Epson G3 Series Manual Download Page 121

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Maintenance 5. Arm #1

G3 Rev.14

109

5.2 Replacing Joint #1 Reduction Gear Unit

A reduction gear unit consists of the following three parts. When replacing the reduction

gear unit, be sure to always replace the waveform generator, flexspline, and circular spline

all together as one set.

Waveform generator / Flexspline / Circular spline

For details of the reduction gear unit, refer to

Maintenance: 14. Maintenance parts list

Name

Quantity

Note

Maintenance

Parts

Reduction Gear Unit

R13B010016

Tools

Hexagonal wrench

width across flats: 2 mm

For M4 set screw

width across flats: 2.5 mm

For M3 screw

width across flats: 3 mm

For M4 screw

width across flats: 5 mm

For M6 screw

Torque wrench

Tightening torque:

6.0 N

⋅

m (61.2 kgf

⋅

cm)

Tightening torque:

22.0 N

⋅

m (224.3 kgf

⋅

cm)

Nippers

Spatula

For apply grease

Wiping cloth

For wiping grease (Flange)

For wiping grease (Bolt)

Screw (M4)

About 20 mm in length

For flexspline removal

Grease

Grease (SK-1A)

16 g

Joint #1

reduction gear

unit

Removal

(1) Remove the Joint #1 motor unit.

Refer to the removal steps (1) to (7) in

Maintenance: 5.1 Replacing Joint #1 Motor

(2) Remove the Reduction gear unit from the Joint

#1 flange.

16-M3

Flange

Reduction gear unit

Summary of Contents for G3 Series

Page 1: ...Rev 14 EM183R3623F SCARA ROBOT G3 series MANIPULATOR MANUAL ...

Page 2: ...MANIPULATOR MANUAL G3 series Rev 14 ...

Page 4: ...anty 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 disas...

Page 5: ...tries Other brand and product names are trademarks or registered trademarks of the respective 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 ...

Page 6: ...tailer 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...

Page 7: ... depending on the Controllers since they have different control methods Details are described in the manual 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 For the Controller composition refer to the table above Shape of Motors The shape of the motors used for the Manipulator that you are using may ...

Page 8: ...vi G3 Rev 14 ...

Page 9: ...ions 27 2 5 How to Set the Model 31 3 Environments and Installation 32 3 1 Environmental Conditions 32 3 2 Base Table 33 3 3 Mounting Dimensions 35 3 3 1 Table Top Mounting Straight Arm 36 3 3 2 Table Top Mounting Left Curved Arm 37 3 3 3 Table Top Mounting Right Curved Arm 38 3 3 4 Multiple Mounting Straight Arm 39 3 3 5 Multiple Mounting Left Curved Arm 40 3 3 6 Multiple Mounting Right Curved Ar...

Page 10: ...l Stops of Joints 1 and 2 65 5 2 2 Setting the Mechanical Stop of Joint 3 69 5 3 Setting the Cartesian Rectangular Range in the XY Coordinate System of the Manipulator for Joints 1 and 2 71 5 4 Standard Motion Range 71 Maintenance 1 Safety Maintenance 75 2 General Maintenance 76 2 1 Maintenance Inspection 76 2 1 1 Schedule for Maintenance Inspection 76 2 1 2 Inspection Point 77 2 2 Overhaul Pars R...

Page 11: ... 7 3 Replacing the Brake 129 8 Arm 4 131 8 1 Replacing Joint 4 Motor 132 8 2 Replacing the Timing Belt 136 9 Replacing Arm 1 144 10 Bellows 153 11 Ball Screw Spline Unit 155 11 1 Greasing the Ball Screw Spline Unit 155 11 1 1 Standard model 156 11 1 2 Cleanroom model Protected model 157 11 2 Replacing the Ball Screw Spline Unit 158 12 Lithium Battery 162 12 1 Replacing the Battery Unit Lithium Bat...

Page 12: ...TABLE OF CONTENTS x G3 Rev 14 15 Maintenance Parts List 185 15 1 Common Parts 185 15 2 Parts by Environment Model 187 ...

Page 13: ...Setup Operation This volume contains information for setup and operation of the G3 series Manipulators Please read this volume thoroughly before setting up and operating the Manipulators ...

Page 14: ......

Page 15: ...ns 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 serious injury or death caused by electric shock exists if the associated instru...

Page 16: ... system Designing and or constructing the robot system without understanding the safety requirements is extremely hazardous may result in serious bodily injury and or severe equipment damage to the robot system and may cause serious safety problems The Manipulator and the Controller must be used within the environmental conditions described in their respective manuals This product has been designe...

Page 17: ...crew spline is applied the load exceeding the allowable value it is necessary to replace the ball screw spline unit The allowable loads differ depending on distance where the load is applied to For calculating the allowable load see the calculation formula below Allowable bending moment G3 M 13 000 N mm Example If 130 N load is applied at 100 mm from the end of the spline nut Moment M F L 100 130 ...

Page 18: ...power status to secure the safety of an operator 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 Immediately press the Emergency Stop switch whenever the Manipulator moves abnormally while the robot system is operated WARNING To shut off power to the robo...

Page 19: ...rings are likely to cause oil film shortage in such situation To prevent early breakdown move the joints larger than 50 degrees for about five to ten times a day Joint 3 If the up and down motion of the hand is less than 10 mm move the joint a half of the maximum stroke for five to ten times a day Oscillation resonance may occur continuously in low speed Manipulator motion Speed approx 5 to 20 dep...

Page 20: ...es work This will shorten the life of the brakes due to the worn friction plates Normal brake life cycle About 2 years when the brakes are used 100 times day 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...

Page 21: ...ting Manipulator cannot stop immediately after the Emergency Stop switch is pressed The free running time angle distance of the Manipulator are shown below However remember that the values vary depending on following conditions Weight of the end effector Weight of work piece Operating pose Weight Speed Accel etc Conditions for Measurement Accel Setting 100 Speed Setting 100 Load kg 3 Weight Settin...

Page 22: ...op switch of the Controller If the Manipulator is stopped by turning OFF the Controller while it is operating following problems may occur Reduction of the life and damage of the reduction gear unit Position gap at the joints In addition if the Controller was forced to be turned OFF by blackouts and the like while the Manipulator is operating make sure to check the following points after power res...

Page 23: ...e distance of the Manipulator are shown below However remember that the values vary depending on following conditions Weight of the end effector Weight of work piece Operating pose Weight Speed Accel etc Conditions for Measurement Accel Setting 100 Speed Setting 100 Load kg 3 Weight Setting 3 Joint 1 Point where the emergency stop signal is input Start point of operation Target point Stop point Jo...

Page 24: ...lied to the joint has been released Move the joint up down while pressing the brake release switch Joint 4 Rotate the shaft by hand Joint 3 brake release switch Joint 1 rotating Joint 2 rotating Joint 3 up and down Joint 4 rotating Arm 1 Arm 2 Base Shaft The brake release switch affects only Joint 3 When the brake release switch is pressed in emergency mode the brake for Joint 3 is released Be car...

Page 25: ...spline Set ACCELS as follows according to the Z axis height ACCELS setting value by Z axis position and tip load Z position mm Tip load 1kg or less 2kg or less 3kg or less __ 0 Z _ 50 25000 or less 25000 or less 24000 or less _ 50 Z 100 24000 or less 16000 or less 100 Z 150 18000 or less 12000 or less Z Z axis height 0 Origin point If the Manipulator is operated in CP motion with the wrong set val...

Page 26: ...nds or fingers from being caught in the Manipulator B Be careful to avoid collision C Hazardous voltage exists while the Manipulator is ON To avoid electric shock do not touch any internal electric parts D You can catch your hand or fingers between the shaft and cover when bringing your hand close to moving parts Manipulators with bellows do not have this label for no danger of your hand or finger...

Page 27: ...Setup Operation 1 Safety G3 Rev 14 15 Location Label H I C D B A C B C Common Table Top Mounting Multiple Mounting G G E F H F A I I H ...

Page 28: ... of overall height compared to E2C Extended motion range The same size of motion range compared with the other brands one up robots Extended range in Z direction Obtain the stroke under the body Succeeded E2C series advantages Compatibility with the E2C series Manipulators The installation procedure and mounting dimensions of end effector for the G3 series are compatible with those for E2C series ...

Page 29: ...ngth 25 250 mm 30 300 mm 35 350 mm Environment Cleanroom model This model has additional features that reduce dust emitted by the Manipulator to enable use in clean room environments For details on the specifications refer to Setup Operation 2 4 Specifications UL specification UL UL compliant Non UL compliant Type Standard R Right Curved L Left Curved Mounting type Table Top Mounting M Multiple Mo...

Page 30: ...ounting Standard 150 G3 301S R Cleanroom 120 G3 301C R Left Curved Table Top Mounting Standard 150 G3 301S L Cleanroom 120 G3 301C L 350 mm Standard Table Top Mounting Standard 150 G3 351S Cleanroom 120 G3 351C Multiple Mounting Standard 150 G3 351SM Cleanroom 120 G3 351CM Right Curved Table Top Mounting Standard 150 G3 351S R Cleanroom 120 G3 351C R Multiple Mounting Standard 150 G3 351SM R Clean...

Page 31: ...lue for ø6 mm pneumatic tube Fittings white for ø6 mm pneumatic tube User connector 15 pin D sub connector LED Lamp Color differs depending on the shipment time The brake release switch affects only Joint 3 When the brake release switch is pressed in emergency mode the brake for Joint 3 is released While the LED lamp is on the current is being applied to the manipulator Performing any work with th...

Page 32: ...0 220 b Max 545 Max 575 Max 595 Max ø11 through hole mechanical stop diameter Conical hole Ø3 90 1 mm flat cut Detail of A Calibration point position of Joints 3 and 4 or more Space for cables indicates the stroke margin by mechanical stop Reference through hole View from the bottom of the base ...

Page 33: ...ng figures show the additional parts and specifications for Cleanroom model Table Top mounting when compared with the Standard model in appearance Upper bellows Plate cover For Anti static Cover for Table Top mounting surface Exhaust port Lower bellows Plate cover For Anti static ...

Page 34: ... Max 575 Max 595 shaft diameter Max ø11 through hole mechanical stop diameter Conical hole Ø3 90 1 mm flat cut Detail of A Calibration point position of Joints 3 and 4 Space for cables indicates the stroke margin by mechanical stop Reference through hole View from the bottom of the base or more ...

Page 35: ...be Fitting white for ø6 mm pneumatic tube User connector 15 pin D sub connector LED lamp Color differs depending on the shipment time The brake release switch affects only Joint 3 When the brake release switch is pressed in emergency mode the brake for Joint 3 is released While the LED lamp is on the current is being applied to the manipulator Performing any work with the power ON is extremely haz...

Page 36: ...Max 450 shaft diameter Max ø11 through hole mechanical stop diameter Conical hole Ø3 90 1 mm flat cut Detail of A Calibration point position of Joints 3 and 4 indicates the stroke margin by mechanical stop Reference through hole View from the bottom of the base or more Space for cables ...

Page 37: ...Cleanroom model G3 1CM The following figures show the additional parts and specifications for Cleanroom model Multiple Mounting when compared with the Standard model in appearance Upper bellows Plate cover For Anti static Exhaust port Lower bellows ...

Page 38: ...Max 450 shaft diameter Max ø11 through hole mechanical stop diameter Conical hole Ø3 90 1 mm flat cut Detail of A Calibration point position of Joints 3 and 4 indicates the stroke margin by mechanical stop Reference through hole View from the bottom of the base or more Space for cables ...

Page 39: ...14 kg 31 lb Driving method All joints AC servo motor Motor energy consumption Joint 1 200 W Joint 2 150 W Joint 3 150 W Joint 4 150 W Option Installation method Multiple Mounting Installation environment Cleanroom ESD 3 Joint 3 down force 150 N Installed wire for customer use 15 15 pin D sub 15 cores Installed pneumatic tube for customer use 2 pneumatic tubes ø6 mm 0 59 MPa 6 kgf cm2 86 psi 1 pneu...

Page 40: ...82543 7427414 Left hand 1747627 6262329 2184534 5825423 Joint 2 Right hand 2457600 2730667 2184534 3003734 Left hand 2730667 2457600 3003734 2184534 Common Joint 3 1706667 0 Joint 4 1494221 Standard model Multiple Mounting Item G3 301SM G3 351SM Max motion range deg mm Straight Joint 1 115 120 Joint 2 135 142 Curved Joint 1 Right hand 105 130 Left hand 130 105 Joint 2 Right hand 120 160 Left hand ...

Page 41: ...t hand 1747627 6262329 2184534 5825423 Joint 2 Right hand 2457600 2639645 2184534 2912712 Left hand 2639645 2457600 2912712 2184534 Common Joint 3 1365334 0 Joint 4 1494221 Cleanroom model Multiple Mounting Item G3 301CM G3 351CM Max motion range deg mm Straight Joint 1 115 120 Joint 2 135 142 Curved Joint 1 Right hand 105 130 Left hand 130 105 Joint 2 Right hand 120 150 Left hand 150 120 Common J...

Page 42: ...r of the motion rang 10 particles or less Exhaust System Exhaust port diameter Inner diameter ø12 mm Outer diameter ø16 mm Exhaust tube Polyurethane tube Outer diameter ø12 mm Inner diameter ø8 mm or Inner diameter ø16mm or larger Recommended exhaust flow rate approx 1000 cm3 s Normal ESD specification uses resin materials with antistatic treatment This model controls adhesion of dust due to elect...

Page 43: ...el may result in abnormal or no operation of the Manipulator 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 ...

Page 44: ...t us The ambient temperature conditions are for the Manipulators only For the Controller the Manipulators are connected to refer to the Controller manual Special Environmental Conditions The surface of the Manipulator has general oil resistance However if your requirements specify that the Manipulator must withstand certain kinds of oil please consult your distributor Rapid change in temperature a...

Page 45: ...oles required for mounting the Manipulator base are M8 Use mounting bolts with specifications conforming to ISO898 1 property class 10 9 or 12 9 For dimensions refer to Setup Operation 3 3 Mounting Dimensions The plate for the Manipulator mounting face should be 20 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 table must...

Page 46: ...le Connector L shaped 35 RC700 A Do not remove the M C cables from the Manipulator For environmental conditions regarding space when placing the Controller on the base table refer to the Controller manual WARNING To ensure safety a safeguard must be installed for the robot system For details on the safeguard refer to the EPSON RC User s Guide NOTE ...

Page 47: ...y may reach Be sure to allow for the following extra spaces in addition to the space required for mounting the Manipulator Controller and peripheral equipment Space for teaching Space for maintenance and inspection Ensure a space to open the rear side cover and the maintenance cover for maintenance Space for cables The minimum bend radius of the power cable is 90 mm When installing the cable be su...

Page 48: ...G3 351S 142 3 8 134 2 142 3 220 350 298 5 303 3 150 9 6 6 7 G3 351C 142 3 8 146 6 120 4 1 10 7 g Length of Arm 1 mm b Joint 1 angle to hit mechanical stop degree h g Length of Arm 2 mm d Joint 2 angle to hit mechanical stop degree m Stroke of Joint 3 mm n Joint 3 range to hit lower mechanical stop mm f Motion range p Joint 3 range to hit upper mechanical stop mm a Motion range of Joint 1 degree j ...

Page 49: ...3 G3 301C L 288 7 201 8 227 5 120 4 1 10 7 3 8 G3 351S L 346 6 205 2 219 4 150 9 6 6 7 167 8 123 8 3 8 G3 351C L 222 9 120 4 1 10 7 n Length of Arm 1 mm b d Joint 1 angle to hit mechanical stop degree p n Length of Arm 2 mm f z Joint 2 angle to hit mechanical stop degree u Stroke of Joint 3 mm v Joint 3 range to hit lower mechanical stop mm m j Motion range w Joint 3 range to hit upper mechanical ...

Page 50: ...27 5 288 7 120 4 1 10 7 8 3 G3 351S R 220 350 205 2 219 4 342 5 346 6 150 9 6 6 7 123 8 167 8 2 8 G3 351C R 222 9 120 4 1 10 7 7 8 n Length of Arm 1 mm b d Joint 1 angle to hit mechanical stop degree p n Length of Arm 2 mm f z Joint 2 angle to hit mechanical stop degree u Stroke of Joint 3 mm v Joint 3 range to hit lower mechanical stop mm m j Motion range w Joint 3 range to hit upper mechanical s...

Page 51: ... 10 7 G3 351SM 150 9 6 6 7 G3 351CM 120 4 1 10 7 g Length of Arm 1 mm b Joint 1 angle to hit mechanical stop degree h g Length of Arm 2 mm d Joint 2 angle to hit mechanical stop degree m Stroke of Joint 3 mm n Joint 3 range to hit lower mechanical stop mm f Motion range p Joint 3 range to hit upper mechanical stop mm a Motion range of Joint 1 degree j Range from center of axis to back end mm c Mot...

Page 52: ... v w G3 351SM L 150 9 6 6 7 G3 351CM L 120 4 1 10 7 n Length of Arm 1 mm b d Joint 1 angle to hit mechanical stop degree p n Length of Arm 2 mm f z Joint 2 angle to hit mechanical stop degree u Stroke of Joint 3 mm v Joint 3 range to hit lower mechanical stop mm m j Motion range w Joint 3 range to hit upper mechanical stop mm a c Motion range of Joint 1 degree q s Range from center of axis to back...

Page 53: ...u v w G3 351SM R 150 9 6 6 7 G3 351CM R 120 4 1 10 7 n Length of Arm 1 mm b d Joint 1 angle to hit mechanical stop degree p n Length of Arm 2 mm f z Joint 2 angle to hit mechanical stop degree u Stroke of Joint 3 mm v Joint 3 range to hit lower mechanical stop mm m j Motion range w Joint 3 range to hit upper mechanical stop mm a c Motion range of Joint 1 degree q s Range from center of axis to bac...

Page 54: ...o get hands or fingers caught The arm is secured with a wire tie Leave the wire tie secured until you finish the installation so as not to get hands or fingers caught To carry the Manipulator have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure bottom of Arm 1 and bottom of the base by hand When holding the bot...

Page 55: ...he Standard Manipulator 3 5 1 Table Top Mounting 3 5 2 Multiple Mounting For Cleanroom model manipulator refer to this section 3 5 3 Cleanroom model 3 5 1 Table Top Mounting CAUTION Install the Table Top Mounting Manipulator with two or more people The Manipulator weights are as follows Be careful not to get hands fingers or feet caught and or have equipment damaged by a fall of the Manipulator G3...

Page 56: ...eful not to get hands fingers or feet caught and or have equipment damaged by a fall of the Manipulator G3 301 M approx 14 kg 31 lb G3 351 M approx 14 kg 31 lb When installing the Manipulator to the wall support the Manipulator and then secure the anchor bolts Removing the support without securing the anchor bolts properly is extremely hazardous and may result in fall of the Manipulator Design and...

Page 57: ...ulator to delivery equipment such as a pallet with bolts so that the Manipulator does not fall 3 Wipe off the dust on the Manipulator with a little alcohol or distilled water on a lint free cloth 4 Carry the Manipulator in the clean room 5 Refer to the installation procedure of each Manipulator model and install the Manipulator 6 Connect an exhaust tube to the exhaust port CAUTION When operating t...

Page 58: ... controller is grounded and the cables are correctly connected If the ground wire is improperly connected to ground it may result in the fire or electric shock CAUTION When connecting the Manipulator to the Controller make sure that the serial numbers on each equipment match Improper connection between the Manipulator and Controller may not only cause improper function of the robot system but also...

Page 59: ...dard 15 pin Suitable Connector JAE DA 15PF N Solder type Clamp Hood JAE DA C8 J10 F2 1R Connector setscrew 4 40 NC Pins with the same number indicated on the connectors on both ends of the cables are connected Pneumatic Tubes Max Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter Inner Diameter 0 59 MPa 6 kgf cm2 86 psi 2 ø6 mm ø4 mm 1 ø4 mm ø2 5 mm Fittings for ø6 mm and ø4 mm outer diamete...

Page 60: ... black or blue for ø6 mm pneumatic tube Fitting white for ø6 mm pneumatic tube User connector 15 pin D sub connector Base back side Multiple Mounting Fitting black or blue for ø6 mm pneumatic tube User connector 15 pin D sub connector Fitting white for ø6 mm pneumatic tube Fitting black or blue for ø4 mm pneumatic tube Base upper side ...

Page 61: ...hen get hands fingers or feet caught To carry the Manipulator have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the bottom of Arm 1 the bottom of the main cable fitting and the bottom of the base by hand When holding the bottom of the base by hand be very careful not to get hands or fingers caught Stabilize the Manipulator with your hands when hoist...

Page 62: ...er on all devices and unplug the cables Remove the mechanical stops if using them to limit the motion range of Joints 1 and 2 For details on the motion range refer to Setup Operation 5 2 Motion Range Setting by Mechanical Stops 2 Cover the arm with a sheet so that the arm will not be damaged Tie the lower end of the shaft and arm and the base and arm together with the wire tie Be careful not to ti...

Page 63: ...or bolts Removing the anchor bolts without supporting is extremely hazardous and may result in fall of the Manipulator 1 Turn OFF the power on all devices and unplug the cables Remove the mechanical stops if using them to limit the motion range of Joints 1 and 2 For details on the motion range refer to Setup Operation 5 2 Motion Range Setting by Mechanical Stops 2 Cover the arm with a sheet so tha...

Page 64: ...it the Manipulator and the robot system may not function properly Use a split muff coupling with an M4 bolt or larger to attach the end effector to the shaft Brake release switch Joint 3 cannot be moved up down by hand because the electromagnetic brake is applied to the joint while power to the robot system is turned OFF This prevents the shaft from hitting peripheral equipment in the case that th...

Page 65: ...ras and Valves Arm 2 has threaded holes as shown in the figure below Use these holes for attaching cameras valves and other equipment Unit mm Common Dimensions Multiple Mounting Table Top Mounting From the base mounting face From the reference hole From the base mounting face ...

Page 66: ...d may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable weight capacity end effector and work piece in G3 series is 1 kg at the default rating and 3 kg at the maximum When the load weight of the end effector and work piece exceeds the rating change the setting of Weight parameter After the setting is changed the m...

Page 67: ...tic speed setting by Weight 140 120 100 80 60 40 20 0 1 1 5 2 2 5 3 kg Weight setting The percentage in the graph is based on the speed at rated weight 1 kg as 100 100 Automatic acceleration deceleration setting by Weight 140 120 100 80 60 40 20 0 1 1 5 2 2 5 3 kg Weight setting The percentage in the graph is based on the acceleration deceleration at rated weight 1 kg as 100 110 80 90 100 G3 25 14...

Page 68: ...ys set the moment of inertia parameter to the correct moment of inertia Setting a value that is smaller than the actual moment of inertia may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable moment of inertia of load for a G3 series Manipulator is 0 005 kg m2 at the default rating and 0 05 kg m2 at the maximum Wh...

Page 69: ...50 mm Always set the eccentric quantity parameter according to the eccentric quantity Setting a value that is smaller than the actual eccentric quantity may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable eccentric quantity of load in G3 series is 0 mm at the default rating and 150 mm at the maximum When the ecc...

Page 70: ...on the acceleration deceleration at rated eccentricity 0 mm as 100 120 100 80 60 40 20 0 50 100 150 mm Eccentricity setting 60 40 20 100 Calculating the Moment of Inertia Refer to the following examples of formulas to calculate the moment of inertia of load end effector with work piece The moment of inertia of the entire load is calculated by the sum of each part a b and c Work piece b Work piece ...

Page 71: ...iped h b L Mass m Rectangular parallelepiped s center of gravity Rotation center m m L 2 b 2 h 2 12 b Moment of inertia of a cylinder m m L 2 r 2 2 Mass m L r Cylinder s center of gravity Rotation center c Moment of inertia of a sphere m r 2 m L 2 2 5 Sphere s center of gravity r Mass m L Rotation center ...

Page 72: ...ipulator motion after considering the relation between the current position and the destination position The upper limit of Joint 3 during horizontal motion using Jump command can be set by the LimZ command Automatic acceleration deceleration vs Joint 3 position 120 100 80 60 40 20 0 30 60 90 120 150 mm Shaft height Figures on the graph are the proportion to the acceleration deceleration speed at ...

Page 73: ...o 5 3 to set the range 5 1 Motion Range Setting by Pulse Range for All Joints Pulses are the basic unit of Manipulator motion The motion range of the Manipulator is controlled by the pulse range between the pulse lower limit and upper limit of each joint Pulse values are read from the encoder output of the servo motor For the maximum pulse range refer to the following sections The pulse range must...

Page 74: ...s the positive and the clockwise pulse value is defined as the negative Y X 0 pulse B B A A Table Top Mounting Arm Standard R L A Max Motion Range deg 25 140 30 125 150 150 125 35 110 165 165 110 B Max Pulse Range pulse 25 1456356 6699236 30 1019449 6990507 1747627 6262329 35 582542 7427413 2184533 5825422 Multiple Mounting Arm Standard R L A Max Motion Range deg 30 115 35 120 105 130 130 105 B Ma...

Page 75: ...tion Range deg 25 141 137 30 142 141 135 150 135 145 150 135 145 135 35 142 120 165 120 160 165 120 160 120 B Max Pulse Range pulse 25 2566827 2566827 2494009 2494009 30 2585031 2585031 2494009 2494009 2457600 2730667 2457600 2639645 2730667 2457600 2639645 2457600 35 2585031 2585031 2184533 3003733 2184533 2912711 3003733 2184533 2912711 2184533 Table Top Mounting S Standard model C Cleanroom mod...

Page 76: ...0 mm 1706667 G3 1C Cleanroom model 120 mm 1365334 For the Cleanroom model G3 1C the motion range set with the Joint 3 mechanical stop cannot be changed 5 1 4 Max Pulse Range of Joint 4 The 0 zero pulse position of Joint 4 is the position where the flat near the end of the shaft faces toward the end of Arm 2 With the 0 pulse as a starting point the counterclockwise pulse value is defined as the pos...

Page 77: ...int 3 Lower limit mechanical stop Do not move the upper limit mechanical stop Mechanical stop of Joint 1 Fixed Mechanical stop of Joint 2 Adjustable Multiple Mounting Mechanical stop of Joint 1 Adjustable Mechanical stop of Joint 1 Fixed The different mechanical stop positions from Table Top mounting are indicated for Multiple mounting 5 2 1 Setting the Mechanical Stops of Joints 1 and 2 Both Join...

Page 78: ...00 100 350 120 105 105 G3 351SM CM R 350 105 130 95 120 G3 351SM CM L 350 130 105 120 95 Setting Angle 90 95 100 105 110 115 120 Pulse Value 5242880 5388516 5534151 5679787 5825423 5971058 6116694 Setting Angle 125 130 140 145 150 165 Pulse Value 6262329 6407965 6699236 6844872 6990507 7427414 Setting Angle 90 95 100 105 110 115 120 Pulse Value 0 145636 291271 436907 582542 728178 873813 Setting A...

Page 79: ...L 350 120 160 110 150 Setting Angle 100 110 115 120 130 135 Pulse Value 1820444 2002488 2093511 2184533 2366577 2457600 Setting Angle 141 142 145 150 160 165 Pulse Value 2566826 2585031 2639644 2730666 2912711 3003733 Setting Angle 100 100 115 120 130 135 Pulse Value 1820444 2002488 2093511 2184533 2366577 2457600 Setting Angle 141 142 145 150 160 165 Pulse Value 2566826 2585031 2639644 2730666 29...

Page 80: ...l it reaches the positions of the minimum and maximum pulse range Make sure that the arm does not hit the mechanical stops Check the position of the mechanical stop and the motion range you set Example Using G3 251S The angle of Joint 1 is set from 110 degrees to 110 degrees The angle of Joint 2 is set from 120 degrees to 120 degrees EPSON RC Execute the following commands from the Command Window ...

Page 81: ...by hand while pressing the button 3 Turn OFF the Controller 4 Loosen the lower limit mechanical stop screw M3 10 A mechanical stop is mounted on both the top and bottom of Joint 3 However only the position of the lower limit mechanical stop on the top can be changed Do not remove the upper limit mechanical stop on the bottom because the calibration point of Joint 3 is specified using the stop 5 Th...

Page 82: ...nt 3 10 Using the Pulse command Go Pulse command move Joint 3 to the lower limit position of the pulse range at low speed If the mechanical stop range is less than the pulse range Joint 3 will hit the mechanical stop and an error will occur When the error occurs either change the pulse range to a lower setting or extend the position of the mechanical stop within the limit If it is difficult to che...

Page 83: ...llowing motion range diagrams show the standard maximum specification When each Joint motor is under servo control the center of Joint 3 s shaft s lowest point moves in the areas shown in the figure Area limited by mechanical stop is the area where the center of Joint 3 s lowest point can be moved when each joint motor is not under servo control Mechanical stop sets the limited motion range so tha...

Page 84: ...Setup Operation 5 Motion Range 72 G3 Rev 14 ...

Page 85: ...Maintenance This volume contains maintenance procedures with safety precautions for G3 series Manipulators ...

Page 86: ...74 ...

Page 87: ...es 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 wh...

Page 88: ... trouble and ensuring 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 five stages daily monthly quarterly biannual and annual The inspection points are added every stage If the Manipulator is operated for 250 hours or longer per month the inspection points m...

Page 89: ...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 it if necessary Inside of Arm 2 Grease conditions Refer to Maintenance 2 3 Greasing Battery Refer to Maintenance 12 Lithium Battery Inspection While the Power is ON Manipulator is operating Inspection Po...

Page 90: ...the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator For the EPSON RC 7 0 Ver 7 2 x or later firmware Ver 7 2 x x or later the recommended replacement time for the parts subject to maintenance motors reduction gear units and timing belts can be checked in the Maintenance dialog box of the EPSON RC 7 0 For details refer to the following m...

Page 91: ...us button to open the Browse For Folder dialog 3 Select the folder where the information is stored 4 Click OK to view the Controller Status Viewer dialog 5 Select Robot from the tree menu on the left side Dialog image EPSON RC 7 0 For the parts subject to overhaul refer to Maintenance 15 Maintenance Parts List For details of replacement of each part refer to the Maintenance section Please contact ...

Page 92: ...on your skin Wash the area thoroughly with soap and water Greasing part Greasing Interval Grease Refer to Maintenance Joint 1 Joint 2 Reduction gear units Overhaul timing SK 1A 5 2 Replacing the Joint 1 Reduction Gear Unit 6 2 Replacing the Joint 2 Reduction Gear Unit Joint 3 Ball screw spline unit At 100 km of operation 50 km for first greasing AFB 11 1 Greasing the Ball Screw Spline Unit Joint 1...

Page 93: ...aintenance dialog box of the EPSON RC 7 0 For details refer to the following manual Robot Controller RC700 RC700 A Maintenance 6 Alarm For the EPSON RC 5 0 Ver 5 4 7 or later firmware Ver 1 16 4 x or 1 24 4 x or later the recommended replacement time for the grease can be checked in the Maintenance dialog box of the EPSON RC 5 0 For details refer to the following manual Robot Controller RC180 Appe...

Page 94: ...fastened in a crisscross pattern as shown in the figure below 1 5 3 7 2 6 4 8 Bolt hole Do not fasten all bolts securely at one time Divide the number of times that the bolts are fastened into two or three and fasten the bolts securely with a hexagonal wrench Then use a torque wrench so that the bolts are fastened with tightening torques shown in the table above 2 5 Matching Origins After parts ha...

Page 95: ...oard Joint 1 motor Joint 2 reduction gear unit Joint 1 reduction gear unit Brake release switch Ball screw spline unit Joint 4 motor Cable unit Z belt U1 belt Joint 2 motor Arm cover U2 belt Joint 3 brake Figure G3 301S LED lamp Power cable Signal cable Joint 3 motor G3 1C Cleanroom model with bellows Bellows Gasket Bellows Gasket Heat release sheet Figure G3 301C ...

Page 96: ... Battery board Signal cable Brake release switch LED lamp Ball screw spline unit Arm cover Joint 4 motor Z belt U1 belt U2 belt Joint 2 motor Joint 2 reduction gear Joint 1 reduction gear Joint 1 motor Joint 3 motor Joint 3 motor Figure G3 301SM G3 1CM Cleanroom model with bellows Bellows Gasket Heat release sheet Gasket Figure G3 301CM Bellows ...

Page 97: ...ated 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 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 ...

Page 98: ...v 14 Table Top Mounting Multiple Mounting Arm bottom cover Arm cap Connector plate Connector sub plate Base bottom cover Arm top cover Connector plate Connector sub plate Arm top cover Arm bottom cover Heatsink plate Heatsink plate ...

Page 99: ...m When routing the cables observe the cable locations after removing the cover Be sure to place the cables back to their original locations Arm Top Cover Removal 1 Turn ON the Controller 2 Press and hold the brake release switch to let the shaft down Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joint 3 When the bra...

Page 100: ...ottom cover mounting bolts and then pull the cover downward and remove it The arm bottom cover may not be removed from the shaft because the end effector is installed If it is necessary to remove the cover completely for replacement of the ball screw spline unit etc remove the end effector If it is not necessary to remove the cover completely move the shaft to the lower limit and lower the arm bot...

Page 101: ...m When installing the connector plate be careful not to allow the cables to interfere with the plate mounting and do not bend these cables forcibly to push them into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper fun...

Page 102: ... result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables observe the cable locations after removing the connector sub plate Be sure to place the cables back to their original locations Unscrew the connector sub plat...

Page 103: ...M4 8 Heat release sheet Be careful of the Heat release sheet at the side of the Motor and be sure to keep it Be careful when you mount the Heatsink plate without the Heat release sheet it may cause the malfunction or break by the heat from the Motor 3 8 Base Bottom Cover Unscrew the base bottom cover mounting bolts and remove the cover G3 1C Cleanroom model Truss 4 M4 8 Base bottom cover A base bo...

Page 104: ...N Be sure to connect the cables properly Do not allow unnecessary strain on the cables Do not put heavy objects on the cables Do not bend or pull the cables forcibly The unnecessary strain on the cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper funct...

Page 105: ...Maintenance 4 Cable G3 Rev 14 93 Table Top mounting Cable Unit Figure G3 301S Cable unit Figure G3 301SM Multiple Mounting ...

Page 106: ...y strain on the cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper function of the robot system Cable unit Removal 1 Turn ON the Controller and change the motor to OFF status MOTOR OFF 2 Press and hold the brake release switch to let the shaft down Be ...

Page 107: ...ise the motor will lose position data and the calibration must be executed again Remember the cable layout so that the cables can be reconnected correctly after replacement 8 Cut off one wire tie binding Base side cables 9 Remove the arm top cover For details refer to Maintenance 3 1 Arm Top Cover 10 Remove the Battery board 2 M4 10 Battery board 2 M4 12 11 Loosen the mounting screws for the User ...

Page 108: ...be executed again 13 Disconnect the D sub cable air tubes and connector of the brake release switch from the user plate Mounting screws for the D sub cable are very small Be sure to keep the screws Press the ring on the fitting and pull out the air tube ø6 2 ø4 2 Be sure to observe the connection for connecting the disconnected parts after replacement 14 Remove the mounting screws for the cable un...

Page 109: ...int mount the ground together 6 Connect the connectors Connectors X21 X22 X31 X32 X33 X41 X61 X221 X231 X241 7 Mount the battery board to the Arm 2 8 Remove the spare battery from XB11 9 Mount the connector plate to the base For the details refer to Maintenance 3 4 Connector Plate 10 Mount the connector sub plate to the base For details refer to Maintenance 3 5 Connector Sub Plate 11 Set and secur...

Page 110: ...e 4 Cable 98 G3 Rev 14 4 2 Wiring Diagrams 4 2 1 Signal Cable Cable color Pink Red Violet White Yellow Code P R V W Y Cable color Black Brown Green Blue Orange Code B BR G L O Mounting plate Detail Board Diagram ...

Page 111: ...Maintenance 4 Cable G3 Rev 14 99 4 2 2 Power Cable RC180 Cable color Pink Red Violet White Yellow Code P R V W Y Cable color Black Brown Green Blue Light green Orange Code B BR G L LG O ...

Page 112: ...Maintenance 4 Cable 100 G3 Rev 14 RC700 A RC700DU A Cable color Pink Red Violet White Yellow Code P R V W Y Cable color Black Brown Green Blue Light green Orange Code B BR G L LG O ...

Page 113: ...r B Black R Red BR Brown V Violet G Green W White L Blue Y Yellow The following table shows the types of the use cable Mounting type Arm length Code S C Table Top Mounting 250 mm R13B020023 300 mm R13B020024 350 mm R13B020025 SM CM Multiple Mounting 300 mm R13B020026 350 mm R13B020027 ...

Page 114: ...connection of the connectors may result in improper function of the robot system For details on the connections refer to Maintenance 4 2 Wiring Diagrams When mounting the cover be careful not to allow the cables to interfere with the cover mounting and do not bend these cables forcibly to push them into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or ...

Page 115: ...Maintenance 4 Cable G3 Rev 14 103 Figure G3 301SM Multiple Mounting M C Cable Figure G3 301S Table Top Mounting M C Cable ...

Page 116: ...ue number Each connector has a different shape Do not disconect the battery connector XB10 Otherwise the calibration must be executed M C Cable Installation 1 Connect new M C cable connectors to those of the Cable Unit Connect to the connectors of the Cable Unit with the same number 2 Mount the Connector Sub Plate For details refer to Maintenance 3 5 Connector SubPlate 3 Connect the power cable an...

Page 117: ...forming any replacement 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 when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder will ...

Page 118: ... plate For details refer to Maintenance 3 4 Connector Plate 2 Remove the connector sub plate For details refer to Maintenance 3 5 Connector Sub Plate 3 Disconnect the following connectors Connectors X111 X10 Hold the claw to remove Connector XB10 4 Remove the heatsink plate For details refer to Maintenance 3 7 Heatsink Plate 5 Remove the heat release sheet from the Motor 6 Unscrew and remove the b...

Page 119: ...lange and Joint 1 flange Be sure to keep the oil seal 4 M4 12 Joint 1 Motor unit Oil seal 8 Remove the waveform generator from the Joint 1 motor There is a brass bushing in one of the set screw holes Be sure to keep the bushing 2 M4 6 Set screw M4 Brass bushing Waveform generator Joint 1 motor 9 Remove the motor flange from the Joint 1 motor 4 M5 12 Motor flange Joint 1 motor ...

Page 120: ...ve for the orientation of the waveform generator Be sure to install the waveform generator properly Improper installation of the waveform generator will result in improper function of the Manipulator 4 Mount the motor unit to the Joint 1 flange Mount the oil seal soft metal hole to the mounting hole The motor cable must face the connector plate side If it is difficult to mount the motor push it wh...

Page 121: ...nal wrench width across flats 2 mm 1 For M4 set screw width across flats 2 5 mm 1 For M3 screw width across flats 3 mm 1 For M4 screw width across flats 5 mm 1 For M6 screw Torque wrench M4 1 Tightening torque 6 0 N m 61 2 kgf cm M6 1 Tightening torque 22 0 N m 224 3 kgf cm Nippers 1 Spatula 1 For apply grease Wiping cloth 1 For wiping grease Flange 1 For wiping grease Bolt Screw M4 2 About 20 mm ...

Page 122: ... CAUTION Never adjust loosen or tighten the mounting bolts between the flexspline and cross roller bearing unit If the mounting bolts are adjusted the flexspline and cross roller bearing unit must be aligned by the maker of the reduction gear unit 2 Fit the O rings into the grooves on both sides of the new circular spline Make sure that the rings do not come out of the grooves Convex side Grooves ...

Page 123: ...rely in a crisscross pattern at the torque specified in the table below 16 M3 15 Flange Reduction gear unit Item Bolt type Number of bolts Tightening torque Joint 1 reduction gear unit M3 15 16 3 0 N m 30 6 kgf cm Be careful not to apply too much force since it may damage the parts 6 Apply grease SK 1A inside the flexspline Grease volume 12 g 7 Execute the installation steps 2 to 10 in Maintenance...

Page 124: ...Performing any replacement 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 when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder wi...

Page 125: ...d the brake for the Joint 3 is released simultaneously Be careful of the shaft while the brake release switch is being pressed because the shaft may be lowered by the weight of an end effector 3 Turn OFF the Controller 4 Remove the arm top cover For details refer to Maintenance 3 1 Arm Top Cover 5 Remove the battery board 6 Remove the user plate 7 Cut off the wire tie used for binding the cables c...

Page 126: ...erator from the Joint 2 motor There is a brass bushing in one of the set screw holes Be careful not to lose it 2 M4 6 Set screw M4 Brass bushing Joint 2 motor Waveform generator 12 Remove the motor flange from the Joint 2 motor Motor flange Joint 2 motor 2 M4 10 ...

Page 127: ... figures above for the orientation of the waveform generator Be sure to install the waveform generator properly Improper installation of the waveform generator will result in improper function of the Manipulator 4 Mount the Joint 2 motor unit on Arm 2 The motor flange touches the intermediate pulley and you cannot insert the motor straight on the arm Therefore tip the motor and insert it avoiding ...

Page 128: ... positions with a wire tie removed in the Removal procedure step 7 Do not allow unnecessary strain on the cables 11 Mount the arm top cover For details refer to Maintenance 3 1 Arm Top Cover 12 Perform the calibration of Joint 2 For details refer to Maintenance 14 Calibration ...

Page 129: ...nge 1 For wiping grease Bolt Screw M3 2 For flexspline removal Material Wire tie 4 Grease Grease SK 2 11 g Joint 2 reduction gear unit Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joints 3 When the brak...

Page 130: ... CAUTION Never adjust loosen or tighten the mounting bolts between the flexspline and cross roller bearing unit If the mounting bolts are adjusted the flexspline and cross roller bearing unit must be aligned by the maker of the reduction gear unit 2 Fit the O rings into the grooves on both sides of the new circular spline Make sure that the rings do not come out of the grooves Convex side Grooves ...

Page 131: ... 4 M3 20 O ring Arm 2 Reduction gear unit Arm 1 Item Bolt type Number of bolts Tightening torque Joint 2 reduction gear unit M3 20 10 3 0 N m 30 6 kgf cm Be careful not to apply too much force since it may damage the parts 6 Apply grease SK 2 inside the flexspline Grease volume 8 g 7 Install the O ring to the Arm 1 8 Install and secure the flexspline Slide the Arm 2 to the right left to adjust the...

Page 132: ...Performing any replacement 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 when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder wi...

Page 133: ...rn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joints 3 When the brake release switch is pressed the brake for Joints 3 is released simultaneously Be careful of the shaft while the brake release switch is being press...

Page 134: ...12 Unscrew the screws securing the ball screw spline unit on the upper part of Arm 2 13 Hold up the upper rotator part of ball screw spline unit and the Joint 3 motor unit together 14 Hold the Joint 3 motor up Pass the Z belt through the upper rotator part of ball screw spline and remove the belt 15 Remove the Joint 3 motor from the Joint 3 motor unit Joint 3 motor Bush M5 Set screw 2 M5 8 Pulley ...

Page 135: ...he Z belt of Joint 3 motor unit through the ball screw spline Place the belt around the pulley Make sure that the gear grooves of the belt are fit into those of the pulleys completely Z1 pulley Z belt 4 Move the Joint 3 motor unit and spline upper rotator part downwards together and put them on the Arm 2 upper side Be sure to keep the belt on the pulley 5 Loosely secure the Joint 3 motor unit to A...

Page 136: ...ply the proper tension to the Z belt and secure the Joint 3 motor unit To do so pass a suitable cord or string around the Joint 3 motor unit near its mounting plate Then pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right 3 M4 12 washer Z belt tension 74N 7 5 0 5 kgf Force gauge Joint 3 motor unit 12 Connect the connectors Connectors X2...

Page 137: ...ment procedure following the removal steps from 1 to 3 Z belt Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joint 3 When the brake release switch is pressed the brake for Joint 3 is released simultaneous...

Page 138: ...are fit into those of the pulleys completely 3 M4 12 washer Joint 3 motor unit 3 M4 12 Ball screw spline unit 4 Put the Joint 3 motor unit and the spline upper rotator parts downwards and place them on the Arm 2 upper surface Be sure to keep the belt on the pulley Z1 pulley Z belt 5 Secure the Joint 3 motor unit to Arm 2 so that the open side faces toward the end of the arm Loosely secure the Join...

Page 139: ... times secure the spline plate to Arm 2 9 Apply the proper tension to the U1 belt and then secure the Joint 4 motor unit To do so pass a suitable cord or string around the Joint 4 motor unit near its mounting plate Then pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right 3 M4 12 washer U1 belt tension 74 N 7 5 0 5 kgf Force gauge Joint ...

Page 140: ... the cable connector to fall off by mistake 13 Re bundle the cables in their original positions with a wire tie removed in step 5 Do not allow unnecessary strain on the cables 14 Install the arm top cover and the arm bottom cover For details refer to Maintenance 3 Covers 15 Perform the calibration of Joint 3 and 4 For details refer to Maintenance 14 Calibration ...

Page 141: ...the shaft down to its lower limit before the replacement procedure following the removal steps from 1 to 3 Joint 3 brake Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joint 3 When the brake release switc...

Page 142: ...gned connect the connector X32 Press the brake release switch and release the brake to manually adjust the position 4 Mount the Joint 3 motor unit to Arm 2 so that the open side faces toward the end of the arm For the brake hub mounting procedure refer to the section 7 1 Replacing Joint 3 Motor Joint 3 motor installation Step 3 19 5 Install the arm top cover and the arm bottom cover For details re...

Page 143: ...orming any replacement 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 when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder will c...

Page 144: ...e shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joint 3 When the brake release switch is pressed the brake for Joint 3 is released simultaneously Be careful of the shaft while the brake release switch is being pressed because the shaft may be lowered b...

Page 145: ... the motor unit upward to remove 3 M4 12 washer Joint 4 motor unit 3 M4 12 washer Joint 3 motor unit Joint 4 Intermediate shaft 3 M4 12 washer 10 Remove the pulley from the Joint 4 motor There is a brass bushing in one of the set screw holes Be sure to keep them 2 M4 6 set screw M4 bushing 11 Remove the motor plate from the Joint 4 motor Screw 2 M4 8 ...

Page 146: ... 4 motor unit 3 M4 12 washer Joint 3 motor unit Joint 4 Intermediate shaft 3 M4 12 washer 4 Loosely secure the Joint 4 motor unit to Arm 2 Make sure the motor unit can be moved by hand and it will not tilt when pulled If the unit is secured too loose or too tight the belt will not have the proper tension Also check the gear grooves of the belt are fit into those of the pulleys completely Joint 4 m...

Page 147: ...er plate Set these screws when mounting the user plate 2 M4 5 Battery board 2 M4 12 9 Mount the user plate and ground wire to Arm 2 10 Re bundle the cables in their original positions with a wire tie removed in step 6 Do not allow unnecessary strain on the cables 11 Install the arm top cover and the arm bottom cover For details refer to Maintenance 3 Covers 12 Perform the calibration of Joint 4 Fo...

Page 148: ...eps from 1 to 3 U2 belt Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joint 3 When the brake release switch is pressed the brake for Joint 3 is released simultaneously Be careful of the shaft while the b...

Page 149: ...ews on the Joint 3 motor unit 12 Hold the upper rotator part of ball screw spline and Joint 3 motor up together 3 M4 12 washer Joint 3 motor unit 3 M4 12 Ball screw spline unit 13 Pass the belt through the upper rotator part of spline and hold the Joint 3 motor up and remove the belt 14 Remove the screws securing the Joint 4 intermediate shaft unit Pull the Joint 4 intermediate shaft unit upwards ...

Page 150: ... 12 Ball screw spline unit 3 Place the Joint motor unit and spline rotator part on the Arm 2 top surface Make sure the belt stays on the pulley Z1 pulley Z belt 4 Loosely secure the Joint 3 motor unit to Arm 2 Make sure the motor unit can be moved by hand and it will not tilt when pulled If the unit is secured too loose or too tight the belt will not have the proper tension 5 Place the U1 belt in ...

Page 151: ...t 4 motor unit U2 belt U1 pulley U1 belt U2 pulley 9 Loosely secure the spline plate to Arm 2 After moving the shaft up and down several times secure the spline plate to Arm 2 10 Apply the proper tension to the U2 belt and then secure the Joint 4 intermediate shaft unit To do so pass a suitable cord or string around the Joint 4 intermediate shaft unit near its mounting plate Then pull the cord usi...

Page 152: ...eir original positions with a wire tie removed in step 7 14 Connect the following connectors Connector X231 X241 X31 X32 and X41 15 Connect the backup connectors of Joint 3 and 4 X63 X64 to the battery board Bundle the cables with wire tie to prevent the backup cable connectors from falling off by mistake 16 Mount the battery board to Arm 2 2 M4 5 Battery board 2 M4 12 17 Mount the user plate and ...

Page 153: ...otor with referring to the procedure of Joint 4 motor Removal 1 to 9 3 M4 12 washer Joint 4 motor unit 3 M4 12 washer Joint 3 motor unit Joint 4 Intermediate shaft 3 M4 12 washer 2 Remove the Joint 4 intermediate shaft unit 3 M4 12 plain washer U1 belt 3 Remove the U1 belt ...

Page 154: ... of the belt are fit into those of the pulleys completely 3 M4 12 washer Joint 4 motor unit 3 M4 12 washer Joint 3 motor unit Joint 4 intermediate shaft 3 M4 12 washer 4 Loosely secure the Joint 4 motor unit to Arm 2 Make sure the motor unit can be moved by hand and it will not tilt when pulled If the unit is secured too loose or too tight the belt will not have the proper tension Joint 4 motor un...

Page 155: ...motor unit 7 Connect the connector Connector X241 X41 8 Re bundle the cables in their original positions with a wire tie removed in step 9 9 Connect the backup connectors of Joint 4 X64 to the battery board Bundle the cables with wire tie to prevent the backup cable connectors from falling off by mistake 10 Mount the battery board to Arm 2 2 M4 5 Battery board 2 M4 12 11 Mount the user plate and g...

Page 156: ...ug 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 CAUTION Be careful not to apply excessive shock to the motor shaft when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassem...

Page 157: ...ple Mounting Standard arm 300 mm 1 Arm 1_M_30ST R12B031919 350 mm 1 Arm 1_M_35ST R12B031920 Curved arm 350 mm 1 Arm 1_M_35B R12B031921 Tools Hexagonal wrench width across flats 2 5 mm 1 For screw M3 Torque wrench 1 Flathead screwdriver 1 When changes the arm length it requires the other cable unit for the new arm length Right Left curved arm have the shared maintenance parts CAUTION Replacing Arm ...

Page 158: ...m 2 unit Do not allow unnecessary strain on the cables For Multiple mounting removal direction of Joint 1 and 2 is the same In this procedure remove the only screws on the left side of figure Table Top mounting Multiple mounting 8 M3 35 Washer 4 M3 20 Washer Arm 2 unit 8 M3 35 Washer 4 M3 20 Washer 3 Remove the O ring on the part where Arm 2 was mounted 4 Remove the Arm 1 covet and hose elbow Thes...

Page 159: ...ove the Arm 1 unit In case of Multiple mounting type Arm 1 falls without mounting screws Support Arm 1 when removing the screws Remove the O ring which is attached to the Joint 1 mounting part Table Top mounting Multiple mounting 8 M3 35 Washer 4 M3 20 Washer Arm 1 unit 8 M3 35 Washer 4 M3 20 Washer Arm 1 unit ...

Page 160: ...to the O ring Fit with the space for the screws head of harmonic drive on Arm 1 side 3 Put washer on screws and mount the Arm 1 unit with specified torque M3 tightening torque 3 0 N m 30 6 kgf cm Use 35 mm screws to all side and the middle one in each side is 20 mm Do not use the screws of different length Otherwise it causes a malfunction Table Top mounting Multiple mounting 8 M3 35 Washer 4 M3 2...

Page 161: ...ng Multiple mounting 8 M3 35 Washer 4 M3 20 Washer Arm 2 unit 8 M3 35 Washer 4 M3 20 Washer 7 Mount the hose elbow and Arm 1 cover These parts are not attached to the Multiple mounting Manipulators Hose elbow Arm 1 cover 8 Put the θ2 movement direction label to the end of Arm 1 in Arm 2 side CAUTION After replacing the arm do not fail to change the robot model in the software If the model is diffe...

Page 162: ...be used with the amplifiers currently in the controller are listed When using Dry Run all robot models are shown in the list 9 4 Click the Apply button to save settings 9 5 Click on Robot Configuration in the tree to open the Robot Configuration page 9 6 Type in a name for the new robot and enter the serial number from the robot s nameplate Any serial number can be used but it is recommended that ...

Page 163: ...se from the Motion System dropdown list If there are no other motion systems installed then Standard will already be selected 9 6 Select a Drive Unit for your robot from the Drive Unit dropdown list 9 7 Select a robot type from the Robot type box 9 8 Select a robot series from the Series dropdown list 9 9 Select a robot model from the Model dropdown list After you select a robot model all robots a...

Page 164: ...no other motion systems installed then Standard will already be selected 9 6 Select a Drive Unit for your manipulator from the Drive Unit dropdown list 9 7 Select a manipulator type from the Robot type box 9 8 Select a manipulator series from the Series dropdown list 9 9 Select a manipulator model from the Model dropdown list After you select a manipulator model all manipulators available for the ...

Page 165: ...or take the necessary countermeasures to prevent dust emission before removing the bellows Name Quantity Note Maintenance parts Bellows 120 mm 1 R13B030704 Tools Cross point screwdriver 1 For clamp band removal Bellows Clamp band Bellows Clamp band Bellows Removal 1 Remove the end effector 2 Remove the wires and tubes from the end effector 3 Turn ON the controller Stop motor excitation MOTOR OFF 4...

Page 166: ...of the bellows The bellows has two joints The larger joint must be attached to the cover side The smaller joint must be attached to the end face side of the shaft Attach the mounting part of the bellows until the end touches the cylindrical part of the cover Then secure them with clamp bands Upper bellows cover side Bottom bellows cover side 4 Secure the end face side of the bellows to the shaft C...

Page 167: ...ult in electric shock and or malfunction of the robot system After parts have been replaced motors reduction gear units brakes timing belts ball screw spline unit etc the Manipulator cannot operate properly because a mismatch exists between the origin stored in each motor and its corresponding origin stored in the Controller After replacing the parts it is necessary to match these origins The proc...

Page 168: ...he upper part of the shaft directly fill the grooves on it by hand Wipe off excess grease from the shaft 6 Turn ON the Controller 7 Move the shaft to its lower limit by hand while pressing the brake release switch 8 Wipe off the old grease from the lower part of the shaft and then apply new grease to it When applying the new grease to the lower part of the shaft directly fill the grooves on it by ...

Page 169: ...h grease by hand Wipe off excess grease from the shaft 6 Shaft 7 Clamp band Lower Part of the Shaft 7 Loosen the clamp band on the bellows and then move the bellows downward 8 Move the shaft to its lower limit manually while pressing the brake release switch 9 Wipe off the old grease from the lower part of the shaft and then apply new grease to it Directly fill the grooves on the shaft inside the ...

Page 170: ...nly for Cleanroom model Force gauge 1 Belt tension 98 N 10 kgf 74 N 7 5 kgf Suitable cord Length about 1000 mm 1 For belt tension Wiping cloth 1 For wiping grease Spline shaft Material Wire tie 2 Ball screw spline unit Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting a...

Page 171: ...e the motor unit by pulling it up Remove the bolts securing the Joint 4 motor unit 3 M4 12 washer Joint 4 motor unit 3 M4 12 washer Joint 2 motor unit Joint 4 intermediate shaft 3 M4 12 washer 11 Remove the screws securing the ball screw spline of Arm 3 surface 12 Remove the screws securing the Joint 3 motor unit 3 M4 12 washer Joint 3 motor unit 3 M4 12 Ball screw spline unit 13 Hold the rotator ...

Page 172: ...nit Remove the unit by pulling it up 3 M4 12 plain washer 16 Remove the U2 belt 17 Hold the spline upper rotator part Remove the U2 belt U2 belt 18 Remove the mounting screws of the ball screw spline shaft on the lower part of Arm 2 4 M4 10 19 Remove the ball screw spline unit by pulling it upward from Arm 2 ...

Page 173: ...he procedure refer to Maintenance 8 Arm 4 8 2 Replacing the Timing Belt U2 belt installation 4 Grease the shaft For details refer to Maintenance 11 1 Greasing the Ball Screw Spline Unit 5 Install the arm top cover and arm bottom cover For details refer to Maintenance 3 Covers 6 Turn OFF the Controller and peripheral equipment 7 Install the end effector and connect wires and tubes 8 This step is on...

Page 174: ...osion or inflammation and may cause serious safety problems Improper Handling Battery Charge Disassembly Incorrect Installation Exposing to Fire Forced Discharge Deformation by Pressure Short circuit Polarity Positive Negative Heating 85 C or more Soldering the terminal of the lithium battery directly When disposing of the battery consult with the professional disposal services or comply with the ...

Page 175: ...nual Robot Controller RC180 Appendix Alarm The battery may run out if it passes the recommended replacement time If no warnings of voltage reduction occur the calibration for all joints is not necessary You need to perform calibration if the position moves from the originals after replaced the battery Always use the lithium battery and battery board designated by us Refer to Maintenance 15 Mainten...

Page 176: ...f the new battery before disconnecting the old battery If the current battery is disconnected before connecting the new one the robot will lose the origin position data and the calibration must be executed again X60A Battery board X60B Wire tie 5 Cut off the wire tie banding the lithium battery and remove the lithium battery Lithium battery battery unit Battery board 6 Cut off the wire tie banding...

Page 177: ...roller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch affects only Joint 3 When the brake release switch is pressed the brake for Joint 3 is released simultaneously Be careful of the shaft while the brake release switch is being pressed because the s...

Page 178: ...rd 2 M4 12 2 Connect the connectors Connectors X61 X62 X63 X64 Battery board X61 X62 X63 X64 3 Fix the connector cable with wiring tie Refer to Removal step 4 4 Mount the arm top cover For details refer to Maintenance 3 1 Arm Top Cover 5 Turn ON the Controller 6 Perform the calibration of all joints For details refer to Maintenance 14 Calibration ...

Page 179: ... is extremely hazardous and may result in electric shock and or malfunction of the robot system Name Quantity Note Maintenance parts LED Lamp 1 R13A030000200 Tools Cross point screwdriver 1 For wire removal Nippers 1 Material Wire tie 1 LED Lamp Removal 1 Remove the arm top cover For details refer to Maintenance 3 1 Arm Top Cover 2 Remove the user plate from the Arm 2 cover 3 Disconnect the X1 and...

Page 180: ...hat no one is inside the safeguarded area The robot system can be operated in the mode for teaching even when someone is inside the safeguarded area The motion of the Manipulator is always in restricted low speeds and low power status to secure the safety of an operator However operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious ...

Page 181: ... Left Arm Orientations to accurately calibrate Joint 2 For details refer to Maintenance 14 3 Accurate Calibration of Joint 2 When calibrating Joint 4 you must calibrate Joint 3 and 4 at the same time You cannot calibrate Joint 4 alone because of the structure of the Manipulator If Err9716 or 5016 Power supply failure of the absolute encoder Replace the battery Check the robot internal wiring occur...

Page 182: ...ot Calibration Only selected robot can be calibrated iii Select the joint and click the Calibrate button 2 Confirm the warning message and click the Yes button 3 Move the joint to calibrate manually to approximate 0 pulse position as shown in the dialog After moving the joint click the Next button NOTE EPSON RC 7 0 ...

Page 183: ... 2 are in a straight line Regardless of the Joint 1 direction 0 pulse 0 pulse position of Joint 3 upper limit position in motion range The height of Joint 3 depends on manipulator model Standard model Cleanroom model 0 pulse position of Joint 4 position where the flat surface or groove in the up down mechanical stop on the shaft faces toward the tip of Arm 2 Groove Flat surface 0 pulse ...

Page 184: ...hen the Controller starts up 5 Reboot the Controller This window will disappear when the Controller starts up 6 Select the reference point to use for calibration and click the Next button Select a point from the current points to use for checking the accuracy 7 Click the Jog button to display the Jog Teach dialog ...

Page 185: ... Rev 14 173 8 Jog the end effector to approximate reference point in the Jog Teach dialog for rough calibration Then click the OK button Before operating the robot open the Jog Teach tab and execute Motor ON 9 Click the Next button ...

Page 186: ...he manipulator moves to the reference point Click the Execute button Input JUMP P0 z 0 Point selected in step 6 11 Confirm the message and click the Yes button 12 After the manipulator moves to the reference point click the Next button JUMP P0 z 0 ...

Page 187: ...v 14 175 13 Jog to the accurate reference position 14 Jog the end effector to approximate reference point in the Jog Teach dialog for rough calibration Then click the OK button Position Joint 2 only and move Joint 3 to around 0 pulse ...

Page 188: ...ure in Calibration Using Right Left Arm Orientations to accurately calibrate Joint 2 Go on to the step 17 for the other joints calibration i Move to another point that has different pose from righty to lefty using Jump command Click the Yes button ii Jog to the accurate reference position ...

Page 189: ...Maintenance 14 Calibration G3 Rev 14 177 iii Jog to the accurate reference position and adjust the position Click the OK button iv Click the Next button ...

Page 190: ...aintenance 14 Calibration 178 G3 Rev 14 17 Calibration is complete Click the Finish button 18 Move the manipulator to other points and check if it can move without problems Teach points where appropriate ...

Page 191: ...ight figure and attach it on the end of the shaft to make the center of the shaft clear Decide a target point and mark a cross on it so that you can easily verify the center of the shaft after switching the arm pose between right and left Calibration jig at the end of the shaft Example Target point The center of the shaft After removing the end effector and performing the calibration install the e...

Page 192: ...from right to lefty click the Free All in the Control Panel and change the arm orientation to lefty by hands Then go to the step 6 7 8 The joints are slightly out of position Adjust the gap with the Z in the Jogging group in the Jog Teach Then teach another point data number unused This pose point is now called P2 Specify point number P2 and click the Teach button in Jog Teach 9 Input the new Hofs...

Page 193: ...the same time The reference point a point to identify the position of the manipulator needs to be specified for calibration Follow steps 1 to 6 described below in order to calibrate the origin 1 Basic Pose Confirmation 1 1 After the part replacement perform the calibration using the point data currently registered Confirm the point data number P to reconstruct the correct manipulator position Poin...

Page 194: ...nge The height of Joint 3 depends on manipulator model Standard model Cleanroom model 0 pulse position of Joint 4 position where the flat surface or groove in the up down mechanical stop on the shaft faces toward the tip of Arm 2 Groove Flat surface 0 pulse 3 3 Connect EPSON RC to the Controller Select the robot to be calibrated Input as below in the Command Window and execute This example uses ro...

Page 195: ... 0 Manipulator does not move 4 2 Execute one of the following commands according to the joint you want to calibrate from the menu Tools Command Window Joint 1 calib 1 Joint 2 calib 2 Joint 3 calib 3 Joint 4 calib 3 4 5 Calibration Accurate Positioning 5 1 Turn ON the motors from the EPSON RC menu Tools Robot Manager Control Panel 5 2 Click the Free All button to free all joints from servo control ...

Page 196: ... the position when calibrating Joint 4 Select the jog mode Joint from Jog Teach to execute the jog motion 5 7 Execute the calibration Enter and execute one of the following commands in Command Window according to the joint being calibrated Joint 1 Calib 1 Joint 2 Calib 2 Joint 3 Calib 3 Joint 4 Calib 3 4 6 Accuracy Testing 6 1 Move the Manipulator to another point to confirm that it moves to the s...

Page 197: ...RC180 R12B020433 For RC700 A Straight R12NZ900KC For RC700 A L shaped R12NZ900KF AC Servo Motor Joint 1 R13B000614 200 W 5 1 Joint 2 3 4 R13B000615 150 W 6 1 7 1 8 1 Reduction Gear Unit Joint 1 R13B010016 5 2 Joint 2 R13B010017 6 2 Solenoid Brake Z axis R13B030501 7 3 Timing Belt Joint 3 R13B030213 Z 7 2 Joint 4 R13B030214 U1 8 2 R13B030215 U2 8 2 O ring Joint 1 R13A030700200 5 2 Joint 2 R13A03070...

Page 198: ...he operation hours can be checked in Controller Status Viewer dialog Motor On Hours For details refer to Maintenance 2 2 Overhaul Parts Replacement 2 Regarding purchase of grease Due to the chemicals regulations of individual countries the UN GHS we are requesting our customers to purchase grease required for maintenance from the manufacturers listed in the table below as of April 2015 Regarding p...

Page 199: ...ails refer to Maintenance 2 2 Overhaul Parts Replacement 15 2 2 C Cleanroom model Part Name Code Note Reference Maintenance Overhaul 1 Ball Screw Spline 120 mm R13B010221 11 1 2 Arm Cover R13B030422 Plating 3 1 Bellows R13B030704 2 10 Gasket Unit R13B031234 3 1 As a rough indication perform the overhaul parts replacement before reaching 20 000 operation hours of the Manipulator The operation hours...

Page 200: ...Maintenance 15 Maintenance Parts List 188 G3 Rev 14 ...

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