Columbia/Okura A700 Operating instructions

A Series Robot Palletizer
Users and Maintenance Manual

INDEX
Safety Section 1
Specifications Section 2
Operation Section 3
Pattern Programming (Teaching) Section 4
Maintenance Section 5
Troubleshooting Section 6
Electrical Wiring and Data Memory Section 7
Installation Section 8
Okura Controller (Oxpa-PLC) Section 9
Technical Training Section 10
Quick Reference
Battery Replacements 5-24
Bolt Torque List 5-13
Circuit Board Information 7-13
Coordinate Systems 4-20
Error History (Error Content Display) 6-4
Error Message Chart 6-14
Glossary 4-161
INPUT and OUTPUT definitions (D, M, X,Y) 7-31
Leveling the end effector 5-22
Lockout/Tagout Example 1-31
Lubrication List 5-12
Memory Switches 5-46
Preventative Maintenance Schedule 5-7
Sequence Commands 4-30
Sequence Program Examples 4-169
Spare Parts List 2-19,5-50
Step Editing 4-60
Steps 4-51
T- Axis Flange Detail 2-12

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Robot Manual
Safety

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Updating history
Version
(Date) Content Page
06.01.05 Columbia/Okura Manual Release All

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THIS MACHINE IS
AUTOMATICALLY CONTROLLED
IT MAY START AT ANY TIME!
WARNING
TO ALL PLANT PERSONNEL
NEVER WORK ON, CLEAN OR SERVICE THIS MACHINE
OR OPEN OR REMOVE ANY PROTECTIVE COVER,
GUARD, GRATE, DOOR, OR MAINTENANCE PANEL
UNTIL THE POWER HAS BEEN TURNED OFF AND
LOCKED OUT.
AVOID PERSONAL INJURY BY TAKING
EVERY PRECAUTION!
SAFETY GUARDS
ARE PROVIDED FOR YOUR PROTECTION
NEVER OPERATE EQUIPMENT WITHOUT GUARDS INSTALLED

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Table of Contents
INTRODUCTION.................................................................................7
Warning____________________________________________________ 7
Safety Summary _____________________________________________ 9
Training Overview___________________________________________ 10
Risk Assessment ____________________________________________ 11
Training Requirements _______________________________________ 11
Training Program Content_____________________________________ 12
Retraining Requirements _____________________________________ 12
WARNING LABELS ...........................................................................13
Guarding Types ...............................................................................14
Fixed Enclosure/Perimeter Fencing/Barrier Guards _________________ 14
Adjustable Barrier/Gate Guard/Access Door ______________________ 15
Belt/Pulleys, Chain/Sprockets, Gear Guards_______________________ 15
Safety Disconnects __________________________________________ 15
Safety Signs/Labels _________________________________________ 15
Safety precautions...........................................................................16
Guidelines _________________________________________________ 16
Precautions Before Use _______________________________________ 18
Precautions Before Daily Operation _____________________________ 18
Precautions when the Main Breaker is turned ON___________________ 19
Precautions Before Automatic Operation _________________________ 20
Precautions During Automatic Operation _________________________ 21
Precautions During Programming _______________________________ 22
Precautions During Maintenance________________________________ 23
Precautions for the INFEED ASSEMBLY ___________________________ 24
Precautions for the PALLET DISPENSER __________________________ 25
Precautions for the SHEET DISPENSER ___________________________ 26
Precautions for Emergency Stop Situations _______________________ 27
Precautions for handling Abnormalities __________________________ 27
Brake Release Procedure.................................................................28
Entering Perimeter Guarding...........................................................29
Daily Operation using the Trapped Key___________________________ 29
Maintenance and Cleaning using Lockout/Tagout___________________ 30
Certifications / Qualifications __________________________________ 30
TYPICAL MINIMUM LOCKOUT/TAGOUT SYSTEM ..............................31
GENERAL __________________________________________________ 31
PURPOSE__________________________________________________ 31
RESPONSIBILITY ___________________________________________ 31
PREPARATION FOR LOCKOUT OR TAGOUT ________________________ 32
SEQUENCE OF LOCKOUT OR TAGOUT SYSTEM ______________________ 32
LOCKOUT (OR TAGOUT) PROCEDURE ____________________________ 34
DEFINITIONS ______________________________________________ 35
Conclusion.......................................................................................37

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INTRODUCTION
Warning
WARNING
TO AVOID SERIOUS BODILY INJURY OR DEATH, LOCKOUT THIS
MACHINE BEFORE CONDUCTING ANY MAINTENANCE, OR
CLEARING OF PRODUCT.
ALWAYS LOCKOUT THIS MACHINE AT THE MAIN CONTROL
PANEL, PNEUMATIC POWER INLET AND HYDRAULIC TANK (IF
APPLICABLE) BEFORE CONDUCTING MAINTENANCE OR
CLEARING PRODUCT.
NEVER USE THE MANUAL CONTROLS AS A SUBSTITUTE
FOR LOCKING OUT THE POWER WHEN CONDUCTING
MAINTENANCE OR CLEARING PRODUCT.

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Safety Summary
Your Columbia/Okura Palletizing System is designed to be totally automated
requiring no operator interface under normal operating conditions. Since the
machine is automatic it is important to remember that any portion of the
machine can start any time without warning. You must never enter or reach
into any portion of the palletizing system until all power sources are locked out.
Columbia/Okura has supplied selected equipment to accommodate a specific
materials handling requirement within your facility. This section of the manual
is intended to familiarize you with general safety precautions relating to your
Columbia/Okura Palletizing System. Additional safety related information is
located throughout the manual. All affected supervisors, operators and
authorized maintenance personnel are also required to totally familiarize
themselves with the manual and all cautions, warnings, guarding devices and
other instructional decals, labels and signs located on the machine as well as
related lockout/tagout procedures.
Safety related information in this manual is designated by well defined, easy to
read graphic symbols. Whenever these specific safety symbols appear they are
intended to draw attention and isolate this information from the manual’s text
for the specific purpose of critical safety awareness. These symbols indicated
safety information that MUST be clearly understood and constantly observed by
all authorized and affected personnel during operating and maintenance
procedures.
For palletizing systems requiring hydraulic power units, the Electrical Main
Power Disconnect located on the main control panel removes power from the
pump unit. When this disconnect is locked out, the hydraulic power unit is
electrically locked out. If the customer remotely located the hydraulic power
unit, Columbia/Okura highly recommends that the wiring configuration to the
pump power unit remain unchanged. If the customer is using a common pump
unit to power more than just the palletizer, some form of lockout protection
must be provided for the hydraulic system serving the palletizer.
It is the customer’s responsibility to install and use Columbia/Okura products in
accordance with provisions of the Occupational Safety and Health Act and/or
other local codes or industry standard that are pertinent to the particular end
use. Installation or use not in accordance with these codes and standards could
be hazardous to personnel and/or equipment.

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Training Overview
Each A Series Robotic Palletizer is equipped with a variety
of safety features. However, an increased level of safety
results when these safety precautions are constantly
reviewed and consistently followed by well trained and
authorized personnel.
Daily maintenance or programming tasks (pallet or sheet
placement) may require personnel to be in the robot’s
proximity while power is available to it. This always
involves some level of risk which is minimized by robot
operators receiving training and retraining on a continuing basis. Okura’s robot
palletizer is designed and sold as a stand alone system, but it interacts with
other machines and equipment, and may be controlled by signals from multiple
sources. For authorized personnel, Training and retraining on not just one
piece of equipment, but all integrated equipment becomes the foundation of a
safe system.
From a practical standpoint, the ultimate responsibility for safeguarding
employees who work with robots lies with the users themselves. The words
“safe” and “safety” are not absolutes. A safe system is one that is well
maintained and used as intended.

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Risk Assessment
Each system is operated under unique conditions. It is ultimately the
customer’s responsibility to determine if the supplied
robot/machinery/equipment is safe to use. The customer must
perform their own risk assessment to evaluate the safety issues that
impact their operation.
A risk assessment shall consider, but is not limited to:
1. The size, capacity, and speed of the robot and associated equipment
2. The anticipated tasks that will be required for continued operation
3. The anticipated failure modes
4. The hazards perceived by the customer and its employees during these tasks
and anticipated failure modes
5. The probability of the hazard occurring
6. The probable frequency for these hazards
7. The probable severity of injury if the hazards actually occurred
8. Any areas of noncompliance
9. The level of expertise of exposed personnel
Training Requirements
The owner of an A series robot shall ensure that any person
who programs, teaches, operates maintains, or repairs robots
or robot systems is trained and demonstrates the competence
to safely perform assigned tasks. (Competency may be
established through formal training, on-the-job training, or a
combination of both.)

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Training Program Content
Training appropriate to each assigned task should include, but not be limited
to:
1. A review of applicable industry safety procedures
2. A review of applicable robot vendor safety recommendations
3. An explanation of the purpose of the robot system and its operation
4. An explanation of the specific tasks and responsibilities for each person
5. A list (by name, location, and phone number) of contacts to call when current
circumstances exceed the ability and/or responsibility levels of the trainee.
6. Identification of the recognized hazards associated with each task
7. Identification of, and appropriate responses to unusual operating conditions
8. An explanation of the functions, limitations and design characteristics of all
system safeguards.
9. A procedure for performing functionality tests or otherwise ensuring proper
functioning of safety devices.
Retraining Requirements
Personnel should be retrained in the event of operating system changes, or
whenever there is reason to believe that additional training is required.

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WARNING LABELS
The following labels are attached to text throughout this manual and signify
importance. Please review their meaning below.
Danger
A statement preceded by DANGER is information that must be acted upon to
prevent the possibility of severe bodily injury or loss of life.
Warning
A statement preceded by WARNING is information that MUST be acted upon to
prevent bodily injury.
Caution
A statement preceded by CAUTION is information that MUST be acted upon to
prevent machine damage.
Important
A statement preceded by IMPORTANT is information that contains special
significance.
Note
A statement preceded by NOTE is information that is handy to know and may
make your job easier.
Decal
The following decals are attached on the robot or controller for warning the
existence of the hazards. Do not take off of change these labels.
No. Decal Meaning
1
High voltage
2
High temperature

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GUARDING TYPES
Safety guards supplied with the
robot/equipment/machinery are designed to provide
safe operation and to reduce the possibility of personal
injury and/or machine damage. It is absolutely
essential to keep all shields, guards and safety devices
in place before, during and after machine operation. If a
shield, guard or safety device has been removed for any
purpose, or is damaged or missing, it must be repaired or replaced BEFORE
beginning any robot/equipment/machine operation.
The following guidelines and descriptions will familiarize affected and
authorized personnel with the purpose and design of safety devices. Additional
or special guarding should be in accordance with acceptable customer
specifications.
SAFEGUARDING MAY INCLUDE, BUT NOT BE LIMITED TO, PRESENCE-
SENSING DEVICES, BARRIERS, AWARENESS BARRIERS, AWARENESS
SIGNALS, SIGNAGE, DESIGNATED PROCEDURES AND TRAINING.
Fixed Enclosure/Perimeter Fencing/Barrier
Guards
1. Provided to keep operating/maintenance personnel from areas of potential
danger during machine operation.
2. This type of guard is fastened to the machine or floor and requires tool(s) for
removal and replacement. Never alter the guard to allow entry without the use
of a tool.
3. Not normally opened or removed except to perform maintenance or repair.
Proper lockout procedures must be observed during time of removal.
4. Lockout/Tagout procedures must be observed when access to area is necessary
and must be in accordance with federal regulations.

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Adjustable Barrier/Gate Guard/Access Door
1. Located at point of operation or where work is being performed.
2. Provided to keep operating/maintenance personnel from areas of potential
danger during machine operation.
3. Remains in place through positive connectors. Can be opened without a tool.
4. Engages the Emergency Stop Circuit when opened. Never defeat the function
of this interlock circuit.
5. Lockout/Tagout procedures must be observed when access to area is necessary
and must be in accordance with federal regulations.
Belt/Pulleys, Chain/Sprockets, Gear Guards
1. Permanent, but with removable mounting.
2. Guarded in accordance with federal regulations
3. These guards must remain in place and should only be removed for
maintenance purposes after locking-out the machine
4. Lockout/Tagout procedures must be observed when access to area is necessary
and must be in accordance with applicable federal regulations.
Safety Disconnects
1. Main Breaker located on panel-interrupts all electrical power to machine for
lockout capability.
2. Central air distribution filter/regulator/on-off located on the machine-interrupts
all supply pneumatic power to machine for lockout capability.
Safety Signs/Labels
Example of Label
(Many Variations)
1. Located on and around various components
included with the robotic machinery. They highlight
specific safety concerns. These signs and labels
vary in format and design.
2. Operators must become familiar with the location and meanings of the signs
and labels.
3. These signs and labels must remain in place. If damaged or removed along
with damaged equipment, they must be replaced by the customer.

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SAFETY PRECAUTIONS
Guidelines
The following is a list of general guidelines when working with Columbia/ Okura
palletizing equipment.
1. Authorized personnel using or affiliated with the robot must take safety
measures for robot operation to prevent accidents. Appropriate
countermeasures such as safety instructions for users, or generation of
standard operating procedures must be taken.
2. Do not attempt to operate any machine until you understand how it functions.
If you are not certain after studying the manual, contact Columbia/Okura for
additional training.
3. Do not operate the machine when you feel unable to perform your duties due to
illness, exhaustion, medication, or distraction.
4. Always wear safety protective equipment in areas that require them. Do not
wear loose clothing or jewelry of any kind which could get caught in moving
parts.
5. Always keep the area around the machine clean, dry, and free of obstructions.
When cleaning agents and/or water is necessary at the machine, be sure to
wear appropriate shoes that do not slip.
6. The robot must not be used for applications other than defined by
Columbia/Okura. (Carrying weight, speed, operation range, or environment of
use.) An A series Robot Palletizer is designed for indoor palletizing or
depalletizing use only. Do not use this for any other use including: under or in
water, digging, construction, or welding.
7. Read the entire Users/Maintenance manual. Thoroughly review Operation
sections for critical step by step, start-up, and shutdown procedures.
8. In addition to the Safety section of the Users/Maintenance Manual, refer to the
other appropriate sections of this manual to insure safe operation of the
equipment.
9. Maintain adequate lighting around working area of entire machine. If
inadequate, improve lighting immediately to meet your plant standards before
continuing production runs or initiating any machinery maintenance.
10.Always maintain secure footing and physical balance while operating machinery.
DO NOT climb on, over, or into any portion of the machine without using the
lockout/tagout procedures.
11.An authorized observer other than the programmer must be present at trial
runs to operate the emergency stop in case of an accident.
12.When two or more personnel are working on, at, around, or in the same
general vicinity at the same time, they must maintain contact to avoid potential
danger.
13.The equipment uses high voltage to operate. Only authorized personnel should
ever enter or reach into electrical panels.

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14.Never operate the machine unless all guards are in place.
15.Do not attempt to or make any safety device inoperative or less functional.
16.Verify everyone is aware of automatic operation before starting.
17.Check all safety switches and other safety devices daily to make sure they
operate.
18.Never perform maintenance or repair work until you are sure the power is
turned off at the main control panel and cannot be turned back on without your
knowledge.
19.Never reach into machinery to clear a jam of any type.
20.Pay strict attention to all caution, warning, and danger signs.
21.Never start a machine until you are certain that all personnel and foreign
objects are clear.
22.Do not enter the guarded area when the robot is in operation or in automatic
mode.
23.Always use Columbia/Okura recommended spare parts. Special grade bolts
must be replaced with equivalent bolts.

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Precautions Before Use
1. The robot must be placed into use (activated) by personnel who have been
authorized by the employer.
2. The robot cell must be clear of personnel before being placed into use
(activated).
3. The robot must be activated by power supplied through the switch provided by
Columbia/Okura.
4. Verify correct operation of each axis of the robot using manual operation.
5. Verify the doors of the control panel(s) are shut at all times.
Precautions Before Daily Operation
Check the following items before switching on main power.
1. Verify the robot looks intact, and is not being serviced or repaired.
2. Verify empty pallets are placed in the correct position.
3. Verify the robot arm position is within the normal operating envelope.
4. Verify compressed air is supplied at the specified pressure and volume.
5. Verify there are no personnel inside the perimeter guarding, and that there are
no obstructions in the material conveyance path.
6. Verify the robot is not overloaded or to be used in an over-capacity condition.