IAI IX Series User manual

Horizontal Articulated Robot – IX Series
Tabletop Type, Arm Length 120/150/180
IX-NNN-1205, IX-NNN-1505, IX-NNN-1805
Operation Manual Second Edition

Please Read Before Use
Thank you for purchasing an IAI product.
This operation manual explains the handling methods, structure and maintenance of this product, among
others, providing the information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained herein
to ensure safe use of the product.
The CD that comes with the product contains operation manuals for IAI products.
When using the product, refer to the necessary portions of the applicable operation manual by printing
them out or displaying them on a PC.
After reading the operation manual, keep it in a convenient place so that whoever is handling this product
can reference it quickly when necessary.
[Important]
•The product cannot be operated in any way unless expressly specified in this operation
manual. IAI shall assume no responsibility for the outcome of any operation not specified
herein.
•Information contained in this operation manual is subject to change without notice for the
purpose of product improvement.
•This operation manual is original.
•If you have any question or comment regarding the content of this manual, please contact
the IAI sales office near you.
•Unauthorized use or reproduction of this operation manual, whether in whole or in part, is strictly
prohibited.

Introduction
Thank you for purchasing an IAI Horizontal Articulated Robot.
This manual describes the handling, structure, maintenance and other important aspects of the
IX-Series Horizontal Articulated Robot (IX-NNN-1205/1505/1805), and provides the user with
information necessary to the safe operation of the robot.
To ensure safe operation, be sure to read this manual and fully understand its content before
using your IX-Series robot. After reading this manual, keep it in a convenient place for reference
whenever needed.
Please refer to the separate manual for other arm sizes, cleanroom specifications, dust-
proof/splash-proof specifications and wall-mount specifications. The standard specifications and
items that apply commonly to all specification types are covered in this manual.
Please refer to the separate controller manual for operation programs and other specifications or
instructions involving the controller.
Caution
The unauthorized use or reproduction of all or part of this manual is strictly
prohibited.
The information contained in this manual is subject to change without notice for
purposes of product improvement.
Should you find any error in the descriptions contained in this manual, or if you have
any comments or feedback, please contact IAI America, Inc.

Table of Contents
1. For Safe Use of Robots ............................................................................................. 1
1.1 Safety Symbols....................................................................................................................... 1
1.2 Safety Precautions ................................................................................................................. 1
1.3 Conducting Special Training on Industrial Robots.................................................................. 7
1.4 Warranty Period and Scope of Warranty................................................................................ 7
2. Names of Robot Parts ............................................................................................... 8
2.1 Robot Body............................................................................................................................. 8
2.2 Robot Controller ..................................................................................................................... 9
2.3 Labels ................................................................................................................................... 10
2.4 Label Positions ......................................................................................................................11
3. Transportation and Handling.................................................................................... 12
3.1 Handling of the Carton ......................................................................................................... 12
3.2 Packing Condition of the Robot............................................................................................ 12
3.3 Handling of Individual Components...................................................................................... 13
3.4 Checking after Unpacking .................................................................................................... 13
3.5 Transporting the Robot......................................................................................................... 14
4. Installation Environment and Storage Environment ................................................. 16
4.1 Installation Environment ....................................................................................................... 16
4.2 Installation Platform .............................................................................................................. 16
4.3 Storage Environment............................................................................................................ 16
5. Installation of the Robot ........................................................................................... 17
5.1 Installing the Robot............................................................................................................... 17
5.2 Connecting the Controller..................................................................................................... 18
5.3 Checking after Installation .................................................................................................... 21
6. Precautions for Use ................................................................................................. 22
6.1 Reference Acceleration/Deceleration Settings..................................................................... 22
6.2 Tools ..................................................................................................................................... 24
6.3 Carrying Load ....................................................................................................................... 25
6.4 Actuator with Vertical Axis Brake (Optional)......................................................................... 26
6.5 User Wiring and Piping......................................................................................................... 27
7. Inspection/Maintenance........................................................................................... 29
7.1 Inspection Items ................................................................................................................... 29
7.2 Encoder Battery Replacement ............................................................................................. 32
7.3 Absolute Reset Procedure ................................................................................................... 35
8. Specifications........................................................................................................... 53
8.1 Specification Table................................................................................................................ 53
8.2 External Dimensions ............................................................................................................ 59
8.3 Robot Operation Area........................................................................................................... 62

1
1. For Safe Use of Robots
1.1 Safety Symbols
Industrial robots are machines offering an advanced programming function and capable of realizing highly
flexible movements. When using industrial robots, therefore, be sure to observe the safety instructions and
precautions applicable to these robots. Failure to provide the necessary safety measures or incorrect
handling of the robot may not only cause the robot to break down or sustain damage, but it can also lead
to a major accident involving the operator (person who installs, operates, adjusts/inspects or otherwise
handles the robot) including injury or even death.
Danger Failure to observe this instruction is likely to result in serious injury or
death.
Warning Failure to observe this instruction may result in serious injury or
death.
Caution Failure to observe this instruction may result in injury or damage to
the equipment.
Note Failure to observe this instruction will not result in injury, but it should
be heeded to ensure proper use of the product.
1.2 Safety Precautions
General precautions regarding the handling of robots are provided on the following pages. For any work
that must be performed with the robot’s operating range, specify a work procedure, etc., and make sure it
is communicated to, and fully understood by, each operator.

2
Precautions for Installation of the Robot
(1) Ensuring a proper service environment
Refer to the section entitled “Installation Environment and Storage Environment” to secure a proper
service environment for the robot.
(2) Ensuring a space to cover the robot’s operating range
Refer to the section entitled “Robot Operation Area” to secure a sufficient operation area for the
robot.
(3) Ensuring work/maintenance space
Ensure a sufficient range of operation for work and maintenance so that operation, adjustment and
inspection can be carried out without a problem.
(4) Location for installation of control unit
Install the control unit, such as a controller, at a location outside the robot’s range of movement, from
which robot operation can be observed in its entirety.
(5) Installation of a safety cage
Install a safety cage or enclosure, or stretch ropes or chains, around the perimeter of the robot’s
range of movement, so that the operator and bystanders cannot easily enter or bring objects into the
robot’s operation area.
(6) Installation of interlocks
Install a switch (sensor) at the entrance to the safety cage, enclosure or other safety barrier and
interlock it to the robot, so that the robot will stop operating the moment the door, ropes, chains, etc.,
are opened. Additionally, make sure that entry into the operating range is not possible other than
from the interlocked entrance.
(7) Installation of an emergency-stop switch
Provide an emergency-stop switch at a location that is instantly accessible by the operator in case of
an emergency.
(8) Attachment of caution labels
Be sure to attach the supplied caution labels at the entrance to and exit from the operation area or
other location, placing such labels where the operator can easily see and recognize them. Also,
maintain the legibility of caution labels by making sure they are not removed or smudged.
(9) Prohibition of robot modification
Never attempt to modify the robot or controller.
(10) Protection against flying work
If there is a possibility that the work held by the robot may be released and allowed to fly off, drop or
otherwise jeopardize the operator’s safety, implement appropriate protective measures in
consideration of the size, weight, temperature, chemical properties and other characteristics of the
work.
zThe safety of the operator and bystanders cannot be assured if the above precautions for
installation are not heeded. Failure to observe these precautions may result in a serious accident
or damage to the robot.
Danger

3

4
Precautions for Work Near the Robot
Contact with a moving robot may result in a serious accident. Be sure to observe the following items:
(1) Prohibition against entering the robot’s range of movement during operation
Never enter the robot’s range of movement while it is operating or in the ready mode.
(2) Before entering the robot’s range of movement
If you must enter the robot’s range of movement, always press the emergency-stop switch or turn off
the power to halt the robot’s operation before entering.
(3) Operation inside the safety cage
For teaching, inspection and other operations that require the operator to work in the safety cage or
enclosure while the robot is operating, specify a work procedure and make sure it is communicated
to, and fully understood by, each operator. Additionally, the following measures should be taken:
•The operator shall carry a hand-held emergency-stop switch at all times so that the robot can be
stopped as soon as an abnormal condition arises.
•A person other than the operator shall monitor the work to ensure that operation of the robot can be
stopped as soon as an abnormal condition arises.
•A person other than the operator shall monitor the work in order to make sure that no unauthorized
person will inadvertently operate the switches or controls.
•A “Work in Progress” sign must be displayed in a conspicuous location.
zFailure to observe the above precautions for work near the robot may result in serious injury or
death.
zDo not enter the robot’s range of movement while it is operating.
zAlways press the emergency-stop switch or turn off the power before entering the robot’s range of
movement.
zA person other than the operator must be sure to monitor the work whenever the operator enters
the robot’s range of movement.
Danger Warning

5
Precautions for Operation of the Robot
(1) Power on
Before turning on the power, confirm that no one is working in the immediate vicinity of the robot.
(2) Performing work when the robot is operating
Before entering the robot’s range of movement to perform setup or any other task, always press the
emergency-stop switch to disable operation of the robot.
(3) Action to take upon detection of abnormality
If noise or vibration is detected when the robot is operating, immediately stop the robot, investigate
the cause, and take appropriate action. Continuing to operate the robot without correcting the
problem will damage the robot.
(4) Acceleration setting
Operate the robot at an appropriate rate of acceleration in accordance with the load being carried.
Failure to set the acceleration properly will shorten the service life of the drive part, cause damage,
and generate vibration during positioning. (See “Reference Acceleration/Deceleration Settings.”)
(5) Program operation check
Prior to running your program, be sure to confirm its proper operation at safe speeds. If the program
contains an error, the robot may move to an unexpected position and damage the work or its own
components.
zFailure to observe the above precautions for robot operation may result in a serious accident or
damage to the robot.
zAlways press the emergency-stop switch before entering the robot’s range of operation.
zIf the robot is found abnormal, stop the robot immediately and investigate the cause. Failure to do
so may damage the robot.
Danger Warning Caution

6
Precautions for Teaching and Inspection/Maintenance/Adjustment Operations
(1) Special training for teaching personnel
Teaching operators must receive “special training on industrial robots.”
(2) Special training for inspection/maintenance/adjustment personnel
Inspection, maintenance and adjustment must be performed by qualified personnel who have
received “special training on industrial robots.”
(3) Participation of inspection/maintenance/adjustment personnel in IAI’s seminar on robots
Inspection, maintenance and adjustment must be performed by qualified personnel who have
participated in the robot seminar organized by IAI or in the presence of personnel who have
participated in the seminar.
(4) Understanding the robot’s characteristics and work procedure
Do not perform teaching, inspection, maintenance or adjustment without a full understanding of the
robot’s characteristics and work procedure. Any attempt to perform work without the required
knowledge may result in a serious accident.
(5) Items to note on teaching and inspection/maintenance/adjustment
Observe the following items in addition to the aforementioned precautions:
•Before commencing the work, confirm that all emergency-stop devices are functioning properly.
•Turn off the power to the robot if work can be performed without the robot being operated.
•Do not enter the robot’s range of operation unless necessary.
•If any externally connected equipment is used, make sure it is not operating. Alternatively, make
an arrangement so that only the operator can control the equipment.
•If you are using the brake type (optional): When releasing the brake of axis 3 (vertical axis), take a
proper measure to prevent axis 3 from dropping.
•Before connecting or disconnecting a cable, always turn off the power to the controller.
Connecting/disconnecting a cable with the power supplied to the controller may cause the robot to
operate abnormally, resulting in a serious accident.
zFailure to observe the above precautions for teaching and inspection/maintenance/adjustment
operations may result in a serious accident. Additionally, it may cause the robot to operate
abnormally or sustain damage.
zAlways confirm that all emergency-stop devices are functioning properly before commencing the
work.
zAlways press the emergency-stop button before entering the robot’s range of movement.
zIf you are using the brake type (optional), releasing the brake of axis 3 (vertical axis) is dangerous
as it may cause the axis to drop. Be careful not to get your fingers, etc., pinched between axis 3
and other part such as the frame.
Danger Warning

7
1.3 Conducting Special Training on Industrial Robots
IAI’s horizontal articulated robots IX120/150 are classified as industrial robots under JIS B 0134, but they
are not regarded as the dangerous/harmful robots defined under Article 59 of the Occupational Health and
Safety Law and other relevant ministerial ordinances, etc.
To ensure safe use of these robots, however, operators who perform any operation (teaching,
programming, operation check, inspection, adjustment, repair, etc.) involving industrial robots must
receive “special training on industrial robots.”
1.4 Warranty Period and Scope of Warranty
Your IX-Series robot has passed the inspections performed by IAI prior to shipment.
However, we offer the following warranty to cover an unforeseen failure.
Warranty Period
The warranty period will end when any of the following periods elapses:
•Elapse of 18 months after shipment from IAI
•Elapse of 12 months after delivery to the location specified by the user
•Elapse of 2,500 hours of operation
Scope of Warranty
Should a manufacturing defect be found during the above warranty period despite proper use of the
product, IAI will repair the defect free of charge.
However, the following items are not covered by the warranty:
•Result of aging, such as natural discoloration of paint
•Consumption of consumable parts (battery, timing belt, cable, etc.) due to use
•A minor irregularity, such as noise, whose severity depends on subjective judgment but does not
affect product quality or function
•A defect arising from improper use or handling by the user
•A defect arising from inappropriate or erroneous maintenance/inspection
•A defect arising from modification not approved by IAI or its agent
•A defect arising from the use of parts other than genuine IAI parts
•A defect arising from an act of God, such as an earthquake, storm, flood or lightning, accident, fire
or other unforeseen event
This warranty only covers the product unit delivered. IAI shall bear no responsibility for any secondary loss
caused by a defect in the delivered product.
The user must bring the defective product to our factory in order to have it repaired.
Separate fees will apply if an engineer is sent to the user’s site, even during the warranty period.

8
2. Names of Robot Parts
2.1 Robot Body
Mechanical stopper for axis 3 (vertical axis)
Axis 4
(Rotational axis)
Ball screw spline shaft
Cover (arm 2)
A
rm 2
Mechanical stopper for axis 3 (vertical axis)
Axis 3
(vertical axis)
A
LM
(indicator)
A
xis 2
A
rm 1
Mechanical stopper for arm 1
Base
Reference surface
Cover (base) Same on the opposite side
Wiring duct
Spacer for user part installation
User connector
User piping; φ3, white
M cable (outside robot)
PG cable (outside robot) U cable (outside robot)
Reference surface
User piping; φ3, black
User piping; φ3, black
User piping; φ3, white
Mechanical stopper for arm 2
Panel
A
xis 1

9
2.2 Robot Controller
Robot Controller (Non-brake type specification)

10
2.3 Labels
The following labels are attached on the robot and controller. Be sure to observe the instructions and
cautions written on the labels to ensure the correct use of the robot/controller.
(1) Labels on the Robot
(2) Labels on the Controller
zFailure to observe the cautionary information provided on the labels may result in serious injury or
damage to the robot.
Prohibition of entry into
the operation area
Warning on handling of
the vertical axis
Warning against
electric shock
Robot serial number CE-certified robot (Provided only for
CE-certified models)
Caution/warning on handling
of the controller Designation of the connected robot
Controller serial number
(Other than CE-certified models)
Controller serial number
(CE-certified models)
Rated
Danger Warning Caution

11
2.4 Label Positions
Label Positions on the Robot
Label Positions on the Controller
Warning on handling of the vertical axis
Warning against electric shock
(Same on the opposite side) Robot serial number
CE-certified robot (Provided
only for CE-certified models)
Designation of the connected robot
Controller serial number
Caution/warning on handling of the controller

12
3. Transportation and Handling
3.1 Handling of the Carton
Each robot is packed with a controller prior to shipment.
When transporting the carton containing the robot and controller, observe the following items and be
careful not to drop the carton or apply impact due to forcible contact:
•If the carton is heavy, one operator should not attempt to carry it alone.
•Place the carton on a level surface if it is to be left there for a while.
•Do not climb upon the carton.
•Do not place on the carton any heavy object that may cause the carton to deform, or an article
whose shape allows a load to be concentrated at one point.
3.2 Packing Condition of the Robot
zThe robot and controller are very heavy. When transporting the carton containing the robot and
controller, handle it with extra care so as not to drop the carton or apply impact due to forcible
contact, as it may cause injury or damage to the robot or controller.
zSerious injury may result if the carton is dropped onto a person during transportation.
zNever stand below the carton as it is hoisted.
zUse a carrier device with sufficient loading capacity.
zIf a machine or method is used that requires specified skills, it must be operated/performed by a
person having the proper qualifications.
Controller, accessories
and other items
(except for the robot)
Warning Caution

13
3.3 Handling of Individual Components
The robot and controller are supplied as a set.
The combination is indicated on the “designation of the connected robot” label attached on the controller.
When handling multiple robots, be careful not to lose their correct pairings with the controllers.
The robot will not stand on its own after being unloaded from the carton pallet.
Hold it by hand, or place a cushioning material on the floor and place the robot on its side upon the
cushion.
3.4 Checking after Unpacking
After unpacking the carton, check the condition of the robot and other items contained in the carton.
Robot 1
Controller 1
Operation manual for robot 1
Operation manual for controller 1
Receptacle housing 1
Pin contact 10
PIO flat cable 1
PC software (type: IA-101-X-MW)
CD-ROM 1
PC connection cable 1
Hand-held emergency-stop switch 1
Operation manual for PC software 1
Absolute reset adjustment jig (type: JG-5)
Positioning jig for axes 1 and 2 (pin) 1
Positioning jig for axis 4 (plate) 1
Absolute-data backup battery (AB-6)
zAlways operate the robot using the controller supplied with the robot in the same carton. Using
another controller may result in an unexpected operation, damaged motor or other problem.
zAfter unpacking, be sure to confirm the condition of the robot and other items contained in the
carton. Should you find a damaged or missing part, please contact IAI immediately.
Standard parts
Accessories
Optional parts
Note
Caution

14
Warning Caution
3.5 Transporting the Robot
When transporting the robot alone, hang the cable over your arm and carry the robot by holding the base
and arm 2 with both hands.
Do not hold the robot only by arm 2 or the wiring duct.
zIf the robot is held only by arm 2 or an excessive load is applied to arm 2, the robot may be
damaged.
zWhile transporting the robot, be careful not to drop the robot as it may result in injury or damage
to the robot.