Okura Yusoki Co., Ltd.

Robot Manual

Safety

JIS-SAF-L1

JIS(L1)

Updating history

Version (Date)

Content Page

L1 (2009.10.26) Newly released

L1（2010.09.03）

Addition of Updating history Reconstruction of a chapter Addition of a model AP30 Date update

This page TOC 2-3,2-5 Last page

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Introduction Thank you for purchasing a model from the Okura Robot Palletizer A series. This manual is a guidebook to help you safely and correctly use your A Series Robot

Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to reconfirm their knowledge. Please read this Manual carefully and use the Palletizer with a clear understanding of its content.

Definition of Operator

ONLY QUALIFIED SERVICE PERSONNEL MAY INSTALL OR SERVICE THE ROBOT SYSTEM. ENSURE COMPLIANCE WITH ALL LOCAL AND NATIONAL SAFETY AND ELECTRICAL CODES FOR THE INSTALLATION AND OPERATION OF THE ROBOT SYSTEM.

Important! Definition of operator: Only AUTHORIZED PERSONNEL can operate the robot. The definition of “AUTHORIZED PERSON” is described below: The only personnel that can operate the robot and/or robot system, are those who have enough knowledge or experience of robot operation and have also been trained to operate the robot. They must also have been authorized by the employer.

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Safety Instructions

Be sure to the following safety instructions are read, understood and become a part of daily practice when operating or maintaining Okura equipment. Help prevent personal injury and/or property damage.

1. Do not attempt to operate any machine until you understand how it functions. If you are not certain after studying the manual, contact your local Okura office or the Agent for assistance.

2. Never operate the machine unless all guards are in place and do not attempt to make any protective device inoperative.

3. Never start a machine until you are certain that all personnel and foreign objects are clear.

4. In cases where a machine cycles automatically, be sure everyone is aware of the automatic cycling.

5. Check all protective switches and other protective devices daily to make sure they operate.

6. Never perform maintenance or repair work until you are sure the power is turned off at the main control panel and cannot be turned back on without your knowledge. Use protective key switch.

7. Do not operate or perform maintenance or repair on a machine when taking any kind of drug, sedative or when under the influence of alcohol or overly fatigued.

8. Never reach into moving parts to clear a jam of any type.

9. Do not wear loose clothing or jewelry of any kind which could get caught in moving parts.

10. Keep the floor around the machine clean and free of obstructions and water. If water is necessary at the machine, be sure to wear shoes that do not slip on wet floors.

11. Always wear safety protective equipment in areas that require them.

12. Pay strict attention to all caution, warning, and danger signs.

13. Always use Okura recommended spare parts. Special grade bolts should be replaced with special grade bolts. Learn the standard bolt grading system. Always replace expansion bearings with expansion bearing, etc.

14. Do not enter the guarded area when the robot is in operation or in automatic mode.

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ALWAYS PRACTICE SAFETY, if in doubt, check it out first. Each A Series Robotic Palletizer is equipped with a variety of protective features. However, an increased level of safety results when these safety precautions are constantly reviewed and consistently followed. Daily maintenance or programming tasks (pallet or sheet placement) may require personnel to be in the robot’s proximity while power is available to it. This always involves some level of risk. Okura’s robot palletizer is designed and sold as a stand alone system. However, it interacts with other machines and equipment, and may be controlled by signals from multiple sources.

From a practical standpoint, the ultimate responsibility for safeguarding employees who work with robots lies with the users themselves. The words “safe” and “safety” are not absolutes. A safe system is one that is well maintained and used as intended. Equally important are well-trained personnel with a safety conscious attitude.

Customer Safety Responsibility

Risk Assessment

Each system is operated under unique conditions. It is ultimately the customer’s responsibility to determine if the supplied robot/machinery/equipment is safe to use. The customer must perform his own risk assessment to evaluate the safety issues that impact his operation. A risk assessment shall consider, but is not limited to:

1) The size, capacity, and speed of the robot and associated equipment 2) The anticipated tasks that will be required for continued operation 3) The anticipated failure modes 4) The hazards perceived by the customer and its employees during

these tasks and anticipated failure modes 5) The probability of the hazard occurring

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6) The probable frequency for these hazards 7) The probable severity of injury if the hazards actually occurred 8) Any areas of noncompliance 9) The level of expertise of exposed personnel

Training Requirements Training shall be taking by Okura (Okura Yusoki and Okura Group) at the initial use. The owner of an A series robot shall ensure that any person who programs, teaches, operates maintains, or repairs robots or robot systems is trained and demonstrates the competence to safely perform assigned tasks. (Competency may be established through formal training, on-the-job training, or a combination of both.) Training Program Content Training appropriate to each assigned task should include, but not be limited to:

1) A review of applicable industry safety procedures 2) A review of applicable robot vendor safety recommendations 3) An explanation of the purpose of the robot system and its operation 4) An explanation of the specific tasks and responsibilities for each

person 5) A list (by name, location, and phone number) of contacts to call

when current circumstances exceed the ability and/or responsibility levels of the trainee.

6) Identification of the recognized hazards associated with each task 7) Identification of, and appropriate responses to unusual operating

conditions 8) An explanation of the functions, limitations and design

characteristics of all system protective guards. 9) A procedure for performing functionality tests or otherwise ensuring

proper functioning of protective devices. 10)A procedure for the release of braking device.

Retraining Requirements Personnel should be retrained in the event of operating system changes, or whenever there is reason to believe that additional training is required.

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Guarding Types

Protective guards supplied with the robot/equipment/machinery are designed to provide protective operation and to reduce the possibility of personal injury and/or machine damage. It is absolutely essential to keep all shields, guards and protective devices in place before, during and after machine operation. If a shield, guard or protective device has been removed for any purpose, or is damaged or missing, it must be repaired or replaced BEFORE beginning any robot/equipment/machine operation. The following guidelines and descriptions will familiarize affected and authorized personnel with the purpose and design of protective devices. Additional or special guarding should be in accordance with acceptable customer specifications.

SAFEGUARDING MAY INCLUDE, BUT NOT BE LIMITED TO, PRESENCE-SENSING DEVICES, BARRIERS, AWARENESS BARRIERS, AWARENESS SIGNALS, SIGNAGE, DESIGNATED PROCEDURES AND TRAINING.

Fixed Enclosure/Perimeter Fencing/Barrier Guards

1) Provided to keep operating/maintenance personnel from areas of potential danger during machine operation.

2) This type of guard is fastened to the machine or floor and requires tool(s) for removal and replacement. Never alter the guard to allow entry without the use of a tool.

3) Not normally opened or removed except to perform maintenance or repair. Proper lockout procedures must be observed during time of removal.

4) Lockout/Tagout procedures must be observed when access to area is necessary and must be in accordance with federal regulations.

Adjustable Barrier/Gate Guard/Access Door

1) Located at point of operation or where work is being performed. 2) Provided to keep operating/maintenance personnel from areas of

potential danger during machine operation. 3) Remains in place through positive connectors. Can be opened

without a tool. 4) Engages the Emergency Stop Circuit when opened. Never defeat

the function of this interlock circuit. 5) Lockout/Tagout procedures must be observed when access to area

is necessary and must be in accordance with federal regulations. Belt/Pulleys, Chain/Sprockets, Gear Guards

1) Permanent, but with removable mounting. 2) Guarded in accordance with federal regulations 3) These guards must remain in place and should only be removed for

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maintenance purposes after locking-out the machine 4) Lockout/Tagout procedures must be observed when access to area

is necessary and must be in accordance with federal regulations.

Protective Disconnects

1) Main Breaker located on panel-interrupts all electrical power to

machine for lockout capability. 2) Central air distribution filter/regulator/on-off located on the

machine-interrupts all supply pneumatic power to machine for lockout capability.

Protective Signs/Labels

Example of Label (Many Variations)

1) Located on and around various components included with the robotic machinery. They highlight specific safety concerns. These signs and labels vary in format and design.

2) Operators must become familiar with the location and meanings of the signs and labels.

3) These signs and labels must remain in place. If damaged or removed along with damaged equipment, they must be replaced by the customer.

Conclusion

The preceding text presents comprehensive protective information and procedures for using the robot/equipment/machinery. Operation and maintenance personnel must use extreme caution when installing, inspecting, operating, repairing, and maintaining this equipment. DO NOT attempt these functions without first initiating the protective procedures stated in this text. Keep in mind that as administrators, operators and maintenance personnel, you have direct safety responsibility for your fellow employees. All affected co-workers must receive safety training specific to this equipment. Each affected co-worker must know where the operating and emergency stop controls are located, which machine areas are potentially unsafe, and how to work safely around the machine. New personnel should immediately be briefed on established plant safety practices. Both affected and authorized personnel should set a good example for other employees by following these practices. In conclusion, it is each employer’s responsibility to implement federal and state plant and safety procedures, and ensure that safe operating practices are followed when operating and maintaining this machinery. A brief overview of the federally

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mandated “Control of Hazardous Energy Sources - Lockout/Tagout Program”, 29 CFR 1910.147, has been included in the appendix for reference. This information is only a guide to Lockout/Tagout procedures, and is not intended as a complete program regarding your plant’s individual needs and requirements. For federal regulation assistance, contact the regional offices of the Occupational Safety and Health Administration, and affiliated state agencies in your area.

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Safety Instructions GENERAL NOTICE

1. In this description of general rules for protective measure, the specific countermeasure for safety required for the use of Robot is discussed, and general matters for safety are not described.

2. The user of the robot must take protective measures for robot operation to prevent the accident by considering actual line structure or peripheral equipment. Appropriate countermeasure must be taken such as instruction of safety for users, or generation of operation standard.

3. The robot must not be used for application works other than defined in the specification (Carrying weight, speed, operation range, or environment of use.)

4. Refer to the following texts before operation in order to prevent the accident during operation. (1) Operation Manual

5. A watchman must be present at trial runs or operation time in order to check operation procedure or for emergency stop if an accident happens.

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Safety Instructions ACTIVATION

1. Activation must be made by personnel who have been authorized by the employer.

2. Activation must be made after checking if the guarded area is clear of personnel.

3. Activation must be made by the defined activation switch. (Reconstruction is prohibited.)

4. At activation time, notice for movement of each section. Activation under the status that the operation can be stopped immediately if any abnormality is found.

5. To avoid unexpected activation by the outsider, the door or cover of the control panel or operation panel must be shut at all times.

6. While the power is supplied, electrical connection section(PBC, or connector) must not be interfered with.

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Safety Instructions PROGRAMMING (TEACHING)

1. Both teaching performer and the watchman must be authorized by the employer.

2. Check all protective devices before any teaching is performed.

3. The watchman must stand in front of the control panel or operation panel to check the operation procedure by the teaching performer and to watch the movement of the robot through the protective structure. If the system is in danger of an accident, stop the robot operation immediately.

4. Enter into the guarded area after checking if MODE switch is set to teach mode.

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Safety Instructions Automatic OPERATION

1. Set AUTO mode after the teaching instructor has exited to the outside of the protective structure, and after the watchman and teaching instructor have confirmed each other “change to automatic mode”

2. After teaching, perform the first operation check at low speed (2) with loads, and feed to the next.

3. Check teaching contents by repeating operations in AUTO mode.

4. Careful attention must be paid when the robot is standing in the status of waiting ID No. selection STB signals in automatic operation.

5. Check the movement of the robot after it has been stopped in mid-cycle and the restart.

6. The following cases are failures of the robot, stop the robot operation. (1) The robot moves in the unexpected direction. (2) The robot does not stop at the defined stop position or standby position.

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Safety Instructions MAINTENANCE

1. Maintenance of robots must be performed by authorized personnel

2. Before the user enters into the guarded area, stop the operation of robot and other equipment.

3. Materials which prevent maintenance operation must not be placed around the robot.

4. To avoid unexpected activation by the outsider, the cover or door of control panel must be shut at any time. The motor power switch key on the control panel must be carried by the user.

5. Daily check or check before work must be performed.

6. The maintenance operation that requires lubrication must be performed by moving the robot in teach mode.

7. When the power is “ON”, electrical connections must not be pull out or plugged in.

8. When maintenance operation is finished, checks must be performed by the qualified person other than the maintenance performer. (Double check must be made.)

9. For maintenance operation, do not use parts other than the parts specified by our company, or do not reconstruct parts. Especially, reconstruction of circuit (containing interlock) concerning to the robot control must not be performed. If reconstruction is required, consult our company in advance.

10. “DO NOT TOUCH” board for ensuring the protective measure at maintenance or at teaching is to be provided by client.

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Table of Contents 1. SAFETY PRECAUTION.............................................................1-1

1.1. GENERAL PRECAUTIONS ................................................................... 1-2 1.2. LABEL ........................................................................................... 1-2 1.3. PRECAUTION BEFORE DAILY OPERATION ............................................. 1-3 1.4. PRECAUTION FOR AUTOMATIC OPERATION ........................................... 1-7 1.5. PRECAUTION FOR EMERGENCY ........................................................... 1-8 1.6. PRECAUTION AT END OF OPERATION ................................................. 1-11 1.7. PRECAUTIONS DURING MAINTENANCE............................................... 1-12 1.8. TAG OUT PROCEDURE ..................................................................... 1-13 1.9. LOCK OUT PROCEDURE.................................................................... 1-13 1.10. ACCESS INTO A PROTECTIVE STRUCTURE............................................. 1-14 1.11. ABOUT TEACHING PENDANT ............................................................. 1-15 1.12. CERTIFICATIONS / QUALIFICATIONS................................................. 1-15 1.13. INITIAL TEST ............................................................................... 1-16

2. BASIC SPECIFICATIONS ........................................................2-1

2.1. IDENTIFICATION OF EACH PART OF THE MAIN UNIT ............................... 2-2 2.2. TABLE OF BASIC SPECIFICATIONS....................................................... 2-4

3. OVERVIEW OF EQUIPMENT....................................................3-1

3.1. CONTROLLER APPEARANCE................................................................ 3-2 3.2. TEACHING PENDANT (INSTALLATION PERSONNEL ONLY) ........................ 3-5 3.3. TABLE OF BASIC SPECIFICATION ........................................................ 3-6

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1.Safety Precaution Each A Series Robotic Palletizer is equipped with a variety of protective features. However, an increased level of safety results when these safety precautions are constantly reviewed and consistently followed.

Definition of operator

Only AUTHORIZED PERSONNEL can operate the robot. The definition of “AUTHORIZED PERSON” is described below: The only personnel that can operate the robot and/or robot system, are those who have enough knowledge or experience of robot operation and have also been trained to operate the robot. They must also have been authorized by the employer.

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1.1. General Precautions

1) A series Robot Palletizer is for indoor palletizing or depalletizing use only. Do not use this for any other use such as underwater, digging, construction, welding.

2) Read the entire Manual. Thoroughly review Manual and Automatic Operation sections for critical step by step, start-up, and shutdown procedures.

3) Do not operate the machine when you do not feel normal, due to illness, exhaustion, medication, distraction, etc..

4) Never operate the system without wearing safe work clothes.

5) Always keep the area around the machine clean and free of dust, foreign matter, etc.. When cleaning agents are used, wear shoes that will not slip.

6) Two or more operators, working on, at, around, or in the same general vicinity at the same time, must maintain contact to avoid potential danger.

7) Do not touch the inside of the controller unless absolutely required for repairs or maintenance.

1.2. Label The following labels are attached on robot or controller for warning the existence of the hazards. Do not take off of change these labels. No. label Meaning 1

High voltage

2

High temperature

Manual

Helmet

Wearing

Shoes

Clean

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1.3. Precaution Before Daily Operation

1.3.1.Precaution Before Daily Operation Check the following items before switching on main power.

1. The robot looks intact, and is not being serviced or repaired.

2. Empty pallets must be placed in the correct position.

3. The robot arm position must be within the normal operating envelope.

4. Compressed air must be supplied at the prescribed pressure and volume, with the prescribed capacity.

5. There are no personnel inside the perimeter guarding, and there are no obstructions in the material conveyance path.

6. Do not use the robot overloaded or over-capacity condition.

7. Check the presence of the grease leakage of the joint of the robot body. Wipe off if the leakage occurs.(*1)

8. Confirm whether grease leaks more than the connector area of the DO axis motor (2 of the robot sides motors). (*2)

*1) Grease leaks as constructional, and the first stage leakage of the bearing it. It wishes that it confirms before it drives and it wipe off because the period of the leakage is different depending on the operation condition.

*2) There is a possibility that grease invades the motor when the grease leakage occurs. It causes the motor breakdown and the danger such as falls of the arm might be caused. Please contact our company or Okura service Ltd. at once when the grease leakage is confirmed.

１

２

３ ４

５

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1

TOUCH PANEL

CE type

1.3.2.Precaution when main breaker ON

Check the following items after turning on the Main power.

1. The main power lamp on the operation panel must be lit.

T O U C H P A N E L

JIS type 1

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1

UL type

2. Initializing starts on the panel display and completed with the message shown below.(It will take 20 seconds to finish initializing)

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3. To initiate Auto mode, press the abnormal reset button. The screen will appear as shown.

Note Pallet quantity shown will vary depending on your system.

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1.4. Precaution for Automatic Operation

1.4.1.Before Automatic operation

1. Visually confirm that all personnel are outside the perimeter guarding.

2. Switch motor Power On and visually confirm that all axes remain still. Press the Emergency Stop button. The Motor Power indicator lamp must go out. (Switch motor power on again after returning the Emergency Stop button to its original position, and press the Reset button.)

3. Move axes in manual operation to assure correct operation. Note: Manual operation speed is controlled to 250mm/sec or less.

1.4.2.During Automatic Operation

1. Absolutely never go inside the perimeter guard during automatic palletizing operations of the robot. Personnel must not be within the robot’s operating envelope during normal product conveyance.

2. During normal operation, authorized personnel will sometimes enter the perimeter guard to fill pallets, place sheets, and to remove dropped or damaged product. To do so safely, stop the robot by pressing the Stop Push-button. When the robot arm has stopped at a suitable position, set the key switch to the OFF position, remove the key, and put it in your pocket BEFORE entering the perimeter guard.

3. Determine the cause of abnormal noise. Repair the problem before operating.

Stay out !

Okay!

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1.5. Precaution for Emergency

1.5.1.Emergency stop

1. If a dangerous situation occurs during operation, and the robot or peripheral equipment must be stopped immediately, press the Emergency Stop Button. (red, mushroom, locking type).

Note The Emergency Stop Button locks if it is pressed. Reset it by turning the

button in the direction of the arrow to release the lock.

2. Never use the emergency stop button for ordinary stopping. Use it only in emergencies.

Note Using the emergency stop on a regular basis creates an unsafe working

environment and shortens the machine service life.

3. If you must enter inside the perimeter guard after an emergency stop, first remove the key from the key switch.

1.5.2.Abnormality handling

1. Abnormalities should be approached with caution. If an abnormality occurs, check for personnel, obstructions, or E-stop activation BEFORE restoring motor power. Abnormalities will create confusion for operators because counter values may change. When abnormalities occur, check the counter values and compare them to the actual work being performed.

Note On the automatic mode menu, the step, layer, and quantity values are for

the next operation cycle.

2. Lightning may cause abnormalities in robot operation. If possible, shut down the robotic palletizer during extreme lightning storms. Counter values will be maintained in memory, but must be checked when restarting.

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1.5.3.Operation without motor power

Each robot arm axis motor brake can be released following the procedure below. If robot servo control system has trouble and need to move robot arm in an emergency situation, follow the procedure below and move robot arm.

【JIS type】 Procedure to release motor brake

1. Turn off the main power supply.

2. Suspend robot arm by crane or other measurements so that it will not move with gravity force.

3. Open controller door and remove the punching metal cover on servo amp.

4. Remove short pin on jumper, which locate on RC105 board.

5. Turn the switch inside the “Use only for Maintenance” cover to “Maintenance” side.

6. Select the axis switch to release motor on RC 105 board and turn it ON (UP)

7. Close controller door and turn on main power supply.

Procedure to return from situation above

1. Turn off the main power supply.

2. Remove the suspend measurement to support arm.

3. Open controller door and turn off (down) axis switch on RC105 board.

4. Set short pin on jumper, which locate on RC105 board.

5. Set punching metal cover on servo amp.

6. Turn the switch inside the “Use only for Maintenance” cover to “Normal operation” side.

7. Close controller door and turn on main power supply.

8. Move robot by manual operation and set in a safety position.

R,T D O

short pin

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O-axis D-axis

【CE,UL type】

Note Two or more personnel are required for this operation.

Brake release button are set on；

(CE type) Inside of Controller

In case of type of No Brake release button (enable button and axis button) in inside of Controller, Follow procedure of 【JIS type】.

(UL type) Front Panel of Controller

Warning label is pasted near Brake release button.

1. Main Power On and Determine the axis you want to operate.

2. If the axis is D or O axis, hang the belt(s) in the position(s) shown in the figure below.

WARNING There is danger of natural fall by gravity if there isn't correct support.

Note: D-axis The direction the arm moves after the brake released is determined by

the robot's posture and the mass of the end effector. Therefore, it is necessary to support two belts by the same length.

Note: O-axis Be careful when the “O” axis is near vertical as it may move in multiple

directions and many swing over center.

3. Push the brake release button (enable button and axis button) on the controller while moving the robot arm.

Note With the brake released the robot should be moved in the desired

direction with a crane.

Warning label for Brake button

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1.6. Precaution at End of Operation

1. For ordinary stopping, refer to the next section “ daily operation”.

2. Ordinary stopping is performed when the station conveyor is empty (pick-up position), and the robot end effector (hand) is “standing by” over the station conveyor.

3. If the system is stopped while the hand is grasping an article, and compressed air is interrupted, the article will fall.

4. If an ordinary stop is performed in the middle of a stacking pattern on a pallet, and the key switch is turned OFF, counter values for the layer (number of layers) and quantity (quantity per layer) are stored in memory. It is possible to continue operation at a later time.

5. Palletize complete loads at the end of the day, to minimize operational problems and reduce the possibility of product damage.

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1.7. Precautions During Maintenance Repairing and cleaning around, on top of, or within the machinery itself can lead to injury or death if maintenance personnel do not absolutely observe the following precautions. During maintenance always follow these precautions to ensure a safe work environment:

1. Place the robot palletizer in manual control, and set the robot palletizer at the desired “at rest” position depending upon the chore to be performed.

2. Lockout the main disconnect switch to turn off power to all the machine motors. After padlocking, the repairman must retain the single padlock key on his person until he has completed the repair. This guarantees that no one will inadvertently unlock the disconnect and start any of the motors.

3. Disconnect, vent, and lockout the pneumatic power supply to the machine. The repairman performing the work must retain the single key to the padlock on his person to prevent inadvertent pressurization of the system. Check for pressurized air that may be trapped in any pneumatic circuit on which maintenance is being performed.

4. Always wear hard hats and safety glasses for cleaning or repair procedures that involve chipping, hammering or cutting.

5. Be especially cautious during manual operation when checking all machinery.

6. Prevent personal injury by following safety rules and exercising good judgment when working on the robot or peripheral equipment.

DANGER LOCK-OUT/TAG-OUT MUST BE PERFORMED DURING MAINTENANCE.

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1.8. Tag out procedure When Tag out procedure is required in a manual, follow the procedures below.

1.8.1.Tag out setting procedure

1. Stop operation of a robot and shut off a motor power supply.

2. Receive the tag of "Under check. Don't touch" from an administrator, and stick on the front of a robot controller.

1.8.2.Tag out release procedure

1. Remove the tag stuck on the front of a robot controller, and pass an administrator

1.9. Lock out procedure When Lock out procedure is required in a manual, follow the procedures below.

1.9.1.Lock out setting procedure

1. Receive a padlock from an administrator.

2. Stop operation of a robot and shut off a motor power supply.

3. Turn the main breaker handle in the front of a robot controller to the left, and make it "OFF."

4. Turn to the left fully, pull out the lock lever in the right end of a handle, and hook it on the base of a handle. A lock lever is fixed now and the hole which lets a padlock pass appears.

5. Pass a padlock to this hole to lock the main breaker handle, and extract and carry a key.

1.9.2.Lockout release procedure

1. Remove a padlock using a key.

2. If the main breaker handle has been turned to the left, a lock lever will be unfixed.

3. Deposit a padlock in an administrator.

The hole which lets a padlock pass

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1.10.Access into a protective structure

1.10.1.Procedure of Entering into a protective structure

In case a robot needs to be moved

1. Switch on the main power supply of controller.

2. Make manual-automatic switch into "manual operation", and extract and carry key.

3. Make motor power supply switch into middle position.

4. Overlook the whole robot system and check that it is normal.

Note -When abnormal, please remove abnormalities safely according to the next In case a robot does not need to be moved and operate it from Procedure 1 again.

5. Carry out the following test of manual operation with teaching pendant. - Motor power supply ON / OFF is possible with an enabling switch. - Each axis moves smoothly.

Note When abnormal, interrupt subsequent work, and please contact the service engineer of our company.

6. Carry out Tag out according to "1.8 Tag out procedure" of this manual.

7. Have teaching pendant.

8. Extract and carry key from the protective structure door switch.

9. Open protective structure door and enter into protective structure.

In case a robot does not need to be moved

1. Carry out Tag out and Lock out according to "1.8 Tag out procedure" and "1.9 lock out procedure" of this manual.

2. Extract and carry a key from the protective structure door switch.

3. Open the protective structure door and enter into the protective structure.

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1.10.2.The procedure coming out of a protective structure

1. Come out of the protective structure after a work end, shut a protective structure door firmly, and implant the key of the protective structure door switch.

2. Cancel Tag out and Lock out according to "1.8 Tag out procedure" and "1.9 lock out procedure" of this manual.

1.11.About teaching pendant

Teaching pendant is not permitted by user operation. Teaching pendant is not connected to controller for daily operation. A teaching pendant is required only for installation when performing manual operation of a robot.

1.12.Certifications / Qualifications

【UL type】 A list of standards that the robot meets and a list of the standards that the robot is third party certified to meet are as below

UL1740, ANSI/RIA 15.06, NFPA79, UL508A, CSA/CAN Z434

【CE type】 ISO10218-1:2006

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1.13.Initial Test Initial test is necessary after change of component parts or addition of equipment as affect the safety functions.

Step No.

content Check Point Reference

1 Installation The Robot system shall be installed to avoid interference with buildings, structures, utilities, other machines and equipment that may create a trapping hazard or pinch points.

1.3.1 Precaution before Daily Operation.

2 Information of Touch Panel

Initial Complete. Error Information.

1.3.2 Precaution when main breaker ON

3 Protective function Confirmation of protective control system performance. （ Interlock of Emergency, Door switch, Light curtain, etc）

1.5 Precaution for Emergency

4 Peripheral I/O Confirmation of I/O Depend on Constructed System

4 Manual Operation Robot position. Axis degree. Axis moving direction.

1.4.1 Before Automatic operation

5 Automatic Operation slow speed by stand alone

Robot moving is avoided interference of structure.

Operation manual

6 Automatic Operation slow speed with peripheral system

Confirmation of system performance.

Depend on Constructed System

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2.Basic Specifications

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Base

Rotor

Lever

Rod

Parallel Link (Lower)

Upper Arm Parallel Link

Lower Arm

T-Axis Flange

Link Lever

Link

2.1. Identification of Each Part of the Main Unit Names of each part of the main unit are as given in the diagram below. 【A400】

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【AP30】

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2.2. Table of Basic Specifications 【A400】

Model A400

Motion Type Vertical, multi-articulated

Load Capacity Max 100 kg

Inertia of Load (At speed

regulated condition)

Max 10.0 kgm2 (Max 30kgm2)

Degree of Freedom

4 Axis

Operating Range

R-axis 330° D-axis 2,300 mm (*) O-axis 1,750 mm (*)

T-axis 440°

Movement Speed

R-axis 70°/s D-axis 1.46 m/s O-axis 0.92 m/s T-axis 202°/s

<Case> 400 C/h <Bag> 350 B/h

Handling Capacity Handling capacity varies depending on conditions like the layout and

hand (i.e. double-grip hands). For details, calculate with “Oxpa-Qm2”.

Accuracy Repeatable position precision ±1 mm

Height Max. 2482 mm

Robot Weight 1200 kg

Noise level 62.1 dB(A)

Distance: 4m Height : 1.5 m

Pneumatic Supply

180 L/min(ANR) (300 L/min(ANR) with pallet dispenser) Max pressure 0.5MPa (72 PSI)

Ambient temperature

0 ~ 40 °C

Relative humidity

35 ~ 85 %

Harness to the controller 10m or less (special correspondence for more than 10m)

The standard color in Mansell 5Y8/1 Nittoko C25-80B. (*) See detail in Installation manual.

JIS(L1)

2-5

【AP30】

Model AP30 Motion Type Vertical, multi-articulated

Load Capacity Max 60 kg

Degree of Freedom

2 Axis （ option 3 axis ）

D-axis 850 mm

O-axis 850 mm Operating

Range C-axis 90°

D-axis 3.0 m/s

O-axis 2.4 m/s Movement

Speed C-axis different in each option

< at 40kg handling > 1850 C/h < at 60kg handling > 1600 C/h

Handling Capacity Handling capacity varies depending on conditions like the

layout and hand (i.e. double-grip hands). For details, calculate with “Oxpa-Qm2”.

Accuracy Repeatable position precision ±1 mm

Height Max 1,750 mm（including harness）

Robot Weight 325 kg

Pneumatic Supply

180 L/min(ANR) (300 L/min(ANR) with pallet dispenser)

Max pressure 0.5MPa (72 PSI)

Ambient temperature

0 ~ 40 °C

Relative humidity

35 ~ 85 %

The standard color in Mansell 5Y8/1 Nittoko C25-80B.

JIS(L1)

3-1

3.Overview of Equipment The following identifies each part of the controller.

JIS(L1)

3-2

FRONT VIEW BACK VIEW

LEFT VIEW RIGHT VIEW

3.1. Controller Appearance

3.1.1.Controller

【CE type】 RC715 RC725

JIS(L1)

3-3

BACK VIEW FRONT VIEW

LEFT VIEW RIGHT VIEW

【JIS type】 RC712 RC722

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3-4

RIGHT VIEW LEFT VIEW

FRONT VIEW BACK VIEW

【UL type】 RC710 RC720

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3-5

3.2. Teaching Pendant (Installation Personnel Only)

Installation Personnel Only

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3-6

3.3. Table of Basic Specification

A400 Model

RC722

Number of control axis 4-axes simultaneous (option 5 Axes: except for UL type)

Path control system PTP (R,T Axes) CP (O,D Axes) Position detection system Absolute encoder Position control system Digital closed loop

Contr

ol Sys

tem

Motor control system Digital AC servo control

Program storage system SRAM battery back-up Compact flash (option)

Mem

ory

Memory capacity 700 patterns (Varies depending on stacking program) ※700 patterns are added with Compact flash (option).

Display 7.7 inch color LCD touch panel

Dis

pla

y

External storage device PC (Needs special program to transfer data. )

Teaching system Teaching play-back Auto programming Off-line programming

Number of simultaneous loading points

6 pallets, 4 stations MAX

Repeat speed 10 levels (1 ~10) Editor functions Revise, Addition, Delete, Transfer, Copy, Labels Outside

Teac

hin

g,

Oper

atio

n

Remote operation Teaching Pendant (For Installation Personnel) ”FROM-TO-DATA” is prepared for operating robot from

PC. (Optional)

Number of I/O points Standard input 76(36) output 60(28) ():JIS [JIS] Optional input 40 output 32

External communication RS422 (Software is optional, Enables link-up with PC, host.)

I/O

I/O points of Hand Input 4, Output 4

W 800

D 640 Dimension [mm]

H 1150

Weight [kg] 165 Ambient temperature 0 ~ 40 Degrees C Relative humidity 35 ~ 85 %

AC 200 / 220V ±5% 50 / 60 Hz, 3phase Required power supply Main unit 2.5 kVA for

peripheral conveyor

Contr

olle

r

Conveyor control Can be equipped with unit for conveyor control.

JIS(L1)

Robot manual

Safety

L1 Version: 2010.09.03

<caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice.

Okura Yusoki Co., Ltd. 900 Furuouchi, Noguchi-cho, Kakogawa,

Hyogo 675-8675 Japan