VN2EA700-MA-24.0E Robot Yushin Manual de Mantenimiento 750

VN -EA
MAINTENANCE MANUAL
VN -EA
This manual provides information on the

following models.
VN -EA-700S
VN -EA-700D
CAUTION
Deliver this manual for the related
department.
Read this manual before installation and
maintenance.
Version 24.0
Greetings
We appreciate very much for your purchase of Take-out Robot of our company, Yushin Precision
Equipment Co., Ltd.
We always develop our technology and manufacture machines, by making it a rule to supply "one
step advanced take-out robot". We are sure that you will be satisfied by using this robot correctly
after reading this description carefully.
We continue to make efforts to develop our technology, give our best services, and to supply Take-
out robot with which you will be satisfied from now on too.
We hope you will take patronage of our company for a long time.
Yushin Precision Equipment Co., Ltd.
The contents of this manual are subject to change in the future without notice.
We have issued this manual very carefully. Please let us know, however, if you
should find any doubts, or unclear points.
To copy any part or all of this manual is prohibited. Besides, please keep in
mind that you cannot use this manual without our permission except in case
of personal use in law of copyright.
Please admit in advance that our company cannot take any responsibility for
loss, losing profit or so on by using this manual.
The copyright on freeware LHA is held by Mr. H. Yoshizaki.
INTRODUCTION
This maintenance manual is provided for the take-out robot. Before installing or maintenance of
the take-out robot, read this manual carefully to utilize the robot's capabilities to the fullest and in
an efficient manner. After reading it, keep it in good order for occasional reference.
The take-out robot manuals

In addition to this maintenance manual, the following manuals are provided.
Operation manual
This manual, provided for an operation staff or a maintenance staff, explains how to operate
the take-out robot.
Parts catalog
This catalog, provided for a maintenance staff, lists the part numbers of parts which need to be
changed for maintenance purposes.
i
Attention marks
This manual employs the following attention marks for the safety of operation.
Pay special attention to the messages with these marks when reading this manual.
Each attention marks has the following meaning.
If you don't follow this instruction, it is quite possible that you will suffer from death
DANGER
or serious injury.
WARNING If you ignore this warning, death or serious injury could result in the worst case.
CAUTION If you act against this advice, some injury or mechanical damage could result.
This mark indicates that you should be careful in han-

dling workpieces.
Inflammables High Electric shock Biting of
temperature fingers
This mark indicates that a certain action is prohibited.
Don't do this Don't Don't cause fire Don't touch

disassemble
This mark indicates that a certain action should be

done.
Do this Disconnect plug Ground terminal
In addition to the above symbols and messages, the following group of symbols are used to give
supplimental information or advice.
This mark is used to give supplemental information or advice.
ii
DANGER
Do not step into the robot motion area when the take-out robot is operated.
The robot motion area is as follows. This area is the dangerous area of the take-out robot. Be sure to operate
the take-out robot outside the safety fence. If you enter the robot motion area during Auto operation, a
serious accident could result.
Motion area
iii
WARNING
Be sure to remove the dust on the power plug and the plug socket. If it is left for a
long time and combined with dampness, a small current may flow through it and
cause abnormal heat or fire.
Do not use an extension cable with insufficient capacity. Abnormal heating or

burning may result.
Do not damage the power cable by pulling, bending, or putting a heavy object on it.
A damaged cable could be the cause of fire or electric shock.
If any of the following cases should occur, immediately stop the operation and turn
OFF the power. If you continue the operation under such conditions, a fire may
result in the worst case.
When fume rises from the robot body or control box, or the outside surface of
the take-out robot emits abnormal heat.
When any abnormal noise is heard.
When water enters inside of the take-out robot.
Do not touch the power plug with wet hands. There is a possibility of electric shock.
To prevent electric shock of possible current leakage, the plug should be grounded
with one of the following methods.
To connect the plug directly with an earthed embedded plug socket.
To connect the earth terminal of the plug with a copper bar embedded in the
ground at the depth of more than 650 millimeters.
To connect the earth terminal of the plug with Class 3 grounding terminal.
iv
WARNING
Do not connect the earth terminal of the plug with the following objects.
Gas pipe (There is a possibility of flashing or explosion.)
Grounding wire from the public telephone line or lightning arrestor (A great
amount of current will flow through the wire in the case of a thunderbolt.)
Water pipe of faucet (If plastic or rubber is used in part, it will not work as a
grounding medium.)
If any air leak is detected, stop the take-out robot and eliminate the cause of air leak.
Safety fence should be provided to prevent anyone from entering dangerous area of
the take-out robot during its operation.
Make sure the safety fence to be provided satisfies the following requirements.
The safety fence shall have strength enough to endure the forces caused during
operations and the environmental conditions. It shall have a structure incapable
of easily being adjusted, taken away, or gotten over.
There shall not be any sharp protrusion or the like on the safety fence that may
possibly cause injury to operators.
The safety fence shall be fixed.
The safety fence shall be provided with a safety device which stops the take-out
robot when the safety gate is opened.
In order to immediately stop the take-out robot, an emergency stop device should
be provided at a position for an operator easy to operate in an emergency.
The take-out robot should be arranged so as to secure the working space required
for teaching and maintenance operations.
v
WARNING
The take-out robot controller and other control devices should be placed at a
position outside of the robot motion area where an operator can look out over the
robot motion.
Any cover should be provided for electrical wiring and pneumatic tubing if it is
feared to be damaged.
The robot mounting section should have sufficient strength and there should not be
any looseness when installing the robot.
In order to be able to effectively activate the emergency stop device in an

emergency, the emergency stop switches should be provided other than on the
operation panel as occasion demands.
Before adjusting the timing belts, be sure to turn OFF the control power.
Before performing maintenance operations in the robot motion area, turn OFF the
circuit breaker of the take-out robot and release the pneumatic pressure. Then put
up a notice, warning not to turn ON the control power because of maintenance
operations in progress, in the vicinity of the operation panel.
When the maintenance is performed in the robot motion area, do not perform it
alone. Be sure to station an authorized supervisor, who is skilled in operating the
take-out robot, at the emergency stop switch to be able to immediately put on
emergency stop.
vi
WARNING
When the maintenance is performed in the robot motion area, place off limits to
personnel other than those conducting the maintenance so as not to enter the robot
motion area.
Before adjusting the mechanical parts, be sure to stop operating the take-out robot
and turn OFF the power . Do not make adjustments of the take-out robot during the
operation.
Do not connect and disconnect the plug with the control power switch turned ON.
Sparks may strike out and be the cause of burning, or electrical noise.
Do not pull the plug by the cable. A damaged cable may be the cause of a fire or an
electric shock.
Before cleaning, maintenance and troubleshooting of the take-out robot, be sure to

turn OFF the control power and pull out the plug. If you attempt to perform any of
these actions without turning OFF the control power, you may suffer from an
electric shock.
Before connecting each connector, be sure to turn OFF the control power.
Otherwise, it is possible that you will suffer from an electric shock.
vii
CAUTION
Before starting operation, make sure the specified power is supplied. Refer to the
specifications for the details of the rated voltage and frequency.
Take sufficient care to keep pneumatic tubing from damage. Damage in the tube
could be the cause of air leakage.
Be sure to release pneumatic pressure before replacing a filter bowl.
Do not use an operating fluid other than compression air.
Pneumatic pressure should be regulated as specified.
Do not use air that contains the following substances. Also make sure such
substances are not contained in the atmosphere. Use only clean air.
Organic solvents
Phosphate oil
Sulfur dioxide
Chlorine gas
Deteriorated compressor oil
Acids
Flushing (compressed air blow off) in the pneumatic tubing should be performed
adequately before doing tubing work for pneumatic pressure. Intrusion of chip, seal
tape or rust generated during tubing operation will be the cause of malfunctions
such as air leakage.
viii
CAUTION
Select an installation location which provides a suitable operational environment
for the take-out robot.
The installation location shall meet the following requirements.
Not exposed to direct sunlight
Free of heavy dirt
Free of the influences of vibrations, high frequency electric fields, magnetic
fields, electrical noise, and static electricity. The area around the robot shall also
be free of corrosive gases and floating particles of electrically conductive
material, such as metal.
Temperature : 0 °C to +45 °C (28 °F to +113 °F)
Storage temperature : -15 °C to +65 °C (5 °F to +149 °F)
Humidity : 35 % RH to 85 % RH (Without dewfall)
An indicating device should be provided to indicate that the take-out robot and the
injection molding machine are operating by using an optical means such as a tower
lamp.
Be sure the power supply for the take-out robot is completely separate from the
power supply of the injection molding machine.
Be sure all connectors are connected correctly. Incorrect correction methods can
result in malfunction of the take-out robot. Be especially careful regarding
connections with the control devices.
When the take-out robot is set, adjusted, or inspected at a height of 2 meters or

more from the floor, a maintenance platform should be provided.
The maintenance platform should have a level surface, sufficient area to work, and
handrails or a fence. Do not make adjustments of the take-out robot during
operation.
Remove water from the mist filter periodically.
ix
CAUTION
Perform the maintenance under adequate lighting.
Maintenance should be done only by those trained concerning maintenance

procedures and granted permission of the injection molding machine cell engineer.
Be sure to use the parts specified for replacement.
Do not modify the robot body or the control device. If it is necessary to do

modification, be sure to consult us in advance.
Do not move or remove the attention plates or stickers.
x
Safety signs
There are safety signs on the take-out robot. Respect the messages on these labels when operating
or performing maintenance on the take-out robot. Do not defile or peel off these labels.
DANGER DANGER
Robot will High speed
come down. moving
Robot(s).
Do not Do not
enter robot enter robot
D-3E operating area. D-1E operating area.
WARNING
Moving
belt(s).
Do not
operate
with guard
W-3E removed.
CAUTION
DO READ AND FOLLOW UNDERMENTIONED CAUTIONS IN ORDER TO PREVENT ANY ACCIDENTS, INJURY OR DAMAGES.
DO CHECK MACHINE SAFETY BEFORE OPERATING OR REPAIR OR MAINTENANCE AND DO NOT ADJUST SPEED OR
SET POSITION BY 1 MAN. DO PROVIDE 2 MEN AND 1 MAN MUST WATCH OTHER.
DO NOT STAND UP NOR HEAD UP NOR PLACE HANDS AGAINST CHUCK HEAD OR OTHER MOVING MECHANISM AT ANY TIME
WHILST ELECTRICAL OR AIR POWER IS SUPPLIED. DO NOT PLACE FOOT ON MACHINE AT ANY TIME.
DO NOT REACH INTO THE AREA WHERE MACHINE IS MOVING NOR ADJUST MACHINE WHILST OPERATION.
DO NOT OPEN NOR REMOVE NOR BYPASS SAFETY COVER AND OTHER SAFETY DEVICES.
DO USE EXACT AND GENUINE PARTS AND SIZE OF BOLT, NUT AND SCREW MUST BE METRIC MEASUREMENT. (ISO)
DO TURN OFF ELECTRICAL AND AIR POWER BEFORE REPAIR OR MAINTENANCE.
DO WEAR HARD SAFETY HAT AND SAFETY SHOES AND PAY SPECIAL ATTENTION FOR SAFETY WHEN WORKING FOR
SETTING, ADJUSTING, REPAIR, MAINTENANCE OR SHIFTING MACHINE.
DO KEEP FACE AND HANDS AWAY FROM HIGHLY HEATED AREA SUCH AS HOTMELT TANK, CONNECTIONS, NOZZLE
OR HOSE OF BASE CUP APPLICATOR AND MOTOR IN ORDER TO PREVENT SEVERE BURN OR INJURY.
DO PERIODICALLY SUPPLY GREASE AND LUBRICATING OIL.
DO PERIODICALLY INSPECT AND MAKE SURE THAT LIMIT SWITCHES AND SENSORS PROPERLY WORK.
DO PERIODICALLY INSPECT AIR HOSES, HOTMELT HOSES, CABLES AND JOINTS FOR FRACTURES OR OTHER DAMAGES.
DO PERIODICALLY INSPECT BOLTS, NUTS AND SCREWS AND TIGHTEN IF THEY ARE LOOSE.
DO PERIODICALLY INSPECT ELECTRIC CIRCUIT TO DETECT LEAKAGE.
DO STOP MACHINE AND TURN OFF ELECTRICAL AND AIR POWER WHEN ANY DEFECTS ARE FOUND AND REPAIR.
DO NOT REMOVE THIS CAUTION MARK FROM THIS MACHINE.
MAKER / SUPPLIER OF MACHINE WILL NOT BE RESPONSIBLE FOR ANY LIABILITY ARISING OUT OF USE OF ROBOT WHICH
ARE MODIFIED WITHOUT APPROVAL OF MAKER / SUPPLIER.
BY MAKER / SUPPLIER : YUSHIN PRECISION EQUIPMENT CO., LTD. 8. 1987
xi
DANGER DANGER
Robot will High speed
come down. moving
Robot(s).
Do not Do not
enter robot enter robot
D-3E operating area. D-1E operating area.
WARNING
Moving
belt(s).
Do not
operate
with guard
removed.
WARNING
Moving
belt(s).
Do not
operate
with guard
W-3E removed.
WARNING
Do not
disassemble.
W-1E
DANGER
High voltage.
Before servicing
turn off,
lock out / tag out
main power
D-5E disconnect.
xii
CAUTION
DO READ AND FOLLOW UNDERMENTIONED CAUTIONS IN ORDER TO PREVENT ANY ACCIDENTS, INJURY OR DAMAGES.
DO CHECK MACHINE SAFETY BEFORE OPERATING OR REPAIR OR MAINTENANCE AND DO NOT ADJUST SPEED OR
SET POSITION BY 1 MAN. DO PROVIDE 2 MEN AND 1 MAN MUST WATCH OTHER.
DO NOT STAND UP NOR HEAD UP NOR PLACE HANDS AGAINST CHUCK HEAD OR OTHER MOVING MECHANISM AT ANY TIME
WHILST ELECTRICAL OR AIR POWER IS SUPPLIED. DO NOT PLACE FOOT ON MACHINE AT ANY TIME.
DO NOT REACH INTO THE AREA WHERE MACHINE IS MOVING NOR ADJUST MACHINE WHILST OPERATION.
DO NOT OPEN NOR REMOVE NOR BYPASS SAFETY COVER AND OTHER SAFETY DEVICES.
DO USE EXACT AND GENUINE PARTS AND SIZE OF BOLT, NUT AND SCREW MUST BE METRIC MEASUREMENT. (ISO)
DO TURN OFF ELECTRICAL AND AIR POWER BEFORE REPAIR OR MAINTENANCE.
DO WEAR HARD SAFETY HAT AND SAFETY SHOES AND PAY SPECIAL ATTENTION FOR SAFETY WHEN WORKING FOR
SETTING, ADJUSTING, REPAIR, MAINTENANCE OR SHIFTING MACHINE.
DO KEEP FACE AND HANDS AWAY FROM HIGHLY HEATED AREA SUCH AS HOTMELT TANK, CONNECTIONS, NOZZLE
OR HOSE OF BASE CUP APPLICATOR AND MOTOR IN ORDER TO PREVENT SEVERE BURN OR INJURY.
DO PERIODICALLY SUPPLY GREASE AND LUBRICATING OIL.
DO PERIODICALLY INSPECT AND MAKE SURE THAT LIMIT SWITCHES AND SENSORS PROPERLY WORK.
DO PERIODICALLY INSPECT AIR HOSES, HOTMELT HOSES, CABLES AND JOINTS FOR FRACTURES OR OTHER DAMAGES.
DO PERIODICALLY INSPECT BOLTS, NUTS AND SCREWS AND TIGHTEN IF THEY ARE LOOSE.
DO PERIODICALLY INSPECT ELECTRIC CIRCUIT TO DETECT LEAKAGE.
DO STOP MACHINE AND TURN OFF ELECTRICAL AND AIR POWER WHEN ANY DEFECTS ARE FOUND AND REPAIR.
DO NOT REMOVE THIS CAUTION MARK FROM THIS MACHINE.
MAKER / SUPPLIER OF MACHINE WILL NOT BE RESPONSIBLE FOR ANY LIABILITY ARISING OUT OF USE OF ROBOT WHICH
ARE MODIFIED WITHOUT APPROVAL OF MAKER / SUPPLIER.
BY MAKER / SUPPLIER : YUSHIN PRECISION EQUIPMENT CO., LTD.
WARNING DANGER WARNING

High voltage.
Before servicing Short
Do not turn off, circuit.
disassemble. lock out / tag out Ground an
main power electric
W-1E D-5E disconnect. wire.
DANGER
High voltage.
Before servicing
turn off,
lock out / tag out
main power
disconnect.
xiii
xiv
CONTENTS
1 GENERAL SPECIFICATIONS
1.1 Installation procedure ................................................................................................. 1-1
1.2 Specifications ............................................................................................................. 1-2
1.3 External dimensions ................................................................................................... 1-4
1.4 Motion area ................................................................................................................. 1-6
1.4.1 Motion prohibition area .............................................................................................. 1-8
1.5 Component identifications ......................................................................................... 1-9
1.5.1 Configuration .............................................................................................................. 1-9
1.5.2 Operator station ........................................................................................................ 1-10
1.5.3 Touch panel controller .............................................................................................. 1-11
1.5.4 Robot body and control box ..................................................................................... 1-13
1.5.5 Floppy discs .............................................................................................................. 1-14
2 INSTALLATION
2.1 Robot body installation .............................................................................................. 2-1
2.2 Electrical interface ..................................................................................................... 2-4
2.3 Pneumatic hook-up ..................................................................................................... 2-5
3 OPERATION CHECK
3.1 Control power ON ...................................................................................................... 3-2
3.2 Manual operation before home position return motion ............................................. 3-3
3.3 Home position return motion ..................................................................................... 3-7
3.4 Interlock check ........................................................................................................... 3-9
3.4.1 Signals ......................................................................................................................... 3-9
3.4.2 Interface signal check ............................................................................................... 3-11
3.5 Emergency stop ........................................................................................................ 3-22
4 POST-INSTALLATION ADJUSTMENT/CHECK
4.1 Entire machine ............................................................................................................ 4-1
4.2 Pneumatic unit ............................................................................................................ 4-1
4.2.1 Pneumatic pressure adjustment .................................................................................. 4-1
4.2.2 Solenoid valves check ................................................................................................ 4-2
4.2.3 Pressure sensor adjustment ......................................................................................... 4-3
4.3 Mechanical adjustments ............................................................................................. 4-5
4.3.1 Runner chuck position adjustment ............................................................................. 4-5
4.3.2 Runner chuck sensor position adjustment .................................................................. 4-7
xv
5 REGULAR MAINTENANCE
5.1 Maintenance check list ............................................................................................... 5-1
5.2 Mechanical section ..................................................................................................... 5-5
5.2.1 Traverse unit ............................................................................................................... 5-5
5.2.2 Traverse axis timing belt tension adjustment ............................................................. 5-7
5.2.3 Kick unit ..................................................................................................................... 5-9
5.2.4 Main and sub arm kick axis timing belt tension adjustment .................................... 5-10
5.2.5 Flip unit ..................................................................................................................... 5-12
5.2.6 Arm unit .................................................................................................................... 5-13
5.2.7 Main and sub arm axis timing belt tension adjustment ............................................ 5-15
5.3 Pneumatic unit .......................................................................................................... 5-18
5.3.1 Pneumatic filter ......................................................................................................... 5-18
5.3.2 Vacuum generator check and vacuum generator filter replacement ......................... 5-19
5.3.3 Exhaust filter ............................................................................................................. 5-21
5.3.4 Balance cylinder pneumatic pressure adjustment .................................................... 5-22
5.4 Electrical section ...................................................................................................... 5-23
5.4.1 Control box ............................................................................................................... 5-23
5.4.2 Operator station ........................................................................................................ 5-25
5.4.3 Sensor and wiring check ........................................................................................... 5-26
6 OVERHAUL
6.1 Traverse unit ............................................................................................................... 6-1
6.1.1 Traverse axis timing belt replacement ........................................................................ 6-1
6.1.2 Traverse axis home position adjustment .................................................................... 6-5
6.2 Kick unit ..................................................................................................................... 6-7
6.2.1 Main and sub arm kick axis timing belt replacement ................................................. 6-7
6.2.2 Kick axis home position adjustment ......................................................................... 6-10
6.3 Arm unit .................................................................................................................... 6-12
6.3.1 Main and sub arm axis timing belt replacement ....................................................... 6-12
6.3.2 Arm axis home position adjustment ......................................................................... 6-16
APPENDIX
A.1 Control box layout drawing....................................................................................... A-1
A.2 Circuit drawing .......................................................................................................... A-2
A.2.1 Pneumatic circuit ....................................................................................................... A-2
A.2.2 Injection molding machine interface ......................................................................... A-3
A.3 Maintenance parts list ............................................................................................... A-4
A.4 Tightening torque ...................................................................................................... A-5
A.5 Digital operator.......................................................................................................... A-6
A.5.1 Type ........................................................................................................................... A-6
A.5.2 Notice ......................................................................................................................... A-6
A.5.3 Digital operator installation ....................................................................................... A-6
A.5.4 Status indication mode ............................................................................................... A-7
A.5.5 Set of parameter ......................................................................................................... A-8
xvi
A.6 Tension meter .......................................................................................................... A-24
A.6.1 Type ......................................................................................................................... A-24
A.6.2 Notice ....................................................................................................................... A-24
A.6.3 General arrangement ................................................................................................ A-24
A.6.4 Operating procedure ................................................................................................ A-25
A.7 YM3: Communication program between FA-M3 and PC/AT ................................ A-27
A.7.1 Operation environment and initial settings .............................................................. A-27
A.7.2 How to use the program ........................................................................................... A-29
A.7.3 Writing to and reading from data files ..................................................................... A-33
A.8 Mechanical lock installation/remotion .................................................................... A-35
A.8.1 MA, MB, MKA and MSA series ............................................................................. A-35
A.8.2 MN series ................................................................................................................. A-38
A.9 Troubleshooting flowchart ...................................................................................... A-40
A.9.1 Control power fails to turn ON ................................................................................ A-40
A.9.2 Servo power fails to turn ON ................................................................................... A-41
A.9.3 Solenoid valve fails to turn ON ............................................................................... A-42
xvii
xviii
1.1 Installation procedure
The general flow from installation to production of the take-out robot is shown below. Refer to
the separate operation manual as necessary.
Refer to:
Robot body installation 2.1 Robot body installation
Electrical interface 2.2 Electrical interface
Pneumatic hook-up 2.3 Pneumatic hook-up
Operation check 3 Operation Check
Adjustment/check 4 Post-Installaiton Adjustment/Check
Teaching/Auto operation 3 Auto Operation and 5 Teaching

in the Operation Manual
1-1
1.2 Specifications
Power voltage : AC200V (50/60 Hz)

Drive method : Digital servo motor (maximum 5 axes)
Control method : Microcomputer control
Working pressure : 4.9 105 Pa (5 kgf/cm2)
Maximum allowable pressure : 7.9 105 Pa (8 kgf/cm2)
Flip angle : 90 degrees
Specification breakdown based on model
Traverse stroke Kick stroke Descent stroke Air Maximum

Maximum consumption Weight
(millimeters) (millimeters) (millimeters) (Nl/cycle) weight
Model power (kg)
capacity
consumption Standard L LL Main arm Sub arm Main arm Sub arm 0.49MPa (kg)
VN -EA-50S 410 - - 5 278
550
VN -EA-50D 350 350 550 5 333
1100 1500 1700
VN -EA-100S 560 - - 5 289
Type S 700
VN -EA-100D Single phase 500 500 700 5 338
AC200V 5
VN -EA-150S X11A Max. 560 - - 5 300
850
VN -EA-150D 500 500 850 5 350
1500 1700 1900
VN -EA-250S 728 - - 7 312
950
VN -EA-250D Type D 668 668 950 7 362
Single phase
VN -EA-350S AC200V 950 - - 13
X14A Max. 1700 1900 2200 1100 10
VN -EA-350D 818 818 1100 13
VN -EA-550S 1060 - - 18
1300 15
VN -EA-550D 845 845 1300 18
2000 2500 -
VN -EA-700S 1170 - - 25
1500 20
VN -EA-700D 905 905 1500 18
Type S
VN -EA-850S Three phase
1305 - - 47
AC200V
2500 3000 - 1600
VN -EA-850D X13A Max. 1040 1040 1600 51
35
Type D
VN -EA-1300S
Three phase
1505 - - 53
AC200V
3000 3500 - 1800
VN -EA-1300D X19A Max. 1240 1240 1800 57 1450
VN -EA-2000S Three phase 3500 4000 - 1750 - 2100 - 110 50 2400

AC200V
VN -EA-3000S X19A Max. 4000 4500 - 2100 - 3000 - 231 100 3500
1-2
Primary power source breakdown based on model
Model Power consumption Circuit breaker Plug socket

VN -EA-50S 2.2KVA
VN -EA-50D 2.8KVA
VN -EA-100S 2.2KVA
VN -EA-100D 2.8KVA
VN -EA-150S 2.2KVA
VN -EA-150D 2.8KVA Motor protection
leakage breaker
VN -EA-250S 2.2KVA BKM2163 single phase
VN -EA-250D 2.8KVA Rated current 16A
Residual operating
VN -EA-350S 2.2KVA current 30mA
VN -EA-350D 2.8KVA WF8420K
VN -EA-550S 2.2KVA (20A)
VN -EA-550D 2.8KVA
VN -EA-700S 2.2KVA
VN -EA-700D 2.8KVA
VN -EA-850S 2.65KVA
VN -EA-850D 3.8KVA Motor protection
leakage breaker
VN -EA-1300S 2.65KVA BKM3253 three phase
VN -EA-1300D 3.8KVA Rated current 25A
Residual operating
VN -EA-2000S 3.75KVA current 30mA
VN -EA-3000S 3.75KVA
The VN -EA-2000 and the VN -EA-3000 are available only in type S.
1-3
1.3 External dimensions
A T I
B C D E
F
S
G Q O L
P M K
R
N
U J
(All dimensions in millimeters.)

Model A B C D E F G H I J K L M N O P Q R S T U
VN -EA-50S - - - 410 - - 122
1182 365 927
VN -EA-50D 2133 1100 50 132 350 350 220 330 182
(2533) (1500)
VN -EA-100S {2733} {1700} - - - 560 - - 122
1268 515
VN -EA-100D 50 132 500 500 220 480 182
280 98 400 115 605 150 185 526 1077
VN -EA-150S 655 - - - 560 - - 122
2533 1500 1329 665
VN -EA-150D 50 132 500 500 220 630 182
(2733) (1700)
VN -EA-250S {2933} {1900} - - - 728 - - 122
1379 765 1245
VN -EA-250D 50 132 668 668 220 730 182
VN -EA-350S 2800 1700 - - - 950 - - 100
(3000) 725 (1900) 350 25 400 185 1660 622 170 264 836 640 1469
VN -EA-350D {3300} {2200} 95 137 818 818 303 797 232
VN -EA-550S 3320 2000 - - - 1060 - - 140
740 350 230 400 252 1971 648 185 305 995 745 1655
VN -EA-550D (3820) (2500) 170 185 845 845 370 930 355
VN -EA-700S 3140 2000 - - - 1170 - - 230
700 329 111 400 260 2150 666 179 305 1195 830 1817
VN -EA-700D (3640) (2500) 200 295 905 905 370 1130 495
VN -EA-850S 3964 - - - 1305 - - 215
944 2500 409 111 560 330 2342 626 300 285 1315 912 2072
VN -EA-850D (4464) (3000) 165 315 1040 1040 340 1260 480
VN -EA-1300S 4464 944 3000 409 - - - 1505 - - 215
111 560 330 2442 626 300 185 1615 912 2272
VN -EA-1300D (5114) (1019) (3500) (484) 165 315 1240 1240 240 1560 480
Dimensions in parentheses “( )” apply to type L.

Dimensions in braces “{ }” apply to type LL.
1-4
A O 1110
B C D H
G
1000
E
610.2
F
L
M
K J I

Model A B C D E F G H I J K L M N O
VN -EA-2000S 5855 3500 2966.5 2100

1539 816 658 750 235 580 1750 350 1100 2800
VN -EA-2000SL 6355 4000 (3216.5) (2600)
560
VN -EA-3000S 6442 4000
1526 916 848 3951 750 235 780 2100 400 3000 1300 3380
VN -EA-3000SL 6942 4500
Dimensions in “( )” apply to extended arm stroke types.

Dimension L varies depending on the injection molding machine model. When L is
changed, dimensions F and G also change.
1-5
1.4 Motion area
D
Reference surface
Reference C
surface
F A
G E
H

Model A B C D E F G H
VN -EA-50S
1100 365 585 482 532
VN -EA-50D
(1500)
VN -EA-100S {1700} 515 735
VN -EA-100D
220 30 632 50 682
VN -EA-150S
665 885
VN -EA-150D 1500
(1700)
VN -EA-250S {1900} 765 985 800 850
VN -EA-250D
VN -EA-350S 1700
(1900) 303 836 1139 955 95 1050
VN -EA-350D {2200}
VN -EA-550S 2000 370 995 1365 1030 170 1200
VN -EA-550D (2500)
VN -EA-700S 2000 370 1195 1565 50 1200 200 1400
VN -EA-700D (2500)
VN -EA-850S 2500 340 1315 1655 1355 165 1520
VN -EA-850D (3000)
VN -EA-1300S 3000
240 1615 1855 1555 165 1720
VN -EA-1300D (3500)
Dimensions in parentheses “( )” apply to type L.

Dimensions in braces “{ }” apply to type LL.
1-6
Reference
D
surface Reference
C
surface
F G
E A
H 235

Model A B C D E F G H
VN -EA-2000S 3500 1750 2100
350 (2250) (2600) 1750 580 2330
VN -EA-2000SL 4000
50
VN -EA-3000S 4000
400 2600 3000 2100 780 2880
VN -EA-3000SL 4500
Dimensions in “( )” apply to extended arm stroke types.

Dimension B varies depending on the injection molding machine model. When B is
changed, dimensions C also change.
1-7
1.4.1 Motion prohibition area
This take-out robot has a motion prohibition area setting, and this setting can be changed. There
are two possible motion prohibition areas: Motion prohibition area 1 and Motion prohibition
area 2. This take-out robot, however, only uses Motion prohibition area 2.
Motion prohibition area 1
Maximum value of sub arm kick axis
Motion prohibition area 2 Maximum value of main arm kick axis
1-8
1.5 Component identifications
1.5.1 Configuration
The take-out robot consists of the following.
Robot body
Control box
Operator station
Interface connector
In this manual, the above mentioned components are referred to collectively as the take-
out robot.
Control box
To control box
Robot body
Injection molding Interface
machine connector
ble
ca
on
icati
Operator station
mun ble
om r ca
C we
Po To injection molding machine
To power supply
1-9
1.5.2 Operator station
Precautions regarding the operator station

The operator station houses the control circuit unit and other precision parts. If the control
circuit unit is damaged, the touch panel controller and the control box will not work and,
consequently, the robot cannot be controlled. Be sure to observe the following precautions.
Place the operator station in a stable, level place which is free of vibration.
Do not turn the operator station over, slam objects into it, or in any other way apply
WARNING physical shock to it. Otherwise the control circuit unit may be damaged.
Do not move the operator station while its power is ON. Otherwise the hard disc may
be crushed, and stored program data may be lost.
Power indicator Control power switch

This lamp lights when the control power Use this switch to turn the control power
is ON. ON and OFF.
Emergency stop switch
Press this switch to turn OFF the servo
power and stop the take-out robot. Turn
Touch panel controller this switch clockwise to reset the
emergency stop condition.
(The switch rises.)
Floppy disc driver

Before inserting a floppy disc, open the
cover.
Operator station backside
Printer connector
PRINTER
Touch panel
controller connector MONITOR
Robot body
connector
Lock-out switch on operator station

Breaker box
Once the touch panel controller is set on
the operator station, the lock-out switch
on the operator station is activated, which
means that axis operation is enabled.
(Basic operation is possible without
having to press the lock-out switch .)
Circuit breaker
The breaker box contains the
circuit breaker which supplies
electric power to the entire take-
out robot.
Open the cover to switch the
circuit breaker.
1-10
1.5.3 Touch panel controller
When the touch panel controller is placed on the operator station, the lock-out switch on
the operator station is activated automatically. Do not carelessly touch the touch panel.
WARNING Otherwise the take-out robot will operate.
Precautions regarding the touch panel controller

The touch panel controller holds precision parts including the liquid crystal display. The
liquid crystal display is made of glass. Be sure to observe the following precautions.
Do not drop or apply physical shock to the touch panel.
When holding the touch panel, be sure to pass your hand through the hand strap. (See
figure.)
When not holding the touch panel, be sure to place it on the operator station properly.
CAUTION Do not place objects on top of the touch panel controller or press it with excessive force.
Otherwise, the glass of the liquid display may break.
Do not press the touch panel surface with sharp objects. Otherwise, the surface may be
scratched or touch panel controller may be damaged.
Do not yank the cable connecting the touch panel controller to the operator station.
Otherwise, the cable may break or the connector may be damaged.

Press this switch to turn OFF the servo power and stop the
take-out robot while operating the touch panel controller.
Turn this switch clockwise to reset the emergency stop
condition. (The switch rises.)
STOP
Stop button area
During Auto operation, even when
the back light of the liquid crystal
display is not lit, pressing this area
turns OFF the servo power and
stops the take-out robot.
LCD touch panel
The touch panel displays buttons,
icons, and operation guidelines.
To operate, press the button or icon
Hand strap with your finger.
1-11
How to hold the touch panel controller
Step 1
Lock-out switch
Pass your arm through the hand strap to
hold the touch panel controller.
To hold the controller with the opposite
hand from the figure, attach the hand
strap on the opposite side.
Step 2
To operate the axes in manual operation,
press either one of the lock-out switches.
P
O
T
S
Operation other than manual axis operation is allowed without the lock-out switches being
pressed.
1-12
1.5.4 Robot body and control box
Junction box
This box houses the solenoid valve
and the remote I/O.
Vacuum gauge
This gauge displays the vacuum
pressure.
Traverse frame
This is a guide frame for
movement in the traverse
direction.
Kick frame
This is a guide frame
for movement in the
kick direction.
Main arm unit

This arm unit raises and Spacer
lowers the end-of-arm tool. Runner chuck
This chuck clasps the runner.
Flip cylinder Sub arm unit
This cylinder flips the end- This arm unit raises and lowers the
of-arm tool 90 degrees. runner chuck. Main arm kick axis
Sub arm kick axis
Tra
ver
se
axi
s
Main arm unit axis
Sub arm unit axis
Control box
This box houses the servo
controller.
1-13
1.5.5 Floppy discs
Floppy discs are used for storing and copying the mold data of the take-out robot.
Only use formatted floppy discs matching following specifications.
3.5 inch, 2HD (DOS/V, DOS18)
Do not use floppy discs which have not been formatted or which do not match the
specifications not above.
Precautions regarding floppy discs

A floppy disc is a memory medium made of a thin magnetic body on which a large amount
of data is written. Observe the following precautions to avoid erasing important data.
Do not open the shutter and touch the memory surface. Otherwise the data may be
lost.
Do not drop, bend, or apply strong physical shock to the floppy disc. Otherwise the
floppy disc may be damaged.
CAUTION
Avoid storing or using in hot places, cold places, or places with direct sunlight.
Never allow the floppy disc to be in close vicinity of magnetic objects (such as magnets,
speakers, etc.).
Write protection switch

Floppy discs have a write protection switch to protect saved data. This switch has a
similar function to that of the erase protection “tabs” on an audio cassette. Slide this
switch so that the hole is open to put the floppy disc into protected mode. By doing this
you can prevent the writing of new data and the accidental erasing of previously saved
data. Attempting to write onto a floppy disc in protected mode will result in an error. Set
the write protection switch to the appropriate position as appropriate.
Back side of floppy disc
Protect Write
Filling out the label

Write the necessary information (name of data, date, etc.) on the label and attach it to the
floppy disc for proper filing.
1-14
Floppy disc insertion
Steps
Open the floppy disc driver cover before insert the floppy disc. Push the floppy disc until a
“click” sound is heard and the eject button pops out.
Floppy disc driver cover
Eject button
Label
Floppy disc removal
Never push the eject button while the access lamp is lit. Otherwise, the floppy disc and/
or floppy disc driver may be damaged, and the data stored on the disc may be lost.
CAUTION
Steps
Open the floppy disc driver cover and make sure the access lamp is not lit. Then push the
eject button to remove the floppy disc.
Access lamp Eject button
1-15
1-16
2 INSTALLATION
2 INSTALLATION
2.1 Robot body installation
Make sure that the injection molding machine power is turned OFF before getting close to
it. An indication should be made on the operator station to inform that personnel are
WARNING working on the injection molding machine.
There are some types of injection molding machine with the robot mounting holes already
drilled. Please contact the injection molding machine manufacturer or us regarding such
information.
In case of quenched stationary platen, holes should be made using a carbide-tipped drill.
Tapping should also be made carefully using roughing, intermediate, and finishing taps.
Make sure there is not any casting, protrusion, and so forth at a place to be tapped on the
stationary platen before tapping.
CAUTION When deciding whether or not to use an spacer, be sure to consider the size of the product
which will be handled by the take-out robot and the ceiling height at the factory where the
take-out robot will be installed.
Unless otherwise specified, apply locking agent before fitting the bolts.
Be sure to tighten the bolts using a torque wrench up to the specified torque.
(See A.4 Tightening torque.)
Step 1
Stationary platen Check whether or not the injection molding machine
stationary platen has six holes tapped as shown in the
figure to the left. If not, tap the stationary platen as
shown in the figure below.
Mold mounting surface
Tapped hole dimensions For standard spacer
D depth E
C
B
A A Mold fixing
surface
Type A B C D E Bolt length
VN -EA-700 200 75 150 M20 40 M20 60
Be sure to mount the spacer so that it does not protrude from the mold mounting surface.
CAUTION
2-1
2 INSTALLATION
Mounting Step 2
Stationary platen base
If necessary, mount the mounting base on the injection
molding machine stationary platen as shown in the
figure to the left. When the mounting base is not
required, proceed to Step 3.
Insert each bolt, along with a washer and a spring
washer, through the mounting base and into the tapped
Mold fixing surface holes. Then tighten the bolts to the specified torque.
Tap holes in the mounting base which match the holes in the stationary platen so that the
mounting base can be mounted to the stationary platen.
Step 3
Spacer
Mount the spacer to the stationary platen either directly
Stationary platen or with the mounting base.
Insert each bolt, along with a washer and a spring
washer, through the spacer and into the tapped holes
of the stationary platen or the mounting base. Then
tighten the bolts to the specified torque.
Mold fixing surface
Be sure to use a crane capable of bearing the robot body weight when slinging the robot
body.
Be sure to use sling points when slinging the robot body. Make sure that each sling point
WARNING fittings is fixed firmly before slinging the robot body.
Care should be used for personnel never to be under the robot body when slinging it.
Remove wiring, piping, parts, or other obstructions from the installation site before
installing the robot body.
CAUTION
2-2
2 INSTALLATION
Step 4
Use a rope or the like to fix the traverse axis so that it
does not move. Then, suspend the robot body as shown
in the figure below.
Belt
Step 5
Place the robot body on the spacer.
Insert each bolt (M16), along with a washer and a
spring washer, into the tapped holes (or nuts). Then
tighten the bolts to a torque of 255 Nm (26 kgm).
2-3
2 INSTALLATION
2.2 Electrical interface
Make sure the power supply to which the take-out robot will be connected is 3-phase
AC200V and is rated for 20A or above.
CAUTION
Connect each cable as shown in the figure below.
Control box
To control box
Robot body Cable (4)

Injection
molding machine
Interface
connector
Communication cable (2)
Power cable (3)
Operation box
To injection
Cable (1) molding machine
Cable (5)
To power supply
Cable (6)
Cable Length (meters) Connection

Cable (1) 5 Operation box - Touch panel controller
Communication cable (2) 8 Operation box - Control box
Power cable (3) 8 Breaker box - Control box
Cable (4) 8 Control box - Interface connector
Cable (5) 6 Interface connctor - Injection molding machine
Cable (6) 7 Breaker box - Power supply
2-4
2 INSTALLATION
2.3 Pneumatic hook-up
An excessively thin pneumatic supply hose may cause a pressure drop. Therefore, use an
adequately thick hose.
Flush (compressed air blow off) the tubing adequately before hooking up the pneumatic
CAUTION hose. The intrusion of chips, seal tape, or rust generated during the piping operation will
be the cause of malfunction, such as air leaks.
Step 1
Connect the hose to the plant air supply.
Pneumatic filter Step 2

Plant air supply
2
1
0
3 4 5
6
8
7 Connect the opposite end of the hose to the coupler
Hose on the pneumatic filter of the take-out robot.
Coupler
Step 3
Supply the plant air. Pull up the adjusting knob and
Regulator
adjust the pneumatic pressure to a range of 0.39 to
2
1
0
3 4 5
6
8
7 0.49 MPa (4 to 5 kgf/cm2).
Adjusting knob
Step 4
Make sure there are no leaks in the pneumatic unit.
2-5
2 INSTALLATION
2-6
3 OPERATION CHECK
3 OPERATION CHECK
After installing the take-out robot, perform the following operation checks.
Control power ON
Manual operation
before home position return motion
Home position return motion
See 4 Manual Operation

Manual operation
in the Operation Manual.
Motion prohibition area setting See 5.13 Motion prohibition area setting
Date and time setting See 8.5 Date and time setting
Control power OFF
Interlock check
Emergency stop
Before starting the operation check, make sure no persons or obstacles exist in the robot
motion area.
WARNING
3-1
3 OPERATION CHECK
3.1 Control power ON
Step 1
Turn ON the breaker box circuit breaker.
Breaker box
Circuit breaker
Step 2
Turn ON the control power.
Control power Make sure the control power lamp
switch
lights.
Control power
lamp
Step 3
Make sure the home position return
screen is displayed on the touch panel
controller after a few moments.
3-2
3 OPERATION CHECK
3.2 Manual operation before home position return motion
Check the robot operation in manual mode before performing the home position return motion.
During manual operation before home position return motion, the take-out robot does not
recognize interlocks or position data. Depending on its position, the take-out arm may
interfere with the mold. Watch the take-out arm carefully and be sufficiently aware of its
WARNING position during manual operation before home position return motion.
Step 1
Access the home position return screen.
(See 3.1 Control power ON.)
Step 2
Touch the Manual (Manual operation)
button.
Step 3
The manual operation screen is
displayed with a caution message as
shown in the figure left.
Step 4
Touch the Check button.
3-3
3 OPERATION CHECK
Step 3
The manual operation screen is
displayed.
Valve operation buttons Axis selection arrow buttons Free Mode button Axis position display
Page change buttons Speed setting buttons Lock-out switch status display
Valve operation buttons

Use these buttons to operate the solenoid valves. Whenever one of the buttons is touched, the
corresponding solenoid valve is turned ON/OFF.
Page change buttons

When all of the solenoid valves cannot be displayed on one page, they are displayed on
multiple pages. In such a case, use the Frwd (Forward) and Bkwd (Backward) buttons to
display the desired solenoid valve.
Axis operation buttons

Use these buttons to operate the selected axis. The button names change depending on the
axis selected. The names of the axis operation buttons for each axis are as follows.
A Traver (Traverse axis)
B M Kick (Main arm kick axis)
C M Arm (Main arm axis)
D S Kick (Sub arm kick axis)
E S Arm (Sub arm axis)
3-4
3 OPERATION CHECK
Speed setting buttons

Use these buttons to set the manual operation motion speed to one of four levels. The selected
speed button frame turns red.
Axis position display

This display indicates the current position in millimeters of all the axes. The axis name, the
current value, and the maximum value are displayed from the left respectively. The data for
the currently selected axis is displayed in yellow.
Lock-out switch status display

This image is displayed when the lock-out switch is not being pressed.
It is not displayed when the lock-out switch is being pressed.
Free Mode button

This button is red framed normally. This means that each axis can be moved to its stroke limit
no matter what teaching positions set. Touching the button to cancel the free mode (and turn
the frame white) stops each axis at the teaching positions during axis operation.
Step 6
Set the speed using the speed setting button.
Select “1” when operating for the first time.
Step 7
Place the touch Operate the axes.
panel controller Place the touch panel controller on the operator station
on the operation
box. or hold the touch panel controller while pressing one
of the lock-out switches with your thumb to turn the
OR
lock-out switch ON.
Lock-out switch Then, select the desired axis by touching the
Press down one of corresponding arrow button and operate the axis using
the lock-out
switches. the axis operation buttons.
3-5
3 OPERATION CHECK
Step 8
Operate the solenoid valves using the solenoid valve
operation buttons. The valve operation buttons and
the corresponding valve operations are listed in the
table to the left.
Button name Red frame White frame

Flip End-of-arm tool flip End-of-arm tool flip return
Vac.Suck (Product vacuum suction) Vacuum suction ON Vacuum suction OFF
PartGrip (Product chuck) Product chuck closed Product chuck open
Run.Grip (Runner chuck) * Runner chuck closed Runner chuck open
Spr.Grip (Sprue chuck) Sprue chuck closed Sprue chuck open
Ptch Adj. (Pitch adjustment) Pitch adjustment ON Pitch adjustment OFF
*: D type only.
Step 9
Touch the MENU button. The menu selection screen
is displayed.
3-6
3 OPERATION CHECK
3.3 Home position return motion
Perform home position return from the home return screen.

The home positin return motion screen is displayed in the following situations.
Directly after the control power is turned ON
When the Home Rtn (Home position return) button on the icon bar at the bottom of the
screen is touched.
During other operation, perform the home position return motion by touching the Home Rtn
(Home position return) button and displaying the home return screen.
Before beginning the home position return motion, make sure no persons or obstacles
exist in the robot motion area.
DANGER
Step 1
Touch the Home Ret (Home position
return) button from the home positin
return screen.
The home position return motion
begins.
Step 2
During the home position return motion,
a message indicating the take-out robot
is in home return motion is displayed.
When continuance of the home position
return motion may result in contact with
the injection molding machine, touch
the STOP button and stop the home
position return motion. Then use
manual operation to move the take-out
robot to a safe position.
3-7
3 OPERATION CHECK
See 4 Manual Operation in the Operation Manual for instructions on how to perform
manual operation.
Step 3
After the home position return motion,
make sure the main screen is displayed.
3-8
3 OPERATION CHECK
3.4 Interlock check
Interlocking is what coordinates the take-out robot operation with the injection molding machine
operation.
3.4.1 Signals
The following input/output signals are used for communication between the take-out robot and
the injection molding machine and between the take-out robot and external equipment.
Input signals from the injection molding machine

Signal name Description
Mold open limit This signal is ON when the injection molding machine has fully opened
the mold. When this signal is ON, arm unit can enter the mold area.
Safety gate closed This signal is ON when the injection molding machine safety gate is
closed. The take-out motion will not start unless this signal is ON.
Injection signal This signal turns ON when the injection molding machine injects. This
signal is used as one of the conditions for starting the take-out motion.
The take-out robot senses when this signal is turns ON and stores the
fact in its memory. If the safety gate is opened or the injection molding
machine is stopped during full-auto operation, this memory is cleared.
The take-out motion will not start unless the memory of the injection
signal turning ON exists. This use of the injection signal assures the
that the take-out motion during Auto operation starts only when injection
molding has been performed.
Injection molding machine full-auto
This signal turns ON when the injection molding machine starts full-
auto operation. During Auto operation, the take-out motion will not
start unless this signal is ON.
Bad part This signal turns ON when the injection molding machine produces
defective product during full-auto operation. When this signal turns
ON, the take-out robot performs the flip motion at the reject discharge
position, before it releases the product.
Input signals from external equipment (conveyer, stocker)

Descent order During Auto operation of the take-out robot, the arm unit descends on
the product release side when this signal is ON.
3-9
3 OPERATION CHECK
Output signals to the injection molding machine

Mold closed interlock This is a permission signal for the mold closed motion. When this signal
is ON, the injection molding machine can perform the mold closed
motion.
Mold open interlock This is a permission signal for the mold open motion. When this signal
is ON, the injection molding machine can perform the mold open motion.
Cycle start During Auto operation, this signal indicates to the injection molding
machine that the take-out motion has been completed. When this signal
turns ON, the injection molding machine performs the mold closed
motion and the next cycle begins.
When a take-out failure occurs, this signal does not turn ON and the
injection molding machine does not perform the mold closed motion.
Ejector order This is a permission signal for the eject motion of the ejector.
Output signals to external equipment (conveyer, stocker)

External signal During Auto operation, this signal turns ON after the product release
motion.
Casing Complete Signal 1
This signal turns ON after the casing motion (palletizing) is complete
(after all of the products have been cased on a pallet or in a container).
This signal is a pulse signal.
Casing Complete Signal 2
This signal is the same as Casing Complete Signal 1.
Hold flags
Injection flag During Auto operation, this flag turns ON when the injection signal is
received from the injection molding machine and remains ON as long
as the safety gate closed signal is ON. The take-out motion will not
start unless this signal is ON. When the safety gate opens even for a
moment after this flag turns ON, this flag turns OFF and the take-out
motion will not start.
Bad part flag During Auto operation, this flag turn ON when the bad part signal is
received from the injection molding machine and remains ON until the
take-out motion is complete. If this flag is ON when the take-out motion
starts, the take-out robot releases the product at the reject discharge
position.
3-10
3 OPERATION CHECK
3.4.2 Interface signal check
Make sure the interface signals function properly as follows.

After starting up the injection molding machine and the take-out robot, use the touch panel
controller to check the status of the signals.
Perform the signal checks listed below. Details are described on the following pages.
(1) Interface signal check performed at start-up (1 of 2)
(3) Interface signal check performed operating the injection molding machine before the
home position return motion
(4) Interface signal check performed using the monitor screen after the home position return
motion
(5) Interface signal check performed operating the injection molding machine after the
(6) Interface signal check performed while the take-out robot is in Auto operation
Step 1
Disconnect the injection molding
machine interface connector and
connect the dummy plug.
Dummy plug
To injection molding machine
Before turning on the control power, make sure no persons or obstacles exist in the robot
and injection molding machine motion area.
WARNING
Step 2
Control power Turn ON the control power.
switch
Control power
lamp
3-11
3 OPERATION CHECK
Step 3
After a few moments, the home position
return motion screen is displayed.
When the dummy plug is connected, the

take-out robot is in the emergency stop
condition. Although the normal screen
is displayed when the control power is
turned ON, if you attempt to operate the
take-out robot, the emergency stop error
message window is displayed and the
take-out robot does not operate.
Step 4
Touch the Home Ret (Home return)
button.
Step 5
Make sure that the emergency stop error
message window is displayed.
Step 6
Control power Turn OFF the control power.
switch
Control power
lamp
3-12
3 OPERATION CHECK
Step 7
Connect the injection molding machine
Interface connector to the take-out robot with the interface
connector.
To take-out robot
To injection
molding machine
Step 8
Control power
switch Turn ON the control power.
Control power
lamp
Step 9
The screen shown to the left is displayed
after a few moments.
Touch the Manual (Manual operation)
button.
3-13
3 OPERATION CHECK
Before starting manual operation, make sure no persons or obstacles exist in the robot
motion area.
During manual operation before home position return motion, the take-out robot does not
recognize interlocks or position data. Depending on its position, the take-out arm may
WARNING interfere with the mold. Watch the take-out arm carefully and be sufficiently aware of its
position during manual operation before home position return motion.
Step 10
A caution message shown in the figure
left is displayed.
Press the Check button.
Step 11
Make sure pre-home return manual
operation does not cause an error
message indicating an emergency stop
is provided to the take-out robot to
appear on the screen.
3-14
3 OPERATION CHECK
(3) Interface signal check performed operating the injection molding

machine before the home position return motion
Mold closed interlock Make sure that the mold close operation of the injection molding
machine is disabled before the take-out robot has performed the the
home position return motion (i.e., when the mold closed interlock
signal is OFF).
Mold open interlock Make sure that the mold open operation of the injection molding
machine is disabled before the take-out robot has performed the home
position return motion (i.e., when the mold open interlock signal is
OFF).
Ejector order Make sure that the injection molding machine ejector is disabled
before the take-out robot has performed the home position return
motion (i.e., when the ejector order is OFF).
If the injection molding machine ejector can be operated, regardless
of the status of the ejector order signal, whenever the injection
molding machine is in manual operation mode, make sure of the
foregoing while the injection molding machine is in auto operation.
Step 12
Touch the MENU button on the icon bar
of the manual operation screen.
3-15
3 OPERATION CHECK
Step 13
Touch the Home Rtn (Home position
return) button on the icon bar of the
menu selection screen.
Before beginning the home position return motion, make sure no persons or obstacles
exist in the robot motion area.
WARNING
Step 14
The home position return motion screen
is displayed.
Touch the Home Ret (Home position
return) button.
During the home position return motion,
a message indicating the take-out robot
is in home position return motion is
displayed.
3-16
3 OPERATION CHECK
Step 15
When the home position return motion
is completed, the main menu screen is
displayed.
Then, touch the MENU button.
Step 16
Touch the Other (Other machines input
and output signal) button of the
monitoring group on the menu selection
screen.
Step 17
The other machines input and output
signal screen is displayed.
Check the status of input/output signals
from/to the injection molding machine
or other external equipment.
3-17
3 OPERATION CHECK
(4) Interface signal check performed using the monitor screen after the
Mold open limit Make sure this signal turns ON when the mold fully opens.
Make sure this signal turns ON when the mold is closed.
Safety gate closed Make sure that this signal turns ON when the safety gate of the
injection molding machine is closed.
Make sure the this signal turns OFF when the safety gate of the
injection molding machine opens.
Injection Make sure this signal is OFF when the injection molding machine is
not performing any operation.
Make sure this signal turns ON when the injection operation is
performed.
Injection molding machine full-auto
Make sure this signal is OFF when the injection molding machine is
in manual or semi-auto mode.
Make sure this signal is ON when the injection molding machine is
in full-auto mode.
Bad part Make sure this signal is normally OFF after the mold opens during
non-defective molding cycles.
Make sure this signal turns ON after the mold opens when a defective
product is molded.
Descent order Make sure this signal turns ON when external equipment is ready to
receive the product.
Make sure this signal turns OFF when external equipment is not
ready to receive the product.
(5) Interface signal check performed operating the injection molding

machine after the home position return motion
Mold closed interlock Make sure that the mold close operation of the injection molding
machine is enabled after the take-out robot has completed the home
position return motion (i.e., when the mold closed interlock signal is
ON).
Mold open interlock Make sure that the mold open operation of the injection molding
machine is enabled after the take-out robot has completed the home
position return motion (i.e., when the mold open interlock signal is
ON).
Ejector order Make sure that the injection molding machine ejector is enabled
after the take-out robot has completed the home position return
motion (i.e., when the ejector order is ON).
If the injection molding machine ejector can be operated, regardless
of the status of the ejector order signal, whenever the injection
molding machine is in manual operation mode, make sure of the
foregoing while the injection molding machine is in auto operation.
3-18
3 OPERATION CHECK
Step 18
Touch the MENU button on the other
machines input and output signal screen.
Step 19
The menu selection screen is displayed.
Touch the MAIN button.
Before starting Auto operation, make sure no persons or obstacles exist in the robot motion
area.
WARNING
3-19
3 OPERATION CHECK
Step 20
The main menu screen is displayed.
Start Auto operation according to the
procedure described in 3. Auto
Operation of the Operation Manual.
(6) Interface signal check performed while the take-out robot is in Auto
operation
Cycle start The cycle start signal is used to continuously operate the injection
molding machine. Make sure that, during Auto operation of the
take-out robot, the injection molding machine is allowed to operate
in full-auto operation when the bad part signal is OFF. Then make
sure the injection molding machine is not allowed to operate in full-
auto operation when the bad part signal is ON.
Casing Complete Signal 1, 2
When the casing complete signal is connected, make sure the external
equipment operation is interlocked with the take-out robot operation
in Auto operation. For example, assuming the external equipment is
a conveyer, make sure the conveyer performs the pitch motion when
the take-out robot arm unit has fully ascended after palletizing is
complete.
Ejector order Make sure that when the ejector interlock is set to Interlock 1 or 2
from the mode selection screen, the ejector ejects at the take-out
robot kick return limit during Auto operation.
Make sure that when the ejector interlock is set to No from the mode
selection screen, the ejector is controlled by the injection molding
machine.
External emergency stop
Make sure the injection molding machine stops when the emergency
stop switch on the take-out robot is pressed.
Take-out robot emergency stop
Make sure the take-out robot stops when the emergency stop switch
on the injection molding machine is pressed.
3-20
3 OPERATION CHECK
Step 21
Touch the STOP button on the Auto
operation screen to stop the Auto
operation.
Step 22
Control power Turn OFF the control power.
switch
Control power
lamp
3-21
3 OPERATION CHECK
3.5 Emergency stop
Make sure the emergency stop switch operates properly.
Step 1
switch
Control power
lamp

Step 2
After the home position return motion
was completed or Manual (Manual
operation) button was touched, press the
emergency stop switch.
Step 3
Make sure the alarm sounds and the
error message window is displayed on
the touch panel controller.
3-22
3 OPERATION CHECK
Emergency stop switch Step 4

Reset the emergency stop switch.
Turning the emergency stop switch
clockwise will release and uplift the
switch.
Step 5
Touch the RESET button on the error
message window.
Step 6
Control power
switch Turn OFF the control power.
Control power
lamp
3-23
3 OPERATION CHECK
3-24
After the operation check, make the following adjustments and checks.
Before beginning the following procedures, be sure the take-out robot control power and
the injection molding machine power are OFF.
Put up notices, warning not to turn ON the control power because of maintenance operations
in progress, on the injection molding machine control panel and on the take-out robot
operator station.
WARNING
When it is necessary to turn ON the take-out robot during procedures, work in pairs with
one person ready to press the emergency stop switch at any time.
4.1 Entire machine
Make sure there are not any flaws and so forth on the entire machine.
4.2 Pneumatic unit
4.2.1 Pneumatic pressure adjustment
Step 1
Control power
switch Make sure the injection molding machine power and
the take-out robot control power are OFF.
Control power
lamp
Step 2
Connect the plant air to the take-out robot. Pull down
Regulator
the adjusting knob as shown in the figure. Adjust the
2
1
0
3 4 5
6
8
7 pneumatic pressure to 0.39 to 0.49 MPa (4 to 5 kg/cm2).
Adjusting knob
Step 3
Make sure there are no leaks in the pneumatic unit.
4-1
4.2.2 Solenoid valves check
Step 1
Control power
Control power
lamp
Step 2
Appropriate pneumatic pressure
(4 to 5 kg/cm 2) Make sure the appropriate pneumatic pressure
(0.39 to 0.49 MPa : 4 to 5 kg/cm2) is being supplied.
3 4 5
2 6
1 7
0 8
Before operating the solenoid valves, make sure no persons or obstacles exist in the robot
motion area.
WARNING
Step 3
Press the manual button of each solenoid valve in the
Junction box
junction box. Then, make sure the corresponding
chuck or cylinder operates properly.
Solenoid valve
Manual button
Indicator
Manual button
The number of solenoid valves differs depending on the options included with the take-
out robot.
4-2
4.2.3 Pressure sensor adjustment
Before turning ON the control power, make sure no persons or obstacles exist in the robot
motion area.
WARNING
Step 1
Control power Make sure the injection molding machine power is
switch
OFF.
Control power Turn ON the take-out robot control power.
lamp
Step 2
Appropriate pneumatic pressure
(4 to 5 kg/cm 2) Make sure the appropriate pneumatic pressure
(0.39 to 0.49 MPa: 4 to 5 kg/cm2)is being supplied.
3 4 5
2 6
1 7
0 8
The pressure sensor can be set in the range of 0 to -100 kPa (0 to 73 cmHg).
The pressure sensor senses a negative pressure in the vacuum suction unit to detect that
the suction pad has sucked a product. When this negative pressure becomes greater than
the setting value (about -70 to -100 kPa: -55 to -76 cmHg), the product vacuum suction
complete signal is transmitted to the control box.
Adjust the pressure sensor setting value under following condition.
A product has been sucked properly, but the take-out failure is occurred.
A product has not been sucked properly, but the take-out failure is not occurred.
Mode switch Step 3

Switch the pressure sensor mode switch inside the
junction box to SET. Set the value to -70 kPa
0 -76 (-55 cmHg) (reference value) by the pressure setting
Operation indicator Display Pressure setting knob
knob.
Pressure sensor When the pressure setting knob is turned clockwise,
the setting value increases.
Normal output continues even when in SET mode.
Junction box
4-3
Mode switch Step 4

Switch the mode switch to RUN. The display shows
the actual pressure.
0 -76
Pressure sensor
Junction box
Turning the pressure setting knob changes the pressure setting value even when in RUN
mode. Do not turn the knob after setting is complete.
CAUTION
Step 5
Control power
switch After adjustment, turn OFF the control power.
Control power
lamp
4-4
4.3 Mechanical adjustments
4.3.1 Runner chuck position adjustment
Adjust the runner chuck position according to the following procedure.
motion area.
WARNING
Step 1
switch
Control power
lamp
Step 2
Move the runner chuck to the runner take-out position
in manual operation.
See 4 MANUAL OPERATION in the Operation manual for instructions on how to

perform manual operation.
Step 3
Control power Make sure the injection molding machine power is
switch
OFF.
Control power Turn OFF the take-out robot control power.
lamp
4-5
The following step requires the operator to enter the motion area of the injection molding
machine and the take-out robot. Be sure to check that the take-out robot control power
DANGER and the injection molding machine power are OFF before entering the motion area.
Step 4
Loosen the two adjusting bolts and match the position
Adjusting bolts of the runner chuck with the sprue.
Step 5
Runner chuck When the position has been adjusted, tighten the
adjusting bolts.
Sprue
4-6
4.3.2 Runner chuck sensor position adjustment
motion area.
WARNING
Step 1
switch
Control power
lamp
Step 2
Move the runner chuck, to the runner take-out position
in manual operation.
See 4 MANUAL OPERATION in the Operation manual for instructions on how to

perform manual operation.
The following step requires the operator to enter the motion area of the injection molding
machine and the take-out robot. Be sure to check that the take-out robot control power is
DANGER OFF before entering the motion area.
Be careful not to get your fingers pinched in the runner chuck.
WARNING
M3 Step 3
adjusting bolt By valve operation, hold a board with the runner chuck
Sensor OFF Sensor ON as shown in the figure. Adjust the sensor so that when
a 1.2 millimeters board is held, the sensor is OFF; and
when a 2.5 millimeters board is held, the sensor is
Runner chuck
ON. Also make sure the sensor is OFF when the runner
A/2 A/2
A/2 A/2
chuck is open. When the sensor is ON, the lamp on

A
the tip of the sensor lights.
1.2 millimeters 2.5 millimeters
4-7
Step 4
Control power
switch After adjustment, turn OFF the control power.
Control power
lamp
4-8
Each procedure described in this chapter is on the condition that the take-out robot control
power and the injection molding machine power are turned OFF, unless otherwise specified.
Without fail, make sure that the control power is turned OFF before performing these
procedures.
in progress, on the injection molding machine control panel and on the take-out robot
WARNING
operator station before beginning maintenance procedures.
one person ready to push the emergency stop switch at any time.
Parts replacement
Be sure to use the specified parts. (See A.3 Maintenance parts list.)
CAUTION
5.1 Maintenance check list
The take-out robot has the following regular maintenance items.

Start-up
Perform this maintenance item before every operation.
Initial one month
Perform this maintenance item one month after installing the take-out robot.
Initial three months
Perform this maintenance item three months after installing the take-out robot.
One month
Perform this maintenance item monthly. However, at one month after installing the take-out
robot, perform the initial one month maintenance item.
Six months
Perform this maintenance item every six months.
Twelve months
Perform this maintenance item every twelve months.
Use the maintenance list to make out a Maintenance Check list for each take-out robot.
Make efficient use of the maintenance list to maintain the take-out robot.
5-1
Frequency
Initial Three Months

Initial One Month
Maintenance Item Checking Reference
12 Months
6 Months
Date Section
Start-up
1 Month
Pulleys, timing belt
1 Check each pulley mounting for slack. 5.2.1.
Travaerse unit
2 Check the timing belt for damage and

slack.
Motor
1 Check the motor mounting for slack. 5.2.1
2 Check the pulley mounting for slack.
3 Check the home position. 6.1.2
Motor, pulleys, timing belt
1 Check the motor mounting for slack. 5.2.3
2 Check the driving pulley mounting for
Kick unit
slack.
3 Check the driven pulley mounting for
slack.
slack.
5 Check the home position. 6.2.2
Flip bracket
1 Check the flip bracket for damage. 5.2.5
2 Check the flip bracket mounting for slack.
Flip cylinder
Flip unit
1 Check for air leaks. 5.2.5

2 Check the cylinder rod for damage and
slack.
3 Check the rod end bearing for slack.
Flip housing
1 Check the flip housing for damage. 5.2.5
2 Check the flip housing bearing for slack.
Frame
1 Check each frame mounting for slack. 5.2.6
2 Check each frame and the arm for damage
and deformation.
Arm unit
3 Check the unit cover for damage and slack

in its mounting.
Pulleys, timing belt
1 Check each pulley mounting for slack. 5.2.6
slack.
5-2
Frequency

Initial One Month
12 Months
6 Months
Date Section
Start-up
1 Month
Filter and regulator unit
1 Check the function of the regulator.
2 Adjust the pneumatic pressure. 4.2.1
3 Check the pneumatic filter condition. 5.3.1
Pneumatic tubing
1 Check connections for air leakage.
2 Check the condition of the pneumatic tube
bindings.
3 Adjust the pneumatic pressure of the 5.3.4
Pneumatic unit
balance cylinder.
Vacuum generator
1 Check the mounting for slack and 5.3.2
damage.
2 Check the function of the vacuum
generator.
3 Check the filter condition.
Exhaust unit
1 Check the mounting for slack.
2 Check the condition of the exhaust cleaner 5.3.3
element.
Solenoid valve
1 Check for air leakage. 4.2.2
2 Check the mounting for slack.
3 Check the function of the solenoid valve.
Robot body
1 Check the mounting base and the spacer
for slack.
Robot body
2 Check the leg mountings for slack.

3 Check the robot body and cover for slack
and damage.
Parts which showed abnormalities in the
previous work day.
1 Check for normal conditions.
5-3
Frequency

Initial One Month
12 Months
6 Months
Date Section
Start-up
1 Month
Control box
1 Check the operation of the power unit and 5.4.1
check the wiring for slack.
2 Check the operation of the servo amplifier
unit and check the wiring for slack.
3 Check the operation of the servo
controller unit.
4 Check the condition of the CPU unit and
the optical connector.
5 Check the condition of the interface board
relay contacts.
6 Check the interlock. 3.4
7 Check the function of the fan. 5.4.1
8 Check the encoder cable and other
Electrical units
connectors for slack.

Operator station
1 Check the emergency stop function. 3.5
2 Check the operation of each switch and
lamp.
3 Check the operation of the floppy disc 1.5.5
driver.
4 Check the operation of the eject button. 1.5.5
Touch panel controller
1 Check the emergency stop function. 3.5
2 Check the function of each screen. 5.4.2
3 Check the monitor for dirt and damage.
Sensors, switches
1 Check the operation and mounting 5.4.3
condition of each sensor and switch.
2 Check the condition of the wiring
bindings.
Wiring
1 Check the connectors and terminal 5.4.3
connections for slack.
2 Check the cables and wiring for damage.
5-4
5.2 Mechanical section
5.2.1 Traverse unit
This procedure is described on the basis of every 12 months check and adjustment. Since
there are unnecessary steps to do depending on the maintenance frequency, perform only
those steps as required.
Step 1
Remove the covers of the driving pulley and the driven
Driving pulley cover
pulley.
Driven pulley cover
Driving pulley Step 2

Check each pulley mounting for slack.
Driven pulley
Timing belt
Step 3
Check the motor mounting for slack.
Mechanical lock bolt
Traverse axis
servo motor
Step 4
Check the timing belt for slack and damage.
See 5.2.2 Traverse axis timing belt tension adjustment regarding adjustment of the
timing belt tension.
5-5
Step 5
Install the removed covers.
Driven pulley cover
5-6
5.2.2 Traverse axis timing belt tension adjustment
Step 1
Control power
Control power
lamp
Step 2
Remove the driven pulley cover.
Driven pulley
cover
Step 3
Loosen the four M10 bolts of the driven pulley.
Four M10 bolts
M12 adjusting bolt
Step 4
Adjust the timing belt tension using the M12 adjusting
bolt.
5-7
Step 5
In manual operation, move the traverse axis to the
position shown in the figure.
Step 6
Input the measurement conditions shown below into
550 millimeters the tension meter.
Measurement conditions
Tension meter
Specific gravity : 0.60 g/cm2
Width : 40 millimeters
Span : 550 millimeters
Step 7
Pluck the belt with a finger and measure the tension.
The tension should be 95 3 kgf. As necessary, return
to Step 4 and adjust the tension to the appropriate
value.
Step 8
Reassemble in the opposite order of disassembly.
Before beginning break-in operation, make sure no persons or obstacles exist in the robot
motion area.
WARNING
Step 9
Perform break-in operation for 10 hours or longer.
Step 10
After the timing belt has stretched, repeat the tension
measurement and adjustment.
5-8
5.2.3 Kick unit
Kick axis servo motor Step 1

pulley cover Remove the kick axis servo motor pulley cover and
guide.
Guide

Timing belt Check the motor mounting for slack.
Check the driving pulley mounting for slack.
Check the driven pulley mounting for slack.
Driven pulley Check the timing belt for slack and damage.
See 5.2.4 Main and sub arm kick axis timing belt tension adjustment regarding
adjustment of the timing belt tension.

pulley cover Install the removed covers.
Guide
5-9
5.2.4 Main and sub arm kick axis timing belt tension adjustment
This section describes how to adjust the tension of the main arm kick axis timing belt.
The following procedure basically applies to the sub arm kick axis timing belt tension
adjustment.
Step 1
Control power Make sure the injection molding machine power and
switch
Control power
lamp
Step 2
Remove the guide as shown in the figure.
Guide
Step 3
M6 adjusting bolt Four M6 bolts
Step 4
Adjust the timing belt tension using the M6 adjusting
bolt.
5-10
Step 5
In manual operation, move the kick axis to the position
shown in the figure.
Step 6
Tension meter Input the measurement conditions shown below into
the tension meter.
500 millimeters
Measurement conditions
Specific gravity : 0.6 g/cm2
Width : 25 millimeters
Span : 500 millimeters
Step 7
Pluck the belt with a finger and measure the tension.
The tension should be 40 3 kgf. As necessary, return
to Step 4 and adjust the tension to the appropriate
value.
Step 8
motion area.
WARNING
Step 9
Step 10
5-11
5.2.5 Flip unit
Step 1
Check the flip bracket for damage.
Check the flip bracket mounting for slack.
Flip cylinder
Step 2
Flip housing Cylinder rod Check the flip cylinder and the pneumatic tubing
Flip bracket for air leakage.
Rod end bearing
Check the cylinder rod for damage and slack.
Check the rod end bearing for slack.
Step 3
Check the flip housing for damage.
Check the flip housing bearing for damage.
5-12
5.2.6 Arm unit
This section describes how to check the main arm unit. The following procedure basically
applies to check the sub arm unit.
Step 1
Check each frame mounting for slack.
Check each frame and arm unit for damage and
deformation.
Check each cover for damage and check each cover
mounting for slack.
Step 2
Remove the cover required for the check.
Cover
Step 3
Check each pulley mounting for slack.
Check each timing belt for damage and slack.
Timing belt
Tension pulley
Driving pulley
See 5.2.7 Main and sub arm axis timing belt tension adjustment regarding adjustment
of the timing belt tension.
5-13
Step 4
Install the removed cover.
Cover
5-14
5.2.7 Main and sub arm axis timing belt tension adjustment
Perform the following procedures while plant air is supplied.

Perform the following procedures without the end-of-arm tool.
The balance cylinder is set so that it is balanced with the arm unit under no-load conditions.
CAUTION If the adjustment procedure is performed with the end-of-arm tool attached, there is the
danger that the arm unit will drop down.
This section describes how to adjust the tension of the main arm axis timing belt. The
following procedure basically applies to the sub arm axis timing belt tension adjustment.
Step 1
switch
Control power
lamp
Step 2
Place a support under the arm unit.
If not, the arm unit may drop down.
Arm frame
Support
Step 3
Remove the cover.
Cover
5-15
Step 4
Adjust the balance cylinder regulator to the following
Junction box
pressure value (factory setting value).
VN -EA-700: 0.2 MPa
Main arm balance cylinder
Step 5
M6 bolts Mechanical lock
Loosen the mechanical lock and then loosen the four
M8 nut
M6 bolts of the tension pulley mounting plate. (Two
of the M6 bolts are attached to the opposite side.)
Step 6
Loosen the M8 lock nut. Then, adjust the timing belt
M6 bolts tension using the M8 adjusting bolt.
M8 adjusting bolt
Step 7
In manual operation, move the arm axis to the position
shown in the figure.
Tension meter
Step 8
500 millimeters: main arm
300 millimeters: sub arm Input the measurement conditions shown below into
the tension meter.
Measurement condition Main arm Sub arm
2
Specific gravity 0.60 g/m 0.60 g/m2
Width 50 mm 40 mm
Span 500 mm 300 mm
Tension 85 3 kgf 55 3 kgf
Step 9
Pluck the timing belt with a finger and measure the
tension. The tension should be as shown in the table.
As necessary, return to Step 6 and adjust the tension
to the appropriate value.
5-16
Step 10
Step 11
Perform the home position adjustment.
See 6.3.2 Arm unit home position adjustment regarding adjustment of the home position.
motion area.
WARNING
Step 12
Step 13
5-17
5.3 Pneumatic unit
5.3.1 Pneumatic filter
Be sure to release the pneumatic pressure before performing the following procedure.
WARNING
Step 1
Remove the hose from the pneumatic filter coupler.
Plant air supply
Pneumatic filter
3 4 5
2 6
1 7
0 8
Hose
Coupler
Step 2
While pressing the red lock button, turn the bowl guard
to the right (opposite direction to the arrow) and align
the lock button with IN.
2
3 4 5
6
Remove the bowl and the bowl guard.
1 7
0 8
Step 3
O-ring
Main body Check the filter element for dirt and damage. When it
Filter element is dirty, blow it clean with compressed air. When the
filter element is badly damaged, replace it.
Mark
Baffle (See A.3 Maintenance parts list.)
Make sure the filer element is clean.
Bowl
Step 4
Drain cock
Bowl guard
5-18
5.3.2 Vacuum generator check and vacuum generator filter replacement
WARNING
Step 1
Turn the regulator adjusting knob so that the pneumatic
Regulator pressure is 0 Pa (0 kgf/cm2).
3 4 5
2 6
1 7
0 8
Adjusting knob
Step 2
Vacuum generator filter
Check the mountings of the vacuum generator and the
Vacuum generator Junction box vacuum generator filter for slack.
Then check the filter for dirt and damage.
Main body
Step 3
When the function of the filter has declined, replace
Filter element the filter.
O-ring (See A.3 Maintenance parts list.)
Cover Remove the mounting screw of the filter. Then, remove
the filter element.
Loosen
Step 4
5-19
Step 5
Pull down the adjusting knob. Then, adjust the
Regulator
pneumatic pressure to 0.39 to 0.49 MPa (4 to 5 kg/cm2).
3 4 5
2 6
1 7
0 8
Adjusting knob
Before turning on the control power, make sure no persons or obstacles exist in the robot
motion area.
WARNING
Step 6
Control power Turn ON the control power. Then, touch the HomeRet
switch
(Home Return) button. In this case, do not turn ON
Control power the injection molding machine power at this time.
lamp
Mode switch Step 7

Check the function of the vacuum generator using the
pressure sensor.
0 -76 Set the mode switch to RUN and check the pressure.
Pressure sensor
Junction box
Step 8
Control power
Control power
lamp
5-20
5.3.3 Exhaust filter
WARNING
Step 1
Turn the regulator adjusting knob so that the pneumatic
Regulator pressure is 0 Pa (0 kgf/cm2).
3 4 5
2 6
1 7
0 8
Adjusting knob
Step 2
Turn the exhaust filter bowl to the left. Then, remove
the bowl.
Exhaust filter
Step 3
Main body
Check the exhaust filter for dirt and damage. When it
is dirty, blow it clean with compressed air. When the
filter element is badly damaged, replace it.
(See A.3 Maintenance parts list.)
Make sure the filer element is clean.
Bowl
Step 4
Filter element Drain cock
5-21
5.3.4 Balance cylinder pneumatic pressure adjustment
Step 1
Attach the desired end-of-arm tool.
Step 2
Adjust the balance cylinder regulator to 0.2 MPa
Junction box (2.0 kg/cm2).
0.2 MPa (2.0 kg/cm2) is the factory setting value.
Step 3
While gradually raising the pressure of the regulator,
move the end-of-arm tool up and down by hand. Raise
the pressure until there are a few millimeters of play.
This is the point where the weight of the balance
cylinder and the arm unit are balanced and mechanical
backlash has developed. Raise the pressure still further
until all of the backlash is gone.
Step 4
Lock the adjusting knob.
5-22
5.4 Electrical section
5.4.1 Control box
Step 1
Remove the control box cover.
Step 2
Check each mounting and terminal for slack.
Control box cover
See A.1 Control box layout drawing regarding the control box layout.
Step 3
If the relay is damaged or the contacts are broken,
replace the relay. (See A.3 Maintenance parts list.)
Step 4
Control box Check the condition of the fan filter.
Filter
5-23
Step 5
Install the control box cover.
Control box cover
5-24
5.4.2 Operator station
Before beginning the following procedures, make sure no persons or obstacles exist in the
robot motion area.
WARNING
Step 1
Control power Turn ON the control power. Then,
switch
perform the home position return
Control power motion.
lamp (See 3.3 Home position return
motion.)
Step 2
Make sure the main menu screen is
displayed.
Touch the SlowCycle (Confirm
operation) button.
Step 3
When the move to the waiting position
is completed, the confirm operation
screen is displayed.
5-25
Step 4
Perform confirm operation and make
sure the take-out robot operates properly
in response to the touch panel controller
operation.
See 3.2 Auto operation procedure in the Operation Manual for instructions on how to
perform confirm operation.
Step 5
Control power
Control power
lamp
5.4.3 Sensor and wiring check
Steps
Check the operation and mounting of each sensor and switch.
Check the wiring for damage, wear, and burns.
Check the wiring connections for slack and damage.
Check each cable connection for slack and damage.
5-26
6 OVERHAUL
6 OVERHAUL
Each procedure described in this chapter is on the condition that the take-out robot control
power and the injection molding machine power are turned OFF, unless otherwise specified.
Without fail, make sure that the control power is turned OFF before performing these
procedures.
WARNING in progress, on the injection molding machine control panel and on the take-out robot
operator station before beginning maintenance procedures.
one person ready to push the emergency stop switch at any time.
Parts replacement
Be sure to use the specified parts. (See A.3 Maintenance parts list.)
CAUTION
6.1 Traverse unit
6.1.1 Traverse axis timing belt replacement
Step 1
Control power
Control power
lamp
Step 2
Remove the covers of the driven pulley and the driving
pulley.
Driven pulley cover
6-1
6 OVERHAUL
Step 3
Four M10 bolts Step 4

Loosen the M12 adjusting bolt to loosen the timing
M12 adjusting bolt
belt tension.
Step 5
Clamp Remove the four M8 bolts to detach the belt clamp
Four M8 bolts
from the traverse base.
Traverse base
Step 6
Six M6 bolts
Remove the six M6 bolts to detach the clamp from the
timing belt.
Clamp Timing belt

Remove the old timing belt. Then, position the new
timing belt in the same manner as the old timing belt
Driven pulley was positioned.
Timing belt
6-2
6 OVERHAUL
Make sure both ends of the timing belt are

Middle Clamp
positioned in the middle of the clamp.
CAUTION
Timing belt ends Timing belt
Step 8
Hold the timing belt between the clamp. Then, tighten
the six M6 bolts to fix the clamp to the timing belt.
Clamp Timing belt
Step 9
Clamp Tighten the four M8 bolts to attach the clamp to the
Four M8 bolts traverse base.
Traverse base
Step 10
Adjust the timing belt tension.
See 5.2.2 Traverse axis timing belt tension adjustment regarding adjustment of the
timing belt tension.
6-3
6 OVERHAUL
Step 11
Adjust the traverse axis home position.
See 6.1.2 Traverse axis home position adjustment regarding adjustment of the home
position.
Step 12
Install the covers of the driven pulley and the driving
pulley.
Driven pulley cover
6-4
6 OVERHAUL
6.1.2 Traverse axis home position adjustment
motion area.
WARNING
Step 1
Control power Turn ON the control power. Then, perform the home
switch
position return motion.
Control power (See 3.3 Home position return motion.)
lamp Perform the adjustment with the traverse axis in the
home position.
Step 2
Remove the traverse axis driving pulley cover.
Step 3
Mechanical lock bolt Loosen the mechanical lock bolts which hold the pulley
to the traverse axis servo motor.
Traverse axis
servo motor
See A.8 Mechanical lock installation/remotion for instructions on how to loosen the
mechanical lock bolts.
6-5
6 OVERHAUL
Control box Step 4

Control box
side Push the kick unit by hand to adjust the position of the
Traverse frame home position sensor to the magnet is as shown in the
Magnet
figure.
Direction sensor
14
Traverse axis
home position sensor Magnet
Step 5
Mechanical lock bolt Retighten the mechanical lock bolts which hold the
pulley to the traverse axis servo motor.
Traverse axis
servo motor
See A.8 Mechanical lock installation/remotion for instructions on how to tighten the
Step 6
Reinstall the traverse axis driving pulley cover.
6-6
6 OVERHAUL
6.2 Kick unit
6.2.1 Main and sub arm kick axis timing belt replacement
This section describes how to replace the main arm kick axis timing belt. The following
procedure basically applies to the sub arm kick axis timing belt replacement.
Step 1
switch
Control power
lamp

pulley cover
Remove the guide and the kick axis servo motor pulley
cover.
Guide
Step 3
M6 adjusting bolt Four M6 bolts
Step 4
Loosen the M6 adjusting bolt to loosen the timing belt
tension.
6-7
6 OVERHAUL
Two M10 bolts Step 5

Remove the two M10 bolts to detach the clamp from
the arm unit.
Clamp
Arm unit
Step 6
Clamp Remove the eight M5 bolts to detach the clamp from
the timing belt.
Timing belt
Eight M5 bolts
Step 7
Driving pulley Remove the old timing belt. Then, position the new
Timing belt
was positioned.
Driven pulley
Step 8
Clamp Hold the timing belt between the clamp. Then, tighten
the eight M5 bolts to fix the clamp to the timing belt.
Timing belt
Eight M5 bolts
6-8
6 OVERHAUL
Two M10 bolts Step 9

Tighten the two M10 bolts to attach the clamp to the
arm unit.
Clamp
Arm unit
Step 10
See 5.2.4 Main and sub arm kick axis timing belt tension adjustment regarding
adjustment of the timing belt tension.
Step 11
Adjust the kick axis home position.
See 6.2.2 Kick axis home position adjustment regarding adjustment of the home position.

pulley cover Install the guide and the kick axis servo motor pulley
cover.
Guide
6-9
6 OVERHAUL
6.2.2 Kick axis home position adjustment
This section describes how to adjust the main arm kick axis home position. The following
procedure basically applies to the sub arm kick axis home position adjustment.
motion area.
WARNING
Step 1
switch
lamp Perform the adjustment with the kick axis in the home
position.

pulley cover Remove the kick axis servo motor pulley cover.
Step 3
Loosen the pulley fixing mechanical lock bolts of the
kick axis servo motor.
Pulley fixing
mechanical
lock bolt
6-10
6 OVERHAUL
Step 4
Push the arm unit by hand to adjust the position of the
Main arm kick axis home position sensor to the magnet is as shown in the
home position sensor
Junction box figure.
side
12 0.5 mm
Kick axis frame
Direction sensor
Magnet Magnet
Magnet
Junction box
side
Sub arm kick axis
home position sensor 12 0.5 mm
Kick axis frame
Direction sensor
Magnet
Step 5
Retighten the pulley fixing mechanical lock bolts of
the kick axis servo motor.
Pulley fixing
mechanical
lock bolt

pulley cover Install the kick axis servo motor pulley cover.
6-11
6 OVERHAUL
6.3 Arm unit
6.3.1 Main and sub arm axis timing belt replacement

When the plant air supply to the take-out robot is OFF, compressed air is not supplied to
the balance cylinder. If the adjustment procedure is performed under such conditions,
there is the danger that the arm unit will drop down due to its own weight when the timing
CAUTION belt is removed.
If the adjustment procedure is performed with the end-of-arm tool attached, there is the
This section describes how to replace the main arm axis timing belt. The following
procedure basically applies to the sub arm axis timing belt replacement.
Step 1
Control power
Control power
lamp
Step 2
Place a support under the arm unit.
If not, the arm unit may drop down.
Arm frame
Support
6-12
6 OVERHAUL
Step 3
Adjust the balance cylinder regulator to the following
Junction box
pressure value (factory setting value).
VN -EA-700 : 0.2 MPa
Step 4
Remove the cover.
Cover
Mechanical lock
Step 5
M6 bolts
M8 nut Loosen the mechanical lock and then loosen the four
M6 bolts of the tension pulley mounting plate. (Two
of the M6 bolts are attached to the opposite side.)
Step 6
Loosen the M8 lock nut. Then, loosen the timing belt
M6 bolts
M8 adjusting bolt tension using the M8 adjusting bolt.
Step 7
Loosen the four M6 bolts to detach the upper clamp.
Timing belt
Upper clamp
Four M6 bolts
6-13
6 OVERHAUL
Step 8
Loosen the four M6 bolts to detach the lower clamp.
Timing belt
Lower clamp
Four M6 bolts
Step 9
Remove the old timing belt. Then, position the new
Timing belt
was positioned.
Step 10
Hold the timing belt between the lower clamp. Then,
tighten the four M6 bolts to fix the lower clamp to the
timing belt.
Timing belt
Lower clamp
Four M6 bolts
Step 11
Hold the timing belt between the upper clamp. Then,
tighten the four M6 bolts to fix the upper clamp to the
timing belt.
Timing belt
Upper clamp
Four M6 bolts
6-14
6 OVERHAUL
Step 12
See 5.2.7 Main and sub arm axis timing belt tension adjustment regarding adjustment
of the timing belt tension.
Step 13
Adjust the arm axis home position.
See 6.3.2 Arm axis home position adjustment regarding adjustment of the home position.
Step 14
Cover
6-15
6 OVERHAUL
6.3.2 Arm axis home position adjustment

CAUTION If the adjustment procedure is performed with the end-of-arm tool attached, there is the
This section describes how to adjust the main arm axis home position. The following
procedure basically applies to the sub arm axis home position adjustment.
motion area.
WARNING
Step 1
switch
lamp
Perform the adjustment with the arm axis in the home
position.
Step 2
Remove the cover.
Cover
6-16
6 OVERHAUL
Step 3
Loosen the mechanical lock of the arm axis driving
pulley.
Mechanical
lock
Step 4
Move the arm unit by hand to adjust the position of
Main arm
proximity switch the proximity switch to the dog is as shown in the
figure.
Arm frame
Main arm dog 20 0.5 mm
Main arm dog
Sub arm
proximity switch
Arm frame
Sub arm dog 32 0.5 mm
Sub arm dog
6-17
6 OVERHAUL
Step 5
Retighten the mechanical lock of the arm axis driving
pulley.
Mechanical
lock
Step 6
Cover
6-18
APPENDIX
APPENDIX
A.1 Control box layout drawing
Front side
X-axis Y-axis Z-axis U-axis V-axis

750W 200W 750W 200W 400W
Traverse Main Main arm Sub Sub

arm arm arm
kick kick
Back side
R1
R2 R4 T1
MC1
Resistor
Switching power supply
P5-V board
E-1 E-4 T-1 I-1 M-1
E-2 E-5 T-3 O-1 M-2

Spare
E-3 S-8 S-9 M-3
A-1
A-2
APPENDIX
6 6 6 6
E8CC
CN0C2B
CV15HR
VF3
V182E1
V182M3F
A.2 Circuit drawing
Main arm cylinder Sub arm cylinder

Flip cylinder CG1BN50 CM2B40
63x85
Nipper unit
A.2.1 Pneumatic circuit
6
ESC6
-1/8-0
C250
8 6 6 6 6 4 6 6 4 4 4
8 Vacuum Product Sprue Runner Nipper Pitch

Flip suction chuck chuck chuck Nipper cut approach adjustment
F300+MF400+R300
8 EF600
10
10 VEX1133-02-G 10
10 VEX1133-02-G 10
Interface connector 24 pin
CN3
17 1 Interface circuit board
K CN1
Mold closed interlock F0 OUT 10 3110 Mold closed interlock
18 *1 5 OUT 10 Mold closed interlock 3110 4
L 20 7
3111 Mold open interlock
OUT 11 Mold open interlock 3111 5
I 3112 Spare output
Mold open interlock F1 OUT 11 OUT 12 3112 6 3113
19 *1 11 Cycle start
J OUT 13 Cycle start 3113 7 3114
21 6 Ejector order
OUT1 OUT 14 Ejector order 3114 8 3115
Spare output F2 OUT 12 3116 Spare output (16)
24 *1 9 OUT 16 3116 10
OUT2 15 2 11
3117 Spare output (17)
G OUT 17 3117 3118
OUT 1C External signal 311C 12
Cycle start F3 OUT 13 3119
16 *1 3 Casing completed (1) 311D 13
H OUT 1D 311A
23 10 OUT 1E Casing completed (2) 311E 14
M 15
311B
Ejector order F4 OUT 1F 311F 311C
22 *1 12
OUT 14 External signal
N OUT ES
1 8
311D Casing completed (1)
E1 311E Casing completed (2)
Take-out robot
emergency stop 2 *1 4
FE OUT ES 311F Spare output (1F)
E2 3000 Mold open completed
3001 Safety gate closed
6 7 R20 C0 R10 LED0 R0 3002 Injection signal
Mold open completed F 1 3 Mold open completed 3000 16
IN 00 4 3003 Injection molding machine full-auto
2 5 Safety gate closed 3001 17
8 8 R21 C1 R11 LED1 R1 3004 Spare input (04)
Safety gate closed E 1 3 Injection signal 3002 18
IN 01 4 3005 Spare input (05)
2 5 Injection molding machine full-auto
7 9 R22 C2 R12 LED2 R2 3003 19 3006 Bad part signal
Injection signal D1 1 3 3004 21
IN 02 4 3007 Spare output (07)
2 5
Injection molding 11 10 R23 C3 R13 LED3 R3 3005 22 3008 Spare output (08)
D2 1 3 Bad part signal 3006 20
machine full auto IN 03 4 3009
2 5
14 4 R24 C4 R14 LED4 R4 3007 23 300A
Spare input IN2 1 3 3008 9
IN 04 4 300B
2 5 Descent order
10 14 R25 C5 R15 LED5 R5 300C 24 300C Descent order
Spare input IN1 1 3 300D 25
IN 05 4 300D Spare input (00)
2 5
9 15 LED6 R6 300E 26 300E Spare input (0E)
Bad part signal S R26 C6 R16 1 3
5 13 IN 06 4 300F 24 300F Spare input (0F)
Interface common C 2 5 P3 1,2,3
A.2.2 Injection molding machine interface
12 3 24G 28,29,30
Y24V 5
13
Y24G +24 6
3 11
+24
P6-A 5
Injection molding P1 4 12
P6-A
P6-B 4
machine emergency P2 P6-B
FG 1,2,6 P3 3
stop FG P3
24G 2
OUT 16
OUT 17
OUT 1C
OUT 1D
OUT 1E
OUT 1F
CN2 24G
1
FG
FG
24G
IN 0D
IN 0E
*1 Indicates
7
1
2
3
4
8
9
6
5
12
11
13
15 IN 07
16 IN 08
17 IN 0C
20 IN 0F
10
14
18
19
dummy plug CN4

jumper
1
2
3
NCS-163R
Descent order
Injection molding machine Control box
Input signal for Take-out robot is DC24V.

APPENDIX
A-3
APPENDIX
A.3 Maintenance parts list
Unit Part name Type Qty. Part No. Remarks

Traverse Timing belt 040-AT10-0565E-L 1 0710610 2000 traverse
040-AT10-0665E-L 1 0024840 2500 traverse
Filter element Element for MF400-02-A-5W 1 0704880
Element for F300-02-A-6W 1 0279570
Magnet MG-C 1 0106480
Main arm Timing belt 050-AT10-0150E-L (bending resistance) 1 0644890 1500 stroke
2240-8M-40 1 0644900 1500 stroke
Flip Speed controller ESC6-PT1/8-0 2 0134370
Sub arm Timing belt 040-AT10-0136E-L (bending resistance) 1 0650600 1500 stroke
2240-8M-30 1 0169120 1500 stroke
Kick Timing belt 025-AT10-0390E-L 1(2) 0710730
Magnet MG-C 1(2) 0106480
Junction Solenoid valve 180-4E2-CPLL-11W 1 0320030 Flip
box A180-4E2-CPLL-12W 1 0360400 Vacuum suction
A180-4E1-CPLL-26W 1 0320040 Product chuck
Nipper cut
Runner chuck
Nipper approach
Pitch adjustment
Sprue chuck
Pressure sensor E8CC-CN0C2B 1 0804820
Vacuum generator CV-15HR 1 0804550
Vacuum generator filter VF-3 1 0113070
Filter EF600-04 1 0147630
Electrical Contact relay MY4N-D2 DC24V 2 0208160
unit
G2R-1-SND DC24V 6 7030040
Contactless relay AQ6904 7 0160720
Timer H3Y-2 DC24V 5S 1 0151590
Fuse FGMB-250V-3A (small) 6 7340110
ZT000133BM14010
A-4
APPENDIX
A.4 Tightening torque

Nm (kg m)
Steel members Aluminum members
M3 1.5 (0.15) 1.1 (0.11)
M4 3.4 (0.35) 2.4 (0.24)
M5 6.9 (0.70) 4.5 (0.46)
M6 12 (1.2) 8.0 (0.82)
M8 29 (2.9) 20 (2.0)
M10 57 (5.8) 39 (4.0)
M12 98 (10.1) 71 (7.2)
M14 157 (16.0) 108 (11.0)
M16 255 (26.0) 159 (16.2)
M20 490 (50.0) 321 (32.8)
M24 843 (86.0) 490 (50.0)
A-5
APPENDIX
A.5 Digital operator
The digital operator is used for the parameters input and the error condition check.
A.5.1 Type
Manufactured by YASKAWA ELECTRIC CORPORATION

TYPE: JUSP-OP03A
A.5.2 Notice
AC SERVOPACK (type SGD) has two control types: speed control (torque control) and position
control. Since each has different operations, make sure of your SERVOPACK control type.
The VNII-EA uses speed control.
A.5.3 Digital operator installation
The digital operator shall install on OPERATOR terminal as shown below. Make sure of the
SERVOPACK control type before installation of the digital operator.
K
AC
BOP
SER
O K
P AC
OP
E RB
SE
R
A T
SE
T DE
MO
O UP
R
TA
DA
WN
03A
DO OP
A-6
APPENDIX
A.5.4 Status indication mode
When this mode is selected, the condition of SERVOPACK is indicated with bits and codes as
shown in the figure below.
Panel Display
SPEED AGREED TGON (CURRENT LIMIT DETECTION) *
BB SPEED REFERENCE INPUT
CODE
POWER SUPPLY ON TORQUE CONTROL
Steps
UP DOWN
: Alarm reset switch
MODE/SET
: Changes state indication mode into setting mode.
* : TGON or current limit detection is displayed according to bit 4 of user constant Cn-01.
Bit Data Contents

Bit data Contents Remarks
Power Supply ON Light goes ON with power supply ON.
BB Light goes ON with base block, and goes OFF

with servo ON.
Speed Agreed Light goes ON when motor rotating speed

reaches internal speed reference set by a speed
reference or parameter.
TGON Light goes ON with motor rotating speed Selected by bit 4

higher than TGON level. of user constant
Cn-01.
Current Limit Detection Light goes ON when torque reference reaches
the torque limit value.
Speed Reference Input Light goes ON with speed reference input equal
to or higher than TGON level.
Torque Reference Input Light goes ON when torque reference input less Only at torque
than 10% of rated torque. control.
Codes and Status

Code Display Status
bb Base Block
run On Operation
pob Forward Running Interrupted
nob Reverse Running Interrupted
R.00 Alarm Status
A-7
APPENDIX
A.5.5 Set of parameter
Setting mode
In this mode, the following operations can be performed.

User constant setup and check. Offset adjustment
Controlling operations from the digital operator Abnormal traceback data clearing
Check of motor parameters Auto tuning
Check of software version
User constant (data) setup and check

(Cn-03 to Cn-23)
Panel Display 1 2 BLINK
DATA
SETTING MODE ITEM No. 6 DATA

4
Step 1
UP DOWN
Set up the item number with the or key.
While the key is held down, the numerical value increases or decreases successively by one.
Step 2
DATA
With the key, display the data related to the selected item number.
Step 3
UP DOWN
With the and key, set up the data. (The same operation as stated in 1.)
While the key is held down, the numerical value increases or decreases successively by one.
Step 4
MODE/SET
Retain the data with the key.
Step 5
Repeat steps 1 through 4 as needed.
Step 6
DATA
With the key, return to the item No. display state.
Step 7
MODE/SET
Using the key, switch from the setting mode to the monitor mode.
A-8
APPENDIX
User Constants Cn-03 through Cn-23 (Constant Setting) List
User Symbol Lower Upper limit Factory setting

Name Unit
constant limit A-axis B-axis C-axis D-axis E-axis
Cn-03 VREFGN Speed Reference Gain (r/min)/V 0 2162 500 500 500 500 500
Gain Constants
Cn-04 LOOPHZ Speed Loop Gain Hz 1 2000 120 250 150 250 200
Cn-05 PITIME Speed Loop Integration Time ms 2 10000 80 150 150 150 150
Constant
Cn-1A POSGN Position Loop Gain* 1/S 1 500 40 40 40 40 40
Cn-06 EMGTRQ Emergency Stop Torque % 0 Max. Torque 316 300 316 300 308
Cn-08 TLMTF Forward Running Torque Limit % 0 Max. Torque 316 300 316 300 308
Torque Constants
Cn-09 TLMTR Reverse Running Torque Limit % 0 Max. Torque 316 300 316 300 308
Cn-13 TCRFGN Torque Reference Gain 1/10 V/Rating 10 100 30 30 30 30 30
Cn-14 TCRLMT Speed Limit with Speed Control 1 r/min 0 Max. Speed 4500 4500 4500 4500 4500
Cn-17 TRQFIL Torque Reference Filter Time 100 s 0 250 30 20 20 20 20
Constant
Cn-18 CLMIF Forward External Current Limit % 0 Max. Torque 100 100 100 100 100
Cn-19 CLMIR Reverse External Current Limit % 0 Max. Torque 100 100 100 100 100
Cn-07 SFSACC Soft Start Time (Accel) ms 0 10000 0 0 0 0 0
Cn-23 SFSDEC Sort Start Time (Decel) ms 0 10000 0 0 0 0 0
Cn-0B TGONLV Zero-speed Level r/min 1 Max. Speed 20 20 20 20 20
Sequence Constants
Cn-0F ZCLVL Zero-clamp Level r/min 0 Max. Speed 10 10 10 10 10

Cn-22 VCMPLV Speed Agreed Signal Output Width r/min 0 100 10 10 10 10 10
Cn-12 BRKTIM Delay Time from Braking Command 10ms 0 50 10 0 10 0 10
to SVOFF
Cn-15 BRKSPD Brake Timing at Motor Rotation r/min 0 Max. Speed 200 0 200 0 200
(speed level at which brake
command is output)
Cn-16 BRKWAI Brake Timing at Motor Rotation 10ms 10 100 10 10 10 10 10
(waiting time from SVOFF to brake
command output)
Constants
Cn-0A PGRAT PG Division Ratio pulses/rev 16 32768 2048 2048 2048 2048 2048
Encoder
Pulse
Cn-11 PULSNO Number of Encoder Pulses pulses/rev 513 32768 2048 2048 2048 2048 2048
Cn-0C TRQMSW Mode Switch (Torque Reference) % 0 Max. Torque 200 200 200 200 200
Cn-0D REFMSW Mode Switch (Speed Reference) r/min 0 Max. Speed 0 0 0 0 0
Other Constants
Cn-0E ACCMSW Mode Switch 10(r/min)/S 0 3000 0 0 0 0 0

(Motor Acceleration Detection)
Cn-10 JOGSPD JOG Speed r/min 0 Max. Speed 100 100 100 100 100
Cn-1F SPEED1 1st Speed r/min 0 Max. Speed 100 100 100 100 100
Cn-20 SPEED2 2nd Speed r/min 0 Max. Speed 200 200 200 200 200
Cn-21 SPEED3 3rd Speed r/min 0 Max. Speed 300 300 300 300 300
*: Cn-1A Position Loop Gain is required when zero-clamp function is used.
A-9
APPENDIX
User constant (memory switch) setup and check

(Cn-01 to Cn-02)
User constants Cn-01 and Cn-02 can be set up or checked as memory switch bits.
Panel Display
EC A8 64 20 LIGHTS AT ON
BIT No.
FD B9 75 31
SETTING BIT No.
Step 1
UP DOWN
With the or key, enter the setup memory switch bit No. at the far right end of the
panel.
Step 2
MODE/SET
With the key, set the memory switch to ON or OFF. The panel indication comes on
when the switch is ON, and goes off when the switch is OFF.
Step 3
Repeat steps 1 and 2 as needed.
Step 4
DATA
Retain the data with the key.
Step 5
DATA
Step 6
MODE/SET
The tables on the following pages describes the memory switches: user constants Cn-01 and Cn-
02.
A-10
APPENDIX
User Constant Cn-01 (Memory Switch)
Selection Bit No. Setting Conditions Standard

0 0 Servo ON/OFF by external input (SV-ON). 0
1 The servo is OFF at all times.
1 0 The external input (SEN) is used.
Sequence (ABSO.PG 1 Regardless of the SEN signal presence, the SERVOPACK automatically 0
Input only) concludes that the "H" level prevails.
Selection
2 0 The P-OT signal prohibits forward running. 0
1 Forward running is permitted at all times.
3 0 The N-OT signal permits reverse running. 0
1 Reverse running is permitted at all times.
4 0 TGON signal is used as a signal output when rotating is detected. (TGON)
Sequence
Output Signal 1 TGON signal is used as a signal when current limit is detected. 0
Changeover
(TGON)
Treatment of 5 0 Maintains the servo alarm status at momentary power loss reset. 0
Momentary
Power Releases the servo alarm status automatically at momentary power loss reset.
Loss Reset 1
6 0 <DB stop> The dynamic brake stops the motor. 0
1 <Coasting to a stop> The motor is freed and brought to a stop.
7 0 < DB OFF after DB stop> 1
The dynamic brake is turned OFF after the motor is stopped.
1 <DB continuously ON after DB stop>
Abnormal
Stop The dynamic brake remains activated after the motor is stopped.
Selection 8 0 The overtravel state stop method agrees with bit 6. 0
Note 1
1 <Overtravel zero speed stop>
In the overtravel state, the motor is stopped at the torque setting defined by user
constant Cn-06.
9 0 In the overtravel state, base blocking (BB) is implemented after zero speed stop. 0
Note 2
1 In the overtravel state, zero clamping is effected after zero speed stop.
D-C 0-0 <Torque reference> 0
Note 3
Based on the torque reference level defined by user constant Cn-0C.
0-1 <Speed reference>
Mode Based on the speed reference level defined by user constant Cn-0D.
Switch
Selection 1-0 <Acceleration>
Based on the acceleration level defined by user constant Cn-0E.
1-1 <None>
The mode switch function is not provided.
E 0 Incremental encoder 0
Encoder
Selection 1 Absolute encoder
F Set nothing. 0
Notes: 1. The abnormal stop method in the torque control mode complies with bit 6.
2. Selects the state prevailing when the zero speed stop method has been selected for the overtravel state (bit 8).
3. Selects the mode switch operating condition. When the mode switch operates, the speed control mode changes from
P-1 control to P control.
A-11
APPENDIX
User Constant Cn-01 (Memory Switch) List (Cont'd)

Selection Bit No. Setting Description Reference Input Sequencer Signal Input Standard
0-0 <Speed control> P - CON 0-0
Regular speed control OFF : P1 control
The P - CON signal (1CN - 15) is used to Speed ON : P control
effect P/P1 control changeover. Reference
0-1 < Zero clamp speed control> (V - REF) P - CON
After the motor is stopped (ZCLVL), the OFF : Zero clamp
speed reference is disconnected to execute function OFF
the zero speed stop function. After this, ON : Zero clamp
maintains the servo lock status. function ON
The P - CON signal (1CN - 15) is used to
turn the zero clamp function ON and OFF.
1-0 <Torque control I> Torque None
The motor output torque is controlled by Reference
Control Mode Selection
the torque reference (T - REF). (T - REF)

The V - REF cannot be used.
B-A 1-1 <Torque control II> P-CON
The P - CON signal (1CN - 15) is used for OFF : Torque control
torque/speed control mode changeover. ON : Speed control
Torque control mode
The motor output torque is controlled by
the torque reference (T - REF).
The speed limit can be entered from
outside (V - REF).
The V - REF voltage (+) limits both the
forward and reverse running speeds.
MOTOR SPEED
SPEED LIMIT RANGE
V-REF
Speed control mode
The speed reference is entered from the V -
REF.
The T - REF cannot be used.
A-12
APPENDIX
User Constant Cn-02 (Memory Switch) List
Selection Bit No. Setting Description Standard

Reverse 0 0 CCW: Forward Running 0
Rotation Note
Mode 1 CW: Forward Running
Home Position 1 0 Home position error is detected. 0

Error Mask (ABSO.PG only) Home position error is not detected.
1
2 0 Contact inputs P-CL and N-CL are used as power supply limit ON/OFF reference inputs. 0
Contact
Reference Contact input P-CON is used as a signal specified in bit A of B of user constant Cn-01.
Mode
1 Contact inputs P-CL and N-CL are used as speed input reference selection (1st
and 3rd speed) signals.
Note: Turn off the power supply once after setting.
Digital operator controlled operation mode selection and operating

procedure
Digital Operator Controlled Operation Mode Selection
When user constant Cn-00 is set to 00, the operations are to be controlled from the digital operator.
Panel Display 1 2 3
DATA
SETTING MODE 5 DATA
ITEM No. 4
MODE/SET
OFF ON 4
Digital Operator Controlled Operation Mode Display
Step 1
UP DOWN
Select the item number 00 with the or key.
Step 2
DATA
Step 3
UP DOWN
With the or key, select the number 00.
Step 4
MODE/SET
With the key, turn ON or OFF the monitor panel controlled operation mode.
A-13
APPENDIX
Step 5
DATA
Step 6
MODE/SET
Digital Operator Controlled Operation Procedure
For speed reference adjustment, use user constant Cn-10.

(See A.5.5 Set of parameter).
Step 1
DATA
With the key, effect SVON/SVOFF changeover.
Step 2
UP
The motor runs in the forward direction while the key is held down.
Step 3
DOWN
The motor runs in the reverse direction while the key is held down.
Speed reference offset adjustment
When user constant Cn-00 is set to 01, the system enters the speed reference offset adjustment
mode.
Panel Display 1 2 3
DATA
SETTING MODE 6 DATA

MODE/SET
ITEM No.
5
Speed reference and torque

reference offset adjustment execution
Step 1
UP DOWN
Step 2
DATA
Step 3
UP DOWN
A-14
APPENDIX
Step 4
Apply the desired zero speed reference voltage with speed reference input. Apply the desired
zero torque reference voltage with torque reference input.
Step 5
MODE/SET
With the key, make speed reference offset adjustment and return to the user constant
Cn-00 data display state.
Step 6
DATA
Step 7
MODE/SET
Clearing abnormal traceback data
When user constant Cn-00 is set to 02, abnormal traceback data are cleared.
Panel Display 1 2 3
DATA
SETTING MODE 5 DATA

MODE/SET
ITEM No.
4
Clearing Abnormal Traceback Data
Step 1
UP DOWN
Step 2
DATA
Step 3
UP DOWN
Step 4
MODE/SET
With the key, clear abnormal traceback data and return to the user constant Cn-00 data
display state.
A-15
APPENDIX
Step 5
DATA
Step 6
MODE/SET
Speed reference offset manual adjustment
Mode Setting in Speed Reference Offset Manual Adjustment
When user constant Cn-00 is set to 03, the system enters the speed reference offset manual
adjustment mode.
Panel Display 1 2 3
DATA
SETTING MODE 5 DATA

MODE/SET
ITEM No. 4
SPEED REFERENCE INPUT OFFSET ADJUSTMENT MODE
MODE/SET
4
TORQUE REFERENCE INPUT OFFSET ADJUSTMENT MODE
MODE/SET
4
Step 1
UP DOWN
Set up the item number 00 with the or key.
Step 2
DATA
Step 3
UP DOWN
A-16
APPENDIX
Step 4
MODE/SET
With the key, switch the adjustment mode.
Step 5
MODE/SET
Speed Reference Offset Manual Adjustment
Input a voltage that will obtain zero speed reference to the speed reference input. Input a voltage
that will obtain zero torque reference to the torque reference input. (Normally “0” V)
Step 1
UP
While the key is held down, the offset is added to the forward running side.
Step 2
DOWN
While the key is held down, the offset is added to the reverse running side.
Step 3
MODE/SET
Using the key, store offset data, then enter the monitor mode.
Offset adjustment is performed so that the LED indication may basically become zero: however,
the perfect zero state of indication does not always off optimum adjustment. Therefore, adjust
the offset carefully, taking actual motor rotation into consideration.
A-17
APPENDIX
Check of motor parameters
Check Method of Motor Parameters
When user constant Cn-00 is set to 04, the system enters the motor parameter check mode.
Panel Display 1 2 3
DATA
SETTING MODE 5 DATA

MODE/SET
ITEM No. 4
MOTOR PARAMETER DISPLAY
MODE/SET
4
Y SPECIFICATION DISPLAY
MODE/SET
4
Step 1
UP DOWN
Set up item number “00” with the or key.
Step 2
DATA
Step 3
UP DOWN
Step 4
MODE/SET
With the key, check the motor parameter.
Step 5
DATA
Step 6
MODE/SET
A-18
APPENDIX
Parameter Display
Monitor Parameter
Monitor Capacity 9E: 30W

b2 : 50W
Motor Type 01 : 100W
0 : Series, 200V 02 : 200W
1 : Series, 100V 04 : 400W
08 : 750W
Y Specification
a b c d
Y Specification No. (Hexadecimal display)

(a 163+b 162+c 16+d) Y Specification No.
Nos. Corresponding to Alphabets

A : 10
b : 11
C : 12
d : 13
E : 14
F : 15
A-19
APPENDIX
Monitor mode
In this mode, the speed reference, torque reference, and other data can be observed on the digital
operator.
Next table lists the data that can be monitored.
Data Monitored
Monitor No. Data Monitored
00 Feedback Speed ( r/min )
01 Speed Reference ( r/min )
02 Torque Reference (%)
03 No. of Pulses from Phase-U edge (Phase-U)
04 Electrical Angle (deg)
05 Internal Status Bit Display 1 (Refer to the table on page A-18)
Panel Display 1 2
DATA
MONITOR MODE MONITOR No. 3 MONITOR DATA

INDICATION
Step 1
UP DOWN
With the or key, select a desired monitor No.
Step 2
DATA
With the key, initiate monitor display.
Step 3
DATA
Using the key, return to the monitor No. selection state.
Step 4
MODE/SET
With the key, switch from the monitor mode to the abnormal traceback mode.
A-20
APPENDIX
Bit Indication of Monitor Mode Un-05 Internal Status
Bit No. Symbol Contents Remarks

SVALN Servo Alarm
DBON Dynamic Braking
DIR Reverse Run Mode
TGON Motor Running
(Motor speed is TGON level or higher) Select by setting of bit 4 of user constant Cn-01.
CLT Current Limit
V-CMP Speed Agreed
MSON Mode Switch ON
P-CL Forward Current Limit
N-CL Reverse Current Limit
B-ON Motor under Present Condition
PA Phase-A
PB Phase-B
PC Phase-C
PU Phase-U Incremental encoder only
PV Phase-V Incremental encoder only
PW Phase-W Incremental encoder only
SVON Servo ON
P-CON P Operation Input
ZCLMP Position Loop Operation at Stopping Select by setting of bit A or B of user constant
DR Rotating Direction Input by External Setting Speed Cn-01 or bit 2 of use constant Cn-02.
(ON at reverse, OFF at forward)
P-ON Forward Running Prohibit Input
N-ON Reverse Running Prohibit Input
SEN SEN Signal Input Absolute encoder only
A-21
APPENDIX
Abnormal traceback mode

In this mode, information on past abnormal occurrences can be displayed.
Information on up to 10 past abnormal occurrences can be stored.
When an abnormality is reset or the control power is turned on, traceback data A.99 is saved.
(These data are also counted as one of a total of 10 stored items of abnormal information.)
For the relationship between traceback data and abnormal descriptions, refer to the table on
page A-18.
Panel Display
ABNORMAL TRACEBACK DATA

OCCURRENCE No.
Step 1
UP DOWN
With the or key, increase or decrease the abnormal occurrence number. The
abnormal information related to the selected number is then displayed. (The higher the
abnormal occurrence number, the older the abnormal occurrence.)
Step 2
MODE/SET
With the key, switch from the abnormal traceback mode to the status display mode.
A-22
APPENDIX
List of Alarm Displays

Alarm Display
Alarm Name Remarks
on Digital Operator
Absolute data error For absolute encoder only
User constant breakdown
User constant setting error
Overcurrent
Detection of regenerative error For SGDB servo amplifier only
Main circuit voltage error detection
Overspeed Detection level = Maximum rotation speed 1.1 or 1.2
Overspeed reference input Detection level = Maximum rotation speed 1.1 or 1.2
Overloaded For SGDA servo amplifier only
Overloaded (high load) Momentary overload
Overloaded (low load) Continuous overload
Absolute encoder error For absolute encoder only
Absolute encoder backup error For 12 bit absolute encoder only
Absolute encoder checksum error For 12 bit absolute encoder only
Absolute encoder battery error For 12 bit absolute encoder only
Absolute encoder data error For 12 bit absolute encoder only
Absolute encoder overspeed For 12 bit absolute encoder only
Heat sink overheated For SGDB servo amplifier only
Reference input read error
Servo overrun detected
Encoder output phase error
Encoder A-, B-phase disconnection
Encoder C-phase disconnection
Power line open phase For SGDB servo amplifier only
Power loss error Only when bit 5 of Cn-01 set to 1
Not an error
Digital operator transmission error 1 These alarms are not stored in alarm trace-back
Digital operator transmission error 2 memory.
A-23
APPENDIX
A.6 Tension meter
The tension meter is used form the timing belt tension adjustment.
A.6.1 Type
Manufactured by UNITTA Co., Ltd.
TYPE: U-303
A.6.2 Notice
Do not drop this unit. Also, do not hit this unit against any hard items.
Do not put water, solvent, or any other liquids on this unit.
Do not leave this unit in a highly dusty condition.
Do not leave this unit in a car or in the sunlight.
Do not use any volatile liquids (such as thinner and benzene) to clean this unit.
The arm of the flexible arm type sensor is a universal pipe. Do not bend the arm at sharp
angles.
Do not pull the cord sensor on the sensor body or the cord.
A.6.3 General arrangement
(1) Connector
easy to install
(12) Liquid crystal display
FREQ. RANGE
STD
(2) Frequency measurement H
range selector L
WEIGHT WIDTH SPAN (11) Input-key of data
7 8 9
(3) Background noise MIC GAIN
cancel control 4 5 6 (10) Numerical key
POWER
(4) Power ON 1 2 3
OFF
(5) Measure switch 0 Hz

MEASURE
(6) Frequency or tension

display select key
SONIC TENSION METER
(9) Microphone
(7) Dry cell (8) AC adapter
A-24
APPENDIX
A.6.4 Operating procedure
Step 1
Microphone connection
Connect the adequate microphone for measurement.
Step 2
Turn on the power
Push the “POWER” switch to turn ON.
Step 3
Input the unit weight
Push the “WEIGHT” button. Then, input the unit weight (gf/cm2) using ten keys.
Step 4
Input the timing belt width value
Push the “WIDTH” button. Then, input the width value (mm) using ten keys.
Step 5
Input the timing belt span length value
Push the “SPAN” button. Then, input the span length (mm) using ten keys.
Step 6
Set the frequency range
Set the frequency measurement range selector to “STD”, “H” or “L”.
STD ............. (10 to 600 Hz)
L .................. (10 to 50 Hz)
H .................. (300 to 600 Hz)
Step 7
Preparation for measurement start up
Put the microphone close to the back side or teeth side of the belt approximately at center of
the belt span. Increase the sensitivity of microphone using the “MIC GAIN” control until the
“MIC GAIN” lamp goes on, and then, slightly reduce the sensitivity level (the lamp goes off.)
In this status, tap the belt span with a finger and make sure that the “MIC GAIN” lamp goes
on.
Step 8
Start measurement
Push the “MEASURE” button. Tap the belt span with a finger and make sure that the belt
vibration. After pressing “MEASURE” button, tap the belt span with in 2.5 seconds, because
the standby time for system to start collecting the data on the vibration of the span has been
limited to 2.5 seconds.
A-25
APPENDIX
Step 9
Tension is displayed
The tension is displayed on the LCD display. When “Hz” button is pressed, the frequency
value is displayed. (When “Hz” button is pressed again, the tension is displayed.)
Step 10
Only frequency measurement
When the procedure without step (3) to (7) is done, only frequency is displayed instead of the
tension.
Belt tension adjustment reference
Main arm Sub arm Kick axis Traverse axis

Specific Width Tension Specific Width Tension Specific Width Tension Specific Width Tension
gravity gravity gravity gravity
g/cm2 mm kgf g/cm2 mm kgf g/cm2 mm kgf g/cm2 mm kgf
Reference span Reference span Reference span Reference span

mm mm mm mm
0.6 50 80 to 90 0.6 40 50 to 60 0.6 25 35 to 45 0.60 40 90 to 100

VN -EA-700
500 300 500 550
A-26
APPENDIX
A.7 YM3: Communication program between FA-M3 and PC/AT
A.7.1 Operation environment and initial settings
The following environment and settings are required in order to use this program.
Personal computer
This program operates using DOS/V Japanese Text mode. It is also compatible with V-Text. Set
the screen mode to 25 lines 80 characters or above. No graphics are used.
(This program can be operated using DOS/V English mode, but the Japanese characters will not
be properly displayed.)
RS232C interface
Connect the personal computer to the FA-M3 using the RS232 communication cable.
COM1 has been set as the communication port in initial settings. By changing the data of
YM3.CGF file (discussed later), other ports may be selected.
Module
The module can be connected to an FA-M3.
YM3.CFG file
When the communication port (channel) or the baud rate setting must be changed, follow the
instructions provided by the communication parameter setting line of the YM3.CFG file.
When anything other than the communication port is changed, the module must also be changed.
[YM3.CFG file example]

;***************************************
; Communication parameter setting
;***************************************
CCT01=0 ; Communication type selection 0 .... Internal 1 .... Board
CCT02=96 ; Baud rate
CCT03=8 ; Data length 5-8
CCT04=1 ; COM channel 1-4
CCT05=2 ; Parity 0 ... None 1 ... Odd 2 ... Even
CCT06=0 ; Flow 0 ... No 1 ... Yes
CCT07=1 ; Stop bit 0 ... No 1 ... Yes
YM3CFG/Communication parameter setting
CCT01 is normally 0.
Enter the baud rate divided by 100. For example, enter 9600bps as 96 and enter 19200bps as
192. (Enter 150bps, however, as 15.)
The data length is fixed at 8.
Set the other items according to the comments in the file.
A-27
APPENDIX
Select from among communication modes 0 to 2 for the communication with the sequencer.
Communication
Sending speed and sending type
mode Speed (bps) Data length Parity check Stop bit
0 9600 8 bit Even 1 bit
1 9600 8 bit None 1 bit
2 19200 8 bit Even 1 bit
[Example of YM3.CFG/Axis Count Setting file]

;***************************************
; Axis Count Setting
;***************************************
AXlS=0xff
YM3.CFG/Axis Count Setting
During parameters setting, input the number of axes required.

The setting is made in bits.
Set bit 0 for one axis, bit 1 for two axes, and so forth. The axis count setting is input in base 16
form. See the table below for details.
[Example of axis setting]

1 axis used 0x01
1 to 2 axes used 0x03
1 to 3 axes used 0x07
1 to 4 axes used 0x0f
1 to 5 axes used 0X1f
1 to 8 axes used 0xff
Set the other items according to the comments in the file.

Unless a change in the setting items is required, there is no need to change the settings.
If parameter settings or ID settings are changed, then the content of the MEMORY.C, PARA.C,
and ID.C files must also be changed. Do not change the settings unless it is necessary to do
so.
A-28
APPENDIX
A.7.2 How to use the program
When YM3.COM is started up, the following screen is displayed.
Parameter Id Quit
FA-M3COMMUNICATIONTOOL
YM3 For PC/AT Ver 1.00
Copyright (C) Yushin Precision Equipment Co.,Ltd.
Select processing.(Alt-)
Press the following keys to display each screen.

[Alt] + [P] Parameter setting screen
[Alt] + [I] ID input screen
[Alt] + [Q] End
Input from the parameter setting screen

Press [Alt] + [P], then display the parameter setting screen.
Move the cursor to the desired item and input the new data.
The function of each key (or combination of keys) is as follows.

Key Function
[ ] Moves cursor one line up
[ ] Moves cursor one line down
[ ] Moves cursor one space to the right
[ ] Moves cursor one space to the left
[SHIFT] + [ ] Moves cursor to the far right
[SHIFT] + [ ] Moves cursor to the far left
[SHIFT] + [ ]/[ ] Fast scroll
[ROLL UP] Half page down
[ROLL DOWN] Half page up
[0] to [9] Input parameter data
[BS] Clears last digit (during numerical input)
[HOMECLR] Clears numerical input
[ESC] Stops input (returns to previous data)
[CR] Finalizes input (moves cursor down)
A-29
APPENDIX
In order to prevent unnecessary input, the number of digits allowed is limited according to
the number of words used.
Data with units of (pulse/ms) have a fixed decimal; input data which includes a decimal.
Numerical values with three digits above and four digits below the decimal point can be
input.
Numerical values with more than three digits above the decimal point cannot be input. (the
decimal point is automatically inserted.)
Be careful regarding values which will become active.
Check the input range before inputting each value.
ID data input screen

The input procedure for ID data is basically the same as that for parameter data. Input the ID
version number, the take-out robot name, the take-out robot model, and the take-out robot number
using ASCII characters (alphabet, numerals, and symbols). For the alphabet, both lower case
and upper case letters are acceptable.
The function of each key (or combination of keys) is as follows.

Key Function
[ ] Moves cursor one line up
[ ] Moves cursor one line down
[SHIFT] + [ ] Moves cursor to the far right
[SHIFT] + [ ] Moves cursor to the far left
[SHIFT] + [ ]/[ ] Fast scroll
[ROLL UP] Half page down
[ROLL DOWN] Half page up
[0] to [9]/ Input parameter data
[Symbol]/[English characters]
[INS] Switches between insert and overwrite
[BS] Clears the character to the left of the cursor
[DEL] Clears the character in the same position as the cursor
[HOME CLR] Clears numerical input
The ID data input differs from the parameter input in that “0” is placed in front of the
input numeral (or alphabet character) when the input is finalized. When nothing has been
input, this “0” is not displayed.
Only positive integers are input for numerical data. Data with decimals and negative data
are not used.
For example, to input a value such as “0.15” for which the digit to the left of the decimal
is 0, input as [0] [.] [1] [5]. (Do not drop the first “0”.)
A-30
APPENDIX
Data communication
The data communication between the Module FA-M3 and the personal computer is as follows.
Parameter data communication
Parameter data for all axes or each axis can be sent and received.
[F1] Pressing this key sends parameter data for all axes immediately.
[F2] Pressing this key receives parameter data for all axes immediately.
[F3] Use this key to send parameter data for each axis. Pressing this key opens a window
requesting you to specify an axis, the data for which you want to send. Move the
cursor to the desired axis and press the [Enter] key. The data will be sent
immediately.
[F4] Use this key to receive parameter data for each axis. Pressing this key opens a
window requesting you to specify an axis, the data for which you want to receive.
Move the cursor to the desired axis and press the [Enter] key. The data will be
received immediately.
When the level meter which is displayed when data is sent or received reaches
100%, the communication is complete.
In data communication
0% 100%
When the data could be sent or received properly, an error message is displayed. Details
are discussed later.
ID data communication
Press [F1] to send and [F2] to receive. Sending or receiving begins after the key is pressed.
When the level meter which is displayed when data is sent or received reaches 100%, the
communication is complete.
A-31
APPENDIX
Error message
When the data could be sent or received properly, an error message is displayed.
When the error message is displayed, press the buttons as indicated in the message to display the
alarm screen. Then press [Alt] + [P], [Alt] + [I], or [Alt] + [Q] to move to the desired condition.
The error messages are as follows.

(1) Send error
This error message is displayed when the data was not sent at all or when the sending stopped
at some stage of the order. Possible causes are: the communication port is wrong; there is a
mistake in the initial variable settings; the data size is wrong.
(2) Receive error

This error message is displayed when the data was sent but no data was received in return.
The data or order* may contain a mistake.
This is because there are times when ER (error) is not sent back — although usually it is —
depending on the timing. This error message is also displayed when the module is not connected
or when the FA-M3 power is not ON.
(*: The order is usually not the cause because it is fixed at the initial conditions.)
(3) ER
This message is displayed when the order or data which was sent contained an error and the
FA-M3 sent back the error code. See pages 6-42 and 6-43 of the Sequence CPU Instruction
Manual, Function Volume.
A-32
APPENDIX
A.7.3 Writing to and reading from data files
Data write
The basic operations are the same for both parameter data and ID data.
The following extensions are attached to the filenames.
Parameter data: .PR
ID data: .ID
Press the [F1] key and display the file save window.
File name c: ym3 test
Title TEST
Y/Write N/Cancel
The file name, including the pass name, can be up to 32 characters.

The filename extension need not be input.
The title can be up to 32 characters.
The function of each key (or combination of keys) is as follows during data write.
Key Function
[ ]/[ ] Selects file name input, title input, or writing
[SHIFT]+[ ] Moves cursor to the far right
[SHIFT]+[ ] Moves cursor to the far left
[HOME CLR] Clears the data input (file name, title)
[Y]/[N] Selects write or cancel
A-33
APPENDIX
Data read
The basic operations are the same for both parameter data and ID data.
The following extensions are attached to the filenames.
Parameter data: .PR
ID data: .ID
Press the [F3] key and display the file save window.
Data file input
Display directory
c: YM3
<.. >
<TMP > Directory
TEST Test file Title
File name
After input or selection of the filename, press the [CR] key to read the data. After the data is
read, the filename is displayed on the upper right of the screen.
The function of each key (or combination of keys) is as follows during data read.
Key Function
[ ]/[[ ] Selects file name input, title input, or writing
[SHIFT]+[ ] Moves cursor to the far right
[SHIFT]+[ ] Moves cursor to the far left
[HOME CLR] Clears the data input (file name, title)
[Y]/[N] Selects read or cancel
A-34
APPENDIX
A.8 Mechanical lock installation/remotion
A.8.1 MA, MB, MKA and MSA series
Inner ring
Lock bolt Outer ring
Remotion tapped holes
Installation
Do not use greases or oils which contain molybdenum or extreme pressure agents. If
using them, torque reduction to well below the allowable limit and slipping may result.
WARNING
Step 1
Wipe off any rust, dust, or dirt from the surface of the shaft and the inside of the hub. Apply
a thin coat of oil or grease.
Step 2
Apply a thin coat of oil or grease to the inner and outer diameter surfaces of the mechanical
lock, the contact points of all tapers, and the lock bolts on the threaded portion and the
bearing surface of the head. (When the mechanical lock is taken apart in order to apply the
oil or grease, put it back together loosely after applying the oil or grease.)
If the inner ring collar and the end of the hub do not fit together precisely, the mechanical
lock and the collar may become warped.
If there is a shoulder behind the back surface of the hub, leave at least a 1 millimeter gap
between the back surface of the hub and the shoulder. If no gap is maintained between the
hub and the shoulder, an inappropriately large amount of force will be required to remove
WARNING the mechanical lock. Such force may result in deformation of the inner ring, rendering it
unfit for reuse.
When tapping with a plastic hammer, do not use excessive force. If doing so, the parts
may be damaged.
A-35
APPENDIX
Step 3
Attach the hub, which has been manufactured to the specified dimensions, to the shaft. Push
on the mechanical lock. Then, make sure the collar fits snugly with the end surface of the
hub. (See the figure below.)
If the outer ring will not fit, loosen the bolts and separate the tapered portions of the inner ring
and the outer ring. Then, insert the outer ring.
If the spigot will not fit, tap it lightly with a plastic hammer to insert it.
Torque wrench
Make sure the collar and the hub fit snugly Gap = 0
Spigot
Hub 1 millimeter or above
Shaft
Apply oil or grease to the mounting bolts.

Be sure to use all of the threaded removal holes and tighten each one a portion at a time.
WARNING Otherwise, the inner ring may be deformed, rendering it unfit for reuse.
Step 4
When all parts are in the proper position, tighten the lock bolts.
Use a torque wrench and tighten alternately between opposing bolts in order from 1 to 10 as
shown below. First tighten lightly (about 1/4 of the specified torque) and then increase the
torque slightly (to about 1/2 of the specified torque). Lastly, tighten to the specified torque.
Step 5
Be sure to tighten the bolts in order until each bolt has been tightened to the specified torque.
Make sure that none of the bolts has been neglected.
1 Strength classification
10 3 Tightening torque
Bolt size
Nm kg m
8 5 M3 1.9 0.2
M4 3.9 (2.7) 0.4 (0.28)
6 7
M5 8.8 (5.6) 0.9 (0.58)
M6 15.7 (9.5) 1.6 (0.98)
4 9 37.3 3.8
2
M8 39.2 4.0
(MB series) (MB series)
M10 78.5 8.0
M12 137.3 14.0
( ) indicates stainless specifications, MSA series.
A-36
APPENDIX
Remotion
Take the proper safety precautions before performing remove operations.
CAUTION
Step 1
Turn OFF the control power. Then, make sure there is no torque or thrust applied to the
mechanical lock. Also, make sure there is no danger of the any parts falling.
Step 2
Loosen the lock bolts in order, a portion at a time. After the lock bolts have been removed,
insert them into the remotion tapped holes and tighten alternately between opposing bolts.
Tighten a portion at a time keeping equal torque on each bolt until the mechanical lock is
removed.
Remotion tapped holes
A-37
APPENDIX
A.8.2 MN series
Configuration
Nut
Outer ring
Inner ring
Installation
Do not use greases or oils which contain molybdenum or extreme pressure agents. If
using them, torque reduction to well below the allowable limit and slipping may result.
WARNING
Step 1
Wipe off any rust, dust, or dirt from the surface of the shaft and the inside of the hub. Apply
a thin coat of machine oil or turbine oil.
Step 2
Apply a thin coat of machine oil or turbine oil to the inner and outer surface of the mechanical
lock, the contact points of all tapers, and the threaded portion of the lock bolts. (When the
mechanical lock is taken apart in order to apply the oil or grease, put it back together loosely
after applying the oil or grease.)
Step 3
Fit the mechanical lock into the hub machined to the specified dimensions, attach the hub to
the shaft, and then lightly tighten the nut by hand to ensure proper positioning.
When the nut is tightened, the hub will move to the A direction to the A direction shown in
the figure on the next page.
CAUTION If the mechanical lock is hard to fit into the hub, loosen the nut slightly.
Step 4
When all parts are in the proper position, tighten the nut lightly, and then tighten the nut
gradually to the specified torque with a torque wrench while taking care not to turn other
parts with the nut.
A-38
APPENDIX
Step 5
Retighten the nut to check if the nut has been tightened to the specified torque.
A
Torque wrench
Hub
Nut types and tightening torque
Nut types and tightening torque

Tightening torque
Nut Type Nm kg·m
MN8 24.5 2.5
MN10 29.4 3.0
MN11 34.3 3.5
MN12 44.1 4.5
MN14 58.8 6.0
MN15 68.6 7.0
MN17 98.1 10.0
MN20 137.0 14.0
MN22 147.0 15.0
MN24 167.0 17.0
MN25 186.0 19.0
MN28 226.0 23.0
MN30 255.0 26.0
MN35 294.0 30.0
Remotion
Take the proper safety precautions before performing remove operations.

CAUTION
Step 1
Turn OFF the power source (control power). Then, make sure there is no torque or thrust
applied to the mechanical lock. Also, make sure there is no danger of the any parts falling.
Step 2
Apply oil to the threaded portion and gradually loosen the nut.
The shaft and hub will be disengaged.
A-39
APPENDIX
A.9 Troubleshooting flowchart
A.9.1 Control power fails to turn ON
Check result Check item Corrective action

Plant power supply
breaker ON?
Breaker ON Breaker OFF Turn the breaker ON.
Primary power supply

plug socket connection
OK?
Connection OK Connection NG Connect the power supply plug
socket.
Connection between
control box and breaker
box OK?
Connection OK Connection NG Connect the connector.
Breaker box breaker ON?
Breaker ON Breaker OFF Turn the breaker ON.
Measure the supply

voltage.
AC200V single phase Voltage

Supply the single phase AC200V
supplied other than AC200V
to the breaker box.
Inside control box,
DC24V OK? (between P1
and 24G)
DC24V ON DC24V OFF (1) The switching power supply

is broken.
Inside control box, MC1
(2) The switching power supply
ON?
wiring is broken.
MC1 ON MC1 OFF (1) MC1 is broken.
(2) The MC1 wiring is broken.
Inside control box, T1
ON?
T1 ON T1 OFF (1) T1 is broken.

(2) The T1 wiring is broken.
Control power switch is broken.
A-40
APPENDIX
A.9.2 Servo power fails to turn ON

Operator station
emergency stop OFF?
Injection molding machine
interface cable connection
OK?
Emergency stop OFF Emergency stop ON Reset the emergency stop switch.
(including external emergency
Servo ON order ON? stop switches)
(1110)
Servo ON order ON Servo ON order OFF (1) Check the alarm message on
the screen.
Inside control box, R2 (2) The I/O module is broken.
relay ON?
R2 ON R2 OFF (1) R2 is broken.

(2) The R2 wiring is broken.
Servo power ON input
signal ON? (1000)
Servo ON input ON Servo ON input OFF (1) The I/O module is broken.
(2) The I/O module wiring is
broken.
Inside control box, R1
relay ON?
R1 ON R1 OFF (1) R1 is broken.

(2) The R1 wiring is broken.
Servo amplifier power
supply OK?
AC200 to 230V Voltage other than (1) Supply AC200 to 230V.
supplied AC200 to 230V (2) The wiring between R1 and
the servo amplifier is broken.
(1) The servo amplifier is broken.

(2) The positioning module is
broken.
(3) The wiring between the servo
amplifier and the positioning
module is broken.
A-41
APPENDIX
A.9.3 Solenoid valve fails to turn ON

Is plant air supplied to
take-out robot?
Plant air supplied Plant air not supplied Supply plant air.
Is output from remote I/O

unit ON?
Output lamp ON Output lamp OFF Remote I/O unit is broken.
Are robot body terminals

loose?
Not loose Loose Tighten terminals.

Measure voltage between
take-out robot terminal
output and +24V supply.
DC24V No voltage (1) Remote I/O unit is broken.
(2) S8 and S7 signal wires are
Lead wire between broken.
terminal and solenoid
valve OK?
Lead wire OK Lead wire defective (1) Repair the lead wire.
(2) Replace the solenoid valve.
The solenoid valve is broken.
A-42
VN -EA Series
Maintenance Manual
1st April, 1999 Version 24.0
Yushin Precision Equipment Co., Ltd.
TEL(075)933-9555 FAX(075)934-4033
YPE990318201

VN2EA700-MA-24.0E Robot Yushin Manual de Mantenimiento 750

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VN2EA700-MA-24.0E Robot Yushin Manual de Mantenimiento 750

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VN -EA

This manual provides information on the

Yushin Precision Equipment Co., Ltd.

The take-out robot manuals

Each attention marks has the following meaning.

This mark indicates that you should be careful in han-

This mark indicates that a certain action is prohibited.

Don't do this Don't Don't cause fire Don't touch

This mark indicates that a certain action should be

This mark is used to give supplemental information or advice.

Do not use an extension cable with insufficient capacity. Abnormal heating or

In order to be able to effectively activate the emergency stop device in an

Before cleaning, maintenance and troubleshooting of the take-out robot, be sure to

Be sure to release pneumatic pressure before replacing a filter bowl.

Do not use an operating fluid other than compression air.

Pneumatic pressure should be regulated as specified.

When the take-out robot is set, adjusted, or inspected at a height of 2 meters or

Remove water from the mist filter periodically.

Maintenance should be done only by those trained concerning maintenance

Be sure to use the parts specified for replacement.

Do not modify the robot body or the control device. If it is necessary to do

Do not move or remove the attention plates or stickers.

WARNING DANGER WARNING

1.1 Installation procedure

Electrical interface 2.2 Electrical interface

Pneumatic hook-up 2.3 Pneumatic hook-up

Operation check 3 Operation Check

Adjustment/check 4 Post-Installaiton Adjustment/Check

Teaching/Auto operation 3 Auto Operation and 5 Teaching

Power voltage : AC200V (50/60 Hz)

Specification breakdown based on model

Traverse stroke Kick stroke Descent stroke Air Maximum

VN -EA-2000S Three phase 3500 4000 - 1750 - 2100 - 110 50 2400

Primary power source breakdown based on model

Model Power consumption Circuit breaker Plug socket

The VN -EA-2000 and the VN -EA-3000 are available only in type S.

1.3 External dimensions

(All dimensions in millimeters.)

Dimensions in parentheses “( )” apply to type L.

(All dimensions in millimeters.)

VN -EA-2000S 5855 3500 2966.5 2100

Dimensions in “( )” apply to extended arm stroke types.

1.4 Motion area

(All dimensions in millimeters.)

Dimensions in parentheses “( )” apply to type L.

(All dimensions in millimeters.)

Dimensions in “( )” apply to extended arm stroke types.

1.4.1 Motion prohibition area

Motion prohibition area 1

Maximum value of sub arm kick axis

Motion prohibition area 2 Maximum value of main arm kick axis

1.5 Component identifications

The take-out robot consists of the following.

1.5.2 Operator station

Precautions regarding the operator station

Power indicator Control power switch

Floppy disc driver

Operator station backside

Lock-out switch on operator station

1.5.3 Touch panel controller

Precautions regarding the touch panel controller

Emergency stop switch

How to hold the touch panel controller

1.5.4 Robot body and control box