Which parts have been damaged?
If the abnormal axes are determined, investigate which parts cause trouble.
There could be many causes for one phenomenon. Refer to [Table 6-1] for
the cause and phenomenon of the trouble.
(3) Step 3 : Dealing with malfunction parts
If the malfunction parts are confirmed, conduct relevant repair procedure
based on the chapter 『6.3 Diagnostics and Resolutions for Major Parts
Failure』. Contact our service office if you have any difficulties in dealing with
problems.
6-2
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6. Trobleshooting
6.2. Trouble Symptoms and Possible Causes
As shown in [table 6-1], there may be many parts as the cause of one phenomenon.
Refer to next page to determine which part is malfunction.
Table 6-1 Trouble phenomenon and cause
Defect parts
Reduction
gear
Fulcrum
bearing
Brake
Motor
Encoder
Trouble phenomenon
Overload
[Note1]
○
○
○
○
○
○
○
○
○
○
○
○
Displacement
○
Abnormal sound occurrence
○
○
○
○
○
Noise in operation
Staggering at stop
Irregular twitching
Abnormal deviation
Free fall of an axis
Overheating
[Note 2]
[Note 3]
[Note 4]
○
○
○
○
○
○
○
○
○
○
○
Incorrect action and out of
controll movement
[Note 1] Overload --------- Phenomenon occurring when a load exceeds the rated
motor load. In specific, thermal relay of circuit protector
is tripped.
[Note 2] Noise in operation -- Phenomenon which occurs vibration on operation.
[Note 3] Staggering at stop - Phenomenon which gives oscillating motion when the
robot stops.
[Note 4] Irregular twitching --- Phenomenon which gives sporadic twitching when the
robot is not in motion.
6-3
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HX200/HX200L-2000/HX300/HX300L/HX400
6.3. Diagnostics and Resolutions for Major Parts Failure
6.3.1. Fulcrum Bearings
Vibration, abnormal sound and overloads are observed when a fulcrum bearing is
damaged. When the Nut holding bearings becomes loose, bearing play occurs. It
may damage the bearings.
ꢀ Diagnostics
① Shake the 1st ARM and 2nd ARM back and forth to check if bearing
exhibits any play. (In case of using a chain block, check the bearings for
the play, with the 1st ARM and 2nd ARM posture maintaining and without
any overload to the reduction gear.
② Check to see if the robot touched other peripheral equipment before the
malfunction.
ꢀ Resolution
① Replace the bearing. A Chain Block is needed to lift and hang the robot
ARM. Contact our service office for any difficulties..
6-4
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6. Trobleshooting
6.3.2. Reduction Gear
Vibration and abnormal sound will be occurred when a reduction gear is damaged. In
this case, it causes overload and abnormal deviation disturbing normal operation.
Sometimes overheating may result. The robot may also become completely
immovable, or a position offset error may occur.
[Main Axes (S, H, V)]
When turning [ON][OFF] the brake release switch of axis H and axis V, be sure to
take necessary precautions to prevent the ARM from dropping, and then switch the
brake release [ON][OFF]..
ꢀ Diagnostics
① Check out any vibration, abnormal sound or overheating of the reduction
gear when the robot is in operation.
② Check out any play and abrasion in the reduction gear. And check if any
abnormality is felt by hand when shaking 1st ARM back and forth with the
brake release switch of axis S [ON].
③ Check if peripheral equipment has been contacted with the robot before
the abnormality.
(Damage may occur to the reduction gear due to the contacting impact.)
ꢀ Resolution
① Replace the reduction gear. A chain block is needed to lift and hang the
robot ARM. Contact our service office for any difficulties.
[Wrist Axes (R2, B, R1)]
When turning [ON][OFF] the brake release switch, be sure to take necessary
precautions to prevent the ARM from dropping, and then switch the brake release
[ON][OFF].
ꢀ Diagnostics
① Check out any vibration, abnormal sound, or overheating of the reduction
gear when the robot is in operation.
② Check out any play in the reduction gear by shaking the End Effector
(such as spot gun and hand devices, etc.) back and forth.
③ Turn motors off , with the brake release switch [ON], and check that the
axis can be rotated by hand. If not, the reduction gear is in bad condition.
④ Check if peripheral equipment has been contacted with the robot before
the abnormality.
(Damage may occur to the reduction gear due to the contacting impact )
6-5
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HX200/HX200L-2000/HX300/HX300L/HX400
ꢀ Resolution
① Replace the reduction gear.
② Replace the entire wrist section.
(The replacement of entire wrist should be a quick and reliable resolution
as it takes time and necessary equipment for reduction gear replacement)
6-6
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6. Trobleshooting
6.3.3. Brakes
In case of brakes failure, each axis possibly drops with the motors [OFF]. Or, in
reverse, brakes possibly operate even with the motors [ON]. The latter causes
overload and noise.
When intending to operate the entire robot without the motors [ON], operate it with
the brake release switch [ON]. Before turning the switch [ON], take necessary
precautions to prevent the ARM from dropping as the robot ARM will drop by gravity.
.
ꢀ Diagnostics
① Check if the brake can be heard in operation, by turning the brake release
switch [ON] [OFF] alternately with the motors[OFF]. If not heard, the vrake
cable may be broken. (When operating the brake release switch
[ON][OFF], be careful of ARM dropping. The brake release switch is
located on the panel in the controller cabinet door.)
ꢀ Resolution
① If cables turn out to be good condition, replace the motor.
6-7
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HX200/HX200L-2000/HX300/HX300L/HX400
6.3.4. Motor
Motor failure causes abnormal operation of robot such as staggering at stop, irregular
twitching and noise in operation. Besides, It may cause overheating and abnormal
sound.
Check the reduction gear and fulcrum bearing as well in order to determine which
part causes the abnormality. It is because that similar phenomenon is observed when
the reduction gear is damaged.
ꢀ Diagnostics
① Check for overheating and abnormal sound. .
ꢀ Resolution
① Replace the motor.
6-8
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6. Trobleshooting
6.3.5. Encoder
Position offset, malfunction, and out of control movement as well as staggering at
stop, irregular twitching may occur when the Encoder is in bad condition. This case
has nothing to do with such phenomena as mechanical abnormal sound, overheating,
and vibration
ꢀ Diagnostics
① Check for any encoder data failure.
② Use reference pins and blocks to check the positional data is correct at
pin position.
③ Check for any irregular variations in the encoder data when moving each
robot axis.
④ Replace the servo amp board, BD440 to check errors.
ꢀ Resolution
① If cabling turns out to be in good condition withouth any damage, replace
the encoder.
② If there is no error after replacing the servo amp board BD440, replace the
servo amp board.
6-9
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HX200/HX200L-2000/HX300/HX300L/HX400
6.4. Motor Replacement
Warning:
When motor is separated, the ARM will drop due to its built-in brakes inside the motor
for holding robot's posture. Take necessary precautions such as fixing A2 FRAME
with 2nd ARM by using M20×250 bolts or lifting and hanging the ARM by using crane
as shown in the Figure in order to prevent such dropping. Do not hold the ARM in
your hand.
In case of contacting the motor right after it stops, ensure the motor temperature.
Motor weights are listed as follows. Be careful when dealing with the motor.
Table 6-2 Motor Weight
Weight of main axes Weight of wrist axes
Robot model
motor
motor
HX300/400/200L/200L-2000/300L
27 kg
10.7 kg
6-10
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6. Trobleshooting
Fig 6.1 How to prevent dropping of ARM Axis H & V
Warning:
In this work, there is a part performed with the motor [ON]. Therefore, perform the
work in pairs. An observer must always be ready to activate an emergency stop. The
other perform the work quickly and carefully. An escape route should be determined
before starting work.
After replacing axis H or V, ensure that M20 bolt for supporting ARM has been
removed before operating the robot.
6-11
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6.4.1. Necessary Tools and Parts
Table 6-3 Necessary Tools
Axis
Tool Name
Part No.(Model)
M12 Torque wrench
Remark
Name
S, H, V
(Lock type)
Use torque wrench
and extension on
the market
Torque wrench
( prepared by user)
M8 Torque wrench (Lock type)
M5 Torque wrench (Lock type)
R2, B, R1
Table 6-4 Necessary parts
Part Name
Axis Name
Use or not Part No.( Model)
main axes ( H, V )
○
-
M20×250(Standard)
-
Dropping preventive bolt
(optional)
Wrist Axis(R2,B,R1)
6-12
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6. Trobleshooting
6.4.2. How to Replace Motor
(1) Put the controller into TEACH mode and select motors [ON]. When the
motors [On] state cannot be obtained, check the respective ARM is firmly
fixed while supporting it to prevent dropping. And then begin at step No.4.
(2) The axis requiring motor replacement takes basic posture.
(3) In case of main axes(S, H, V) : Refer to [Fig 6.1].
Insert a supporting bolt to prevent ARM dropping.
In case of wrist axes (R2, B, R1) : Set the origin by using SACLES.
(4) Turn the main power[OFF] with the controller power [OFF].
(5) Disconnect the connector from the motor.
(6) Remove attachment bolts of motor and pull the motor out of robot. When
removing motors of axis H or V, be sure not to damage the lip of oil seal due
to the gear attached to the axis of motor.
(7) Detach the gear from the motor shaft. not give excessive impact to the motor
shaft.
(8) Assemble the gear after lightly applying grease to the shaft.
The bolt used to attach the gear to the shaft should be cleaned and removed
of grease before using. Apply loctite 243 to the screw part of the bolt, and
then tighten it using a torque wrench in a regular torque. , Besides, slowly
tighten the bolt in a symmetrical order.
(9) Assemble the motor on the robot after applying a small amount of grease to
the lip of oil seal and applying a moderate amount of grease to the teeth of
gear. When assembly the main axis motor, be sure not to damage the lip of
oil seal.
(10) Connect the connector to the motor.
(11) When repalcing the axis H or V, replenish the grease as the amount as it
lost.
(12) Reset the encoder of the axis whose motor is replaced.
6-13
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Warning
Before encoder correction, check motor connections, with motors [ON], while
pressing the Enable switch for 2~3 seconds.
(13) Perform the encoder calibration about the axis whose motor is replaced.
Refer to the chapter [Encoder Calibration] in the controller operating
manual..
(14) Remove M20 bolt, a supporting bolt for preventing possible dropping of axis
H or V.
(15) Confirm that there is no error in robot's motion.
6-14
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6. Trobleshooting
6.5. Encoder Zero Setting
It is necessary to reset the origin when encoder data has been corrupted due to
some problems and when the motor is replaced.
Level and Block is adopted as the position setting method for each axis. The origin
must be set in order of axis 4, 5, and 6 considering axis interference of the wrist due
to its structural characteristic.
Warning
In this work, there is a part performing in the state of motor [ON]. Therefore, this
work must be performed in pairs. One must always be ready to activate an
emergency stop. The other must perform the work quickly but carefully.
An escape route should be determined before starting work.
6-15
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HX200/HX200L-2000/HX300/HX300L/HX400
6.5.1. Zero Setting
① Put the controller into TEACH mode and select [MOTORS ON]. If you cannot
select MOTOR On due to abnormality, set the origin position of the robot by
using the brake release switch.
② Move respective axes to the basic posture, then set them by the scale mark.
③ Reset the Encoder. Refer to 『6.5.2 Encoder Reset』for the method of
encoder reset.
④ Correct the encoder. Refer to 『Hi4a Controller Operation Manual』.
⑤ Confirm that there is no problem in robot motion.
6-16
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6. Trobleshooting
6.5.2. Encoder Reset
① Turn the controller power [ON] for 3 minutes, and then turn it [OFF].
② Take off the rear cover of the robot. (Check the batteries/encoder backup
batteries are well conneceted.)
③ Turn the controller power [ON].
④ After connecting the reset connector(CNRST1∼6) of the axis to reset with the
plug located in the cover of the rear robot for 5 seconds, pull the reset plug
out. (Reset connectors of the respective axis should be connected for the
reset work only. Besides, there is usually no connection in the reset
connector.
⑤ Cover the rear of the robot.
Table 6-5 Reset connectors corresponding to axes
Axis NameConnectin of Reset connector pin [CNRST1 ↔ RESET CONNECTOR]
S
H
RST1 ↔ RST(1), P5E ↔ RST(2)
RST2 ↔ RST(1), P5E ↔ RST(2)
RST3 ↔ RST(1), P5E ↔ RST(2)
RST4 ↔ RST(1), P5E ↔ RST(2)
RST5 ↔ RST(1), P5E ↔ RST(2)
RST6 ↔ RST(1), P5E ↔ RST(2)
V
R2
B
R1
6-17
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HX200/HX200L-2000/HX300/HX300L/HX400
Fig 6.2 Encoder Reset Connector
6-18
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6. Trobleshooting
6.5.3. Confirming the Reset
Warning
This operation is used to verify an encoder reset was performed correctly. Note this
procedure is different from『Encoder Calibration』which determines encoder data
from basic posture of the robot.
The number of pulses per revolution of the currently used encoder data is 8192bit
irrespective of the robot model. The current value of encoder displays what is added
by compensation value to the actual encoder value. In other word, the difference
between the current value of encoder and the absolute compensation value of
encoder is real encoder value.
After reset, the actual encoder value is classified as what it becomes less than 1
revolution and as what it becomes less than minus 1 revolution depending on the
robot model. Follow the procedure below to confirm the encoder has been
successfully reset.
① Connect the encoder connectors of motors and turn controller power on.
Select 『Encoder Calibration』in a constant setting mode, and select
『Encoder Calibration (Data Input)』at the next display. The encoder
calibration value for each axis is displayed in left-side and the present
encoder value in right-side.
② Move the cursor to the encoder calibration value of axis that were reset, and
press 『0』.
③ Confirm that the present encoder value is within the range of 0~8192. If not,
reset the encoder again.
Warning
After connecting the motor, the following errors may occur according to the discharge
of electricity of the encoder internal capacitor.
ꢁ E0107 Encoder error: Poor bit sequence
ꢁ W1014
: Voltage drop of encoder battery.
In this case, turn controller power on for more than 10 minutes, and reset encoder.
And then, turn controller power 『OFF』once again, and power 『ON』. It will be
restored to normal condition.
6-19
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HX200/HX200L-2000/HX300/HX300L/HX400
6.5.4. Encoder Calibration(Data input) and Selection
ꢁ IT is necessary to compensate encoder data for the basic position of each
axis.
ꢁ Refer to 『Encoder calibration』in the Controller Manual for details.
ꢁ Select 『Encoder calibration (Position Rec)』in the mode of Constant.
[Encoder Calibration Screen]
08:09:05 *** Encoder offset *** A:0 S:3
S =［00400000］ S =［00400000］ ［ 0.0］
H =［00400000］ H =［00400000］ ［ 90.0］
V =［00400000］ V =［00400000］ ［ 0.0］
R2=［00400000］ R2=［00400000］ ［ 0.0］
Use Arrow key and press [SET].
>
All Comp
Complete
Table 6-6 Data range after resetting
Number of pulses
per an encoder revolution
Axis
Data range after resetting
All of Axes
0 ~8191
8192
(1) Press [SET] key after moving the revolving bar into the desired location to set
by using [↓][↑] keys, and the following message is displayed.
After axis Oper, press [REC].[ESC]usable
>
(2) Move the robot to the position that the origin pin becomes [ON] with axis
operating button, and press [REC] key.
(3) Press 『[PF5]: Complete』to complete setting.
Warning
In case of encoder DATA compensation after replacing motor, check if the motor
power is on with the power 『ON』.
6-20
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7
Recommended
Spare Parts
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HX200/HX200L-2000/HX300/HX300L/HX400
7. Recommended Spare Parts
The recommended spare parts for robot are as follows. Please check robot serial
number and manufacturing date when purchasing, and contact our serive office.
[Category]
A : Regular maintenance parts(what is replaced regularly)
B : Essential spare parts (what is of high frequency)
C : Essential component parts
D: Machine parts
Table 7-1 Spare Parts ListⅠ
Manufacturer
Specification
HHI
Per Unit
Category Part Name
Applicable Model
Application
Use Rec.
Common
use for
Axis S, H,
and V
AC servo
motor
B
3EA 1EA
3EA 1EA
3EA 1EA
1EA 1EA
1EA 1EA
1EA 1EA
1EA 1EA
HX300/400/200L
/200L-2000
R15-211007-00
HHI
Common
use for
Axis S, H,
and V
AC servo
motor
B
R15-331007-00
HHI
HX300L
Common
use for
Axis R2,
B, and R1
AC servo
motor
B
HX300/400/200L
/200L-2000/300L
R13-212051-00
HHI
RV
C
C
C
C
Reduction
gear
Axis S
Axis H
Axis V
Axis V
HX300/400/200L
/200L-2000/300L
R13-210101-00
HHI
RV
Reduction
gear
HX300/400/200L
/200L-2000/300L
R13-21108H-00
HHI
RV
Reduction
gear
HX300/400/200L
/200L-2000
R13-21108V-00
RV
Reduction
gear
R13-33108V-00
HX300L
7-2
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7. Recommended Spare Parts
Manufacturer
Specification
HHI
Per Unit
Category Part Name
Applicable Model
Application
Use Rec.
RV
C
C
C
C
C
C
C
C
Reduction
gear
1EA 1EA Axis R2
R13-212052-00
HHI
HX300/400/300L
HX300/300L
HX400
RV
Reduction
gear
1EA 1EA
1EA 1EA
Axis B
Axis B
R13-213101-00
HHI
RV
Reduction
gear
R13-223101-00
HHI
RV
Reduction
gear
1EA 1EA Axis R1
1EA 1EA Axis R1
1EA 1EA Axis R2
R13-213102-00
HX300/300L
HX400
RV
Reduction
gear
R13-223102-00
HHI
RV
Reduction
gear
R13-232052-00
HHI
HX200/200L
HX200/200L
HX200/200L
RV
Reduction
gear
1EA 1EA
Axis B
R13-233101-00
HHI
RV
Reduction
gear
1EA 1EA Axis R1
R13-233102-00
7-3
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HX200/HX200L-2000/HX300/HX300L/HX400
Table 7-2 Spare Parts ListⅡ
Manufacturer
Per Unit
Caterogy Part Name
Applicable Model
Application
Specification
Use Rec.
Teijin seiki
HX300/400/200L
/200L-2000/300L
16kg
/CAN
S,H,V axis
reduction gear
A
A
A
C
C
C
C
Grease
Grease
Moly white RE00
Shell
R2,B,R1 axis
reduction grear
Gear and
Bearing of each
axis
HX300/400/200L
/200L-2000/300L
16kg
/CAN
Alvania 0769
HHI
Encoder
Battery
Replace every 2
years,
regardless of
operating hours
HX300/400/200L
/200L-2000/300L
3EA
1EA
1EA
1EA
1EA
3EA
1EA
1EA
1EA
1EA
HX300-LB*-
A,*:1~6
HHI
Wrist ass'y
Wrist ass'y
R12-217013-00
HHI
HX300/400/300L
HX200/200L
R12-237014-00
Axis S
Wiring
ASS’Y
Cable from BJ1
to main axis
motor and
right/left side of
robot
HX300/400/200L
/200L-2000/300L
HX300-J2-A
Axis A2
Wiring
ASS’Y
Cable from
right/left side of
robot to each
wrist axis motor
HX300/400/200L
/200L-2000/300L
HX300-J3-A
7-4
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7. Recommended Spare Parts
Table 7-3 Spare Parts List Ⅲ
Manufacturer
Per Unit
CategoryPart Name
Applicable Model
Application
Use Rec.
Specification
HHI
R15-211011-00
HHI
Taper
Roller
Bearing
Support center
2 EA 2EA
D
D
D
D
D
D
D
D
D
D
shaft in A2
HX300/400/200L
/200L-2000/300L
Joint lower and
Taper
Bearing
4 EA 4EA
2 EA 2EA
4 EA 4EA
2 EA 2EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
2 EA 2EA
upper Link of
axis V in A2
HX300/400/200L
/200L-2000/300L
R15-211041-00
HHI
Taper
Bearing
Joint upper
ARM in A2
HX300/400/200L
/200L-2000/300L
R15-211201-00
HHI
Double
Row
Roller
Bearing
Support lower
balance spring
in A2
HX300/400/200L
/200L-2000/300L
R15-211034-00
HHI
shperical
Roller
bearing
Support upper
balance spring
in A2
HX300/400/200L
/200L-2000/300L
R15-211035-00
HHI
Wrist holder
cast-iron
(holder) in W1
Oil-Seal
Oil-Seal
Oil-Seal
Oil-Seal
V-ring
R15-213181-00
HHI
HX300/400/300L
HX200/200L
Wrist holder
cast-iron
(holder) in W1
R15-233171-00
HHI
Center shaft in
A2
HX300/400/200L
/200L-2000/300L
R15-211017-00
HHI
Motor Base in
S1
HX300/400/200L
/200L-2000/300L
R15-210104-00
HHI
Upper shaft of
upper ARM in
A2
HX300/400/200L
/200L-2000/300L
R15-211205-00
7-5
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HX200/HX200L-2000/HX300/HX300L/HX400
Table 7-4 Spare Parts List Ⅳ
Part Name Manufacturer
Per Unit
Applicable
Model
Category
Application
Specificatio
n
Dwg. No.
Use Rec.
HHI
Case surface of
axis B reduction
gear
D
D
D
D
D
D
D
D
D
D
D
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
1 EA 1EA
R15-213091-00 HX300/400/300L
HHI
Case surface of
axis R1 reduction
gear
1 EA 1EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
1 EA 1EA
R13-213092-00 HX300/400/300L
HHI
Bearing housing in
W1
R13-213092-00 HX300/400/300L
HHI
Case surface of
axis B reduction
gear
R15-233117-00
HHI
HX200/200L
HX200/200L
HX200/200L
Case surface of
axis R1 reduction
gear
R15-233176-00
HHI
Bearing housing in
W1
R15-233175-00
HHI
Assemble surface
of frame and pipe
in A1
HX300/400/200L
/200L-2000/300L
R15-212072-00
HHI
Case of Axis R2
reduction gear in
A1
R15-212075-00 HX300/400/300L
HHI
Case of Axis R2
reduction gear in
A1
R15-232075-00
HHI
HX200/200L
Case of Axis H and
2 EA 2EA V reduction gear in
A2
HX300/400/200L
/200L-2000/300L
R15-211013-00
HHI
2 EA 2EA
Motor Base in A2
HX300/400/200L
/200L-2000/300L
R15-211020-00
7-6
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7. Recommended Spare Parts
Table 7-5 Spare Parts List Ⅴ
Part Name Manufacturer
Per Unit
Category
Applicable Model
Application
Use Rec.
Specification
Dwg. No.
HHI
V axis reduction
D
O-ring
2EA
2EA
1EA
1EA
2EA
1EA
1EA
1EA
2EA
2EA
1EA
1EA
2EA
1EA
1EA
1EA
gear output
outlet
HX300/400/200L
/200L-2000/300L
R15-211021-00
HHI
Balance spring
ASS’Y in A2
D
D
D
D
D
D
D
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
HX300/400/200L
/200L-2000/300L
R13-211022-00
HHI
A2 part between
upper arm and
collar
HX300/400/200L
/200L-2000/300L
R13-211027-00
HHI
Assemble
surface of
reduction gear
shaft and base
body in S1
HX300/400/200L
/200L-2000/300L
R15-210108-00
HHI
Axis S1
reduction gear
case and output
shaft
HX300/400/200L
/200L-2000/300L
R15-210114-00
HHI
Assemble
surface of
reduction gear
shaft and base
body in S1
HX300/400/200L
/200L-2000/300L
R15-210115-00
HHI
S1 part between
reduction gear
shaft and
HX300/400/200L
/200L-2000/300L
R15-211116-00
HHI
reduction gear
S1 motor base
and motor
assemble
surface
HX300/400/200L
/200L-2000/300L
R15-210110-00
7-7
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8
Internal
Wiring
Diagram
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HX200/HX200L-2000/HX300/HX300L/HX400
8. Internal Wiring Diagram
Internal wiring is shown in a connection diagram per unit, and thus utilize it to inspect
and replace the wiring.
8.1. Manipulator Configuration
Fig 8.1 Manipulator Configuration
8-2
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8. Internal Wiring Diagram
8.2. Wiring Diagram
3 A B
2 A B
1 A B
3 S T
S T
B M
Fig 8.2 Motor and Brake wiring connection No.1
8-3
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HX200/HX200L-2000/HX300/HX300L/HX400
3 A B
2 A B
1 A B
3 S T
S T
B P
Fig 8.3 Motor and Brake wiring connection No.2
8-4
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8. Internal Wiring Diagram
Fig 8.4 Encoder wiring Connection No.1
8-5
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HX200/HX200L-2000/HX300/HX300L/HX400
Fig 8.5 Encoder Wiring Connection No.2
8-6
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8. Internal Wiring Diagram
Fig 8.6 Encoder Wiring Connection No.3
8-7
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HX200/HX200L-2000/HX300/HX300L/HX400
Fig 8.7 Application Wiring Connection No.1
8-8
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8. Internal Wiring Diagram
Fig 8.8 Application Wiring Connection No.2
8-9
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9
Decommissioning
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HX200/HX200L-2000/HX300/HX300L/HX400
9. Decommissioning
The robot is made up of several materials as shown in [Table 9-1]. Some of them
should be properly arranged and sealed up to eliminate any bad influence on the
human body or environment.
Table 9-1 Materials of each part
Parts
Battery
Materials
NiCad or Lithium
Copper
Wiring, Motor
Base body, A2 frame, Upper arm, Link, Hinge etc.
A1 pipe
Cast Iron
Steel
Brakes, Motors
Samarium Cobalt(or Neodymium)
Plastic / Rubber
Oil / Grease
Wiring, Connectors
Reduction gears, Bearings
Wrist cover etc.
Aluminum alloy cast
9-2
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ꢃ Head Office
1, Jeonha-Dong, Dong-Gu, Ulsan, Korea
TEL : 82-52-230-7901 Ex 11 / FAX : 82-52-230-7900
ꢃ Seoul Office
140-2, Gye-Dong, Jongno-Gu, Seoul, Korea
TEL : 82-2-746-4711 Ex 5 / FAX : 82-2-746-4720
ꢃ Suwon Office
537-3, Yeongdeok-Ri, Giheung-Eup, Yongin-Si, Kyenggi-Do, Korea
TEL : 82-31-205-4713 / FAX : 82-31-205-3200
ꢃ Daegu Office
223-5, Bumeo 2-Dong, Susung-Gu, Daegu, Korea
TEL : 82-53-746-6232 Ex 3 / FAX : 82-53-746-6231
ꢃ Cheonan Office
355-15, Daga-Dong, Cheonan, Chungnam, Korea
TEL : 82-41-576-4294 Ex 5 / FAX : 82-41-576-4296
ꢃ Gwangju Office
415-2, Nongsung-Dong, Seo-Gu, Gwangju, Korea
TEL : 82-62-363-5272 / FAX : 82-62-363-5273
ꢃ 본사
울산광역시 동구 전하동 1 번지
TEL : 052-230-7901~11 / FAX : 052-230-7900
ꢃ 서울 사무소
서울특별시 종로구 계동 140-2 번지
TEL: 02-746-4711~5 / FAX : 02-746-4720
ꢃ 수원 사무소
경기도 용인시 기흥읍 영덕리 537-3 번지
TEL: 031-205-4713 / FAX : 031-205-3200
ꢃ 대구 사무소
대구광역시 수성구 범어 2 동 223-5 번지
TEL : 053-746-6232~3 / FAX : 053-746-6231
ꢃ 천안 사무소
충남 천안시 다가동 355-15 번지
TEL : 041-576-4294~5 / FAX : 041-576-4296
ꢃ 광주 사무소
광주광역시 서구 농성동 415-2 번지
TEL : 062-363-5272 / FAX : 062-363-5273
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