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6. Replacing the Reduction Gear Units

Part 2: Maintenance

146

(6) Mount the waveform generator to the motor shaft with two flat point setscrews (M4

×

6

for ES series; M5

×

6 for EL series). Match the end face of the waveform generator to

the end face of the motor shaft. One of the setscrews should touch the flat face in the
motor shaft perpendicularly. Insert a bush to the other setscrew hole and tighten the
screw so as not to scratch the motor shaft.

Bush

M4

×

6

Waveform generator

EL

ES

Flat face

Bush

M5

×

6

Flat face

End face of motor shaft

End of the wave-
form generator

(7) Remove the old liquid gasket and apply new liquid gasket on the junction surface of

the reduction gear unit.

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Summary of Contents for EL Series

Page 1: ...ES EL series Rev 9 EM019R893F SCARA ROBOT MANIPULATOR MANUAL ...

Page 2: ...MANIPULATOR MANUAL ES EL series Rev 9 ...

Page 3: ...i SCARA ROBOT ES EL series Manipulator manual Rev 9 Copyright 1997 2001 SEIKO EPSON CORPORATION All rights reserved ...

Page 4: ...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 disasters such as earthquake flood etc Warnings Cautions Usage 1 If the robot or associated equipment is used outside of the usage conditions and product...

Page 5: ...o part of this manual may be copied or reproduced without authorization The content of this manual is subject to change without notice We ask that you please notify us if you should find any errors in this manual or if you have any comments regarding its content Please direct any inquiries about the use of this manual to ES EL series manipulator manual SEIKO EPSON CORPORATION Sales Engineering Gro...

Page 6: ...ction manual or User s manual Please read these manual first This robot has been designed and manufactured strictly for use in a normal indoor environment Do not use the robot in an environment that exceeds the conditions set forth in the manuals for the manipulator and controller Do not use the robot outside of the usage conditions and product specifications described in the manuals Doing so will...

Page 7: ...dure when using EPSON RC Robot Control System Procedure when using SPEL 95 SRC5 controllers Procedure when using SRC 3 controllers If the manipulator is a Clean model refer to the chapters Clean Model and Clean Model Maintenance which provide a summary of differences between the Clean and Standard specifications If the manipulator is a Protected model refer to the chapters Protected Model and Prot...

Page 8: ...SUPPLIERS section SUPPLIERS Japan Others SEIKO EPSON CORPORATION Okaya Plant No 2 1 16 15 Daiei cho Okaya shi Nagano ken 394 0025 Japan TEL 81 266 23 0020 switchboard 81 266 24 2004 direct FAX 81 266 24 2017 North South EPSON AMERICA INC America Factory Automation Robotics 18300 Central Avenue Carson CA 90746 TEL 562 290 5900 FAX 562 290 5999 E MAIL info robots epson com Europe EPSON DEUTSCHLAND G...

Page 9: ...eceleration 25 Moment of inertia and the ACCEL setting 26 Calculating the moment of inertia 27 Eccentricity of Joint 4 29 6 Attaching a Camera Valve and Other Devices 31 7 External Dimensions 33 8 Motion Range and Robot Coordinates 35 8 1 Standard motion range 35 8 2 Pulse range 41 8 3 Changing the motion range 44 Methods of setting the motion range 44 1 Changing motion range using pulse range 45 ...

Page 10: ...er 90 2 4 Base Connector Plate 91 3 Replacing the Cable Unit 93 3 1 Cable Unit Replacement Procedure 94 3 2 Wiring Schematic 1 98 3 3 Wiring Schematic 2 99 4 Connector Pin Assignments 101 5 Replacing the Motors 107 5 1 Replacing the Joint 1 Motor 108 5 2 Replacing the Joint 2 Motor 112 5 3 Replacing the Joint 3 Motor 116 5 4 Replacing the Joint 4 Motor 122 6 Replacing the Reduction Gear Units 127 ...

Page 11: ...s 1 2 and 4 195 Accurate calibration of Axis 2 196 12 Clean Model Maintenance 199 12 1 Greasing the Ball Screw Spline Unit 199 12 2 Replacing the Bellows 201 13 Protected Model Maintenance 203 13 1 Safety Precautions 203 13 2 Sealing the Manipulator 204 13 3 Internal Layout 206 13 4 Replacing the Cable Unit 207 13 5 Wiring Schematic 1 211 13 6 Wiring Schematic 2 212 13 7 Greasing the Ball Screw Sp...

Page 12: ...x ...

Page 13: ...ion Part 1 contains information for setup and operation of the EPSON ES and EL Series Manipulators including Installation Safety User wiring and pneumatics Attaching external devices Motion range adjustments Specifications ...

Page 14: ...2 ...

Page 15: ... Series name ES EL 1 If the Manipulator is a Clean model refer to chapter 11 Clean Model 2 If the Manipulator is a Protected model refer to chapter 12 Protected Model Manipulator parts MT label M CODE label for SRC 3 Joint 1 rotating Joint 2 rotating Joint 3 up and down Joint 4 rotating Arm 1 Arm 2 Base Cable unit Shaft Sensor monitor Signature label Fitting for φ 6 mm pneumatic tube Fitting for φ...

Page 16: ...1 Manipulator Part Names Part 1 Setup Operation 4 ...

Page 17: ...s Keep away from flammable or corrosive solvents and gases Keep away from water Keep away from shocks or vibrations Keep away from sources of electric noise The standard manipulator is not suitable for operation in harsh environments such as painting etc Contact the service center or the suppliers for details 2 2 Installation area In addition to the space necessary for installing the manipulator c...

Page 18: ...andard range of the manipulator ES45 ES55 ES65 EL65 EL85 A arm 1 length B arm 2 length C D motion range of the Joint 1 E motion range of the Joint 2 F G range to the stop of Joint 1 H range to the stop of Joint 2 215 mm 235 mm 156 mm 125 140 136 mm 130 145 315 mm 235 mm 203 mm 125 140 182 mm 130 145 415 mm 235 mm 280 mm 125 140 260 mm 130 145 300 mm 350 mm 228 mm 130 140 201 mm 132 145 500 mm 350 ...

Page 19: ...be at least 20 mm thick to reduce vibration The surface roughness of the steel plate should be 25µm or less The table must not only be able to bear the weight of the manipulator it must also be able to withstand the dynamic movement of the manipulator when the manipulator is operating at maximum acceleration The table must be anchored to the floor or wall to prevent it from moving The manipulator ...

Page 20: ...anipulator s arms before transporting it Refer to section 3 5 Relocating the manipulator Safeguard design For safety reasons it is necessary to equip robot systems with safeguards Refer to the Safety chapter in the EPSON RC User s Guide Refer to the Safety section of the SRC5 SPEL 95 Introduction manual Refer to the Safety section of the User s manual for SRC 300 320 Base table design Make certain...

Page 21: ...ndition After unpacking to prevent the manipulator from falling secure the manipulator to a transporter such as a cart or lift or have it carried by two or more people The manipulator weighs approximately 20kg ES or 31kg EL Be careful not to get hands or fingers caught when holding the manipulator by hand Hold here when lifting and transporting the manipulator Figure 3 Lifting the manipulator Leav...

Page 22: ...ES or M12 for EL conform to ISO898 1 property class 10 9 or 12 9 Plain washer watertight washer for Protected model 20 mm 150 mm ES 200 mm EL 150 mm ES 200 mm EL Threaded hole for M8 bolt ES Threaded hole for M12 bolt EL depth 20 mm or more M8 bolt ES M12 bolt EL Spring washer Shank length 40mm Figure 4 Manipulator installation 2 Cut off the wire tie binding the bottom of the shaft and arm retaini...

Page 23: ...se If they are not removed the motion range of Joint 1 will be limited Arm retaining bracket M8 10 bolt ES M12 20 bolt EL Figure 6 Removing the arm retaining bracket The arms of the manipulator must be secured to prevent them from moving when transporting Refer to 3 5 Relocating the manipulator Please keep the arm retaining bracket and bolt in case you need them in the future NOTE ...

Page 24: ...k and or malfunction Plug the manipulator signal cable securely into the jack Do not damage the signal cable by placing heavy objects on it or by bending it at extreme angles A damaged signal cable may cause the robot s abnormal operation When connecting the manipulator and Drive Unit cables make sure the serial number on the Drive Unit matches the serial number on PC Control Unit When connecting ...

Page 25: ...al cable D I O MOTION interface cable E STOP switch safeguard I O equipment AC 200 V I O equipment EMERGENCY PC power cable Monitor AC power cable Mouse Keyboard Optional Devices Controller Programming unit Personal computer or Teaching pendant option Operating unit Safeguard etc Manipulator M C power cable M C signal cable Power supply RS 232C 20 RS 232C 21 REMOTE1 REMOTE2 TEACH I O 1 Figure 7 Ca...

Page 26: ...personnel should teach and operate the robot and the robot system Teaching operations should be performed in the automatically set condition low power condition The work area should be well lighted over 750 lx during teaching operations If entering the safeguarded area for some reasons during teaching operations first lock ATTEND mode to ON to prevent another person changing the operating mode Use...

Page 27: ...starting operation Refer to Part 2 Maintenance Perform inspections and maintenance periodically in accordance with the instructions in Part 2 Maintenance Joint 3 with an end effector mounted to it descends under its own weight while the joint 3 brake release button is pushed Refer to 5 1 Attaching an end effector ...

Page 28: ... direction until it touches the previous bolt 5 Gently push Arm 2 in the plus direction counterclockwise direction until it touches the mechanical stop Tie the bottom of the shaft to the arm retaining bracket with a wire tie See Figure 5 Be careful not to tie too tight It may bend the shaft 6 To prevent the manipulator from falling hold the arm 1 with the hand and remove the manipulator from the b...

Page 29: ...c pressure Number of pneumatic tubes Outer diameter Inner diameter 2 φ 6 mm φ 4 mm 0 59MPa 6kgf cm2 1 φ 4 mm φ 2 5 mm The ends of each pneumatic tube are equipped with fittings for connecting pneumatic tubes having an outer diameter of φ 6 mm and φ 4 mm Fitting white for φ 6 tube Spare 15 pin D sub connector Joint 3 Brake release button Fitting black for φ 6 tube Fitting for φ 4 tube 15 pin d sub ...

Page 30: ...4 User Wires and Pneumatic Tubes Part 1 Setup Operation 18 ...

Page 31: ...tion to the interference area of the end effector If the manipulator is a Clean model refer to chapter 11 Clean Model If the manipulator is a Protected model refer to chapter 12 Protected Model ES 1S ES 3S EL 3S a 170 320 320 b 119 31 10 c 385 535 535 The shaft of E 3S will reach lower than the bottom of the manipulator base when it is fully lowered Pay attention to it when you design a layout 15 ...

Page 32: ...nts Joint 3 from descending under the weight of the end effector and striking any peripheral equipment and the like when the power is cut during robot operation or when the power is on but in the MOTOR OFF condition If you want to raise and lower Joint 3 when you are attaching an end effector turn ON the controller and keep on the Joint 3 brake release button pushing This button is a momentary typ...

Page 33: ...les depth 10 mm for M4 bolts for tooling See Figure 10 WARNING If you use an end effector equipped with a gripper or chuck set up electrical signals and or pneumatics in such a way that the gripper does not release its object when the robot is turned OFF All I O s are set at the factory so that they automatically shut entirely OFF 0 when the robot is turned OFF when the emergency stop switch is pr...

Page 34: ...eters dialog Refer to the chapter EPSON RC GUI in the EPSON RC User s Guide You may also execute the WEIGHT command from the EPSON RC Monitor Window Enter their combined total weight into the Weight text box in the WEIGHT panel of the Setup Robot Parameters dialog Refer to the section Setting up the Robot Parameters in chapter 11 of the User s Guide Enter their combined total weight as the Hand We...

Page 35: ...d Effectors 23 The percentage in the graph is based on the speed at rated weight 2kg as 100 The percentage in the graph is based on the speed at rated weight 2kg as 100 Figure 12 1 Automatic speed setting by WEIGHT 300 RC SPEL 95 ...

Page 36: ...n 24 The percentage in the graph is based on the speed at rated weight 2kg as 100 The percentage in the graph is based on the speed at rated weight 2kg as 100 Figure 12 2 Automatic acceleration deceleration setting by WEIGHT 300 RC SPEL 95 ...

Page 37: ...or moves with Joint 3 at a higher position the motion acceleration deceleration is faster but it takes more time to move Joint 3 up and down Adjust the position of Joint 3 for the robot motion after considering the relations between the current position and the destination position The upper limit of Joint 3 during horizontal motion is set by the LimZ command The percentage in the graph is based o...

Page 38: ... 2 0 03 0 02 0 01 0 04 I kg m 2 W kg 0 0 1 2 3 4 5 Rated allowable moment of inertia Maximum allowable moment of inertia Figure 14 Allowable moment of inertia When the moment of inertia of the end effector is equal to or less than the rated allowable moment of inertia you may operate the robot at the maximum acceleration deceleration speed setting ACCEL 100 100 When the rated allowable moment of i...

Page 39: ...effector and work piece such as those shown in the diagram below The moment of inertia of the entire load is found using the sum of each of the parts a to c Moment of inertia of the whole Moment of inertia of end effector a Moment of inertia of work piece b Moment of inertia of work piece c Work piece b Work piece c Joint 3 shaft Rotation center End effector a Figure 15 Example of load end effecto...

Page 40: ...piped s center of gravity Rotation center h L b Mass m Figure 16 a Rectangular parallelepiped r2 b Moment of inertia of cylinder m 2 m L2 Cylinder s center of gravity Rotation center Mass m L r Figure 16 b Cylinder 2 c Moment of inertia of a sphere m 5 r2 m L2 Sphere s center of gravity Rotation center r Mass m L Figure 16 c Sphere ...

Page 41: ...tion deceleration speed using the ACCEL command Using the results of the following table and formula as a guideline use a suitable value for the given conditions A Ai Ah 100 A ACCEL setting value Ai ACCEL setting value according to moment of inertia Ah ACCEL according to amount of eccentricity 0 10 20 30 40 50 Amount of eccentricity mm Ah 100 90 80 70 60 50 40 Figure 18 Eccentricity and ACCEL Exam...

Page 42: ...5 End Effectors Part 1 Setup Operation 30 ...

Page 43: ...work piece and the attached device to the parameter When you attach a camera or other device to the arm calculate the weight as equivalent weight of Joint 3 add this to the load weight Refer to section 5 2 The end effector and acceleration deceleration for details on WEIGHT parameters Equivalent weight is found using the formula below When you attach the equipment near Joint 2 WM M L1 2 L1 L2 2 Wh...

Page 44: ...6 Attaching a Camera Valve and Other Devices Part 1 Setup Operation 32 ...

Page 45: ...chapter 12 Protected Model View A detail Calibration point position of Joint 3 4 Signal cable connector 65 50 Power cable connector Figure 20 1 External dimensions of ES unit mm ES45 S ES55 S ES65 S a 215 315 415 ES 1S ES 3S b 170 320 c 119 31 d 674 824 The shaft of ES 3S will reach lower than the bottom of the manipulator base when it is fully lowered Pay attention to it when you design a layout ...

Page 46: ...ed Model Duct support for EL853S only View A detail Calibration point position of Joint 3 4 Signal cable connector 65 50 Power cable connector Figure 20 2 External dimensions of EL unit mm EL653S EL853S a 300 500 b 178 185 including the duct support The shaft of EL 3S will reach lower than the bottom of the manipulator base when it is fully lowered Pay attention to it when you design a layout ...

Page 47: ...be moved when each axis motor is not engaged The center of Joint 3 cannot move beyond this area mechanically Maximum space is the area that contains the farthest reach of the arms If the maximum radius of the end effector is over 60 mm then it will extend beyond the maximum space If this is the case then the end effector itself dictates the maximum space The physical relationship of the manipulato...

Page 48: ...p Operation 36 Center of Joint 3 Maximum space Area limited by mechanical stops Space for cables Maintenance space Point P Motion range ES45 S ES45 C ES45 P a 5 5 3 Value of dimensions in of Z stroke is option Figure 21 1 Motion range of ES45 unit mm ...

Page 49: ...Coordinates 37 Center of Joint 3 Maximum space Motion range Area limited by mechanical stops Space for cables Maintenance space Point P ES55 S ES55 C ES55 P a 5 5 3 Value of dimensions in of Z stroke is option Figure 21 2 Motion range of ES55 unit mm ...

Page 50: ...p Operation 38 Center of Joint 3 Maximum space Motion range Area limited by mechanical stops Space for cables Maintenance space Point P ES65 S ES65 C ES65 P a 5 5 3 Value of dimensions in of Z stroke is option Figure 21 3 Motion range of ES65 unit mm ...

Page 51: ...p Operation 8 Motion Range and Robot Coordinates 39 Center of Joint 3 Maximum space Motion range Area limited by mechanical stops Space for cables Maintenance space Point P Figure 22 1 Motion range of EL65 unit mm ...

Page 52: ...nge and Robot Coordinates Part 1 Setup Operation 40 Center of Joint 3 Maximum space Motion range Area limited by mechanical stops Space for cables Maintenance space Point P Figure 22 2 Motion range of EL85 unit mm ...

Page 53: ...ut Here we show the pulse range of each joint The 0 zero pulse position of Joint 1 is the position at which Joint 1 faces in the positive direction of the X coordinate axis The pulse value is positive in the counterclockwise direction from the 0 pulse position and negative in the clockwise direction Y X 0 pulse C pulse B pulse A A ES series EL series A 125 130 B pulse 31858 45512 C pulse 195698 25...

Page 54: ...e pulse value is taken in the clockwise direction 0 pulse 140 140 79645 pulse ES 127432 pulse EL 79645 pulse ES 127432 pulse EL Figure 24 Pulse range of Joint 2 The 0 pulse position of Joint 3 is the upper limit of Joint 3 Joint 3 descends from the 0 pulse position and the pulse is negative A 0 pulse Manipulator ES 1S E 3S ES 1C P E 3C P A Joint 3 stroke mm 170 320 150 300 Pulse range pulse 0 5222...

Page 55: ...ce of the Joint 4 shaft faces the positive direction of the X coordinate axis when Joint 1 and 2 are parallel to the X coordinate axis The pulse value is positive in the counterclockwise direction from the 0 pulse position and negative in the clockwise direction Direction X 0 pulse 65536 pulse Y Direction Figure 26 Pulse range of Joint 4 ...

Page 56: ...er This is the manipulator s maximum motion range It is possible to change the motion range for reasons of layout efficiency or safety Make any changes in the motion range in accordance with the following instructions Methods of setting the motion range You can set the motion range by doing any of the following 1 Set the pulse range for all joints 2 Set the mechanical stops for Joint 1 to 3 of Sta...

Page 57: ...g the Robot Parameters in chapter 11 of the User s Guide You can set the pulse range by using either the RANGE command or the JRANGE command Each command has special features as explained below Use the command that best fits your application Refer to the reference manual for details about each command RANGE Sets the pulse ranges for all joints at once JRANGE Sets the pulse ranges for one joint The...

Page 58: ... 100 70 40 10 10 40 70 100 130 2 E S C 140 120 95 95 120 140 3 E S less than the maximum stroke When you change the position of the mechanical stops you must also input the corresponding pulse range The methods of changing area settings using the mechanical stops are shown below Changing the mechanical stop positions for Joint 1 and 2 Both Joint 1 and Joint 2 has threaded holes in positions corres...

Page 59: ...lts Recommended tightening torque ES M8 10 3720N cm 380kgf cm 1 EL M12 20 12740N cm 1300kgf cm 2 ES EL M8 10 1 side 3720N cm 380kgf cm Threaded hole locations corresponding to the angle setting are shown below Joint 1 EL series ES series 35 40 65 70 95 100 125 130 35 40 65 70 95 100 125 130 5 10 5 10 EL series ES series Mechanical stop for joint 1 5 10 5 10 35 40 35 40 65 70 65 70 95 100 95 100 12...

Page 60: ...nical stops using either the RANGE or JRANGE command The pulse value corresponding to the angle setting in Figure 29 is described in the tables below Always set the pulse range to the inside of the position of the mechanical stops ES series Angle setting and Pulse value Joint 1 Joint 2 angle setting pulse value angle setting pulse value angle setting pulse value angle setting pulse value 5 86472 5...

Page 61: ... of Joint 2 RANGE Displays RANGE values 22756 168392 68267 54045 52224 0 65536 65536 5 Check the following Move the arm by hand until it touches the mechanical stop The arm should not hit any obstructions such as peripheral equipment Using the PULSE GO PULSE command operate the joint at slow speed until it reaches the position of the smallest and largest pulse range settings The arm should not hit...

Page 62: ...0 0 Moves to the largest pulse position of Joint 2 The PULSE GO PULSE command moves all joints to the specified positions at the same time Please specify safe positions after considering motion of not only the joints whose pulse range have been changed but also other joints In this example when you check Joint 2 Joint 1 is moved to the center of its motion range pulse value 81920 If the arm is tou...

Page 63: ...up and down while you are holding down the brake release button Push the shaft all the way up to the upper limit Joint 3 brake release button shaft 3 Lower limit mechanical stop for Joint 3 Figure 30 Mechanical stop for Joint 3 2 Exit EPSON RC shut down the SPEL Runtime Drivers and turn OFF the Drive Unit 2 Exit SPEL 95 and turn OFF the Drive Unit 2 Turn OFF the controller 3 The lower limit mechan...

Page 64: ... the split muff coupling once it is in the appropriate position Recommended tightening torque is 490N cm 50kgf cm 6 Turn ON the Drive Unit and start EPSON RC 6 Turn ON the Drive Unit and start SPEL 95 6 Turn ON the controller 7 Move the shaft to the lowest position by hand while pushing the brake release button Make sure that the shaft is not too high for the operation points 8 Calculate the lower...

Page 65: ...er limit pulse position is approximately 5 mm Example in 8 Execute the following commands from the Monitor Window MOTOR ON Turn the motor on SPEED 5 Sets on slow speed PULSE 0 0 30720 0 Moves to lower limit pulse position of Joint 3 In the example all pulses other than that of Joint 3 are 0 You should substitute these zeroes with a pulse for a position in which there is no interference even when y...

Page 66: ...and from the EPSON RC Monitor Window For only ES45 at the factory shipping it is set as follows coordinate lower limits mm upper limits mm Refer to X 90 90 Y 450 0 Figure 21 1 in this chapter For only EL65 at the factory shipping it is set as follows coordinate lower limits mm upper limits mm Refer to X 120 120 Y 650 0 Figure 22 1 in this chapter For example XYLIM 90 90 450 0 Set the X Y range by ...

Page 67: ...or SRC 300 320 11 Set up Set the robot parameters in Function volume For ES45 at the factory shipping it is set as follows XYLIM 90 90 450 0 Refer to Figure 21 1 in this chapter For EL65 at the factory shipping it is set as follows XYLIM 120 120 650 0 Refer to Figure 21 1 in this chapter 300 ...

Page 68: ...8 Motion Range and Robot Coordinates Part 1 Setup Operation 56 ...

Page 69: ...wever you should not press the emergency stop switch during normal operation unnecessarily The braking distance depends on timing to activate the emergency stop switch and motion speed but robot arm may overrun the stop position under servo control and may collide with peripheral equipment We recommend pressing the emergency stop switch when the arm is not moving when you want to prevent the robot...

Page 70: ...9 Emergency Stop Part 1 Setup Operation 58 ...

Page 71: ... the standard specifications for the ES and EL series manipulators If the manipulator is a Clean model refer to the section 11 5 Additional Specifications in chapter 11 Clean Model If the manipulator is a Protected model refer to the section 12 6 Additional Specifications in chapter 12 Protected Model ...

Page 72: ...578 pulse 0 0032552 mm pulse 0 005493 pulse Motor power consumption Joint 1 Joint 2 Joint 3 Joint 4 200 W 100 W 100 W 100 W Payload rated max 2kg 5kg Joint 4 allowable moment of inertia 3 rated max With rated payload 2kg 0 01kg m2 0 02kg m2 With max payload 5kg 0 02kg m2 0 04kg m2 Diameter of the shaft through hole φ 20 h7 mm φ 14 mm Joint 3 down force 100 N 10 2kgf Installed wire for customer use...

Page 73: ... rated max 2kg 5kg Joint 4 allowable moment of inertia 3 rated max With rated payload 2kg 0 01kg m2 0 02kg m2 With max payload 5kg 0 02kg m2 0 04kg m2 Diameter of the shaft through hole φ 20 h7 mm φ 14 mm Joint 3 down force 100 N 10 2kgf Installed wire for customer use 15 wires 15 pin D sub connector Installed pneumatic tube for customer use φ 6 mm 2 pneumatic tubes φ 4 mm 1 pneumatic tube Allowab...

Page 74: ...asic Settings panel that is displayed when Setup Robot Manipulator Settings is executed Refer to Chapter 11 in the User s Guide for the section Setting the Robot Paramters Manipulator models used with the controller SRC 3 are pre set by DIP switch SD1 on the MPU board in the controller Be sure not to change the DIP switch settings Also if an MT label is attached the manipulator has custom specific...

Page 75: ... referred to Clean model requirements specify a maximum of 10 particles 0 13 µm or more in diameter in 28317 cm3 1cft sample air around the center of the motion range 11 1 Manipulator part names For basic information on manipulator part names refer to 1 Manipulator Part Names Model names that end with a C indicate models that meet Clean model requirements ES 55 1 C Option Clean model Joint 3 strok...

Page 76: ...n of dust particles from the manipulator Exhaust port size Inner diameter φ 12 mm Outer diameter φ 16 mm Exhaust tube Outer diameter φ 12 mm Inner diameter φ 8 mm or the polyethylene tube with inner diameter φ 16 mm or over Recommended exhaust flow rate Approximately 1000cm3 s Normal The gap between the exhaust port and the exhaust tube must be sealed with vinyl tape so that the junction is airtig...

Page 77: ... 65 50 Power cable connector 12 ES45 C ES55 C ES65 C a 215 315 415 ES 1C ES 3C b 150 300 c 117 33 d 785 935 35 12 Mechanical stop diameter View A detail Calibration point position of the Joint 3 4 The shaft of ES 3C will reach lower than the bottom of the manipulator base when it is fully lowered Pay attention to it when you design a layout ...

Page 78: ...3C a 300 500 b 178 185 including the duct support Mechanical stop diameter View A detail Calibration point position of the Joint 3 4 The shaft of EL 3C will reach lower than the bottom of the manipulator base when it is fully lowered Pay attention to it when you design a layout Signal cable connector 65 50 Power cable connector 12 ...

Page 79: ... range of Joint 3 Value in is option 150mm 300mm 300mm Cleanliness level Maximum of 10 particles 0 13 µm or more in diameter in 28317 cm3 1cft sample air located near the center of the work area Exhaust tube Outer diameter φ 12 mm inner diameter φ 8 mm or the polyethylene tube with inner diameter φ16 mm or over Recommended exhaust flow rate Approximately 1000cm3 s Normal ...

Page 80: ...11 Clean Model Part 1 Setup Operation 68 ...

Page 81: ...ot apply if the jet stream is a substance other than water For example if the manipulator is hit by oil or detergent the degree of protection may deteriorate Please note that this degree of protection is tested using the specified testing procedure Depending on the pressure of an actual jet stream the protection may be more or less effective than defined This digit 6 stands for the degree of prote...

Page 82: ...1 P Option Protected model Joint 3 stroke 1 150 mm 3 300 mm Arm length 45 450 mm 55 550 mm 65 650 mm 85 850 mm Series name ES EL Some parts of the following diagram differ from the standard manipulator s external view Upper bellows User cable duct Duct rotation Duct rotation Waterproof wiring Cable seal box Lower bellows Waterproof cover 3 Waterproof cover 1 Waterproof cover 2 Encoder reset cover ...

Page 83: ... 6kV max Environment Install indoors Keep away from direct sunlight Keep away from flammable or corrosive solvents and gases Keep away from shocks or vibrations Keep away from sources of electric noise Manipulators with this standard specification are not suitable for operation in a harsh environment such as painting etc Contact the service center or the suppliers for details WARNING To avoid elec...

Page 84: ...anipulator If your requirements specify that the manipulator handles food please consult with your local sales dealer to test the equipment prior to use Ensure that no damage to food occurs due to the manipulator s handling The manipulator cannot be used in corrosive environments where strong acid or alkaline is used In a salty environment where the rust is likely to gather the manipulator is susc...

Page 85: ...0 is designed to be water proof when connected Please make sure that no moisture or dust is left on the pins on both ends when connected The controller s power cable connector X2 is not designed water proof Therefore the controller unit s power cable must be connected in the same environment as the controller unit itself is set up 2 Signal cable The manipulator s signal cable connector is connecte...

Page 86: ...tor is connected to the relay board on the back of the base body The relay board area is shielded from dust or moisture The cable is 0 8 m long with its end simply cut off The user wire connector on the end effector s side is connected inside the Arm Cover to go through the user cable duct and the spline shaft until it comes out from the end effector s side The cable on this end is 1 m long and le...

Page 87: ...t to φ 4 mm black pneumatic tube on the end effector Fitting white for φ 6 mm pneumatic tube Connect to φ 4 mm blue pneumatic tube on the end effector Fitting for φ 4 mm pneumatic tube Connect to φ 4 mm yellow pneumatic tube on the end effector Spare Signal cable User wire 10 m Encoder reset cover ...

Page 88: ...nal cable connector Power cable connector 50 65 12 Ф4 10 Through hole ES45 P ES55 P ES65 P a 215 315 415 ES 1P ES 3P b 150 300 c 117 33 d 789 939 e 980 1130 Through hole Shaft diameter φ4 90 Conical hole Flat cut 1 mm Calibration point position of Joint 3 4 View A detail Mechanical stop diameter The shaft of ES 3P will reach lower than the bottom of the manipulator base when it is fully lowered Pa...

Page 89: ...e diameter Signal cable connector Power cable connector 50 65 12 Ф4 16 Through hole EL653P EL853P a 300 500 b 178 185 including the duct support Through hole Shaft diameter φ4 90 Conical hole Flat cut 1 mm Calibration point position of Joint 3 4 View A detail Mechanical stop diameter The shaft of EL 3P will reach lower than the bottom of the manipulator base when it is fully lowered Pay attention ...

Page 90: ...or standard specifications refer to section 10 Specifications The table below contains additional information about protected models Model ES P EL P Max motion range of Joint 3 Value in parentheses is optional 150 mm 300 mm 300 mm The specified grade of protection shielding IP65 ...

Page 91: ...rt 2 Maintenance Part 2 contains maintenance information for the ES and EL Series Manipulators including instructions for Maintenance schedules Connection diagrams How to replace parts Calibration Parts list ...

Page 92: ...80 ...

Page 93: ...ot be sure to use the specified locking procedure for each robot system before starting work When connecting or disconnecting the cables between the manipulator and the controller make sure the power is turned off and pull out the power plug from the power source Failure to turn off the power can result in electric shock or malfunction After replacing parts do not test the manipulator within the s...

Page 94: ...Maintenance Safety Precautions Part 2 Maintenance 82 ...

Page 95: ...r longer per month the inspection schedule is different In this case each step of inspection should be added every 250 hours 750 hours 1500 hours and 3000 hours operation Monthly 250H Inspection Monthly 250H Inspection Monthly 250H Inspection Quarterly 750H Inspection Monthly 250H Inspection Monthly 250H Inspection Monthly 250H Inspection Monthly 250H Inspection Monthly 250H Inspection Monthly 250...

Page 96: ...crews and tighten them if necessary Follow the torque values in the table on the next page to tighten them Bolts and screws which secure motors reduction gears etc External connectors on manipulator on the base connector plate Check looseness of connectors If looseness is found plug it in securely or tighten Manipulator cable unit External appearance of manipulator Visually check for external defe...

Page 97: ...uarterly Biannual Annual Check motion range Motion range of each joint Check disconnection by swinging cables External cables including cable unit Check backlash by pushing arms during MOTOR ON condition Each arm Check if any malfunctions occur or not such as strange sound and vibration during robot operation Whole Measure repeatability by gauge Repeatability ...

Page 98: ...ng the Ball Screw Spline Unit If the manipulator is a Clean model refer to chapter 11 Clean Model If the manipulator is a Protected model refer to chapter 13 Protected Model 6 Replacing the Reduction Gear Unit It is not necessary to change grease of the reduction gear periodically under normal condition if the grease has been changed when replacing motor However in a case of severe working conditi...

Page 99: ...J1 value pls J2 value pls J3 value pls J4 value pls Click the DEBUG button and input them to the Command Execution window as follows Refer to the User s Guide for details of Command Execution window WHERE pulse 1 Joint 1 pulse value 2 Joint 2 pulse value 3 Joint 3 pulse value 4 Joint 4 pulse value PULSE Joint 1 pulse value Joint 2 pulse value Joint 3 pulse value Joint 4 pulse value 1 6 Differences...

Page 100: ...del refer to chapter 13 Protected Model The outline and name of internal configuration are shown below Joint 4 motor Joint 3 motor Joint 2 motor Signal relay board Joint 1 motor U1 belt U2 belt Z belt Ball screw spline shaft Joint 1 reduction gear unit Joint 4 counter shaft Joint 2 reduction gear unit ...

Page 101: ...e covers Be sure to reseal the covers after you finish maintenance operations For details on sealing the covers refer to 13 2 Sealing the Manipulator in 13 Protected Model 2 1 Arm Top Cover The arm top cover can be opened by pulling upward after four bolts ES M4 8 EL M4 12 are removed It can not be removed completely because user s wiring and piping are connected but normal maintenance is possible...

Page 102: ... is installed If there is no problem e g inspection of timing belt lower Joint 3 to the position shown in the figure below in advance Then loosen the bolts and remove the cover M4 8 Arm bottom cover 2 3 Joint 1 Cover If the manipulator is a Protected model the waterproof cover 2 must be removed before removing Joint 1 cover Refer to Sealing in chapter 13 Protected Model The Joint 1 cover can be re...

Page 103: ...f the manipulator with four M4 8 bolts with six bolts for Protected model The base connector plate is separated from the base when these bolts are removed However the base connector plate is internally connected to connectors and ground wires Be careful not to pull the base connector plate forcibly M4 8 Base connector plate ...

Page 104: ...2 Opening the Covers Part 2 Maintenance 92 ...

Page 105: ...onnector the position data of the motor will be retained after the main power is turned OFF However when the signal connector is removed the position data will only be retained by the super capacitor The position data cannot be retained beyond the time duration mentioned above after which it will be lost If this happens errors will occur when the power is turned ON RC Error 5016 SRC5 SPEL 95 Error...

Page 106: ...ocated at the rear of the manipulator 3 Remove the four mounting bolts M6 12 from the main cable elbow fitting 3 M6 12 Main cable elbow fitting 4 Remove the mounting bolts from the base connector plate Pull the cover forward refer to chapter 2 Opening the Covers Be careful not to pull the base connector plate forcibly since the strain on the cables may cause wire disconnection Also remember the ap...

Page 107: ... by first pushing the fitting release ring The ground wire terminals are fastened with bolts M4 8 8 Open the arm top cover refer to chapter 2 Opening the Covers Be careful not to pull the arm top cover off forcibly since the strain on the connected cables may cause wire disconnection Also pay attention to and remember the approximate cable arrangement so that the cables can be reconnected similarl...

Page 108: ...nector number on the motor side For manipulators whose serial number start with 1 their motors must be connected to the signal relay board of the new cable unit within 2 hours Otherwise the motor will lose the position data and it is necessary to calibrate again 12 Remove the cable bracket from the arm 3 M4 8 bolts M4 8 Cable bracket 13 Cut off the wire tie binding cables to the cable bracket 14 R...

Page 109: ...ly 5 Mount the receptacle on the base connector plate using four bolts M3 8 6 Bind the cables with wire ties as they were before the unit replacement The following must be paid attention to when binding the cables with a wire tie The cables must not touch the pulley timing belt or other movable parts or areas Do not pinch the cables when closing the cover Do not allow unnecessary strain on the cab...

Page 110: ...ntenance Wire tie Ground Ground Receptacle D sub connector X53 Cable unit Joint 1 Power X110 Joint 1 Signal X11 Signal connectors Joint 1 X10 Joint 2 X20 Joint 3 X30 Joint 4 X40 User connector X50 Joint 3 Power X131 Joint 3 Signal X31 Joint 3 Brake X32 Joint 3 Brake release switch X33 Joint 4 Power X141 Joint 4 Signal X41 Fitting for φ 6 tube 2 Fitting for φ 4 tube 1 White fitting Blue tube Black ...

Page 111: ...Part 2 Maintenance 3 Replacing the Cable Unit 99 3 3 Wiring Schematic 2 If the manipulator is a Protected model refer to chapter 13 Protected Model ...

Page 112: ...3 Replacing the Cable Unit Part 2 Maintenance 100 ...

Page 113: ... YLW X11 4 6 1Z WHT GRN 4A 1Z GRN WHT X11 5 7 1S RED WHT 4B 1Z WHT GRN X11 6 8 1S WHT RED 5A 1S RED WHT X11 7 9 BAT BLU BRN 5B 1S WHT RED X11 8 10 BAT BRN BLU 6A ENC 5V PPL WHT X11 12 11 RES YLW BRN 6B EGND WHT PPL X11 13 12 ENC 5V PPL WHT 7A BAT BLU BRN X11 9 13 EGND WHT PPL 7B BAT BRN BLU X11 10 14 FGND GRN Joint 1 motor encoder SIGNAL 8A RES YLW BRN X11 11 8B N C 9A N C 9B N C Motor for the man...

Page 114: ...Z WHT GRN 4A 2Z GRN WHT X21 5 7 2S RED WHT 4B 2Z WHT GRN X21 6 8 2S WHT RED 5A 2S RED WHT X21 7 9 BAT BLU BRN 5B 2S WHT RED X21 8 10 BAT BRN BLU 6A ENC 5V PPL WHT X21 12 11 RES YLW BRN 6B EGND WHT PPL X21 13 12 ENC 5V PPL WHT 7A BAT BLU BRN X21 9 13 EGND WHT PPL 7B BAT BRN BLU X21 10 14 FGND GRN Joint 2 motor encoder SIGNAL 8A RES YLW BRN X21 11 8B N C 9A N C 9B N C Motor for the manipulators whos...

Page 115: ...D X31 8 10 BAT BRN BLU 6A ENC 5V PPL WHT X31 12 11 RES YLW BRN 6B EGND WHT PPL X31 13 12 ENC 5V PPL WHT 7A BAT BLU BRN X31 9 13 EGND WHT PPL 7B BAT BRN BLU X31 10 14 FGND GRN Joint 3 motor encoder SIGNAL 8A RES YLW BRN X31 11 8B N C X32 brake connector 9A N C No Line color Connect to 9B N C 1 EMB2 GRN BRN 10A BRK SW BRN YLW X33 2 2 24V BRN GRN Joint 3 brake Y1 10B N C 11A N C X33 brake SW connecto...

Page 116: ... 4Z WHT GRN 4A 4Z GRN WHT X41 5 7 4S RED WHT 4B 4Z WHT GRN X41 6 8 4S WHT RED 5A 4S RED WHT X41 7 9 BAT BLU BRN 5B 4S WHT RED X41 8 10 BAT BRN BLU 6A ENC 5V PPL WHT X41 12 11 RES YLW BRN 6B EGND WHT PPL X41 13 12 ENC 5V PPL WHT 7A BAT BLU BRN X41 9 13 EGND WHT PPL 7B BAT BRN BLU X41 10 14 FGND GRN Joint 4 motor encoder SIGNAL 8A RES YLW BRN X41 11 8B N C 9A N C 9B N C Motor for manipulators whose ...

Page 117: ... 4 WHT YLW X53 4 3A GRN WHT X51 5 5 GRN WHT X53 5 3B WHT GRN X51 6 6 WHT GRN X53 6 4A RED WHT X51 7 7 RED WHT X53 7 4B WHT RED X51 8 8 WHT RED X53 8 5A PPL WHT X51 9 9 PPL WHT X53 9 5B WHT PPL X51 10 10 WHT PPL X53 10 6A BLU BRN X52 1 6B BRN BLU X52 2 X52 Signal connector 7A YLW BRN X52 3 No Line color Connect to 7B BRN YLW X52 4 1 BLU BRN X53 11 8A GRN BRN X52 5 2 BRN BLU X53 12 8B GRN shield 3 Y...

Page 118: ...ED X121 3 X121 Motor power connector 15 3U BLK X131 1 No Line color Connect to 13 3V WHT X131 2 1 2U BLK 9 3W RED X131 3 2 2V WHT 4 4U BLK X141 1 3 2W RED 2 4V WHT X141 2 4 FGND GRN YLW Joint 2 motor POWER 7 4W RED X141 3 5 FGND GRN X131 Motor power connector 17 FGND GRN YLW No Line color Connect to 8 N C 1 3U BLK 12 N C 2 3V WHT 11 N C 3 3W RED 4 FGND GRN YLW Joint 3 motor POWER X141 Motor power ...

Page 119: ...annot be used again in this case The mechanical origin position changes when the motor is replaced As a result the previous teach points change After motor replacement adjust the origin position as described in Chapter 11 Calibration Motor Types Specify the Z code when ordering a replacement motor Description Series Joint Specification Serial number Old code New code 0 ZA000614 R13ZA00061400 1 200...

Page 120: ...ipulator in chapter 13 Protected Model Maintenance plate Maintenance hole M4 8 3 Disconnect the connectors X110 and X11 To disconnect X110 pull it out while pushing the presser tongue next to the connector number on the motor side 4 Remove the four bolts M4 15 for the ES series M5 15 for the EL series from the motor flange and pull the motor downward In this case insert a hexagon head wrench from ...

Page 121: ...tscrews M5 6 Remove the waveform generator from the motor One of the setscrews has a brass bush inside which must not be lost Between the ES and EL series the direction in which the waveform generator is attached is different Bush M5 6 Waveform generator ES EL Motor flange Bush M5 6 6 Remove the four bolts M5 12 from the motor and remove the motor flange M5 12 ...

Page 122: ...ndicularly Insert a bush in the other setscrew hole and tighten the screw Do not over tighten to avoid damage to the motor shaft For the ES and EL series manipulators the direction in which the waveform generator is attached is different See below For ES the setscrews should be located at the end of the motor shaft For EL the setscrews should be located at the mid point of the motor shaft ES Bush ...

Page 123: ...ES M4 15 EL M5 15 Maintenance hole 4 Connect the connectors X110 and X11 X11 X110 5 Attach the maintenance plate with two bolts M4 8 If the manipulator is a Protected model the maintenance plate must be sealed and the waterproof cover 1 must be installed Refer to the section Sealing the Manipulator in chapter 13 Protected Model Maintenance 6 Install the base connector plate Refer to chapter 2 Open...

Page 124: ...wire ties which fasten the Joint 2 motor and cables 4 Disconnect the connectors X121 and X21 To disconnect X121 pull it out while pushing the presser tongue next to the connector number on the motor side 5 Remove the four bolts M4 10 for the ES series M4 15 for the EL series from the motor flange and pull the motor unit upward If it is difficult to extract the motor extract it while moving Arm 2 s...

Page 125: ...ws M4 6 for the ES series M5 6 for the EL series Remove the waveform generator from the motor One of the setscrew holes has a brass bush inside which must not be lost Bush M4 6 Waveform generator Motor flange Bush ES EL M5 6 7 Remove the bolts 2 M4 10 for the ES series 4 M5 12 for the EL series from the motor and remove the motor flange ES M4 10 EL M5 12 ...

Page 126: ...f the setscrews should touch the flat side of the motor shaft perpendicularly Insert a bush in the other setscrew hole and tighten the screw Do not over tighten to avoid damage to the motor shaft Bush M4 6 Waveform generator EL ES Flat face Bush M5 6 Flat face End face of motor shaft End of the wave form generator 3 Fasten the Joint 2 motor unit in Arm 2 with the four bolts M4 10 for the ES series...

Page 127: ...re ties in their original positions Do not allow unnecessary strain on the cables 7 Install the arm top cover Be careful not to bend the cables forcibly and push them into the cover Refer to chapter 2 Opening the Covers If the manipulator is a Protected model seal the arm top cover Refer to the section Sealing the Manipulator in chapter 13 Protected Model Maintenance 8 The mechanical origin positi...

Page 128: ...int 3 to its lower limit in advance Joint 3 operates while the Joint 3 brake release button is pushed with the power turned ON See Figure 11 in the chapter End Effectors in Part 1 Lower Joint 3 taking care that the end effector does not strike against peripheral equipment Turn OFF the power before replacing the Joint 3 motor Removal Joint 3 1 Open the arm top cover and arm bottom cover Refer to ch...

Page 129: ...ing a hexagon head wrench in the screw holes of the pulley remove the two flat point setscrews M4 8 that secure the pulley to the motor shaft One of the setscrews has a brass bush inside which must not to be lost Bush Pulley M4 8 7 Remove the two bolts M4 8 from the motor And extract the motor upward M4 8 Motor plate ...

Page 130: ...crewed on the pulley is attracted to the brake magnet If you force it to separate the leaf spring will stretch Leaf spring Brake Pulley Rotor hub 2 Insert the gap gauge 0 15 mm which is mounted in the arm bottom cover between the brake and rotor hub and set the pulley on the brake At this time the screw holes of the pulley are in the position shown in the figure below Gap gauge 0 15mm Screw holes ...

Page 131: ...e pulley to the motor shaft with two flat point setscrews M4 8 One of them should touch the flat face in the motor shaft perpendicularly Insert a bush to the other setscrew hole then insert the setscrew and tighten it carefully to avoid damage to the motor shaft 5 After the pulley is secured pull out the gap gauge 6 Fasten the brake cables to the motor unit to prevent interference with the pulley ...

Page 132: ...lts M4 10 Z1 pulley Z belt Z2 pulley Motor plate 9 Pass a cord or string around the Joint 3 motor near its mounting plate Loosen the bolts for the Joint 3 motor plate fastened in the step 8 and pull the cord by a force gauge or similar tool Fasten the Joint 3 motor plate securely where the Z belt is pulled at 29 4N 3kgf Adjust in the range of 20N 39N 2kgf 4kgf Force gauge 10 Connect the connectors...

Page 133: ...vers 13 If the manipulator is a Protected model seal the arm top cover and arm bottom covers Refer to the section Sealing the Manipulator in chapter 13 Protected Model Maintenance 14 The mechanical origin position and teach points will change when the motor is replaced Be sure to calibrate Joint 3 Refer to chapter 11 Calibration ...

Page 134: ...ff the wire ties which fasten the Joint 4 motor and cables 3 Disconnect connectors X141 and X41 To disconnect X141 pull it out while pushing the presser tongue next to the connector number on the motor side 4 Remove the four bolts M4 10 from the motor plate And remove the pulley from the U1 belt to remove the Joint 4 motor unit from the arm M4 10 Motor plate U1 belt U1 pulley U2 belt ...

Page 135: ...ley remove the two flat point setscrews M4 8 that secure the pulley to the motor shaft Remove the pulley from the motor One of the setscrews has a brass bush inside which must not to be lost Bush M4 8 flat point setscrew 6 Remove the two bolts M4 8 from the motor and remove the motor plate M4 8 Motor plate ...

Page 136: ...otor shaft perpendicularly Insert a bush to the other setscrew hole and tighten the screw so as not to scratch the motor shaft Bush M4 8 flat point setscrew Flat face 3 Place the Joint 4 motor unit in Arm 2 The motor cables should be facing Joint 3 4 Fit the U1 belt around the large U2 and U1 pulleys Ensure that the gear grooves of the belt and pulleys engage properly Be careful not to slip the be...

Page 137: ... Adjust in the range of 29N 68N 3kgf 7kgf Force gauge 7 Connect the connectors X141 and X41 8 Fasten the motor cables with wire ties in their original positions Do not allow unnecessary strain on to the cables 9 Install the arm top cover and arm bottom cover Refer to chapter 2 Opening the Covers If the manipulator is a Protected model seal the arm top cover and arm bottom cover Refer to the sectio...

Page 138: ...5 Replacing the Motors Part 2 Maintenance 126 ...

Page 139: ...nance parts list at the end of this manual For the adequate quantity of grease necessary for each manipulator series refer to the table below as an approximate aid Series Joint 1 Joint 2 ES approx 40g approx 16g EL approx 80g approx 40g When replacing the Joint 2 reduction gear unit prepare the liquid gasket Refer to the maintenance parts list at the end of this manual The mechanical origin positi...

Page 140: ...6 Replacing the Reduction Gear Units Part 2 Maintenance 128 Location of reduction gear units Joint 1 reduction gear unit Joint 2 reduction gear unit ...

Page 141: ...ring of bearings is secured to the cam while the outer ring is capable of flexible deformation through the ball bearings 2 Fleck spline A thin elastic cup shaped metal body with gear teeth around the outer circumference of the opening 3 Circular spline A rigid ring shaped body with gear teeth on the inner circumference The circular spline has twice as many teeth as the fleck spline but at identica...

Page 142: ...le the arm is being supported have another person unscrew the eight fastening bolts M4 40 for the ES series M5 55 for the EL series and remove Arm 1 CAUTION When removing or installing 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 others remove the bolts and so on The arm will drop immediately when the fastening bolts are removed This i...

Page 143: ...hapter 2 Opening the Covers and disconnect the signal connector X11 and power connector X110 To disconnect X110 pull it out while pushing the presser tongue next to the connector number on the motor side X11 X110 Base connector plate 5 Remove the four bolts M8 20 for the ES series M8 25 for the EL series from the reduction gear flange Reduction gear flange ES M8 20 EL M8 25 ...

Page 144: ...132 6 Lift up the reduction gear unit 7 Remove the four bolts M4 15 for the ES series M5 15 for the EL series from the motor flange and pull the motor flange out of the reduction gear flange Joint 1 motor ES M4 15 EL M5 15 Reduction gear flange Motor flange ...

Page 145: ...r flange ES M4 18 EL M5 25 9 Using a hexagon head wrench 2 5mm wide in the screw holes of the waveform generator remove the two flat point setscrews M5 6 Remove the waveform generator from the motor One of the setscrews has a brass bush inside which must not to be lost Between the ES and EL series the direction in which the waveform generator is attached is different Bush M5 6 Waveform generator E...

Page 146: ...ting surface Waveform generator Circular spline Fleck spline Cross roller bearing unit Oil sealing ring L Oil sealing ring S 2 Never touch to loosen or tighten the bolts holding the fleck spline and cross roller bearing unit together If the bolts are moved the fleck spline and cross roller bearing unit must be readjusted at the suppliers since they are centered when attached together 2 Fit the oil...

Page 147: ...nge onto the circular spline First using a hexagon wrench position the twelve 12 bolts Loosely fasten each bolt in a crisscross pattern so that the bolts will be fastened evenly When the bolts are positioned tighten each bolt securely at the torque specified in the table below using a torque wrench Tighten each bolt in a crisscross pattern Be careful not to apply too much force since it may damage...

Page 148: ... a bush into the other setscrew hole and tighten the screw carefully to avoid damage to the motor shaft Between the ES and EL series the direction in which the waveform generator is attached is different See below ES The setscrews should be fixed at the end of the motor shaft EL The setscrews should be fixed at the foot of the motor shaft ES Bush M5 6 Waveform generator Flat face End face of motor...

Page 149: ...lator base and secure it with four bolts M8 20 for the ES series M8 25 for the EL series Be sure that the joint label on the reduction gear flange is at the front Never touch to loosen or tighten the four bolts on the top surface shown in the picture below If the bolts are moved the fleck spline and cross roller bearing unit must be readjusted at the suppliers since they are centered when attached...

Page 150: ...stening bolts ES M4 40 EL M5 55 11 Connect the signal connector X11 and power connector X110 Then attach the base connector plate to the base Refer to chapter 2 Opening the Covers X11 X110 Base connector plate 12 Connect the power cable and signal cable to the base connector plate 13 Attach the Joint 1 cover to Arm 1 with a bolt M4 8 14 The mechanical origin position and teach points change when t...

Page 151: ...8 Duct plate 3 Cut off the wire ties which fasten the Joint 2 motor and cables 4 Disconnect the signal connector X21 and power connector X121 of the Joint 2 motor To disconnect X121 pull it out while pushing the presser tongue next to the connector number on the motor side Joint 2 motor Signal connector X21 Power connector X121 Presser tongue 5 Support Arm 2 with more than one person While the arm...

Page 152: ...t at least one of them can support the arm while others remove the bolts and so on The arm will drop immediately when the fastening bolts are removed This is highly dangerous Also it may cause damage or malfunction if the arm is dropped or hit at this time Joint 2 motor Fastening bolt for Arm 2 Arm 2 Joint 2 motor Place the removed arm gently on the floor ...

Page 153: ...the EL series from the Joint 2 motor flange Motor flange ES M4 10 EL M4 15 7 Remove the Joint 2 motor unit from Arm 1 8 Remove the eight bolts M3 40 with plain washer for the ES series M4 45 for the EL series from the Joint 2 reduction gear unit at the bottom of Arm 1 ES M3 40 with plain washer EL M4 45 Bottom of Arm 1 ...

Page 154: ... easily because of liquid gasket on the junction surface to prevent grease from leaking use a flat screwdriver between the flange and the arm 10 Remove the twelve bolts M3 18 for the ES series M4 18 for the EL series from the reduction gear flange and remove the flange from the circular spline Reduction gear flange ES M3 18 EL M4 18 ...

Page 155: ...es of the waveform generator remove the two flat point setscrews M4 6 for ES series M5 6 for the EL series Remove the waveform generator from the motor One of the setscrew holes has a brass bush inside which must be paid attention so as not to be lost Bush M4 6 Waveform generator Motor flange Bush ES EL M5 6 ...

Page 156: ...ting surface Waveform generator Circular spline Fleck spline Cross roller bearing unit Oil sealing ring L Oil sealing ring S 2 Never touch to loosen or tighten the bolts holding the fleck spline and cross roller bearing unit together If the bolts are moved the fleck spline and cross roller bearing unit must be readjusted at the suppliers since they are centered when attached together 2 Fit the oil...

Page 157: ...the circular spline First using a hexagon wrench position the twelve 12 bolts Loosely fasten each bolt in a crisscross pattern so that the bolts will be fastened evenly When the bolts are positioned tighten each bolt securely at the torque specified in the table below using a torque wrench Tighten each bolt in a crisscross pattern Be careful not to apply too much force since it may damage the part...

Page 158: ...face of the motor shaft One of the setscrews should touch the flat face in the motor shaft perpendicularly Insert a bush to the other setscrew hole and tighten the screw so as not to scratch the motor shaft Bush M4 6 Waveform generator EL ES Flat face Bush M5 6 Flat face End face of motor shaft End of the wave form generator 7 Remove the old liquid gasket and apply new liquid gasket on the junctio...

Page 159: ... the Joint 2 reduction gear unit back inside Arm 1 and secure it with eight bolts M3 40 with plain washer for the ES series M4 45 for the EL series 9 As shown below grease inside the reduction gear unit ES 16g EL 40g and build the motor unit inside Joint 2 SK 1A grease ...

Page 160: ...model so that the motor cable will come to the position shown in the picture below Motor flange ES M4 10 EL M4 15 11 Secure Arm 2 Support the arm with more than one person While the arm is being supported have another person fasten four bolts M6 18 for the ES series M8 18 for the EL series to attach Arm 2 Be careful not to drop or hit the arm ...

Page 161: ...ire ties in their original positions Do not allow unnecessary strain on the cables 14 Place the duct plate back on and secure it with three bolts M4 8 M4 8 Duct plate 15 Attach the arm top cover Refer to chapter 2 Opening the Covers 16 The mechanical origin position and teach points change when the reduction gear unit is replaced Be sure to calibrate the Joint 2 Refer to chapter 11 Calibration ...

Page 162: ...6 Replacing the Reduction Gear Units Part 2 Maintenance 150 ...

Page 163: ...s rendered inoperable while the brake is being replaced Joint 3 moves while the brake release button is held down while the power is ON See Figure 11 in the chapter End Effectors in Part 1 Lower Joint 3 carefully to prevent from striking against nearby equipment The power should be OFF while replacing the brake Removal 1 Remove the Joint 3 motor as described in 5 3 Replacing the Joint 3 Motor step...

Page 164: ...aintenance 152 4 Remove four bolts M3 5 that fasten the brake to the brake plate then remove the brake from the brake plate Brake Brake plate M3 5 5 Remove the rotor hub from the end of the pulley 3 M2 3 machine screw Rotor hub M2 3 ...

Page 165: ...the positions of the pulley setscrew holes are as shown in the figure below Gap gauge 0 15 mm Pulley screw holes 5 Place the new motor to the motor plate so that the motor cables turn to the direction of the figure below and fasten it with two bolts M4 8 The direction of the motor shaft flat face should face one of the screw holes of the pulley Flat face M4 8 M4 8 Flat point setscrew Bush 6 Secure...

Page 166: ...3 motor plate fastened in the step 9 and pull the cord using a force gauge or similar tool Fasten the Joint 3 motor plate securely where the Z belt is pulled at 29 4N 3kgf Adjust in the range of 20N 39N 2kgf 4kgf Force gauge 11 Connect the connectors X131 X31 and X32 Fasten the cables with wire ties in their original positions Do not allow unnecessary strain on the cables 12 Install the arm top co...

Page 167: ...timing belt is being replaced The power should be OFF while replacing the timing belt Once the timing belt is removed or replaced the origin position changes As a result the teach points you have been using also deviate from position In order to use the original teach points you need to adjust the origin position You need to choose one point from among the currently held teach points The accuracy ...

Page 168: ...elt 1 Remove the Joint 3 motor unit as described in 5 3 Replacing the Joint 3 Motor steps 1 through 4 2 Remove the bolts 3 M4 10 from the spline plate M4 10 Spline plate 3 Lift the spline plate and draw the Z belt up make it through under the spline plate and pull the Z belt upward Z belt ...

Page 169: ...te pulley Spline plate 3 Fasten the spline plate with three bolts M4 10 4 Place the Joint 3 motor unit in the arm The motor cables should be facing Joint 2 5 Place the Z belt around the Z1 and Z2 pulleys Ensure that the gear grooves of the belt and pulleys engage properly Be careful not to slip the Z belt from the pulleys while maintaining proper interval between the pulleys Fasten the Joint 3 mot...

Page 170: ...Force gauge 6 Connect the connectors X131 X31 and X32 Fasten the motor cables with wire ties in their original positions Do not allow unnecessary strain on the cables 7 Install the arm top cover and arm bottom cover Refer to chapter 2 Opening the Covers If the manipulator is a Protected model seal the arm top cover and arm bottom cover Refer to the section Sealing the Manipulator in chapter 13 Pro...

Page 171: ... Covers 2 Loosen the four bolts M4 10 holding the Joint 4 motor plate 2 4 M4 10 3 2 M4 12 Joint 4 countershaft unit Joint 4 motor plate 3 Loosen the two bolts M4 12 holding the Joint 4 countershaft unit 4 Remove the U2 belt from the small U2 pulley the lower side U1 belt Small U2 pulley Large U2 pulley U2 belt 5 Remove the U1 belt from the large U2 pulley the upper side ...

Page 172: ...perly U1 belt Small U2 pulley Large U2 pulley U2 belt U1 pulley 2 Position the Joint 4 countershaft unit and Joint 4 motor plate on the arm Be careful not to slip the belts from the pulleys while maintaining proper interval between the units Mount them loosely for the time being using the following bolts 2 M4 12 for the Joint 4 countershaft unit 4 M4 10 for the Joint 4 motor plate 4 M4 10 2 M4 12 ...

Page 173: ...unting plate Loosen the bolts for the Joint 4 motor plate fastened in the step 2 and pull the cord using a force gauge or similar tool Fasten the Joint 4 motor plate securely where the U1 belt is pulled at 49N 5kgf Adjust in the range of 29N 68N 3kgf 7kgf Force gauge 5 Install the arm top cover and arm bottom cover Refer to chapter 2 Opening the Covers If the manipulator is a Protected model seal ...

Page 174: ...eplacing the Joint 3 Motor steps 1 through 4 2 Loosen the four bolts M4 10 holding the Joint 4 motor plate 2 4 M4 10 3 2 M4 12 Joint 4 countershaft unit Joint 4 motor plate 3 Loosen the two bolts M4 12 holding the Joint 4 countershaft unit 4 Remove the U2 belt from the small U2 pulley the lower side U1 belt Small U2 pulley Large U2 pulley U2 belt ...

Page 175: ...Maintenance 8 Replacing the Timing Belts 163 5 Remove the bolts 3 M4 10 from the spline plate M4 10 Spline plate 6 Lift the spline plate and then extract the Z belt and the U2 belt from the shaft upward Z belt ...

Page 176: ... of the belts and pulleys engage properly Z belt U2 belt Small U2 pulley Z2 pulley U3 pulley Z1 pulley 4 Secure the spline plate with three bolts M4 10 5 Position the Joint 3 motor plate Joint 4 countershaft unit and Joint 4 motor plate on the arm Be careful not to slip the belts from the pulleys while maintaining proper interval between the units Secure them lossely for the time being using the f...

Page 177: ...l Fasten the Joint 4 countershaft securely where the U2 belt is pulled at 98N 10kgf Adjust in the range of 78N 117N 8kgf 12kgf Force gauge 7 Pass a suitable cord or string around the Joint 4 motor near its mounting plate Loosen the bolts for the Joint 4 motor plate fastened in the step 5 and pull the cord using a force gauge or similar tool Fasten the Joint 4 motor plate securely where the U1 belt...

Page 178: ...kgf 4kgf Force gauge 9 Connect the connectors X131 X31 and X32 Fasten the cables with a wire tie on their original positions Do not push them forcibly 10 Install the arm top cover and arm bottom cover Refer to chapter 2 Opening the Covers If the manipulator is a Protected model seal the arm top cover and arm bottom cover Refer to the section Sealing the Manipulator in chapter 13 Protected Model Ma...

Page 179: ...uitable point to check the calibration accuracy must be selected from the teach points Refer to chapter 11 Calibration Types of ball screw spline units There are six types of the ball screw spline unit Specify the Z code when ordering a ball screw spline unit for replacement Name Stroke of Joint 3 Specification Old code New code Ball screw spline unit for Z170 170 mm BNS2020A 385B ZA001208 R13ZA00...

Page 180: ...tenance If the manipulator is a Protected model remove the bellows Refer to the section 13 8 Replacing the Bellows in chapter 13 Protected Model Maintenance 2 Remove the Joint 3 motor unit Refer to section 5 3 Replacing the Joint 3 Motor steps 1 through 4 3 Remove the Z and U2 belts from the shaft Refer to section 8 3 Replacing the U2 Belt steps 2 through 6 4 Remove the four bolts M4 10 from the b...

Page 181: ...M4 10 at the ball screw spline unit under the arm Beware so that the timing belts will not be pinched between the nut and arm M4 10 3 Temporarily tighten three bolts M4 10 on the spline plate M4 10 Spline plate 4 Move the shaft up and down several times and tighten the bolts on the spline plate temporarily tightened before securely 5 Place the Joint 3 motor unit in the arm The motor cables should ...

Page 182: ...Z belt U2 belt Small U2 pulley Z2 pulley U3 pulley Z1 pulley Large U2 pulley U1 pulley U1 belt 7 Position the Joint 3 motor plate Joint 4 countershaft unit and Joint 4 motor plate on the arm Be careful not to slip the belts from the pulleys while maintaining proper interval between the units Mount them loosely for the time being using the following bolts 4 M4 10 for the Joint 3 motor plate 2 M4 12...

Page 183: ...ool Fasten the Joint 4 countershaft securely where the U2 belt is pulled at 98N 10kgf Adjust in the range of 78N 117N 8kgf 12kgf Force gauge 9 Pass a suitable cord or string around the Joint 4 motor near its mounting motor plate Loosen the bolts for the Joint 4 motor plate fastened in the step 7 and pull the cord using a force gauge or similar tool Fasten the Joint 4 motor plate securely where the...

Page 184: ...ition Refer to chapter 8 Motion Range and Robot Coordinates in Part 1 13 Install the arm top cover and arm bottom arm cover Refer to chapter 2 Opening the Covers If the manipulator is a Protected model reseal the covers For detail on sealing the covers refer to Sealing the Manipulator in chapter 13 Protected Model Maintenance 14 Grease the shaft refer to Greasing the Ball Screw Spline Unit on the ...

Page 185: ...he Drive Unit power ON 1 Disengage the motors by the MOTOR OFF command while keeping the Controller power ON 2 Move the arm to a position where Joint 3 can be moved in full stroke If necessary cover the surrounding area so that grease will not damage the end effector and peripheral equipment etc 3 Lower the shaft manually to its lower limit while pushing the Joint 3 brake release button Push Joint...

Page 186: ...9 Replacing the Ball Screw Spline Unit Part 2 Maintenance 174 ...

Page 187: ... retain the data for about 2 days The position data cannot be retained beyond the time duration mentioned above after which it will be lost If this happens Error 5016 Error 195 will occur when the power is turned ON In this case all the joints need to be calibrated all over again Refer to chapter 11 Calibration 10 1 Replacing the Signal Relay Board If the manipulator is a Protected model refer to ...

Page 188: ...m in any way Abnormal signals may cause the malfunction of the robot 3 Mount the base connector plate on the back of the manipulator Refer to chapter 2 Opening the Covers 4 Connect the cables to the base connector plate 5 Turn ON the Controller power and test it with a few teach points to make sure that the teach positions have not been offset When you have confirmed that the position data has bee...

Page 189: ...the battery on the signal relay board The motors for those manipulators whose serial number starts with 0 can retain position data for about 2 days If the motor is disconnected from the battery for more than the above hold time the position data will be lost and errors will occur when software is started RC Error 5016 SPEL 95 Error 5016 SRC 3 Error 195 When this happens all the joints must be reca...

Page 190: ... 2 Opening the Covers If the manipulator is a Protected model reseal the base connector plate Refer to Sealing the Manipulator in chapter 13 Protected Model Maintenance 5 Connect the cables to the base connector plate 6 Turn ON the Drive Unit Controller power and test it with a few teach points to make sure that the teach positions have not been offset When you have confirmed that the position dat...

Page 191: ...eviously used teach points are lost The process of realigning the origin position is called origin calibration This chapter includes calibration instructions for three different controller types designated by the following icons Procedure when using EPSON RC Robot Control System Procedure when using SPEL 95 SRC5 controllers Procedure when using SRC 3 controllers Refer to section in this chapter th...

Page 192: ... power of the RC520 Drive Unit and RC520 PC Control Unit after moving all joints to within motion range Check if an error occurs If an error does not occur proceed to next step Error F 5001 occurs when the capacitor in the motor encoder is insufficiently charged because for example the motor is new To change the capacitor leave the power ON for 3 or more minutes 2 Manually move joints to be calibr...

Page 193: ...button Error F 5136 will be displayed Click the RESET button The error should clear 7 Return all DIP switch bits to the OFF position 8 Close the acrylic plate on the sensor monitor For protected models attach the O ring to the encoder reset cover and fasten the cover to the base connector plate with four bolts M3 8 Refer to Sealing the Manipulator in chapter 13 Protected Model Maintenance 9 Visual...

Page 194: ...ple JUMP P1 Z 0 Set Joint 3 high to prevent interference with surrounding machinery 12 Display the coordinates of this position with the PLIST command and note the C value Example PLIST 1 P1 A B C D 0 13 Calculate the number of Joint 3 pulses at this point from the coordinate value that was noted in step 11 Multiply C by the Joint 3 resolution 307 2 pulse mm and round off after the decimal point T...

Page 195: ...otor 4 5 One revolution of the Joint 2 motor 7 2 One revolution of the Joint 4 motor 22 5 We will use P1 in these steps Move Joint 3 above this point using the JUMP command Example JUMP P1 Z 0 Set Joint 3 high to prevent interference with surrounding machinery 12 Display the number of pulses at this position using the PULSE command and note the four values Example PULSE PULSE 16000 pls 10000 pls 0...

Page 196: ... the arm orientation between right and left at a given point Using the PALLET command During CP control such as linear or circular interpolation Using the LOCAL command For statements using relative coordinates Example P1 X100 If the methods above require accuracy of Joint 2 then calibrate for both right and left arm orientations Note that this method cannot be used if Joint 4 has excessive run ou...

Page 197: ...own while pushing the brake release button Then execute SLOCK SLOCK All joints are under servo control 6 Display the number of pulses at the P1 position again using PULSE and note the Joint 2 value F2 Example PULSE PULSE E pls F2 pls G pls H pls 7 Calculate the new HOFS value from the values that were noted add the left and right pulse numbers F1 and F2 then add to B in step 1 on previous page and...

Page 198: ... step Error F 5001 occurs when the capacitor in the motor encoder is insufficiently charged because for example the motor is new To change the capacitor leave the power on for 3 or more minutes The error display does not change 2 Manually move joints to be calibrated into approximately the 0 pulse position Joint 1 0 pulse position aligned with X axis in robot coordinate system See the figure below...

Page 199: ...or F 5136 will be displayed Click the RESET button The error should clear 7 Return all DIP switch bits to the OFF position 8 Close the acrylic plate on the sensor monitor For protected models attach the O ring to the encoder reset cover and fasten the cover to the base connector plate with four bolts M3 8 Refer to Sealing the Manipulator in chapter 13 Protected Model Maintenance 9 Visually determi...

Page 200: ...Z 0 Set Joint 3 high to prevent interference with surrounding machinery 12 Display the coordinates of this position with the PLIST command and note the C value Example PLIST 1 P1 A B C D 13 Calculate the number of Joint 3 pulses at this point from the coordinate value which was noted in step 12 Multiply C by the Joint 3 resolution 307 2 pulse mm and round off after the decimal point This value is ...

Page 201: ... these steps Move Joint 3 above this point using the JUMP command Example JUMP P1 Z 0 Set Joint 3 high to prevent interference with surrounding machinery 12 Display the number of pulses at this position using the WHERE command and note the four values Example WHERE pulse 1 16000 2 10000 3 0 4 10 Joints 1 4 pulses 13 Enter the numbers noted in step 12 using the CALPLS command Example CALPLS 16000 1...

Page 202: ...n the required accuracy of Joint 2 calibrate for both right and left arm orientations Note that this method cannot be used in the event of run out due to rotation of Joint 4 1 Display HOFS values using the HOFS command and note the A B C and D values Example HOFS A B HOFS values for Joints 1 and 2 C D HOFS values for Joints 3 and 4 2 Select a point for teaching that is within the region accessible...

Page 203: ...er of pulses at the P1 position again using WHERE and note the Joint 2 value F2 Example WHERE Pulse 1 E 2 F2 3 G 4 H Joints 1 4 pulses 7 Calculate the new HOFS value from the values that were noted add the left and right pulse numbers F1 and F2 add to B in step 1 above and take the mid way value Incorporate and signs in the calculation The new HOFS value is called I I B F1 F2 2 8 Substitute I usin...

Page 204: ...the power ON for 3 or more minutes 2 Manually move axes to be calibrated into approximately the 0 pulse position Axis 1 0 pulse position aligned with X axis in robot coordinate system See the figure below Axis 2 0 pulse position parallel with Arm 1 i e straight regardless of axis 1 direction Axis 3 0 pulse position uppermost position in working area Axis 4 0 pulse position flat surface on shaft ti...

Page 205: ...r and fasten the cover to the base connector plate with four bolts M3 8 Refer to Sealing the Manipulator in chapter 13 Protected Model Maintenance 8 Close the acrylic plate on the sensor monitor 9 Visually determine the current position and enter that as the 0 pulse position with the CALPLS command CALPLS 0 0 0 0 10 Execute CALIB commands for axes requiring point alignment Example CALIB 1 Calibrat...

Page 206: ... Z0 Set the Axis 3 high to prevent interference with surrounding machinery 12 Display the coordinates of this position with the PLIST command and note the C value Example PLIST 1 P1 A B C D 0 13 Calculate the number of Axis 3 pulses at this point from the value which was noted in step 12 Multiply the C by Axis 3 resolution 307 2 pulse mm and round off after the decimal point This value is called E...

Page 207: ...xis 2 motor 7 2 One revolution of Axis 4 motor 22 5 We will use P1 in these steps Move Axis 3 above this point using the JUMP command Example JUMP P1 Z0 Set Axis 3 high Z0 to prevent interference with surrounding machinery 12 Display the number of pulses in this position using the PULSE command and note the four values Example PULSE 16000 10000 Axes 1 and 2 pulses 0 10 Axes 3 and 4 pulses 13 Enter...

Page 208: ...een right and left at a given point Using the PALET command During CP control such as liner or circular interpolation Using the LOCAL command For statements using relative coordinates Example P1 X100 If the methods above require accuracy of Axis 2 then calibrate for both right and left arm orientations Note that this method cannot be used if Axis 4 has excessive run out 1 Display HOFS values using...

Page 209: ...ake release button SLOCK All axes are under servo control 6 Display the number of pulses at the P1 position again using PULSE and note the axis 2 value F2 Example PULSE E F2 Axes 1 and 2 pulses G H Axes 3 and 4 pulses 7 Calculate the new HOFS value from the values which were noted previously add the left and right pulse values F1 and F2 add to B in step 1 on previous page and take the mid way valu...

Page 210: ...11 Calibration Part 2 Maintenance 198 ...

Page 211: ...he bellows must be removed before greasing the shaft Removing the bellows to enable greasing emits a large amount of dust Therefore take the unit to an outer room such as the room in front of the clean room s entrance or set up a dust emission prevention device before removing the bellows in the clean room When greasing do not allow any grease to get on the outside of the bellows Grease may drip C...

Page 212: ...t 7 Fill the groove of the ball screw spline shaft with grease Apply it directly by hand Wipe off excess grease from the shaft 8 Move the shaft up and down several times to spread grease all over the shaft while pushing the brake release button Wipe off excess grease from the shaft 9 Reattach the upper bellows lift the bottom of the bellows until it covers at least 10 mm of the cylindrical part of...

Page 213: ...le fits onto the cover side and its smaller hole fits onto the shaft side 5 Attach the bearing case on both ends of the bellows The blue plastic casings comes in two sizes one wider and the other narrower to fit in with each respective ends of the bellows The wider end of the bellows should be attached to the arm top cover while the narrower end should be attached to the user cable duct 6 Slide th...

Page 214: ...12 Clean Model Maintenance Part 2 Maintenance 202 ...

Page 215: ...tions outlined in the beginning Part 2 Maintenance WARNING Invasion of water or dust may cause the electric shock or malfunction Do not expose a manipulator connectors and pins to water or dust during maintenance operation Do not expose a manipulator to water or dust during its power cable connector is disconnected Invasion of water or dust may cause the electric shock or malfunction Seals will be...

Page 216: ... fitting C D Upper bellows C Upper bellows C Duct joint B D Arm top cover A D Base connector plate A D Joint 1 cover A Waterproof cover 2 watertight washers Duct joint B D Arm bottom cover A D Flange of Joint 1 reduction gear unit C Lower bellows C Lower bellows C Duct rotation C Flange of Joint 2 reduction gear unit C Bearing surface of bolts for duct plate D Bearing surface of bolts for user pla...

Page 217: ...er to be bulged out or torn C O ring packing A rubber packing to be applied on bellows flange of reduction gear encoder reset cover and main cable elbow fitting Make sure that the rings are not squeezed nor deformed D Liquid gasket The liquid gasket supplied with the manipulator to be applied on the cover plate duct joint cable bracket bolts cable seal box and receptacle When using for covers plat...

Page 218: ...nfiguration are shown below Signal relay board U1 belt Joint 4 middle axis U2 belt Joint 3 motor Joint 4 motor Upper bellows Joint 2 motor Lower bellows Z belt Joint 1 motor Cable seal box User cable duct Cable unit Joint 1 reduction gear unit Joint 2 reduction gear unit Ball screw spline shaft Extension shaft ...

Page 219: ...board via signal connector the position data of the motor will be retained after the main power is turned OFF However when the signal connector is removed the position data will only be retained by the super capacitor The position data Cannot be retained beyond the time duration mentioned above after which it will be lost If this happens errors will occur when the power is turned ON RC Error 5016 ...

Page 220: ...3 8 Receptacle 3 2 M4 16 5 Cut off the wire tie inside the main cable elbow fitting Wire tie 6 Remove the four bolts M3 8 from the receptacle and receptacle itself If the receptacle does not come out easily because of the liquid gasket on the junction surface use a flat screwdriver between the receptacle and the base connector plate 7 Disconnect the ground wires and pneumatic tubes from the base c...

Page 221: ... disconnect the connectors from the base and arm To disconnect the power connector pull it out while pushing the presser tongue next to the connector number on the motor side For manipulators whose serial number start with 1 their motors must be connected to the signal relay board of the new cable unit within 2 hours Otherwise the motor will lose the position data and it is necessary to calibrate ...

Page 222: ...able or bend it extremely This may damage the signal cable and cause the robot to malfunction 4 Referring to the section Wiring Schematic 1 in this chapter connect the ground wires and pneumatic tubes properly 5 Apply liquid gasket on the clamp face before the receptacle is secured on the base connector plate with four bolts 4 M3 8 6 Bind the cables with wire ties as they were before the unit repl...

Page 223: ... φ4 pneumatic tube 1 Wire tie Cable unit Wire tie φ4 pneumatic tube 3 User cable 15 Signal connector X1 connects with following connectors on the other side Joint 1 X10 Joint 2 X20 Joint 3 X30 Joint 4 X40 Joint 1 Power connector X110 Joint 1 Signal connector X11 Signal cable User cable Fittings for φ4 6 pneumatic tube 2 Fitting for φ4 pneumatic tube 1 User connector X51 X52 Connectors Joint 3 Powe...

Page 224: ...13 Protected Model Maintenance Part 2 Maintenance 212 13 6 Wiring Schematic 2 ...

Page 225: ...ise electric shock or malfunction can occur when power is connected When greasing do not allow any grease to get on the outside of the bellows Grease may drip Cover peripheral units with a sheet if necessary 1 Disengage the motors using the motor OFF button or command while keeping the Drive Unit power ON 1 Disengage the motors using the MOTOR OFF command while keeping the Controller power ON 2 Ra...

Page 226: ...he groove of the ball screw spline shaft with grease Apply it directly by hand Wipe off excess grease from the shaft 8 Move the shaft up and down several times to spread grease all over the shaft while pushing the brake release button Wipe off excess grease from the ball screw spline shaft 9 After checking that the O ring fits onto the groove of the flange fasten the mounting ring on the bottom of...

Page 227: ...ve Unit power ON 1 Disengage the motors using the MOTOR OFF command while keeping the Controller power ON 2 Lower the shaft manually to its lower limit while pushing the brake release button 3 Remove the six bolts M4 6 from the mounting ring on the top of the lower bellows There is an O ring between the bellows and flange that is fitted into a groove of the flange Mounting rings Shaft Lower bellow...

Page 228: ...stop Slide the stop upward about 50 mm M4 18 bolt Upper limit mechanical stop 6 Lift up the flange and loosen the bolt M6 18 on the set ring Remove the set ring flange O rings lower bellows and mounting rings from the shaft M6 18 bolt Flange Set ring 7 Push the shaft all the way up to the upper limit while pushing the brake release button ...

Page 229: ...lows Extension shaft 8 Mounting rings Flange 9 Flange 10 9 Remove the six bolts M4 6 from the mounting ring on the top of the upper bellows There is an O ring between the bellows and flange that is fitted into a groove of the flange 10 Remove the two bolts M4 15 from the extension shaft 11 Pull the cable and tubes out of the shaft 12 Remove the upper bellows mounting rings and O rings from the sha...

Page 230: ... 4 Mounting rings Flange 5 Flange 3 4 Fit the O ring into the groove of the flange Fasten the flange and the mounting ring on the top of the upper bellows with six bolts M4 6 5 Fit the O ring into the groove of the flange Fasten the flange and the mounting ring on the bottom of the upper bellows with six bolts M4 6 6 Pass the shaft through the O ring bellows O ring flange and set ring Secure the s...

Page 231: ...n the flange and the mounting ring on the bottom of the lower bellows with six bolts M4 6 10 Fit the O ring into the groove of the flange Fasten the flange and the mounting ring on the top of the lower bellows with six bolts M4 6 11 To make sure that the bellows can expand and contract smoothly without excessive force raise and lower manually Joint 3 while pushing the brake release button and move...

Page 232: ...rewdriver to remove the base connector plate from the manipulator base 2 Remove all connectors from the signal relay board X10 X20 X30 X40 X50 X1 and user connector Open up the top and bottom clips and pull off connector X10 X20 X30 and X40 3 Remove the four screws M3 6 on the signal relay board and remove the board Installation 1 Install a new signal relay board with four screws M3 6 2 Securely c...

Page 233: ...1300 ZA000613 AC servo motor EL Joint 3 4 S N 1 R13ZA00062400 ZA000624 100W ABS Common to Joint 2 3 and 4 of ES Brake Joint 3 R13ZA00350100 ZA003501 ERS 135L Signal cable R13ZA00200300 ZA002003 3 m standard Z belt R13ZA00321400 ZA003214 264 2GT 6 U1 belt R13ZA00321300 ZA003213 240 2GT 9 T434N1 U2 belt R13ZA00321200 ZA003212 366 2GT 20 T434N1 U2 pulley R13ZA003B0100 ZA003B01 Grease for ball screw s...

Page 234: ...int 1 of ES Joint 2 of EL Common to Clean model 14 3 Maintenance Parts for Clean model Parts Name New code Old code Standard Note ES 1C R13ZA00370400 ZA003704 φ 90 φ 45 st 150 2 bellows for only ES Bellows Round type ES 3C EL 3C R13ZA00370500 ZA003705 φ 90 φ 45 st 300 2 bellows ES 1C R13ZA00121600 ZA001216 BNS2020A 385B CL For 150 mm stroke Only for ES Ball screw spline unit ES 3C EL 3C R13ZA00121...

Page 235: ...w splin unit ES 3P EL 3P R13ZA00121900 ZA001219 BNS2020A 535B P For 300 mm stroke ES45 P ES55 P ES65 P EL65 P R13ZA00204800 ZA002048 MPI11100100 P Cable unit EL85 P R13ZA00204900 ZA002049 MPI11100200 P ES 1P R13ZA00206200 ZA002062 ES 3P R13ZA00206300 ZA002063 User cable unit EL 3P R13ZA00206400 ZA002064 R13ZA00205000 ZA002050 3 m Wash down R13ZA00205100 ZA002051 5 m Wash down Power cable R13ZA0020...

Page 236: ...14 Maintenance Part Lists Part 2 Maintenance 224 ...

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