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Maintenance  1. Safety Maintenance 

 

C12  Rev.3 

71 

1. Safety Maintenance 

Please read this chapter, this manual, and other relevant manuals carefully to understand 
safe maintenance procedures before performing any maintenance. 

 

Only authorized personnel who have taken safety training should be allowed to 

perform the robot maintenance.   

Safety training is the program for industrial robot operators to follow the laws and 

regulations of each nation.     

The personnel who have taken safety training acquire knowledge of industrial 

robots (operations, teaching, etc.), inspections, and related rules/regulations.     

The personnel who have completed the robot system-training and maintenance- 

training held by the manufacturer, dealer, or locally-incorporated company are 

allowed to perform maintenance. 

 

 

WARNING 

■

 

Do not remove any parts unless otherwise instructed by this manual.  Follow the 

maintenance procedure strictly as described.  Improper removal of parts or 

improper maintenance may cause not only malfunction of the robot system but 

serious safety problems. 

■

 

If you have not received training, keep away from the Manipulator while the power 

is ON.  Do not enter the operating area while the power is ON.  Entering the 

operating area with the power ON is extremely hazardous and may cause serious 

safety problems as the Manipulator may move even it seems to be stopped. 

■

 

When you check the operation of the Manipulator after replacing parts, be sure to 

check it while you are outside of the safeguarded area.    Checking the operation 

of the Manipulator while you are inside of the safeguarded area may cause serious 

safety problems as the Manipulator may move unexpectedly. 

■

 

Before operating the robot system, make sure that both the Emergency Stop 

switches and safeguard switch function properly.  Operating the robot system 

when the switches do not function properly is extremely hazardous and may result 

in serious bodily injury and/or serious damage to the robot system as the switches 

cannot fulfill their intended functions in an emergency. 

 

 

WARNING 

■

 

To shut off power to the robot system, disconnect the power plug from the power 

source.    Be sure to connect the AC power cable to a power receptacle. 

DO NOT connect it directly to a factory power source. 

■

 

Before  performing  any replacement procedure,  turn OFF the  Controller  and 

related equipment, and then disconnect the power plug from the power source. 

Performing any replacement procedure with the power ON is extremely hazardous 

and may result in electric shock and/or malfunction of the robot system. 

■

 When connecting /  replacing the brake release unit or  the external short 

connector, turn OFF the power to the Controller and the brake release unit.  

Connecting or disconnecting the connector while the power is ON may result in 

electrical shock. 

 

 

 

Summary of Contents for C12 Series

Page 1: ...Rev 3 EM204R4255F 6 Axis Robots C12 series MANIPULATOR MANUAL ...

Page 2: ...Manipulator manual C12 series Rev 3 ...

Page 3: ...C12 Rev 3 i 6 Axis Robots C12 series Manipulator Manual Rev 3 Copyright 2019 2020 SEIKO EPSON CORPORATION All rights reserved ...

Page 4: ...rranty period information However customers will be charged for repairs in the following cases even if they occur during the warranty period 1 Damage or malfunction caused by improper use which is not described in the manual or careless use 2 Malfunctions caused by customers unauthorized disassembly 3 Damage due to improper adjustments or unauthorized repair attempts 4 Damage caused by natural dis...

Page 5: ...spective holders NOTICE No part of this manual may be copied or reproduced without authorization The contents of this manual are subject to change without notice Please notify us if you should find any errors in this manual or if you have any comments regarding its contents MANUFACTURER CONTACT INFORMATION Contact information is described in SUPPLIERS in the first pages of the following manual Rob...

Page 6: ...ler where you purchased this product Use of the chemical symbols Pb Cd or Hg indicates if these metals are used in the battery This information only applies to customers in the European Union according to DIRECTIVE 2006 66 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and accumulators and repealing Directive 91 157 EEC and le...

Page 7: ...y Software EPSON RC This manual contains setup procedures using the software Those sections are indicated by the symbol on the left Turning ON OFF Controller When you see the instruction Turn ON OFF the Controller in this manual be sure to turn ON OFF all the hardware components Photos and Illustrations Used in This Manual The appearance of some parts may differ from those on an actual product dep...

Page 8: ...vi C12 Rev 3 ...

Page 9: ...2 4 Outer Dimensions 16 2 5 Standard Motion Range 17 2 6 Specifications 18 2 6 1 Specifications table 18 2 6 2 Option 21 2 7 How to Set the Model 22 3 Environment and Installation 23 3 1 Environmental Conditions 23 3 2 Unpacking Transportation and Relocation 24 3 3 Mounting Dimensions 27 3 3 1 Cable Backward Model 27 3 3 2 Cable Downward Model 28 3 4 Installation 29 3 5 Connecting the Cables 32 3 ...

Page 10: ...Robot 58 5 6 Setting the Cartesian Rectangular Range in the XY Coordinate System of the Manipulator 59 6 Options 60 6 1 Brake Release Unit 60 6 2 Camera Plate Unit 64 6 3 Tool Adapter ISO Flange 66 6 4 Adjustable Mechanical Stops 67 6 5 User Wires and Pneumatic Tubes 68 Maintenance 1 Safety Maintenance 71 2 General Maintenance 72 2 1 Maintenance Inspection 72 2 1 1 Schedule for Maintenance Inspect...

Page 11: ...Replacing the Cable Unit M C Cable Downward 136 4 2 Connector Pin Assignment 141 4 2 1 Signal Cable 141 4 2 2 Power Cable 144 4 2 3 User Cable 146 4 2 4 Color of Cables 146 5 Joint 1 147 5 1 M C Cable Backward Joint 1 148 5 1 1 Joint 1 Replacing the Motor M C Cable Backward 148 5 1 2 Joint 1 Replacing the Reduction Gear Unit M C Cable Backward 156 5 1 3 Joint 1 Replacing the Timing Belt M C Cable ...

Page 12: ...tic Brake 243 9 Joint 5 244 9 1 Joint 5 Replacing the Motor 245 9 2 Joint 5 Replacing the Reduction Gear Unit Replacing the Joint 5 6 Reduction Gear Unit Set 252 9 3 Joint 5 Replacing the Timing Belt 256 9 4 Joint 5 Replacing the Electromagnetic Brake 257 10 Joint 6 259 10 1 Joint 6 Replacing the Motor 260 10 2 Joint 6 Replacing the Reduction Gear Unit Replacing the Joints 5 6 Reduction Gear Unit ...

Page 13: ...Table of Contents C12 Rev 3 xi 15 Replacing the Fan 288 16 Calibration 290 16 1 Overview 290 16 2 Calibration Procedure 293 17 Maintenance Parts List 297 18 Option Parts List 300 ...

Page 14: ...Table of Contents xii C12 Rev 3 ...

Page 15: ...Setup Operation This volume contains information for setup and operation of the Manipulators Please read this volume thoroughly before setting up and operating the Manipulators ...

Page 16: ......

Page 17: ...nsiderations are indicated throughout the manual by the following symbols Be sure to read the descriptions shown with each symbol WARNING This symbol indicates that a danger of possible serious injury or death exists if the associated instructions are not followed properly WARNING This symbol indicates that a danger of possible harm to people caused by electric shock exists if the associated instr...

Page 18: ... or constructing the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and or severe equipment damage to the robot system The Manipulator and the Controller must be used within the environmental conditions described in their respective manuals This product has been designed and manufactured strictly for use in a normal indoor ...

Page 19: ...problems in case that the Manipulator moves unexpectedly Immediately press the Emergency Stop switch whenever the Manipulator moves abnormally during operation Continuing the operation while the Manipulator moves abnormally is extremely hazardous and may result in serious bodily injury and or severe equipment change to the robot system WARNING Be sure to connect the AC power cable to a power recep...

Page 20: ...operating angle less than 5 degrees they may get damaged early because the bearings are likely to cause oil film shortage in such situation To prevent early breakdown move the joints larger than 30 degrees for about five to ten times a day Vibration resonance may occur continuously depending on the combination of robot motion speed Arm orientation and end effector load Vibration arises from natura...

Page 21: ... the Robot Controller manual for instructions on how to wire the Emergency Stop switch circuit Do not turn OFF the Controller while the Manipulator is operating If you attempt to stop the Manipulator in emergency situations such as Safeguard Open make sure to stop the Manipulator using the Emergency Stop switch of the Controller If the Manipulator is stopped by turning OFF the Controller while it ...

Page 22: ...N Manipulator is operating Free running distance in emergency The Manipulator in operation cannot stop immediately after the Emergency Stop switch is pressed However time angle and distance of the free running vary by following factors Hand weight WEIGHT Setting ACCEL Setting Workpiece weight SPEED Setting Posture etc Approximate time and distance of the free running are as follow Conditions of Me...

Page 23: ... the arm using the brake release unit Follow the method when you just unpack the delivered boxes or when the Controller does not start up yet 1 5 2 Moving the arm using the software Follow the method when you can use the software While the electromagnetic brake is ON such as in emergency mode you cannot move any arm by pushing manually Arm Motion Joint 1 Base Arm 1 Lower Arm Arm 2 Joint 6 Joint 3 ...

Page 24: ...arm falling may cause equipment damage to and or malfunction of the Manipulator EPSON RC After releasing the Emergency Stop switch execute the following command in Command Window Reset Brake Off the number from 1 to 6 corresponding to the arm whose brake will be turned OFF Execute the following command to turn on the brake again Brake On The number from 1 to 6 corresponding to the arm whose brake ...

Page 25: ...moving the base mounting screws B Do not enter the work space when the Manipulator is operating It is extremely hazardous since the Arm may collide and cause serious safety problems C Do not touch the current carrying parts inside the Manipulator while the power is ON It may cause electrical shock D When releasing the brakes be careful of the arm falling due to its own weight This warning label is...

Page 26: ...Rev 3 Location Warning Label Note Location Label G HOT Be careful not to burn yourself H I Location of Labels Top View Back View Lateral View Front View C C C C C C A B C H Cable Downward model Bottom View C Lateral View D E F C I G G ...

Page 27: ... interference with peripherals walls and ceiling permits more compact installation The system cost and installation cost can be reduced Manipulator weight 63 kg 139 lbs Skillful Wrist Compact wrist Joint 5 with wide motion range enables smooth movement and the ability to work from many angles Minimal interference with surroundings improves flexibility in hand design 2 2 Model Number C12 A 14 0 1 S...

Page 28: ...oint 5 The wrist swings Joint 6 The hand rotates Upper Arm Arms 3 to 6 LED Lamp This lamp lights up while the motors are ON When the LED lamp is lighting or the Controller power is on current is being applied to the Manipulator The LED lamp may not be seen depending on the Manipulator s posture Be very careful Performing any work with the power ON is extremely hazardous and it may result in electr...

Page 29: ...n room model Exhaust port For ø12 mm pneumatic tube Cable downward model Power cable Signal cable Standard model Cover Clean room model Exhaust port For ø12 mm pneumatic tube User cable connector 15 pin D sub connector For ø6 mm pneumatic tubes Air1 Air2 F sensor cable connector Ethernet cable connector Cable backward model Cable downward model Signature label Serial No of Manipulator Bolt hole M5...

Page 30: ...Setup Operation 2 Specifications 16 C12 Rev 3 2 4 Outer Dimensions Unit mm ...

Page 31: ... 1 center P point center 2 P point from top with Joint 3 tilting up 202 Joint 1 center P point center 3 P point from lateral with Joint 3 declining 61 Joint 2 center P point center 4 P point from lateral with Joint 3 tilting up 202 Joint 2 center P point center CAUTION Pay attention to the arm pose of the basic arms Arms 1 2 and 3 when operating the Manipulator Arm 5 moves keeping a constant angle...

Page 32: ...range Joint 1 240 Joint 2 135 to 55 Joint 3 61 to 202 Joint 4 200 Joint 5 135 Joint 6 360 Max pulse range Joint 1 15736800 Joint 2 10616940 to 4325420 Joint 3 3997696 to 13238272 Joint 4 8738240 Joint 5 4915350 Joint 6 6553800 Resolution Joint 1 0 0000153 pulse Joint 2 0 0000127 pulse Joint 3 0 0000153 pulse Joint 4 0 0000229 pulse Joint 5 0 0000275 pulse Joint 6 0 0000549 pulse Motor rated capaci...

Page 33: ...eight 3 12 Inertia 0 03 0 2 Safety standard CE Marking EMC Directive Machinery Directive RoHS Directive KC Marking KCs Marking ANSI RIA R15 06 NFPA 79 1 Mounting types other than Table Top mounting is out of specification 2 In case of PTP control 3 Do not apply the load exceeding the maximum payload 4 If the center of gravity is at the center of each arm If the center of gravity is not at the cent...

Page 34: ...istatic treatment This model controls adhesion of dust due to electrification 9 In general use Accel setting 100 is the optimum setting that maintains the balance of acceleration and vibration when positioning Although values larger than 100 can be set to Accel it is recommended to minimize the use of large values to necessary motions since operating the Manipulator continuously with the large Acc...

Page 35: ...elease box 1 For EU power supply voltage 200 V short connector included For US JP power supply voltage 100 V short connector included Short connector for the brake release box 1 When using the brake release box with C12 series it is necessary to connect the short connector to the M C power cable or connect the M C power cable with the Controller The brake release box can be used while the Controll...

Page 36: ...and or cause safety problems If the custom specifications number MT is described on MODEL of the signature label S N label the Manipulator has custom specifications A label with only the custom specifications number may be attached depending on shipment time The custom specifications may require a different configuration procedure check the custom specifications number MT and contact the supplier ...

Page 37: ... oily smoke salinity metal powder or other contaminants Keep away from flammable or corrosive solvents and gases Keep away from water Keep away from shock or vibration Keep away from sources of electric noise 1 The ambient temperature conditions are for the Manipulators only For the Controller which the Manipulator is connected to refer to the Robot Controller manual When using the Manipulators in...

Page 38: ...r severe equipment damage to the robot system as the fall of the Manipulator CAUTION When removing the anchor bolts support the Manipulator to prevent falling Removing the anchor bolts without supporting the Manipulator may get hands fingers or feet caught as the Manipulator may fall To transport the Manipulator secure it to the delivery equipment or have at least 2 people to hold it by hand Also ...

Page 39: ...or 1 Turn OFF the power for all devices and unplug the power cable connector and signal cable connector from the Controller Do not unplug the M C cable power cable and signal cable from the Manipulator M C cable 3 m 2 kg Remove the mechanical stops if using them to limit the motion range For details on the motion range refer to the Setup Operation 5 2 Motion Range Setting by Mechanical Stops 2 Uns...

Page 40: ...may fall if the balance is lost and this is extremely hazardous To prevent damage on the covers and arms it is recommended to protect the contacting parts of the wire and arm with a cloth Be very careful not to damage the covers since they are made of plastic Manipulator weight 63 kg 139 lbs Holes for eye bolt 2 M12 depth 25 Locations of the screw holes for eyebolts are common to all models CAUTIO...

Page 41: ...ipment Space for teaching points Space for maintenance and inspections for installing jigs Space for cables The minimum bend radius of the power cable is 90 mm When installing the cable be sure to maintain sufficient distance from obstacles In addition leave enough space for other cables so that they are not bent forcibly Make sure to leave 35 mm or more space around the fan cover Unit mm 3 3 1 Ca...

Page 42: ...Setup Operation 3 Environment and Installation 28 C12 Rev 3 3 3 2 Cable Downward Model The following part differs from the cable backward model ...

Page 43: ...nd may result in serious bodily injury and or severe equipment damage to the robot system as the Manipulator may fall down Before installing and operating the Manipulator make sure that all parts of the Manipulator are in place and have no external defects Missing or defective parts may cause improper operation of the Manipulator Improper operation of the Manipulator is extremely hazardous and may...

Page 44: ...s Max Horizontal rotating torque 2600 N m Max Horizontal reaction force 1000 N Max Vertical rotating torque 3400 N m Max Vertical rotating torque 7900 N The plate for the Manipulator mounting face should be 30 mm thick or more and made of steel to reduce vibration The surface roughness of the steel plate should be 25 μm or less The base table must be secured on the floor to prevent it from moving ...

Page 45: ...npack the Manipulator outside of the clean room 2 Secure the Manipulator to delivery equipment such as a pallet with bolts so that the Manipulator does not fall over 3 Wipe off the dust on the Manipulator with a little alcohol or distilled water on a lint free cloth 4 Transport the Manipulator into the clean room 5 Secure the Manipulator to the base table ...

Page 46: ...th the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Grounding the Manipulator is done by connecting with the Controller However it is recommended to use the grounding hole on the base to ground directly for more secure grounding If the ground wire is improperly connected to ground it may result in the fire or electric shock When connecting...

Page 47: ... for other electric power motor power welding devices etc Using the ground line for the Manipulator in common with other ground lines or grounding electrodes may result in electric shock and or malfunction of the robot system When using metal ducts metallic conduits or distributing racks for cable ground in accordance with national and local electric equipment technical standards Grounding that do...

Page 48: ...ector 15 pin D sub connector Detail of B A Detail of A Cable backward model Standard model Cover Clean room model Exhaust port One touch fitting for ø12 mm pneumatic tube B F Sensor cable connector Ethernet cable connector F Sensor cable connector Ethernet cable connector User cable connector 15 pin D sub connector One touch fitting for ø6 mm pneumatic tube Air1 Air2 Power cable Signal cable Stand...

Page 49: ... pin Connector JAE DA 15PF N Solder type Clamp Hood HRS HDA CTH 4 40 10 Connector setscrew 4 40 UNC Two parts are attached for each 8 pin RJ45 Cat 5e or equivalent For the standard and cleanroom model Manipulators commercially available Ethernet cables can be used Other The 6 pin cable for the F sensor option is included Pneumatic tubes Max Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter ...

Page 50: ... gap is called Calibration At the time of shipment the basic orientation of the Manipulator shown below is set as the origin position After installing the Manipulator and setup the operating environment move the Manipulator to the origin position and check if it moves to the basic position properly To make the Manipulator move to the origin position select Tool Robot Manager Control Panel and clic...

Page 51: ... outputs are configured at the factory so that they are automatically shut off 0 by power disconnection the Emergency Stop switch or the safety features of the robot system Wrist Flange Detail of A A Arm 6 Attach an end effector to the end of the Arm 6 using the M5 bolts Layouts When you operate the Manipulator with an end effector the end effector may interfere with the Manipulator body depending...

Page 52: ...s Decks are equipped to Arms 3 and 5 to enable the easy installation of air valve To mount the camera the camera plate unit is necessary We provide the optional Camera Plate Unit For details refer to Setup Operation 6 Options Rotation Center of the Upper Arm Arm 3 Deck Arm 5 Deck ...

Page 53: ...g parameters makes the operation of the Manipulator optimal reduces vibration to shorten the operating time and improves the capacity for larger loads In addition it reduces persistent vibration produced when the inertia moment of the end effector and work piece is bigger The allowable load for C12 series Manipulators is 12 kg at the maximum Due to the limitations of the moment and inertia moment ...

Page 54: ...Moment 0 50 100 150 200 250 300 0 50 100 150 200 250 300 1kg 2kg 3kg 4kg 5kg 6kg 7kg 8kg 9kg 10kg 11kg 12kg Center of gravity of load from the Arm 5 rotation center mm Center of gravity of load from the Arm 6 rotation center mm Max Eccentric Quantity of Load Distance between the joint rotation center and the load s center of gravity Joint 1 kg 3 kg 5 kg 8 kg 10 kg 12 kg 4 300 mm 300 mm 300 mm 296 ...

Page 55: ...the maximum payload The C12 series Manipulators can operate without limitations on the condition unless and until the load exceeds this maximum payload Always set the Weight parameters of the WEIGHT command according to the load Setting a value that is smaller than the actual load may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mecha...

Page 56: ...he fore end of Arm 6 Details of the deck 2 M4 depth8 4 M4 depth8 Arm 5 Deck Arm 3 Deck Unit mm When you attach the equipment to the decks on the upper arm convert its weight into equivalent weight assuming that the equipment is attached to the end of theArm 6 Then this equivalent weight added to the load will be a Weight parameter ...

Page 57: ...deck Length of the upper arm 315 mm Distance between the Joint 3 and the center of gravity of the air valve on the Arm 3 deck mm Distance between the Joint 3 and the center of gravity of the camera on the Arm 5 deck mm Example The fore end of the Arm 6 is 730 mm L away from the Joint 3 of C12 A1401 C12XL Load on the fore end of Arm 6 is 5 kg Mw Load on the Arm 3 deck is 1 5 kg Ma The deck is 0 mm ...

Page 58: ... Manipulators are not designed to work with inertia moment exceeding 0 2 kg m2 Always set the inertia moment INERTIA parameter according to the inertia moment Setting a value that is smaller than the actual inertia moment may cause errors excessive shock insufficient function of the Manipulator and or shorten the life of parts mechanisms The acceptable inertia moment of load for C12 series Manipul...

Page 59: ...ximum When the eccentric quantity of the load exceeds the rating change the setting of eccentric quantity parameter using the INERTIA command After changing the setting the maximum acceleration deceleration speed of Manipulator corresponding to eccentric quantity is set automatically Position of Load s Center of Gravity Rotation Center a b Eccentric Quantity 300 mm or less Flange a b To set the pa...

Page 60: ...0 0 05 0 1 0 15 0 2 慣 設定 度 140 100 30 60 kg m 2 Inertia moment The percentage in the graph is based on the acceleration deceleration at rated eccentricity 0 03 kg m2 as 100 Automatic setting by eccentricity setting 0 20 40 60 80 100 120 0 50 100 150 200 250 300 50 100 25 15 mm Eccentricity The percentage in the graph is based on the acceleration deceleration at rated eccentricity 50 mm as 100 ...

Page 61: ...t of the entire load is calculated by the sum of a b and c Work Piece b Work Piece c End Effector a Rotation Center Moment of Inertia of End Effector a Moment of Inertia of Work Piece b Moment of Inertia of Work Piece c Whole Moment of Inertia The methods for calculating the inertia moment for a b and c are shown in this and the next page Figure out the whole inertia moment using the basic formula...

Page 62: ...llelepiped h b L m Rectangular Parallelepiped s Center of Gravity Rotation Center m m L2 b2 h2 12 b Inertia moment of a cylinder m m L2 r 2 2 m L r Cylinder s Center of Gravity Rotation Center c Inertia moment of a sphere m r 2 m L2 2 5 Sphere s Center of Gravity r m L Rotation Center ...

Page 63: ...ng The acceleration deceleration of Arm 6 are controlled according to the inertia moment set by the INERTIA command The acceleration deceleration of the whole Manipulator are controlled according to the eccentricity set by the INERTIA command The more the inertia moment and eccentricity of the load increase the more the acceleration deceleration are reduced Auto Acceleration Deceleration According...

Page 64: ...ged due to layout efficiency or safety follow the descriptions in 5 1 through 5 4 to set the range 5 1 Motion Range Setting by Pulse Range for Each Joint Pulses are the basic unit of Manipulator motion The motion range of the Manipulator is controlled by the pulse range the lower limit and the upper limit of each axis Pulse values are read from the encoder output of the servo motor The pulse range...

Page 65: ...on are positive and values in clockwise direction are negative 240 240 15736800 pulse 15736800 pulse Arm 1 0 pulse position 5 1 2 Max Pulse Range of Joint 2 Pulse values in clockwise direction are positive and values in counterclockwise direction are negative 135 55 4325420 pulse 10616940 pulse Arm 2 0 pulse position ...

Page 66: ...sitive and values in counterclockwise direction are negative 61 202 13238272 pulse 3997696 pulse Arm 3 0 pulse position 5 1 4 Max Pulse Range of Joint 4 From the angle of arm end clockwise pulse values are positive and counterclockwise pulse values are negative 5461400 pulse 5461400 pulse 200 200 Arm 4 0 pulse position ...

Page 67: ...sitive and values in counterclockwise direction are negative Arm 5 0 pulse position 4915350 pulse 4915350 pulse 135 135 5 1 6 Max Pulse Range of Joint 6 From the angle of arm end clockwise pulse values are positive and counterclockwise pulse values are negative Arm 6 0 pulse position 6553800 pulse 6553800 pulse 360 360 ...

Page 68: ...r details on the pulse range setting refer to the Setup Operation 5 1 Motion Range Setting by Pulse Range for All Arms Be sure to set the pulse range not to exceed the setting angles of the mechanical stop 5 2 1 Motion Range Setting of Joint 1 Install the adjustable mechanical stop J1 to the threaded hole corresponding to the angle you want to set Normally the mechanical stop is not installed Hexa...

Page 69: ...d e Angle 125 45 135 55 Pulse pulse 9830500 3538980 10616940 4325420 Adjustable mechanical stop J2 Applied Applied standard 5 2 3 Motion Range Setting of Joint 3 Remove the mechanical stop installed as standard and install the adjustable mechanical stop J3 Joint 3 standard motion range 61 to 202 Hexagon socket head cap bolt M6 15 2 bolts Tightening torque 13 0 0 6 N m 133 6 kgf cm f g f g Angle 51...

Page 70: ...striction to Manipulator operation is enabled During CP motion command execution When you attempt to execute the motion command for moving the Manipulator to a target point or pose in the specified motion range The restriction to the Manipulator operation is disabled The Arms of the Manipulator momentarily go through the specified motion range during the PTP motion command execution even though th...

Page 71: ...nge C12 Rev 3 57 5 4 Coordinate System The origin point is where the Manipulator s installation face intersects with the rotation axis of Joint 1 For details on the coordinate system refer to the EPSON RC Users Guide manual Z X Y ...

Page 72: ...save the calibration data by following the procedure below 1 Select the EPSON RC 7 0 menu Setup System Configuration 2 Select Controller Robots Robot Calibration from the tree list Then click Save 1 Select the EPSON RC 7 0 menu Setup System Configuration 2 Select Controller Robots Robot from the tree list 3 Click the Change button 4 The following dialog box will be displayed Input the robot name a...

Page 73: ...ation area and the XYLIM setting The limited Manipulator operation area is defined so that the end effector does not interfere with the rear side of the Manipulator The XYLIM setting that you can determines the upper and lower limits of the X and Y coordinates The limited Manipulator operation area and the XYLIM setting apply only to the software Therefore these settings do not change the physical...

Page 74: ... power to the Controller and the brake release unit Inserting and removing the connector while the power is ON may result in electrical shock CAUTION Normally release the brake of joints one by one Take extra care if you need to release the brakes of two or more joints simultaneously Releasing the brakes of two or more joints simultaneously may cause hands and fingers to be caught and or equipment...

Page 75: ...nnot be released and it may cause damage on them After using the brake release unit be sure to connect the external short connector to the Manipulator or check connection of the connector for the brake release unit Keep the external short connector Otherwise you cannot release the brakes If you turn ON the brake release unit while the brake release switch is being pressed an unintended arm may mov...

Page 76: ...ler Go to the step 3 3 Remove the external short connector External short connector 4 Connect the brake release unit to the connector of the connection cable Connection cable Connector Remove the brake release unit 1 Turn OFF the brake release unit 2 Remove the power cable of the brake release unit 3 Disconnect the brake release unit from the connector of the connection cable 4 If the M C short co...

Page 77: ...perating the Manipulator it may lead to the breakdown of the Manipulator or you may get your hand or fingers caught Power cable Power switch Brake release switches Power lamp 1 Plug the power cable into the brake release unit 2 Plug the power cable into the power supply plug 3 Turn ON the brake release unit When the brake release unit is enabled the power lamp lights up 4 Press the switch of the a...

Page 78: ...s included Qty A Camera adapter plate 1 B Camera mid plate 1 C Camera base plate 1 D Hexagon socket head screws M4 12 6 E Hexagon socket head screws M4 20 2 F Plain washer for M4 small washer 2 Installation Mounting holes for the camera base plate on the C12 series Manipulator Camera base plate mounting hole For the installation steps refer to the following manual EPSON RC Option Vision Guide 7 0 ...

Page 79: ... mounting position of camera mid plate and the camera you are using The table below shows the motion range reference values based on the available cameras for this option and the mounting positions of the camera mid plate The values in the table may vary depending on how to secure the cables By changing the Y position you can extend the distance from the end effector mounting surface to the camera...

Page 80: ...pth 12 at 90 pitch depth 5 depth 4 To mount the ISO flange 1 Press fit the pin to the Arm 6 end flange Pin projection 4 mm from the flange Pin 2 Align the pin and the pin hole on the flange and then mount the flange Hexagon socket head screw 4 M5 15 Hexagon socket head screw 4 M5 15 Flange 3 Press fit the pin to the installed flange Pin protrusion 4 mm from the flange Pin 4 Align the pin and the p...

Page 81: ...sures refer to Setup Operation 5 2 Motion Range Setting by Mechanical Stops Adjustable mechanical stop J1 Item Qty Adjustable mechanical stop J1 1 Hexagon socket head screw M12 30 2 Adjustable mechanical stop J2 Item Qty Adjustable mechanical stop J2 1 Hexagon socket head screw M10 35 2 Adjustable mechanical stop J3 Item Qty Adjustable mechanical stop J3 1 Hexagon socket head screw M6 15 2 ...

Page 82: ... can be additionally purchased in case of lost or shortage Fitting for customer use ø6 straight Item Qty Manufacturer Standard ø6 straight fitting 2 SMC KQ2S06 M6N Fitting for customer use ø6 elbow Item Qty Manufacturer Standard ø6 elbow fitting 2 SMC KQ2L06 M6N Standard user connector kit D sub Item Qty Manufacturer Standard Connector 2 JAE DA 15PF N Solder type Clamp hood 2 HRS HDA CTH 4 40 10 C...

Page 83: ...Maintenance This volume contains maintenance procedures with safety precautions for C12 series Manipulators ...

Page 84: ......

Page 85: ...oblems as the Manipulator may move even it seems to be stopped When you check the operation of the Manipulator after replacing parts be sure to check it while you are outside of the safeguarded area Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly Before operating the robot system make ...

Page 86: ...otors Be careful when performing maintenance 2 General Maintenance This chapter describes maintenance inspection procedures Performing maintenance inspection properly is essential to prevent trouble and ensure safety Be sure to perform the maintenance inspections in accordance with the schedule 2 1 Maintenance Inspection 2 1 1 Schedule for Maintenance Inspection Inspection points are divided into ...

Page 87: ...ess of connectors If the connectors are loosen push it securely or tighten External connectors on Manipulator on the connector plates etc Manipulator cable unit Visually check for external defects Clean up if necessary External appearance of Manipulator External cables Check for bends or improper location Repair or place it properly if necessary Safeguard etc Check tension of timing belts Tighten ...

Page 88: ...Each arm Check whether unusual sound or vibration occurs Whole Measure the accuracy repeatedly by a dial gauge Whole When brake release unit is installed Connect the brake release unit and check the sound of the electromagnetic brake with the brake released If there is no sound replace the brake When brake release unit is not installed Execute Brake off command brake off joint from the command win...

Page 89: ...acement The time between overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on usage condition and degree of the load such as when operated with the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator For EPSON RC 7 0 the recommended replacement time for the parts subject to maintenanc...

Page 90: ...ontroller Status button to open the Browse For Folder dialog box 3 Select the folder where the information is stored 4 Click OK to view the Controller Status Viewer dialog box 5 Select Robot from the tree menu on the left side For the parts subject to overhaul refer to Maintenance 17 Maintenance Parts List For details of replacement of each part refer to the Maintenance section Please contact the ...

Page 91: ...or the repairs If grease gets into your eyes mouth or on your skin follow the instructions below If grease gets into your eyes Flush them thoroughly with clean water and then see a doctor immediately If grease gets into your mouth If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water thoroughly If grease gets on your skin Wa...

Page 92: ...s Cross point screwdriver 2 1 For cross recessed head screws Flat head screwdriver 1 For grease plug Before greasing move the Manipulator so that the grease inlet is not directed down Do not remove the grease plug while the grease inlet is directed down Otherwise the oil content separated from the grease may leak out Do not use any tool to install and remove the grease nipple and grease line exten...

Page 93: ...cated inside the Arm 1 3 Attach the grease nipple to the Joint 1 grease inlet 4 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 11g 5 Remove the grease nipple from the Joint 1 grease inlet 6 Attach the grease plug to the Joint 1 grease inlet If the grease plug is damaged or deteriorated replace it with a new one 7 Install the Arm 1 side cover For details refer to...

Page 94: ...let of the Arm 1 2 Attach the grease nipple to the Joint 2 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 12g 4 Remove the grease nipple from the Joint 2 grease inlet 5 Attach the grease plug to the Joint 2 grease inlet If the grease plug is damaged or deteriorated replace it with a new one ...

Page 95: ...nlet of the Arm 2 2 Attach the grease nipple to the Joint 3 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 3g 4 Remove the grease nipple from the Joint 3 grease inlet 5 Attach the grease plug to the Joint 3 grease inlet If the grease plug is damaged or deteriorated replace it with a new one ...

Page 96: ...ole located near the label with 4 printed is the Joint 4 grease inlet The grease inlet position differs depending on the model Carefully identify the correct position 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 2g 4 Remove the grease nipple from the Joint 4 grease inlet 5 Attach the grease plug to the Joint 4 grease inlet If the grease plug is damaged or de...

Page 97: ...r the label with 5 printed is the Joint 5 grease inlet Be careful not to confuse it with the Joint 6 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 1g Be careful not to mix with the grease used in the Joint 6 SK 2 4 Remove the grease nipple from the Joint 5 grease inlet 5 Attach the grease plug to the Joint 5 grease inlet If the grease plug is dam...

Page 98: ... the label with 6 printed is the Joint 6 grease inlet Be careful not to confuse it with the Joint 5 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 2 Grease amount 0 5g Be careful not to mix with the grease used in the Joint 5 SK 1A 4 Remove the grease nipple from the Joint 6 grease inlet 5 Attach the grease plug to the Joint 6 grease inlet If the grease plug is da...

Page 99: ...y grease to the mating surface of the bevel gear inside the Arm 5 Grease SK 2 Grease amount 2g 4 Apply a thin coat of grease SK 2 to the O ring Fit the O ring into the base groove Do not allow the O ring to come out of the groove If the O ring is swollen damaged or deteriorated replace it with a new one 5 Install the Arm 5 grease inlet cover Hexagon socket head cap bolts 4 M3 6 Tightening torque 2...

Page 100: ...set screw M3 2 0 0 1 N m 21 1 kgf cm Set Screw Tightening Torque M4 4 0 0 2 N m 41 2 kgf cm M4 2 4 0 1 N m 26 1 kgf cm M5 8 0 0 4 N m 82 4 kgf cm M5 3 9 0 2 N m 40 2 kgf cm M6 13 0 0 6 N m 133 6 kgf cm M6 8 0 0 4 N m 82 4 kgf cm M8 32 0 1 6 N m 326 16 kgf cm M10 58 0 2 9 N m 590 30 kgf cm M12 100 0 5 0 N m 1 020 51 kgf cm It is recommended to fasten the bolts aligned on a circumference in a crissc...

Page 101: ...elt Joint 1 Reduction gear unit Joint 3 Reduction gear unit Joint 3 Motor Electromagnetic brake Joint 3 Timing belt LED lamp Joint 5 Motor Electromagnetic brake Joint 5 Timing belt Joint 6 Motor Electromagnetic brake Joint 6 Timing belt Joints 5 6 Reduction Gear Unit Set Joint 4 Electromagnetic brake Joint 4 Motor Joint 4 Reduction gear unit Joint 4 Timing belt Battery board Battery Control board ...

Page 102: ...nt and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exist in them is e...

Page 103: ...eft 1 1822063 Side cover right 1 1822064 Arm 1 Side cover 2 1674548 Cleanroom model Plating cover Arm 2 Side cover left 1 1655127 Side cover right 1 1674550 Arm 3 Cover 1 1674551 Arm 4 Side cover left 1 1822065 Side cover right 1 1822066 Gasket Base Gasket for heat sink 1 1694610 Cleanroom model Tools Hexagonal wrench width across flats 2 5 mm 1 For M3 hexagon socket head cap bolts width across fl...

Page 104: ...n electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the Arm 1 center cover Cross recessed truss head small screws 5 M4 10 Installation Install the Arm 1 center cover to the Manipulator Cross recessed truss head smal...

Page 105: ...bles check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the Arm 1 side cover Cross recessed truss head small screws 4 M4 10 one side Installation Install the Arm 1 side cover to the Manipulator Cross recessed truss head small screws 4 M4 10 one side Tightening torque 0 9 0 1 N m Be careful not to ge...

Page 106: ...r Cross recessed truss head small screws 4 M4 10 one side Tightening torque 0 9 0 1 N m Be careful not to get the cables caught between the cover and the Manipulator body 3 4 Arm 3 Cover CAUTION When mounting the cover be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or conta...

Page 107: ...When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Before removing the Arm 3 maintenance cover move the arm to the position where you can remove the cover easily 2 Remove the screws and then remove the Arm 3 maintenance cover Cross recessed truss head small screws 4 M4 8 Installation Install the Arm 3 maint...

Page 108: ...of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Remove the screws and then remove the Arm 4 side cover Cross recessed truss head small screws 7 M4 10 one side The Arm 4 side cover andArm 4 side are the same between right and left 2 Remove the connectors RJ45 connector left Remove the ...

Page 109: ...onnector to the connector on the cover 2 Install the Arm 4 side cover to the Manipulator Cross recessed truss head small screws 7 M4 10 one side Tightening torque 0 9 0 1 N m Be careful not to get the cables caught between the cover and the Manipulator body When replacing the cover attach the electrical shock warning label and other labels to the places indicated in the photos NOTE ...

Page 110: ...hen routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Before removing the Arm 4 maintenance cover move the arm to the position where you can remove the cover easily 2 Remove the screws and then remove the Arm 4 maintenance cover Cross recessed truss head small screws 4 M4 10 Installation Install the Arm 4 maint...

Page 111: ...h into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the D sub attachment Be sure to place the cables back to their original locations Removal Remove the screws and ...

Page 112: ...or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations The base cover of the M C cable backward model is located on the bottom face of the base Removal Remove the bolts and then remove the base cover Hexagon socket head cap bolts 8 M4 10 Installation Install the base cover to the ...

Page 113: ...the cable locations at removing the cover Be sure to place the cables back to their original locations The base cover of the M C cable downward model is located on the backside of the base Removal 1 Remove the fan For details refer to Maintenance 15 Replacing the Fan 2 Remove the bolts on the heat sink Hexagon socket head cap bolts 4 M4 15 3 Remove the heat sink For cleanroom model remove the gask...

Page 114: ...iquid gasket becomes solid and the gasket is fixed 3 Install the base cover to the Manipulator Hexagon socket head cap bolts 11 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover and the Manipulator body Replace the gasket if there are flaws or deteriorations For cleanroom model install the gasket between the heat sink and the base cover 4 Inst...

Page 115: ...in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the base maintenance cover Cross recessed truss head small screws 6 M4 10 Installation Install the base maintenance cover to the Manipulator Hexagon socket head c...

Page 116: ...on and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the connector plate Be sure to place the cables back to their original locations Removal 1 Remove the fan For details refer to Maintenance 15 Replacing the Fan 2 Remove the bolts on the heat sink Hexagon ...

Page 117: ... gasket becomes solid and the gasket is fixed 3 Install the connecter plate to the Manipulator Hexagon socket head cap bolts 11 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover and the Manipulator body Replace the gasket if there are flaws or deteriorations For cleanroom model install the gasket between the heat sink and the connector plate 4...

Page 118: ...to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the connector plate Be sure to place the cables back to their original locations Removal Remove the bolts ...

Page 119: ...he connector sub plate be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the connector s...

Page 120: ...ctric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous and may result in electric shock and or malfunction of the robot system Be sure to connect the cables properly Do not allow unnecessary stra...

Page 121: ... including a mask protective goggles and oil resistant gloves If alcohol or adhesive gets on your skin wash the area thoroughly with soap and water If alcohol or adhesive gets into your eyes or mouth flush your eyes or wash out your mouth with clean water thoroughly and then see a doctor immediately Wear protective gear including a mask protective goggles and oil resistant gloves during grease up ...

Page 122: ...cessed head screws Torque rench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use this jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when perfo...

Page 123: ...Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base maintenance cover Connector plate M C cable backward 4 Remove the two air tubes inside the base 5 Remove the two D sub connectors 6 Disconnect the cables from the base and disconnect the following connectors Connectors X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 7 Disconnect the follow...

Page 124: ... the brake power supply Cross recessed head screws with washer 2 M3 6 11 Disconnect the following cables through the opening of the base D sub cable Ground wire RJ45 connector F sensor connector 12 Remove the Joint 1 motor unit For details refer to Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Removal steps 6 and 7 13 Remove the plate for preventing cable interference Hexagon so...

Page 125: ...ket head cap bolts 2 M3 6 15 Remove the Joint 1 timing belt 16 Remove the battery from the battery box 17 Disconnect the battery connector Hold the board by hand and pull up the battery cable to disconnect the connector 18 Remove the plate to which the battery board is fixed Hexagon socket head cap bolts 2 M4 10 NOTE ...

Page 126: ... and 5 to 9 22 Cut off the wire tie that binds the cables inside the Arm 1 and remove the connector connected to the control board 1 Connector GS01 23 Remove the Joint 1 cable fixing plate Arm 1 side Hexagon socket head cap bolts 2 M4 10 24 Disconnect the internal cables from the base side to the Arm 1 side Protect the connectors with masking tapes To protect the connector s clips To avoid adheren...

Page 127: ...1 cable brackets C2 and S2 one each and cable protection tube Hexagon socket head cap bolts 2 M3 6 C2 2 M4 10 S2 27 Remove the Arm 2 cable bracket C2 and cable protection tube Hexagon socket head cap bolts 2 M3 6 28 Remove the Arm 2 cable fixing plate Hexagon socket head cap bolts 2 M4 10 29 Cut off the wire tie that binds the cable protection coils inside the Arm 2 ...

Page 128: ... Hexagon socket head cap bolts 2 M4 8 C3A 2 M4 8 S3 33 Remove the two air tubes inside the Arm 3 Remove the air tube fittings from the air tubes The air tube fittings will be used again Be careful not to lose them 34 Remove the two ground wire terminals from the Arm 3 Cross recessed head screws with washer 2 M4 8 35 Disconnect the connectors inside the Arm 3 Connectors X141 X151 X161 BR041 BR051 X...

Page 129: ...d cap bolts 2 M4 10 38 Remove the Arm 3 cable bracket C3B Hexagon socket head cap bolts 2 M3 6 39 Remove the Arm 3 cable fixing plate 1 Hexagon socket head cap bolts 2 M4 10 40 Cut off the wire tie that binds the cable protection coils inside theArm 3 41 Disconnect the cables from the Arm 3 side to the Arm 2 side ...

Page 130: ... the connectors with a plastic bag Then pass the cable unit through the arm 43 Remove the Arm 3 cable fixing plate 2 Hexagon socket head cap bolts 2 M4 10 44 Remove the Arm 3 cable bracket C4 and the cable protection sheet Hexagon socket head cap bolts 2 M3 6 Remove the cable bracket C4 and the cable protection sheet at the Arm 4 maintenance cover Hexagon socket head cap bolts 2 M3 6 ...

Page 131: ... socket head cap bolts 2 M4 10 48 Remove the ground wire terminals from the cable protection plate Cross recessed head screws with washer 4 M4 8 49 Remove the Joints 5 and 6 motor units For details refer to Maintenance 9 1 Joint 5 Replacing the Motor Removal steps 4 to 8 and Maintenance 10 1 Joint 6 Replacing the Motor Removal steps 4 to 7 The air tube fittings removed together with the Joint 5 mo...

Page 132: ...ng parts from the Arm 4 D sub attachment D sub connector D sub connector fixing plate 52 Remove the Arm 4 cable fixing plate Hexagon socket head cap bolts 2 M4 10 53 Remove the cable bracket C4 Hexagon socket head cap bolts 2 M3 6 54 Disconnect the following cables that have no relays from the Arm 4 side to the Arm 3 side Ethernet cable X052 X062 cable Ground wire green yellow ...

Page 133: ...3 sheets 25 mm 120 mm 2 Remove the Ethernet cable from the connector Protect the cable ends with masking tapes to prevent the clip from damage 3 Remove the locking screws and nuts of the D sub connector The screws and nuts will be used again for fixing the connector Be careful not to lose them 4 Disconnect the following connectors to separate the cables Connectors X051 X061 X151 X161 XGND BR051 BR...

Page 134: ...the connector end Air tube 210 mm from the end 130 mm 6 Pass the separated cable unit base side from theArm 2 to theArm 1 To protect the connectors and facilitate the work first cover the connectors with a plastic bag Then pass the cable unit through the arm Pass the following cables that have no relays through the arm to the Arm 3 side Ethernet cable X052 X062 cable Ground wire green yellow ...

Page 135: ... through the braid tube as shown in the photo and fix the tube with the wire tie so that connectors are not to be pulled out Then pull the braid tube from the Arm 4 side while pushing the cables from the Arm 3 side to pass the cables through See the photo 8 Pass the separated cable unit Arm 4 side from the Arm 4 to theArm 3 Silicone tube is provided Leave out the silicone tube on the Arm 4 side Pa...

Page 136: ...ning torque 4 0 0 2 N m 10 Use a cable bracket C4 to fix the cables Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube 11 Install the D sub connector to the D sub attachment of the Arm 4 D sub connector fixing plate is provided Hold the D sub connector between...

Page 137: ...de Lower photo Joint 6 motor side Place the other cables and the air tube clear on the front side Fix the cables by binding them with a wire tie INSULOC AB150 or equivalent inserted through the hole of the cable fixing plate so that the cables do not interfere with the Joint 6 motor pulley Pay attention so that no connector is installed incorrectly and no cable is caught between components For det...

Page 138: ...g torque 4 0 0 2 N m Be careful not to get the cables caught It may cause cable breakage 16 Fix the cables to the Arm 4 maintenance cover using a cable bracket C4 Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m 17 Apply grease to the cables in the sleeve Grease Krytox Amount ap...

Page 139: ...tall the Arm 3 cable fixing plate 2 to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 20 Use the cable protection spring to bind cables at the Arm 3 cable fixing plate 1 Type of wire tie AB100 Number of wire ties 4 21 Install the Arm 3 cable fixing plate 1 to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m When installing the Arm 3 cable...

Page 140: ...Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 24 Connect the connector to the control board 2 Connector GS02 25 Connect the cable connectors inside the Arm 3 Connectors X141 X151 X161 BR041 BR051 X041 X71 X72 PS LED BT51 BT4 Hold the clip to remove 26 Install the two ground wire terminals to the Arm 3 Green yellow Left side Green Right side Cross recessed head screws wi...

Page 141: ...tion where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M4 8 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables 30 Push up the whole cables by 10 mm to the direction indicated with the arrow in the photo to allow for some space 31 Fix the cables to the Arm 2 by fixing the cable bracke...

Page 142: ...careful of the orientation of the Arm 2 cable fixing plate The side with two U shaped grooves should be placed down 35 Use cable brackets C2 to fix the cables to the Arm 2 cable fixing plate temporarily Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M3 6 Rough guide of temporary...

Page 143: ...o fix the cables to the Arm 2 temporarily Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M3 6 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables 40 Push up the whole cables by 10 mm to the direction indicated with the arrow in the photo to a...

Page 144: ...he connector 44 For the X021 X121 BR021 and CN3 cables place a mark at a position 160 mm from the connector respectively 45 Use cable brackets C1 to fix the cables to the Arm 1 cable fixing plate temporarily 2 positions Temporarily fix the silicone tube by aligning its end to the mark Hexagon socket head cap bolts 4 M3 6 Rough guide of temporary fixing The cables can be pushed up even after fixing...

Page 145: ... connectors should reach the end face of the Arm 1 when they are pulled out The cables should not be too long 47 Place a mark on the cables at the sleeve outlet on the base side 48 Fix the cable bracket C1 A on the near side so that the cable positions do not change Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m 49 Remove the Arm 1 cable fixing plate fixed temporarily and fix a...

Page 146: ...able fixing plate to the Arm 1 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 52 Install the connector GS01 to the control board 1 53 Install the Joint 2 motor and connect the connector For details refer to Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 4 and 9 54 Fix the two ground wire terminals to the Arm 2 Green Right side Green yellow Left side 55 Connect ...

Page 147: ...t the battery connectors 58 Install the battery to the battery box 59 Pass the Joint 1 timing belt through the cable 60 Use cable brackets C1 to fix the cables to the base cable fixing plate Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 0 0 1 N m ...

Page 148: ...re RJ45 connector F sensor connector 64 Install the brake power supply to the plate The cables should be located in the direction as shown in the photo See the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 65 Install the ground wire terminals to the plate Cross recessed head screws with washer 9 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45 0 1 N m M3 6 Th...

Page 149: ...b connector for brake release with a wire marker SW1 B release Right D sub connector for user wiring without a wire marker With round terminal D sub 70 Install the two air tubes according to the marks on the connector plate Air1 Clear Air2 Blue Install the air tube with the correct color 71 Install the covers and plate indicated below Arm 4 side covers both sides Arm 4 maintenance cover Arm 3 cove...

Page 150: ...cessed head screws Torque rench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use this jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when perfo...

Page 151: ...overs and plate indicated below Arm 4 side covers both sides Arm 4 maintenance cover Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base cover M C cable downward Base maintenance cover Connector plate M C cable downward For details refer to Maintenance 3 Covers 5 Remove the two air tubes in the base 6 Remove the two D sub connectors...

Page 152: ...ad screws with washer 9 M4 8 2 M3 6 10 Remove the brake power supply Cross recessed head screws with washer 2 M3 6 11 The subsequent steps are the same as those for the M C cable backward For details refer to Maintenance 4 1 1 Replacing the Cable Unit M C Cable Backward Removal steps 13 to 54 ...

Page 153: ...te The cables should be located in the direction as shown in the photo See the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1N m 4 Install the ground wire terminals to the plate Cross recessed head screws with washer 9 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45 0 1 N m M3 6 5 Install the following connectors according to the marks on the connector plate RJ45...

Page 154: ...llowing covers and plate Arm 4 side covers both sides Arm 4 maintenance cover Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base cover M C cable downward Base maintenance cover Connector plate M C cable downward For details refer to Maintenance 3 Covers 10 Perform calibration For details refer to Maintenance 16 Calibration NOTE ...

Page 155: ...Maintenance 4 Cable Unit C12 Rev 3 141 4 2 Connector Pin Assignment 4 2 1 Signal Cable ...

Page 156: ...Maintenance 4 Cable Unit 142 C12 Rev 3 ...

Page 157: ...Maintenance 4 Cable Unit C12 Rev 3 143 ...

Page 158: ...Maintenance 4 Cable Unit 144 C12 Rev 3 4 2 2 Power Cable ...

Page 159: ...Maintenance 4 Cable Unit C12 Rev 3 145 ...

Page 160: ...lor of Cables The following table shows the codes and cable colors indicated in the pin assignments 4 2 1 Signal Cable 4 2 2 Power Cable 4 2 3 User Cable Code Cable color B Black W White R Red G Green Y Yellow BR Brown L Blue V Violet A Azure O Orange GL Gray P Pink ...

Page 161: ...g the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and encoder Disassembled motor and encoder will cause a p...

Page 162: ...width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Nippers 1 For cutting the wire tie Pliers 1 For tightening the wire tie Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance steps The bra...

Page 163: ...onnector BT1 If the connector is disconnected perform calibration Remove the heat radiation block 1 Remove the wire tie and the bolts to remove the heat radiation block Hexagon socket head cap bolts M5 15 Wire tie AB350 2 Remove the heat radiation sheet between the heat radiation block and the motor The heat radiation block the heat radiation sheet and the bolts will be used again Be careful not t...

Page 164: ...nce 5 Joint 1 150 C12 Rev 3 7 Remove the Joint 1 motor unit from the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Be careful not to tear and lose the heat radiation sheet attached to the motor ...

Page 165: ...motor generates heat and the error may occur If the heat radiation sheet has the protection film remove the film Pass the pulley 1 of the Joint 1 motor unit to the Joint 1 timing belt and loosely secure it to the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Make sure that the gear grooves of the timing belt are fit into those of the pulley completely When securing the motor unit ...

Page 166: ...limit Vibration abnormal noise or reduction in life of the parts may occur if the value exceeds the upper limit When you replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 J3 to...

Page 167: ...rake If the J1 brake positioning jig cannot be inserted all the way the motor and the brake core may be misaligned In such a case use the brake release unit option part to release the brake and then align the brake Correct Wrong 5 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed ...

Page 168: ...ction film remove the film Image of the protection film 2 Fix the upper part of the heat radiation block to the Joint 1 motor plate with the bolts Hexagon socket head cap bolts M5 15 Tightening torque 4 0 0 2 N m 3 Fix the lower part of the heat radiation block to the motor with the wire tie Wire tie AB350 3 1 Insert the wire tie under the motor 3 2 Hold the end of the wire tie 3 3 While holding t...

Page 169: ...the wire tie around the motor 3 5 Tighten the wire tie to hold the heat radiation sheet firmly Make sure that the heat radiation sheet sticks out of the heat radiation block Do not tighten the wire tie too much It may result in cable breakage NOTE ...

Page 170: ...rque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig and J1 brake positioning jig are assembly jigs Use the jigs when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not ...

Page 171: ... it so that at least one of them can support the arm while the others are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 1 Remove the following parts Connector plate Connector Cable grounding plate Brake power supply For details refer to Maintenance 5 1 3 Joint 1 Replacing the Timing Belt M C Cable...

Page 172: ...t C1 Hexagon socket head cap bolts 2 M3 6 7 Remove the Joint 1 timing belt 8 Remove the Joint 2 motor unit For details refer to Maintenance 6 1 Joint 2 Replacing the Motor Removal steps 1 to 9 9 Remove the Joint 1 cable fixing plate Arm 1 side Hexagon socket head cap bolts 2 M4 10 10 Remove the connector connected to the control board 1 Connector GS01 ...

Page 173: ... grease tube between the base and the Arm 1 on the Arm 1 side from the fitting 13 Remove the Arm 1 from the base Hexagon socket head cap bolts 15 M6 30 with a plain washer CAUTION By removing the bolts the Arm 1 2 3 4 5 and 6 end effector can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when removing the arm H...

Page 174: ... 9 N m CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 3 Connect the grease tube for the Arm 1 side to the fitting 4 Pass the internal cables from the Arm 1 side to the base Protect th...

Page 175: ...er to Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 4 to 9 8 Pass the cables and the air tube inside the Joint 1 timing belt 9 Mount the base cable bracket C1 Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 0 0 1 N m 10 Install the cable interference prevention plate Hex...

Page 176: ...ensor connector 13 Connect the ground wires Cross recessed head screws with washer 9 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45 0 1 N m M3 6 The ground terminals of the D sub cables have fixed installation positions Install them to the two screw holes Photo indicated by the arrows 14 Install the following parts Connector plate Connector Cable grounding plate Brake power supply For details ...

Page 177: ...lt width across flats 5 mm 1 For M6 hexagon socket head cap bolt Box wrench width across flats 5 mm 1 For D Sub connector Long nose pliers 1 For removing the air tube Cross point screwdriver 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in rele...

Page 178: ...kward For details refer to Maintenance 3 Covers 4 Remove two air tubes inside the base 5 Remove two D sub connectors 6 Disconnect the cables from the base and disconnect the connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 7 Disconnect the following connectors RJ45 connector Hold the clip to remove F sensor connector Open the clips on the both ends o...

Page 179: ...her 2 M3 6 9 Remove the ground wire plate M C cable backward Hexagon socket head cap bolts 2 M4 10 10 Remove the following ground wire terminals D sub cable ground wire terminals 2 Ground wire green yellow terminal 1 indicated by an arrow Cross recessed head screws with washer 3 M4 8 Positions of the ground wire green yellow terminals may differ from the photo Check the positions of the terminals ...

Page 180: ...wire RJ45 connector F sensor connector 12 Remove the Joint 1 motor unit For details refer to Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Removal steps 6 to 7 13 Remove the Joint 1 cable fixing plate Hexagon socket head cap bolts 2 M3 6 Do not remove the base cable bracket C1 14 Remove the Joint 1 timing belt ...

Page 181: ... Disconnect the following parts from the hole inside the base to the upper side of the base D sub cable Ground wire RJ45 connector F sensor connector 5 Install the terminals of the D sub cable ground wire and ground wire green yellow D sub cable ground wire terminals 2 indicated by arrows Ground wire green yellow terminal 1 Cross recessed head screws with washer 3 M4 8 Tightening torque 0 9 0 1 N ...

Page 182: ...ctor plates RJ45 connector Ether F sensor connector F sensor Install the ground wire to each connector To connect the ground wire insert it while holding the connector by hand 9 Connect the M C cable connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 10 Install the D sub connectors in accordance with the indications on the connector plates Left D sub for brake release with a ...

Page 183: ...Install the connector plate M C cable backward For details refer to Maintenance 3 Covers 13 Install the base maintenance cover For details refer to Maintenance 3 Covers 14 Calibrate the Joint 1 For details refer to Maintenance 16 Calibration ...

Page 184: ...For M4 hexagon socket head cap bolt Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance steps The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF st...

Page 185: ...ke from the brake plate Hexagon socket head cap bolts 3 M4 25 Installation Joint 1 Electromagnetic brake M C Cable Backward 1 Install the Joint 1 brake to the brake plate Hexagon socket head cap bolts 3 M4 25 Tightening torque 4 0 0 2 N m Be careful of the assembly direction of the Joint 1 electromagnetic brake See the photo 2 Mount the Joint 1 brake plate to the Joint 1 motor unit For details ref...

Page 186: ...s width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Nippers 1 For cutting the wire tie Pliers 1 For tightening the wire tie Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance steps The b...

Page 187: ... details refer to Maintenance 3 Covers 4 Disconnect the cables from the base and disconnect the following connectors Connector X11 X010 BT1 BR011 Hold the clip to remove When only replacing the brake do not disconnect the connector BT1 If the connector is disconnected perform calibration Remove the heat radiation block 1 Remove the wire tie and the bolts to remove the heat radiation block Hexagon ...

Page 188: ...rake plate from the Joint 1 motor unit Hexagon socket head cap bolts 3 M4 20 7 Remove the Joint 1 motor unit from the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Be careful not to tear and lose the heat radiation sheet attached to the motor ...

Page 189: ...ke sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 3 Connect the following connectors Connector X11 X010 BT1 BR011 4 Install the following covers Connector plate M C cable downward Base cover M C cable downward Base maintenance cover For details refer to Maintenance...

Page 190: ...rque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig and J1 brake positioning jig are assembly jigs Use the jigs when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not ...

Page 191: ...removing the Arm 1 there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 1 Remove the following parts Connector plate Connector Brake power supply For details refer to Maintenance 5 2 3 Joi...

Page 192: ...Joint 1 Replacing the Reduction Gear Unit M C Cable Backward Installation steps 1 to 11 2 Install the ground terminals to the plate Cross recessed head screws with washer 9 M4 8 2 M3 6 3 Install the following parts Connector plate Connector Brake power supply For details refer to Maintenance 5 2 3 Joint 1 Replacing the Timing Belt M C Cable Downward Installation steps 4 to 10 ...

Page 193: ... M6 hexagon socket head cap bolt Box wrench width across flats 5 mm 1 For D Sub connector Long nose pliers 1 For removing the air tube Cross point screwdriver 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance steps The brake...

Page 194: ... of the robot system 3 Remove the following covers Base maintenance cover Base cover M C cable downward Connector plate M C cable downward For details refer to Maintenance 3 Covers 4 Disconnect the cables from the base and disconnect the following connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 5 Disconnect the following parts Air tubes RJ45 connect...

Page 195: ...he ground wire plate M C cable downward Hexagon socket head cap bolts 2 M4 12 8 Remove the Joint 1 motor unit For details refer to Maintenance 5 1 1 Joint 1 Replacing the Motor M C cable backward Removal steps 6 to 7 9 Remove the Joint 1 motor unit ...

Page 196: ... 4 0 0 2 N m 4 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 5 Connect the following connectors in accordance with the indications on the connector plates RJ45 connector Ether F sensor connector F sensor Install the...

Page 197: ...ith a round terminal D sub 8 Install two air tubes in accordance with the indications on the connector plates Air1 Semitransparent Air2 Blue Be careful not to install the air tube of wrong color 9 Install the following covers Connector plate M C cable downward Base cover M C cable downward Base maintenance cover For details refer to Maintenance 3 Covers 10 Calibrate the Joint 1 For details refer t...

Page 198: ...ats 3 mm 1 For M4 hexagon socket head cap bolt Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control The J1 brake positioning jig is an assembly jig Use the jig in relevant maintenance steps The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The bra...

Page 199: ... plate from the Joint 1 motor unit For details refer to Maintenance 5 2 1 Joint 1 Replacing the Motor M C Cable Downward Removal steps 1 to 6 Do not disconnect the connector BT1 If the connector is disconnected perform calibration 2 Remove the Joint 1 brake from the brake plate Hexagon socket head cap bolts 3 M4 25 NOTE ...

Page 200: ...t 1 Replacing the Motor M C Cable Backward Installation step 4 3 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 4 Connect the M C cable connectors Connector X11 X010 BT1 BR011 5 Install the following covers Connector...

Page 201: ...t procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement It may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be use...

Page 202: ...2 For pulley position adjustment Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when ...

Page 203: ... falls by its weight when the Joint 2 motor unit is removed Therefore release the brake and tilt the Arm 2 in advance Put a cloth between the Arm 1 and Arm 2 so that the arms do not touch each other EPSON RC Command brake off 2 CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when moving the Manipulator 3 Turn OFF the ...

Page 204: ...ecessed head screws with captive washer 2 M3 6 8 Loosen the bolts securing the Joint 2 motor unit and remove the belt Hexagon socket head cap bolts 3 M5 25 with a plain washer WARNING Loosening the bolts while the Arm 2 is not bent may cause the belt come off and the Arm 2 falls down and it is extremely hazardous Be sure to do the Removal steps 1 and 2 before loosening the bolts ...

Page 205: ... shaft A Hexagon socket set screws 2 M5 12 Do not remove the pulley and drive boss screws B in the figure There is a brass bushing on one of the set screws If you removed the screws B be careful not to lose the brass bushing A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss screws Do not remove these screws C Bushing Pulley Drive boss A A C B B 11 Remove the J...

Page 206: ...Maintenance 6 Joint 2 192 C12 Rev 3 12 Remove the motor plate from the Joint 2 motor Hexagon socket head cap bolts 4 M6 20 ...

Page 207: ...screws 2 M6 6 with a brass bushing Tightening torque 8 0 0 4 N m Be careful of the assembly direction of the Joint 2 electromagnetic brake See the photo Fix the set screws while pressing the electromagnetic brake to the motor plate The brass bushing is not necessary for the screw for the flat surface D cut Set the bushing to the other screw and then fix the screw If the screw positions are incorre...

Page 208: ... Hexagon socket set screws 2 M5 8 with a brass bushing Tightening torque 3 9 0 2 N m If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the part and may result in the part being unable to be removed Set the set screws to the positions indicated in the right figure A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss ...

Page 209: ... parts may occur if the value exceeds the upper limit When you replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 and J3 with the screws 2 M4 35 and push the rubber against the ...

Page 210: ...and the heat dissipation sheet to the Arm 2 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 10 Mount the Arm 1 cover and the Arm 1 side cover For details refer to Maintenance 3 Covers 11 Perform calibration For details refer to Maintenance 16 Calibration ...

Page 211: ...tightening torque control Belt tension meter 0 5 mm 2 For adjusting the pulley position Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The ...

Page 212: ...oard Removal steps 3 to 6 3 Remove the battery box Countersunk screws 2 M3 8 4 Arm 1 side arm fixing bolts Hexagon socket head cap bolts 8 M6 25 with a plain washer 5 Remove the Joint 2 pulley 2 from the Joint 2 shaft Hexagon socket set screws 2 M5 10 There is a brass bushing on one of the set screws Be careful not to lose it Remove the key from the shaft The key will be used again Be careful not ...

Page 213: ...removing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts The Arms are connected by the internal cables When replacing the parts place the removed arm while not applying load on the cables It may result in cable disconnection 8 Remove the wave generator from the reduction gear unit If the wave generator unit does not come off ea...

Page 214: ...Maintenance 6 Joint 2 200 C12 Rev 3 10 Remove the O ring from the groove on the Arm 2 Wipe grease on the part while removing it ...

Page 215: ...ged or deteriorated replace it with a new one 2 Install the reduction gear unit to the Arm 2 Hexagon socket head cap bolts 12 M6 45 Tightening torque 18 0 0 9 N m Installation face of the Arm 2 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes 3 Grease the inner side of the flexspline Grease SK 1A Grease amount 102g 4 Insert the wav...

Page 216: ... Arm 1 Hexagon socket head cap bolts 8 M6 2 5 with a plain washer CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 7 Fix the Arm 2 Hexagon socket head cap bolts 16 M6 35 with a plain wa...

Page 217: ... the screw for the flat surface Set the bushing to the other screw and then fix the screw If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the brake and may result in the part being unable to be removed 10 Install the battery box Countersunk screws 2 M3 8 Tightening torque 0 45 0 1 N m 11 Install the following parts Battery Battery board Battery con...

Page 218: ... performing maintenance work When removing the Joint 2 motor tilt the Arm 2 and press it against the Arm 1 Reference Maintenance 6 1 Joint 2 Replacing the Motor Removal step 2 When pressing the arm put a piece of cloth or a similar material between the arms to avoid contacting each other This protects the arm surfaces from scratching and paint peeling off Removal Joint 2 Timing belt 1 Follow Remov...

Page 219: ...lt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work When removing the Joint 2 motor tilt the Arm 2 and press it against the Arm 1 Reference Maintenance 6 1 Joint 2 Replacing the Motor Removal step 2 When...

Page 220: ...h the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be used again ...

Page 221: ...t Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Whe...

Page 222: ...the Arm 3 and push it against the Arm 2 The Arm 3 falls by its weight when the Joint 3 motor unit is removed Therefore release the brake and tilt the Arm 3 in advance EPSON RC Command brake off 3 CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when moving the Manipulator Put a cloth between the Arm 2 and Arm 3 so that...

Page 223: ...sen the bolts securing the Joint 3 motor unit and remove the belt Hexagon socket head cap bolts 3 M4 20 with a plain washer WARNING Loosening the bolts while the Arm 3 is not bent may cause the belt come off and the Arm 3 falls down and it is extremely hazardous Be sure to do the Removal steps 1 and 2 before loosening the bolts ...

Page 224: ... the figure Pulley and motor shaft screws A Hexagon socket set screws 2 M5 12 Do not remove the pulley and drive boss screws B in the figure There is a brass bushing on one of the set screws If you removed the screws B be careful not to lose the brass bushing Pulley and drive boss screws B Hexagon socket set screws 2 M5 6 with a brass bushing A Pulley and motor shaft screws D cut part of the motor...

Page 225: ...emove the Joint 3 electromagnetic brake Hexagon socket set screws 2 M5 10 with a brass bushing The screws have a brass bushing Be careful not to lose them 11 Remove the motor plate from the Joint 3 motor Hexagon socket head cap bolts 4 M5 15 ...

Page 226: ...ews 2 M5 10 with a brass bushing Tightening torque 3 9 0 2 N m Be careful of the assembly direction of the Joint 3 electromagnetic brake See the photo Fix the set screws while pressing the electromagnetic brake to the motor plate The brass bushing is not necessary for the screw for the flat surface D cut Set the bushing to the other screw and then fix the screw If the screw positions are incorrect...

Page 227: ...m Hexagon socket set screw 2 M5 6 with a brass bushing Tightening torque 3 9 0 2 N m Set the set screws to the positions indicated in the right figure A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss screws Do not remove these screws C Bushing Pulley Drive boss A A C B B If the screw positions are incorrect or the bushing is not set it may cause damage on the...

Page 228: ...ew belt belt may stretch and the belt tension will decrease in the initial stage of operation Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 J3 with the screws 2 M4 35 and push the rubber against the pulley Tension is applied by pushing the set screw M6 25 with the...

Page 229: ...h 1 For tightening torque control Feeler gauge 0 5 mm 2 For adjusting the pulley position Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status Th...

Page 230: ...p bolts 16 M4 25 with a plain washer Remove a wave washer on the Arm 1 side The wave washer will be used again Be careful not to lose it Wipe grease on the parts while removing them CAUTION By removing the bolts the Arm 2 side arm the Arm 3 4 5 and 6 end effector can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very carefu...

Page 231: ...pulley 2 as shown in the photo to the shaft and pull out the parts Wipe grease on the wave generator while removing it 6 Remove the reduction gear unit from the Arm 3 Hexagon socket head cap bolts 12 M4 30 Wipe grease on the reduction gear unit while removing it 7 Remove the O ring from the groove on the Arm 3 Wipe grease on the O ring while removing it ...

Page 232: ...p bolts 12 M4 30 Tightening torque 5 5 0 2 N m Installation face of the Arm 3 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes 3 Grease the inner side of the flexspline Grease SK 1A Grease amount 26 g 4 Insert the wave generator to the reduction gear unit and fix it 5 Apply a thin coat of grease SK 1A to the O ring Fit the O ring i...

Page 233: ...ry careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 7 Fix the Arm 3 Hexagon socket head cap bolts 16 M4 25 with a plain washer Tightening torque 5 5 0 2 N m After fixing the Arm check that there is no backlash or misalignment on the reduction gear unit by moving the Arm by hand 8 After fixing the Arm 3 fi...

Page 234: ...face of the shaft The brass bushing is not necessary for the screw for the flat surface Set the bushing to the other screw and then fix the screw If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the brake and may result in the part being unable to be removed 10 Install the Joint 3 timing belt For details refer to Maintenance 7 3 Joint 2 Replacing th...

Page 235: ...orming maintenance work When removing the Joint 3 motor tilt the Arm 2 and press it against the Arm 2 Reference Maintenance 7 1 Joint 3 Replacing the Motor Removal step 2 When pressing the arm put a piece of cloth or a similar material between the arms to avoid contacting each other This protects the arm surfaces from scratching and paint peeling off Removal Joint 3 Timing belt 1 Follow Removal st...

Page 236: ...d on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work When removing the Joint 3 motor tilt the Arm 2 and press it against the Arm 2 Reference Maintenance 7 1 Joint 3 Replacing the Motor Removal step 2 When pressing the arm put a piece ...

Page 237: ...dure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be use...

Page 238: ...auge 0 5 mm 2 For pulley position adjustment Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance wo...

Page 239: ...ce 3 Covers 3 Pull out the cables from the Arm 3 and disconnect the following connectors Connector X141 X041 BT4 BR041 Hold the clip to remove 4 Remove the brake power supply Cross recessed head screws with captive washer 2 M3 6 5 Remove the cable bracket Hexagon socket head cap bolts 2 M4 10 6 Remove the Joint 4 motor unit from the Arm 3 Hexagon socket head cap bolts 2 M4 15 with a small plain wa...

Page 240: ...xagon socket set screws 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B 8 Remove the Joint 4 electromagnetic brake Hexagon socket set screws 3 M3 15 with a spacer Be careful not to lose the spacers 9 Remove the motor plate from t...

Page 241: ...e the photo Electromagnetic brake wire 3 Mount the drive boss and the pulley 1 to the Joint 4 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may result in breakage while the motor is moving Set the set screws to the ...

Page 242: ...of the timing belt engage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 4 timing belt and fix the Joint 4 motor unit Joint 4 timing belt tension 15 to30 N Belt tension meter setting value Weight 2 5 ...

Page 243: ...t M4 15 Tension is applied as the Joint 4 motor unit is stretched by tightening the screw 7 Install the plate for fixing the cables Hexagon socket head cap bolts 2 M4 10 8 Install the brake power supply to the plate Install the brake power supply so that the cable is facing downward Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Connect the following connecto...

Page 244: ...r M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to it...

Page 245: ...nce 10 1 Joint 6 Replacing the Motor 4 Remove the cables passing through the Arm 4 as shown in the photo For details refer to the Removal steps in Maintenance 4 1 Cable Unit 5 Loosen the fixing bolts of the Joint 4 motor plate and remove the belt Do not remove the Joint 4 motor Hexagon socket head cap bolts 2 M4 15 with a small plain washer 6 Remove the bolts fixing the J4 flange and remove the Ar...

Page 246: ... tool in a gap between the J4 flange and the Arm and remove the wave generator little by little Be careful not to damage the parts 9 Remove the Joint 4 reduction gear unit Hexagon socket head cap bolts 12 M3 28 10 Remove the J4 sleeve holder Then remove the J4 sleeve Hexagon socket head cap bolts 4 M3 6 The J4 sleeve is attached by gasket and may not be removed easily If the part cannot be removed...

Page 247: ...of the bearing holder on the pulley Hexagon socket head cap bolts 3 M3 8 with a plain washer 12 Remove the pulley from the pulley spacer Hexagon socket set screws 2 M4 4 13 Remove the pulley spacer from the wave generator Hexagon socket head cap bolts 4 M3 8 ...

Page 248: ... J4 sleeve holder Hexagon socket head cap bolts 4 M3 6 Tightening torque 2 0 0 1 N m 2 Install the O ring to the O ring groove Install the Joint 4 reduction gear unit Hexagon socket head cap bolts 12 M3 28 Tightening torque 2 4 0 1 N m 3 Apply grease to the Joint 4 reduction gear unit Grease SK 1A Grease amount 20 g Apply 10g of grease to the wave generator Apply the remaining 10 g to the inner si...

Page 249: ...ng groove on the Joint 4 reduction gear unit Then install the J4 flange Hexagon socket head cap bolts 16 M3 20 Tightening torque 2 4 0 1 N m 6 Fix the pulley spacer to the wave generator of the Joint 4 reduction gear unit Hexagon socket head cap bolts 4 M3 8 Tightening torque 2 0 0 1 N m 7 Fix the J4 pulley to the J4 pulley spacer Hexagon socket set screws 2 M4 4 ...

Page 250: ...socket head cap bolts 8 M5 30 Tightening torque 10 0 0 5 N m 10 Install the Joint 4 timing belt with a proper tension For details refer to Maintenance 8 1 Joint 4 Replacing the Motor Installation steps 5 and 6 11 Pass the cables to the Arm 4 For details refer to Installation steps in Maintenance 4 1 Cable Unit 12 Install the Joints 5 and 6 motors For details refer to Installation steps of Maintena...

Page 251: ...e cables Braid tube 600 mm or longer 1 For passing the cables The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 4 Timi...

Page 252: ...cket head cap bolts 2 M4 10 7 Remove the green yellow ground wire and the green ground wire connected to X052 and X062 from the cable protection plate Cross recessed head screws with captive washer 2 M4 8 Positions of the ground wire terminals may differ from the photo Check which connector the terminal is connected to 8 Remove the following connectors Connector X052 X062 9 Remove the Arm 4 cable ...

Page 253: ... protection sheet Hexagon socket head cap bolts 2 M3 6 The Arm 4 cable bracket and cable protection sheet will be used again Be careful not to lose them 13 Pull the following parts from the Arm 4 to the Arm 3 LAN cable X052 and X062 cables Ground wire Air tube blue Protect the connectors with masking tapes To protect the connector s clips To avoid adherence of cable grease 14 Remove the Joint 4 ti...

Page 254: ...Then pull the braid tube from the Arm 4 side while pushing the cables from the Arm 3 side to pass the cables through See the photo Pulling the cables forcibly may cause falling off or breakage of the connectors and disconnection of the cables If it is difficult to pass the cables pass the cables one by one in the following order X052 and X062 cables LAN cable Ground wire Air tube blue 4 Wrap the c...

Page 255: ... N m 8 Install the brake power supply to the plate Install the brake power supply so that the cable is facing downward Cross recessed head screws with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Connect the connectors inside the Arm 3 and the air tube transparent Connector X71 X72 X041 BR041 BR051 PS BT4 BT51 X141 X151 X161 10 Connect the ground wire terminals inside the Arm 4 to the Ar...

Page 256: ... Arm 4 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may cause cable breakage 13 Install the air tube blue to the fitting 14 Install the following covers Arm 3 cover Arm 3 maintenance cover Arm 4 side cover Arm 4 maintenance cover For details refer to Maintenance 3 Covers NOTE ...

Page 257: ... prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work The electromagnetic brakes are common for Joints 4 5 and 6 The Joints 5 and 6 electromagnetic brakes have an identification label for preventing misconnection of the connectors The label is not neces...

Page 258: ...he power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be used again Aft...

Page 259: ...r width across flats 8 mm 1 For air tube fitting Feeler gauge 0 5 mm 2 For adjusting the drive boss position Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not w...

Page 260: ...exagon socket head cap bolts 2 M4 10 4 Remove the brake power supply for the brake connected to the connector BR052 from the plate Cross recessed head screw with captive washer 2 M3 6 5 Disconnect the following connectors Connector X052 X152 BT52 BR052 6 Remove the air tube fitting located in the front of the Joint 5 motor unit 7 Loosen the screws fixing the Joint 5 motor unit and remove the belt ...

Page 261: ...aft of the Joint 5 motor unit Pulley 1 and drive boss screws Hexagon socket set screws 2 M4 4 with a brass bushing Drive boss and motor shaft screws Hexagon socket set screws 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B ...

Page 262: ...C12 Rev 3 10 Remove the Joint 5 electromagnetic brake Hexagon socket head cap bolts 3 M3 15 with a spacer Be careful not to lose the spacers 11 Remove the motor plate from the Joint 5 motor Hexagon socket head cap bolts 2 M4 10 ...

Page 263: ...ring See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 5 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may result in breakage while the motor is moving Set the set screw...

Page 264: ... fix it temporarily Make sure that the teeth of the timing belt engage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 5 timing belt and fix the Joint 5 motor unit Joint 5 Timing belt tension 15 to 30 ...

Page 265: ...ir leakage due to screw breakage or gasket deformation Fitting is too loose It may cause loose screws and air leakage 8 Connect the following connectors Connectors X052 X152 BT52 BR052 9 Install the power supply of the brake to the plate Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 10 Fix the cable protection bracket to the Arm 4 Hexagon socket head cap bolts...

Page 266: ...width across flats 3 mm 1 For M4 hexagon socket head cap bolts width across flats 4 mm 1 For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Spanner width across flats 8 mm 1 For air fittings Feeler gauge 0 5 mm 2 For drive boss position adjustmen...

Page 267: ...t 5 Replacing the Motor and Maintenance 10 1 Joint 6 Replacing the Motor 4 Remove the cables passing through the Arm 4 as shown in the photo For details refer to the Removal steps in Maintenance 4 1 Cable Unit 5 Remove the Joints 5 6 reduction gear unit Remove the bolts fixing the Arm 4 extension flange and remove the Joints 5 and 6 reduction gear unit from the Arm 4 extension part Hexagon socket ...

Page 268: ...e Joint 5 and 6 reduction gear unit Install the Arm 4 extension flange to the Arm 4 extension part Hexagon socket head cap bolts 4 M6 20 Tightening torque 13 0 0 6 N m 3 Pass the cables to the Arm 4 Connect all the connectors inside the Arm 3 and bind them together Fix the cables inside the Arm 4 and connect the D sub to the Arm 4 For details refer to Installation steps in Maintenance 4 1 Cable Un...

Page 269: ...details refer to Installation steps in Maintenance 9 1 Joint 5 Replacing the Motor and Maintenance 10 1 Joint 6 Replacing the Motor 5 Install the removed covers For details refer to Maintenance 3 Covers 6 Perform the calibration For details refer to Maintenance 16 Calibration ...

Page 270: ...o prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 5 Timing belt 1 Turn OFF the Controller power 2 Remove the Arm 4 side cover For details refer to Maintenance 3 Covers 3 Loosen the Joint 5 motor unit set screws Hexagon socket head cap...

Page 271: ...er Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Attaching the labels The electromagnetic brakes are common for Joi...

Page 272: ...tic brake For details refer to Maintenance 9 1 Joint 5 Replacing the Motor Removal steps 1 through 10 Installation Joint 5 Electromagnetic brake 1 Mount the Joint 5 electromagnetic brake to the Joint 5 motor unit For details refer to Maintenance 9 1 Joint 5 Replacing the Motor Installation steps 2 through 12 ...

Page 273: ...the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be used again Af...

Page 274: ...ws Feeler gauge 2 For adjusting the drive boss position Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing mai...

Page 275: ... 10 4 Remove the brake power supply for the brake connected to the connector BR062 from the protection plate Cross recessed head screw with captive washer 2 M3 6 5 Pull out the cables from the Arm 4 and disconnect the following connectors Connectors X062 X162 BT62 BR062 6 Loosen the bolts securing the Joint 6 motor unit and remove the belts Hexagon socket head cap bolts 2 M4 15 with a plain washer...

Page 276: ...socket set bolts 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B 9 Remove the Joint 6 electromagnetic brake Hexagon socket set bolts 3 M3 15 with a spacer Be careful not to lose the spacers 10 Remove the motor plate from the Join...

Page 277: ...ing See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 6 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may result in breakage while the motor is moving Set the set screws...

Page 278: ...e of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 6 timing belt and fix the Joint 6 motor unit Joint 6 timing belt tension 15 to 30 N m Belt tension meter setting value Weight 2 5 g mm width m span Width 6 mm Spa...

Page 279: ...ectors Connectors X062 X162 BT62 BR062 8 Install the brake power supply to the plate Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Fix the cable protection plate to the Arm 4 Hexagon socket head cap bolt 2 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may result in cable breakage 10 Install the Arm 4 side cover For details re...

Page 280: ...xagon socket head cap bolts width across flats 4 mm 1 For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Spanner width across flats 8 mm 1 For air fittings Feeler gauge 0 5 mm 2 For drive boss position adjustment Belt tension meter 1 Refer Unitta...

Page 281: ... from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 6 Timing belt 1 Turn OFF the Controller power 2 Remove the Arm 4 side cover For details refer to Maintenance 3 Covers 3 Loosen the Joint 6 motor unit set screw Hexagon socket head cap bolt 2 M4 15 with...

Page 282: ...ly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Attaching the labels The electromagnetic brakes are common to Joints 4 5 and 6 In order to prevent misconnection of...

Page 283: ...tic brake For details refer to Maintenance 10 1 Joint 6 Replacing the Motor Removal steps 1 through 9 Installation Joint 6 Electromagnetic brake 1 Mount the Joint 6 electromagnetic brake to the Joint 6 motor unit For details refer to Maintenance 10 1 Joint 6 Replacing the Motor Installation steps 2 through 11 ...

Page 284: ...g Connecting batteries improperly Exposing to fire Forcing discharge Deforming by pressure Short circuit Polarity Positive Negative Heating 85 C or more Soldering the terminal of the lithium battery directly When disposing the battery consult with the professional disposal services or comply with the local regulation Make sure that the battery terminal is insulated even for a used buttery If the t...

Page 285: ...om the originals after replaced the battery Designated parts must be used for the lithium battery and battery board Be careful of the battery polarity to connect it correctly Battery board Battery Name Qty Note Maintenance Parts Battery unit Lithium battery 1 2172925 Two lithium batteries for replacement Battery board 1 2173216 Tools Cross point screwdriver 2 1 For cross recessed head screws Hexag...

Page 286: ...you removed all the batteries before connecting the new ones the calibration data will be deleted and you will need to perform calibration Follow the steps below to remove the lithium batteries 4 Connect the two new batteries to the connectors of the battery board which are not connected to anything 5 Remove the old batteries Hold the board by hand and pull the battery cable upward to remove the c...

Page 287: ... Covers 8 Turn ON the Controller power 9 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 10 If the Manipulator is out of position calibrate all the joints and axes For details refer to Maintenance 16 Calibration ...

Page 288: ... match these origins after replacing the parts The process of aligning the two origins is called Calibration Refer to Maintenance 16 Calibration and perform the calibration after the parts replacement Removal Battery board 1 Turn OFF the Controller power 2 Remove the Arm 1 side cover For details refer to Maintenance 3 Covers 3 Remove the battery from the battery box 4 Remove the battery connectors...

Page 289: ...Maintenance 11 Replacing the Battery Unit C12 Rev 3 275 6 Remove the connectors Connectors CN3 CN6 7 Remove the battery board fixed to the plate Cross recessed head screws 3 M3 6 ...

Page 290: ...he connectors to the battery board Connector CN3 CN6 3 Install the plate where the battery board is installed to Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 4 Connect the battery connectors 5 Install the battery to the battery box 6 Install the Arm 1 side cover For details refer to Maintenance 3 Covers 7 Perform the calibration For details refer to Maintenance 16 Calibratio...

Page 291: ...to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot syste...

Page 292: ...nance 3 Covers 3 Remove the connector connected to the control board 1 Connector GS01 4 Remove the control board 1 fixed to the Arm 1 Cross recessed head screws 3 M3 8 Be careful not to drop the screws inside the Manipulator while removing them 5 Remove the control board 1 protection plate Cross recessed head screws with captive washer M3 6 It is not necessary to remove the spacer from the plate N...

Page 293: ...d screws 3 M3 8 Tightening torque 0 45 0 1 N m Be careful not to drop the screws inside the Manipulator while removing them 3 Connect the connector to the control board 1 Connector GS01 4 Install the Arm 1 center cover For details refer to Maintenance 3 Covers 5 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of...

Page 294: ...n OFF the Controller power 2 Remove the Arm 3 cover For details refer to Maintenance 3 Covers 3 Remove the connector connected to the control board 2 Connector GS02 4 Remove the plate fixed to the Arm 3 Hexagon socket head cap bolts 2 M4 10 5 Remove the control board 2 fixed to the plate Cross recessed head screws 4 M3 8 ...

Page 295: ...rm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 3 Connect the connector to the control board 2 Connector GS02 4 Install the Arm 3 cover For details refer to Maintenance 3 Covers 5 Turn ON the Controller power 6 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 7 If...

Page 296: ...t off power to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is ex...

Page 297: ...he Arm 3 cover Connector LED 4 Remove the LED lamp from the Arm 3 Turn the plastic nut securing the LED lamp in the Arm 3 counterclockwise Plastic nut Installation LED lamp 1 Install the LED lamp to the Arm 3 Remove the plastic nut from the LED lamp Pass the lamp from the inside of the Arm 3 Turn the nut clockwise and secure the lamp to the Arm 3 2 Connect the following connector Connector LED 3 I...

Page 298: ...ment procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION When disconnecting the connectors during the replacement of the cable unit be sure to reconnect the connectors to their proper positions Improper connection of the connectors may result in improper function of the robot system For details on the connections please...

Page 299: ... m Straight 1 R12NZ900YC L shaped 1 R12NZ900YB 20 m Straight 1 R12NZ900S4 L shaped 1 R12NZ900S8 M C cable flexible 3 m Straight 1 R12NZ900S9 L shaped 1 R12NZ900SD 5 m Straight 1 R12NZ900SA L shaped 1 R12NZ900SE 10 m Straight 1 R12NZ900SB L shaped 1 R12NZ900SF 15 m Straight 1 R12NZ900YE L shaped 1 R12NZ900YD 20 m Straight 1 R12NZ900SC L shaped 1 R12NZ900SG Tools Hexagonal wrench width across flats ...

Page 300: ...ntenance 3 Covers Do not pull the connector plate forcibly Do not disconnect the M C cable from the connector plate 4 Remove the connectors Connectors X11 X12 X14 BR010 X010 X020 X040 LED GS01 Each connector is numbered and has a different shape Do not disconnect the battery connector BT1 Otherwise calibration will be required For details refer to Maintenance 16 Calibration 5 Remove the connector ...

Page 301: ...ce 3 Covers 4 Connect the following connectors to the Controller Power cable connector Signal cable connector 5 Turn ON the Controller power 6 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 7 If the battery connector BT1 was disconnected calibrate the Joint 1 For details refer to Mainte...

Page 302: ...ystem To shut off power to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the po...

Page 303: ...o support the cover 2 Remove the fan cover 3 Remove the fan connectors 4 Remove the fan Installation Fan 1 Install the fan Be careful of the installation direction of the fan The arrow on the fan indicated with the arrow in the photo should point the heat sink and the cables should come to the upper side of the fan Heat sink side 2 Connect the fan connectors 3 Install the fan cover Cross recessed ...

Page 304: ...r However operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly In EPSON RC a coordinate point including the arm pose is defined as point and its data is called point data There are two methods to move the Manipulator during calibration Releasing the electromagnetic br...

Page 305: ...t in Manipulator malfunction When the home positions of the Joints 1 and 4 are uncertain check torsion of the internal cables The home positions are where the Manipulator has the internal cables not twisted at the basic orientation described in Setup Operation 3 7 Checking the Basic orientation Torsion of the internal cables can be checked by removing the following covers Joint 1 Base cover Cable ...

Page 306: ...int at a time whenever possible If you calibrate the origins for multiple joints simultaneously it will be more difficult to verify their origins and obtain the origin correct positions However joint 5 cannot be calibrated alone due to the structure of the Manipulator Make sure you calibrate joint 5 and 6 at the same time Calibration Flowchart 4 Calibration Yes Start 1 Basic Pose Confirmation 2 Pa...

Page 307: ...on gear unit or belt is necessary for the calibration Verify the recorded pulse values of the basic pose obtained in the Setup Operation 3 7 Checking the Basic orientation 2 Part Replacement Replace parts as instructed in this manual Be careful not to injure yourself or damage parts during part replacement 3 Encoder Initialization Turn ON the Controller while all joints are in the motion range The...

Page 308: ... to the procedure indicated above When the origin of the Joint 5 is calibrated the Joint 6 will be out of position Due to the structure of the Manipulator any offset in the position of the Joint 5 affects the Joint 6 Calibrate the origin of the Joint 6 together when calibrating the Joint 5 4 Calibration Calibration marks of each joint EPSON RC 4 1 Move the arm you want to calibrate to the position...

Page 309: ...t the command in the Command window and execute it Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Window calpls 0 0 0 0 0 0 Manipulator does not move EPSON RC 4 5 Perform the calibration Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Window Joint 1 cal...

Page 310: ...the Joint jog mode from Jog Teach to operate in the jog motion Enter the command below in the command window and execute it Execute the command below in the menu Tools Command Window calpls ppls P1 1 ppls P1 2 ppls P1 3 ppls P1 4 ppls P1 5 ppls P1 6 The Manipulator will not move Perform the calibration Input one of the following commands according to the joint being calibrated Joint 1 calib 1 Join...

Page 311: ...95 mm 5 1 3 5 2 3 Joint 2 1655927 Width 14 mm 540 mm 6 3 Joint 3 1655919 Width 10 mm 501 mm 7 3 Joint 4 1655931 Width 6 mm 243 mm 8 3 Joint 5 1655932 330 mm 9 3 Joint 6 1655933 339 mm 10 3 Belt tensile jig 1674582 Assembly tool 5 6 7 8 9 10 Battery unit 2172925 2 lithium batteries for replacement 11 1 Battery board 2173216 11 2 Grease 3 Joints 1 2 3 4 5 SK 1A For purchasing grease liquid gasket an...

Page 312: ...1675754 1 bag 100 pcs white AB350 1697428 1 bag 50 pcs white 5 1 5 2 Felt sheet For Arm 3 1673981 Square 8 For Arm 3 maintenance cover 1673980 Square 8 For Joint 4 1673979 Round 8 For Joint 5 1673978 Round 9 Fan 2177465 15 Heat radiation sheet For heat radiation block 1694609 5 1 5 2 For Motor 1655043 Joint 1 2 common 5 1 5 2 6 2 Cover Arm 1 Center cover 1675435 Metal cover Common to Standard Clea...

Page 313: ...ar teeth around the outer circumference of the opening Circular spline A rigid ring shaped body with gear teeth on the inner circumference The circular spline has two more teeth than the flexspline does The splines are greased Be sure to keep the grease from being attaching to the clothes 3 Regarding purchase of grease liquid gasket and adhesive Due to the chemicals regulations of individual count...

Page 314: ...an 100V MC short connector R12NZ900N7 For brake release unit Camera plate unit R12B031922 Common to C3 C4 C8 R12NZ9003F 6 2 Tool adapter ISO flange R12NZ900LQ 6 3 Adjustable mechanical stop J1 R12NZ900LR 6 4 J2 R12NZ900LT J3 R12NZ900LU Fittings for customer use ø6 straight R12NZ900LV 6 5 ø6 elbow R12NZ900LW Standard user connector kit D sub R12NZ900LX Waterproof user connector kit D sub R12NZ900LY...

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