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Maintenance 10. Ball Screw Spline Unit

138

LS10-B Rev.6

10. Ball Screw Spline Unit

WARNING

■

Do not connect or disconnect the motor connectors while the power to the robot

system is turned ON. Connecting or disconnecting the motor connectors with

the power ON is extremely hazardous and may result in serious bodily injury as

the Manipulator may move abnormally, and also may result in electric shock

and/or malfunction of the robot system.

■

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

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

DO NOT connect it directly to a factory power source.

■

Before performing any replacement procedure, turn OFF the Controller and

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

Performing any replacement procedure with the power ON is extremely hazardous

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

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 process of aligning the two origins is called “Calibration”.
Refer to

Maintenance: 13. Calibration

to perform the calibration.

10.1 Greasing the Ball Screw Spline Unit

Name

Qty.

Note

Grease

For Ball Screw Spline Unit
(AFB grease)

Proper

quantity

Tools

Wiping cloth

1

For wiping grease
(Spline shaft)

Cross-point screwdriver

1

For clamp band removal
Only for Cleanroom-model

The brake release switch affects both Joints #3 and #4. When the brake release switch is

pressed in emergency mode, the brake for both Joints #3 and #4 are released simultaneously.
Be careful of the shaft falling and rotating while the brake release switch is pressed because the
shaft may be lowered by the weight of an end effector.



NOTE



NOTE

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Summary of Contents for LS10-B

Page 1: ...Rev 6 EM204R4257F SCARA ROBOT LS10 B series MANIPULATOR MANUAL ...

Page 2: ...MANIPULATOR MANUAL LS10 B series Rev 6 ...

Page 3: ...LS10 B Rev 6 i SCARA ROBOT LS10 B series Manipulator Manual Rev 6 Copyright 2018 2020 SEIKO EPSON CORPORATION All rights reserved ...

Page 4: ...warranty 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 d...

Page 5: ...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 CONTACT INFORMATION Contact information is described in SUPPLIERS in the first pages of the following manual R...

Page 6: ...e or the retailer 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 ...

Page 7: ...e of Motors The shape of the motors used for the Manipulator that you are using may be different from the shape of the motors described in this manual because of the specifications Setting by Using Software This manual contains setting procedures by using software They are marked with the following icon Figures in this Manual The figures of manipulators indicated in this manual are basically Stand...

Page 8: ...vi LS10 B Rev 6 ...

Page 9: ...odel 22 3 Environments and Installation 23 3 1 Environmental Conditions 23 3 2 Base Table 24 3 3 Mounting Dimensions 25 3 4 Unpacking and Transportation 26 3 5 Installation Procedure 27 3 5 1 Standard Model 27 3 5 2 Cleanroom Model 28 3 6 Connecting the Cables 28 3 7 User Wires and Pneumatic Tubes 30 3 8 Relocation and Storage 31 3 8 1 Precautions for Relocation and Storage 31 3 8 2 Relocation 32 ...

Page 10: ...al Maintenance 58 2 1 Maintenance Inspection 58 2 1 1 Schedule for Maintenance Inspection 58 2 1 2 Inspection Point 59 2 2 Overhaul Parts Replacement 60 2 3 Greasing 62 2 4 Tightening Hexagon Socket Head Cap Bolts 63 2 5 Matching Origins 63 2 6 Layout of Maintenance Parts 64 3 Covers 65 3 1 Arm Top Cover 66 3 2 Arm Bottom Cover 67 3 3 Connector Plate 67 3 4 Connector Sub Plate 69 3 5 User Plate 70...

Page 11: ... 3 Replacing the Brake 132 8 4 Checking the Timing Belt Tension U1 U2 Belts 135 9 Bellows 136 10 Ball Screw Spline Unit 138 10 1 Greasing the Ball Screw Spline Unit 138 10 1 1 Standard model 139 10 1 2 Cleanroom model 140 10 2 Replacing the Ball Screw Spline Unit 141 11 Boards 144 11 1 Replacing the Converter Board 145 11 2 Replacing the Control Board 147 12 LED Lamp 148 13 Calibration 149 13 1 Ab...

Page 12: ...TABLE OF CONTENTS x LS10 B Rev 6 ...

Page 13: ...Setup Operation This volume contains information for setup and operation of the LS10 B series Manipulators Please read this volume thoroughly before setting up and operating the Manipulators ...

Page 14: ......

Page 15: ...rations 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 i...

Page 16: ...t 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 design...

Page 17: ...rew 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 M 50 000 N mm Moment M F L 100 200 20 000 N mm Example If 100 N 10 2kgf load is applied at 200 mm from the end of...

Page 18: ...e 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 Continuing the operation while the Manipulator moves abnormally is extremely hazardous and may result in serious bodily injur...

Page 19: ...ngs 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 LS10 B 50 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 2...

Page 20: ...ife 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 restoration Whether or not the reduction gear is damaged Whether or not the joints are in their proper positions If there is a position gap perform calibration ...

Page 21: ...ctor Weight setting Weight of work piece Speed setting Operating pose Accel setting Conditions for Measurement LS10 B Accel Setting 100 Speed Setting 100 Load kg 10 Weight Setting 10 Joint 1 Stop point Point where the emergency stop signal is input Target point Start point of operation Joint 2 Controller RC90 B Manipulator LS10 B60 LS10 B70 LS10 B80 Free running time Joint 1 Joint 2 sec 0 7 0 9 0 ...

Page 22: ...t 4 The shaft cannot be rotated by hand until the electromagnetic brake applied to the shaft has been released Move the shaft while pressing the brake release switch Joint 3 4 brake release switch Joint 1 rotating Joint 2 rotating Joint 3 up and down Joint 4 rotating Arm 1 Arm 2 Shaft Figure LS10 B702S The brake release switch affects both Joints 3 and 4 When the brake release switch is pressed in...

Page 23: ...the ball screw spline Example Maximum value of ACCELS is corrected automatically depending on the Z axis height The following is an example of values which are corrected per 100mm Z axis height Maximum ACCELS correction values by Z axis height and tip load Z axis height mm Tip load 3kg 6kg 10kg Z 0 25000 or less 25000 or less 25000 or less Z 100 18000 or less Z 200 18000 or less 11000 or less Z 30...

Page 24: ...re loosening the base mounting screws hold the arm and secure it tightly with a band to prevent hands or fingers from being caught in the Manipulator B Do not enter the operation area while the Manipulator is moving The robot arm may collide against the operator This is extremely hazardous and may result in serious safety problems C Hazardous voltage exists while the Manipulator is ON To avoid ele...

Page 25: ...Setup Operation 1 Safety LS10 B Rev 6 13 LS10 B Figure LS10 B702S ...

Page 26: ...ves the tact time of long range movements by readjusting the highest speed It improves the tact time of delicate movements by acceleration deceleration speed optimized for each payload and stop short technology Ethernet connector for camera cable is equipped by default Ethernet connector is equipped on 2 arm and base of the manipulator by default Easier to equip a camera option Vision Guide than t...

Page 27: ...s 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 Models Payload Arm length Environment Joint 3 stroke Model Number 10 kg 600 mm Standard 200 mm LS10 B602S 300 mm LS10 B603S Cleanroom 170 mm LS10 B602C 270 mm LS10 B603C 700 mm Standard 200 mm LS10 B702S 300 mm LS10...

Page 28: ...6 mm pneumatic tube User connector 15 pin D sub connector Ethernet connector The brake release switch affects both Joints 3 and 4 When the brake release switch is pressed in emergency mode the brakes for both Joint 3 and Joint 4 are released simultaneously While the LED lamp is on current is being applied to the manipulator Performing any work with the power ON is extremely hazardous and it may re...

Page 29: ... LS10 B Rev 6 17 LS10 B S Standard Model LS10 B602S LS10 B702S LS10 B802S LS10 B603S LS10 B703S LS10 B803S a 225 325 425 225 325 425 b 577 577 577 677 677 677 c 200 200 200 300 300 300 d 53 53 53 153 153 153 e 565 580 580 565 580 580 ...

Page 30: ...ons 18 LS10 B Rev 6 2 3 2 Cleanroom Model LS10 B C The following figures show the additional parts and specifications for Cleanroom model when compared with the Standard model in appearance Upper bellows Lower bellows Exhaust port ...

Page 31: ... LS10 B Rev 6 19 LS10 B C Cleanroom Model LS10 B602C LS10 B702C LS10 B802C LS10 B603C LS10 B703C LS10 B803C a 225 325 425 225 325 425 b 627 627 627 727 727 727 c 170 170 170 270 270 270 d 53 53 53 153 153 153 e 565 580 580 565 580 580 ...

Page 32: ...s 23 kg 50 7lbs Driving method All joints AC servo motor Motor rated capacity Joint 1 520 W Joint 2 520 W Joint 3 200 W Joint 4 150 W Option Installation environment Cleanroom 3 Joint 3 down force 200 N Installed wire for customer use 15 15 pin D sub Equivalent to 8 pin RJ45 Cat 5e Installed pneumatic tube for customer use 2 pneumatic tubes ø6 mm 0 59 MPa 6 kgf cm2 86 psi 1 pneumatic tube ø4 mm 0 ...

Page 33: ... the outer part of the arm which can cause increased dust emission Cleanliness level Class ISO 4 ISO14644 1 Exhaust System Exhaust port diameter Inner diameter ø12 mm Exhaust tube Polyurethane tube Outer diameter ø12 mm Inner diameter ø8 mm Recommended exhaust flow rate approx 1000 cm3 s Normal 4 Conditions of Manipulator during measurement as follows Operating conditions Under rated load 4 joints...

Page 34: ...lt 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 the custom ...

Page 35: ...f your region 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 contact the supplier of your region Rapid cha...

Page 36: ...ed holes 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 ...

Page 37: ...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 covers and plates for maintenance Space for cables The minimum bend radius of the power cable is 90 mm When installing the cable be sure to maintain sufficient distance from obstacl...

Page 38: ...he Manipulator can fall Be careful not to 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 ...

Page 39: ...r 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 LS10 B60 approx 22 kg 48 5 lbs LS10 B70 approx 22 kg 48 5 lbs LS10 B80 approx 23 kg 50 7 lbs 1 Secure the base to the base table with four bolts Use bolts with specifications conforming to ISO898 1 Property Class 10 9 or 12 9 Tightening torque 32 0 N m 326 kgf cm 1...

Page 40: ...source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Be sure to connect the cables properly Do not allow unnecessary strain on the cables Do not put ...

Page 41: ...details on the connection refer to the Controller manual When the Manipulator is a Cleanroom model be aware of the followings For the Manipulator of Cleanroom model use it with an exhaust system For details refer to Setup Operation 2 4 Specifications Cable Connections Connect the power cable and the signal connector of the M C cable to the Controller as shown below Signal connector Power connector...

Page 42: ... 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 ø 6 mm ø 4 mm 1 ø 4 mm ø 2 5 mm Fittings for ø6 mm and ø4 mm outer diameter pneumatic tubes are supplied on both ends of the pneumatic tubes Fitting bl...

Page 43: ...ght To carry the Manipulator have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the shaded area bottom of Arm 1 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 LS10 B60 approx 22 kg 48 5 lbs LS10 B70 approx 22 kg 48 5 lbs LS10 B80 approx 23 kg 50 7 lbs Stabilize the Man...

Page 44: ...s LS10 B80 approx 23 kg 50 7 lbs 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 that the arm will not be damaged Refer to the following figure and fix the arm Wire tie B...

Page 45: ...chanical stop on the lower side of the shaft Otherwise when Jump motion is performed the upper limit mechanical stop may hit 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 and 4 cannot be moved up down by hand because the electromagnetic brake is applied to the j...

Page 46: ...uter diameter of the end effector the size of the work piece or the position of the arms When designing your system layout pay attention to the interference area of the end effector 4 2 Attaching Cameras and Valves The bottom of the Arm 2 has threaded holes as shown in the figure below Use these holes for attaching cameras valves and other equipment Unit mm From base installation surface ...

Page 47: ...ector and the workpiece must not exceed 10 kg The LS10 B series Manipulators are not designed to work with loads exceeding 10 kg Always set the Weight parameters according to the load Setting a value that is smaller than the actual load may cause errors excessive shock and insufficient function of the Manipulator Also the life cycle of parts will shorten and belt tooth jumping will occur which wil...

Page 48: ...ter of gravity of camera etc Example A 1 kg camera is attached to the end of the LS10 B series arm 475 mm away from the rotation center of Joint 2 with a load weight of 1 kg M 1 L2 375 LM 475 WM 1 4752 3752 1 604 1 7 round up W WM 1 1 7 2 7 Enter 2 7 for the Weight Parameter Shaft Weight of camera M 1kg W 1kg L2 375 mm LM 475 mm Joint 2 Automatic speed setting by Weight 140 120 100 80 60 40 20 0 2...

Page 49: ...l objects such as an end effector attached to the shaft the moment of inertia of load must be considered CAUTION The moment of inertia of the load weight of the end effector and workpiece must be 0 30 kg m2 or less The LS10 B series Manipulators are not designed to work with a moment of inertia exceeding 0 30 kg m2 Always set the Weight parameters according to the load Setting a value that is smal...

Page 50: ... into the Load inertia text box on the Inertia panel Tools Robot Manager You may also execute the Inertia command from the Command Window Automatic acceleration deceleration setting of Joint 4 by Inertia moment of inertia 0 0 05 0 1 0 15 0 2 0 25 0 3 kg m2 Moment of inertia setting 120 100 80 60 40 20 113 60 30 10 100 Moment of inertia setting kg m2 Automatic acceleration deceleration setting of J...

Page 51: ...oad in LS10 B series is 0 mm at the default rating and 200 mm at the maximum When the eccentric quantity of load exceeds the rating change the setting of eccentric quantity parameter of Inertia command After the setting is changed the maximum acceleration deceleration speed of the Manipulator at PTP motion corresponding to the eccentric quantity is set automatically Position of load s center of gr...

Page 52: ...ter mm Automatic acceleration deceleration setting by Inertia eccentric quantity 0 100 50 60 100 26 200 15 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 Workpiece b Workpiece c End effector a Joint 3 shaft R...

Page 53: ...of inertia using the basic formulas a Moment of inertia of a rectangular parallelepiped h b L m Rectangular parallelepiped s center of gravity Rotation center m m L2 b2 h2 12 b Moment of inertia of a cylinder m m L2 r 2 2 m L r Cylinder s center of gravity Rotation center c Moment of inertia of a sphere m r 2 m L2 2 5 Sphere s center of gravity r m L Rotation center ...

Page 54: ...sition of Joint 3 for the Manipulator 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 Figures on the graph are the proportion to the acceleration deceleration speed at the shaft upper limit posi...

Page 55: ... 5 1 through 5 3 to set the range 5 1 Motion Range Setting by Pulse Range 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 be ...

Page 56: ...ive and the clockwise pulse value is defined as the negative Y X 0 pulse B B A A A Max Motion Range B Max Pulse Range LS10 B 132 152918 808278 pulse 5 1 2 Max Pulse Range of Joint 2 The 0 zero pulse position of Joint 2 is the position where Arm 2 is in line with Arm 1 With the 0 pulse as a starting point the counterclockwise pulse value is defined as the positive and the clockwise pulse value is d...

Page 57: ...pulse 300 mm 405504 pulse LS10 B C Cleanroom model 170 mm 229786 pulse 270 mm 364954 pulse For the Cleanroom model 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 counterclockwis...

Page 58: ...ng to the angle for the mechanical stop settings Install the bolts in the holes corresponding to the angle that you want to set Joints 3 can be set to any length less than the maximum stroke Mechanical stop of Joint 2 Fixed Mechanical stop of Joint 1 Adjustable Mechanical stop of Joint 3 Lower limit mechanical stop Do not move the position of upper limit mechanical stop Mechanical stop of Joint 1 ...

Page 59: ...top settings Install the bolts in the holes corresponding to the angle that you want to set Install the bolts for the mechanical stop to the following position Views from the bottom of Arm 1 a b Joint 1 Mechanical Stops a b LS10 B Setting Angle 115 115 Pulse Value pulse 746382 91022 Views from the top of Arm 1 b a Joint 2 Mechanical Stops a b LS10 B Setting Angle 125 125 Pulse Value pulse 284444 2...

Page 60: ... 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 LS10 B602S The angle of Joint 1 is set from 110 to 110 The angle of Joint 2 is set from 110 to 110 Execute the following commands from the Command Window MOTOR ON Turns ON the motor POWER LOW Enters low power mode SPEE...

Page 61: ... by hand while pressing the button 3 Turn OFF the Controller 4 Loosen the lower limit mechanical stop screw set screws 2 M5 6 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 ...

Page 62: ...f Joint 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 t...

Page 63: ...et the upper and lower limits of the X and Y coordinates This setting is only enforced by software Therefore it does not change the physical range The maximum physical range is based on the position of the mechanical stops Set the XYLim setting on the XYZ Limits panel shown by selecting Tools Robot Manager You may also execute the XYLim command from the Command Window EPSON RC ...

Page 64: ... the Area limited by mechanical stop and radius of the end effector The total value is specified as the maximum area A Center of Joint 3 B Motion range C Maximum range D Base mounting face E Area limited by a mechanical stop LS10 B60 LS10 B70 LS10 B80 a Arm 1 Arm 2 length mm 600 700 800 b Arm 1 length mm 225 325 425 c Arm 2 length mm 375 d Joint 1 motion angle 132 e Joint 2 motion angle 150 f Moti...

Page 65: ...Setup Operation 5 Motion Range LS10 B Rev 6 53 Standard model LS10 B S ...

Page 66: ...Setup Operation 5 Motion Range 54 LS10 B Rev 6 Cleanroom model LS10 B C ...

Page 67: ...Maintenance This volume contains maintenance procedures with safety precautions for LS10 B series Manipulators ...

Page 68: ......

Page 69: ...rses 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 ...

Page 70: ...ng 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...

Page 71: ...hten External connectors on Manipulator on the connector plates etc Manipulator cable unit Visually check for external defects Clean up if necessary External appearance of Manipulator External cables Check for bends or improper location Repair or place it properly if necessary Safeguard etc Check tension of timing belts Tighten it if necessary Inside of Arm 2 Grease conditions Refer to Maintenance...

Page 72: ...ts parts replacement The time between overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on usage condition and degree of the load such as when operated with the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator Recommended replacement time for the parts subject to maintenance motors...

Page 73: ... Controller Status 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 For the parts subject to overhaul refer to Maintenance 14 Maintenance Parts List For details of replacement of each part refer to the Maintenance section Please contact the suppli...

Page 74: ...nterval Grease Refer to Maintenance Joint 1 Reduction gear units Overhaul timing SK 1A 5 Joint 1 Joint 2 SK 1A 6 Joint 2 Joint 3 Ball screw spline unit At 100 km of operation 50 km for first greasing AFB 10 Greasing the Ball Screw Spline Unit Joint 1 2 reduction gear units As a rough indication perform greasing at the same timing as overhaul However it may vary depending on usage condition and deg...

Page 75: ...ference should be 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 Orig...

Page 76: ... Joint 4 motor Z belt U2 belt U1 belt Joint 2 motor Joint 2 reduction gear unit Joint 1 reduction gear unit Joint 1 motor Joint 3 motor Figure LS10 B602S Control board Arm Bottom Cover Joint 4 brake Intermediate pulley Converter board Cleanroom model with optional bellows For the Cleanroom model the following parts are added to the Standard model Bellows Bellows Clamp Band Figure LS10 B602C Clamp ...

Page 77: ... sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot...

Page 78: ...er function of the robot system 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 Unscrew the Arm Top Cover mounting bolts and then lift the cover When bellows are installed to the manipulator remove the upper bellows and then remove the Arm Top Cover For bellows removal refer to Maintenan...

Page 79: ...ve the connector plate forcibly Removing the connector plate forcibly 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 When mounting the connector plate be careful not to allow the cables to interfere with the plate mounting and...

Page 80: ...revent the air tube from bending sharply inside the manipulator Also do not block the air flow If there is a kink in the air tube air flow is blocked while the manipulator is operating and may cause a trouble Put the air tube along the left side wall as shown in the picture GOOD Curved BAD Bended NOTE ...

Page 81: ...ith 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 function of the robot system When routing the cables observe the cable locations after rem...

Page 82: ...m Top Cover Refer to Maintenance 3 1 Arm Top Cover 2 Unscrew the User Plate mounting bolts and remove the plate 2 M4 10 User Plate User Plate Installation 1 Put the User Plate to the arm and secure using the mounting bolts 2 Mount the Arm Top Cover Refer to Maintenance 3 1 Arm Top Cover ...

Page 83: ...nect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous...

Page 84: ...cessary Name Qty Note Maintenance parts Cable unit 1 LS10 B60 2196931 LS10 B70 2196932 LS10 B80 2196933 Tools Hexagonal wrench width across flats 3 mm 1 For M4 screw Spanner width across flats 5 mm 1 For D sub connector removal Nut screwdriver width across flats 5 mm 1 For D sub connector removal Torque wrench 1 Nippers 1 For cutting wire tie Material Wire tie Cable unit Figure LS10 B602S NOTE ...

Page 85: ... shock and or improper function of the robot system When routing the cables observe the cable locations after removing the cover Be sure to place the cables back to their original locations 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 resul...

Page 86: ...sed because the shaft may be lowered by the weight of an end effector 3 Turn OFF the Controller 4 Remove the Connector Sub Plate from the Connector Plate For details refer to Maintenance 3 4 Connector Sub Plate 5 Disconnect M C cable For details refer to Setup Operation 3 6 Connecting the Cables Connect and disconnect M C cable 6 Remove the Connector Plate For details refer to Maintenance 3 3 Conn...

Page 87: ...e air tube and Ethernet cable RJ45 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 fittings to pull out the air tube ø6 2 ø4 1 Remember the cable layout for reconnecting the disconnected parts after replacement 16 Remove the two ground wires from the User Plate Unscrew the cable clamp binding the cables in the Arm side and rem...

Page 88: ...late Air tube D sub cable Ethernet cable RJ45 Connectors X11 X111 X121 CV11 CV12 CV13 6 Connect the ground wire on the Base side to the mount base 7 Connect the air tube D sub cable and Ethernet cable RJ45 to the User Plate 8 Fix the ground wire on the User Plate 9 Mount the User Plate For the details refer to Maintenance 3 5 User Plate 10 Connect the connectors Connectors X22 X33 X42 X43 X44 X51 ...

Page 89: ...Maintenance 4 Cable LS10 B Rev 6 77 4 2 Wiring Diagrams 4 2 1 Signal Cable ...

Page 90: ...Maintenance 4 Cable 78 LS10 B Rev 6 4 2 2 Power Cable ...

Page 91: ...of Cables The following table shows the codes and cable colors indicated in the pin assignments 4 2 1 Signal Cable 4 2 2 Power Cable 4 2 3 User Cable Code Cable color B Black W White R Red G Green Y Yellow BR Brown L Blue V Violet O Orange P Pink SB Sky blue GY Gray ...

Page 92: ... 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 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 ob...

Page 93: ... to Maintenance 3 3 Connector Plate Finger screws 4 M3 10 4 Slide the plate to remove it from the base Do not pull the M C cable after removing the plate M C cables are connected by the connectors Doing so may result in disconnection of the cables 5 As shown on the right pull out the cables from the Manipulator 6 Disconnect the connectors in the order as shown on the right Clips of the connectors ...

Page 94: ...to disconnect for safety purpose To disconnect the connector securely push the clip If you cannot disconnect it push the connector once and then disconnect it by pushing the clip Do not pull the cables Doing so may result in disconnection Do not remove the M C cable form the plate NOTE ...

Page 95: ...wn on the right 2 3 1 3 Slide the plate to install it Finger screws 4 M3 10 Tightening torque 0 6 0 1 N m Finger screws 4 M3 10 Slide the plate until it will be parallel to the base table Be careful not to tighten the screws with the cables get caught on the plate 4 Connect the following connectors to the controller Power cable connector Signal cable connector 5 Turn ON the Controller NOTE NOTE ...

Page 96: ... the direction Correct direction is where the letters WARNING of warning label of electric shock will be parallel to the base table If the plate is installed in wrong direction the cables inside the Manipulator will be twisted and may result in disconnection Correct Cables are not twisted Wrong Cables are twisted ...

Page 97: ...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 98: ...tor Plate 2 Disconnect the connector Connectors X41 X211 Hold the clip to remove 3 Remove the Arm 1 mounting bolt in the Joint 1 side and remove the arm There is an O ring CO0551A between the Joint 1 unit and the arm Be sure to keep the O ring 4 Remove the screws mounting the Joint 1 flange on the Base 6 M5 15 5 Hold up the Joint 1 unit and remove it from the base Be careful not to damage the moto...

Page 99: ...ss bushing in one of the set screw holes Be careful not to lose the bushing A Brass Bushing M5 B Set Screw 2 M5 6 B Set Screw A Brass Bushing Waveform Generator Joint 1 Motor 8 Remove the motor mounting screws to remove the motor flange and O ring CO0538A 4 M4 12 Joint 1 Motor Motor Flange O ring 4 M4 washer ...

Page 100: ... Waveform Generator Joint 1 Motor A Brass Bushing M5 B Set Screw 2 M5 6 CAUTION See the figure 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 3 Set an O ring CO0538A on the motor flange and assemble the motor with the Joint 1 flange To insert t...

Page 101: ...and the following errors are detected Error 5041 Motor torque output failure in low power state Error 4241 Over speed during low power mode was detected or when the joint other than Joint 1 moves the connector for the other joint might be connected to the Joint 1 motor Check the connector connection 9 Execute the calibration for the Joint 1 For details refer to Maintenance 13 Calibration ...

Page 102: ...y Note Maintenanc e Parts Reduction Gear Unit 1 1765530 Tools Hexagonal 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 Torque wrench 1 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 in length For flexspline removal Grease Grease SK 1A Join...

Page 103: ...ng 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 Groove...

Page 104: ...urely in a crisscross pattern at the torque specified in the table below Flange Reduction Gear Unit 16 M4 25 Item Bolt type Bolts Tightening torque Joint 1 reduction gear unit M4 25 16 5 4 N m 55 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 37 g 7 Mount the Joint 1 motor Follow the installation steps in Mainten...

Page 105: ...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 106: ...teps Joint 2 Motor 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 is applied to both Joints 3 and Joint 4 When the brake release switch is pressed the respective brakes of the Joint 3 and Joint 4 are released simultan...

Page 107: ...ounting screw 4 M4 15 To pull out the motor smoothly move the Arm 2 slowly by hand while pulling the motor Joint 2 Motor Unit Arm 2 4 M4 15 9 Remove the waveform generator from the Joint 2 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 Joint 2 Motor Waveform Generator ...

Page 108: ...unt the Joint 2 motor unit on the Arm 2 To insert the motor slowly move the Arm 2 by hand and push in Motor mounting screw 4 M4 15 Joint 2 Motor Unit Arm 2 4 M4 15 4 Mount the User Plate For details refer to Maintenance 3 5 User Plate 5 Connect the connectors Connectors X221 X42 6 Bind the cables with a wire tie in their original positions as before removed in the removal step 6 Do not allow unnec...

Page 109: ...Maintenance 6 Joint 2 LS10 B Rev 6 97 9 Execute the calibration for Joint 2 For details refer to Maintenance 13 Calibration ...

Page 110: ...agonal 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 Torque wrench 1 Spatula 1 For apply grease Wiping cloth 1 For wiping grease Flange 1 For wiping grease Bolt Screw M3 Length about 20 mm 2 For removing the flexspline Material Wire tie Grease Grease SK 1A A brake is mounted on the motor of Joints 3 and 4 to preven...

Page 111: ...ng 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 waveform generator from the Joint 2 motor Follow the removal steps in Maintenance 6 1 Replacing Joint 2 Motor 5 Remove the Arm 2 by removing the screws mounting the Arm 2 on the reduction gear unit A 16 M3 28 B 8 M3 32 8 M3 small washer C 4 M3 ...

Page 112: ...or 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 Groove...

Page 113: ...wrench tighten each bolt securely in a crisscross pattern at the torque specified in the table below Item Bolt type Tightening torque Joint 2 reduction gear unit M3 2 35 N m 24 kgf cm Be careful not to apply too much force since it may damage the parts 6 Apply grease between the motor flange and waveform generator and next inside the flexspline Between the motor flange and waveform generator Greas...

Page 114: ...rce 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 encode...

Page 115: ... steps Joint 3 motor 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 is applied to both Joints 3 and Joint 4 When the brake release switch is pressed the respective brakes of the Joint 3 and Joint 4 are released simult...

Page 116: ...4 18 Washer 9 Remove the Joint 3 motor from the Joint 3 motor unit Joint 3 Motor 4 M4 15 Washer 10 Loosen the screws of the pulley remove it from the Joint 3 motor There is a brass bushing in one of the set screw holes Be sure to keep the bushing Joint 3 Motor M5 8 Set screw M5 Bushing Pulley M5 8 Set Screw ...

Page 117: ...nt make sure that the Joint 3 motor unit can be moved by hand and it will not tilt when pushed by tensioner If the unit is secured too loose or too tight the belt will not have the proper tension 4 Apply the proper tension to the Z belt and secure the Joint 3 motor unit Nut Plate Bolt Tensioner Install the tensioner in front of the Joint 3 motor unit Rotate the hexagonal bolt of the tensioner and ...

Page 118: ...o Maintenance 3 1 Arm Top Cover 9 Check if the Joint 3 moves in a Jog motion by operating from EPSON RC menu Tools Robot Manager Jog Teach If the Manipulator oscillates with MOTOR ON and the following errors are detected Error 5041 Motor torque output failure in low power state Error 4241 Over speed during low power mode was detected or when the joint other than Joint 3 moves the connector for oth...

Page 119: ...ft 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 is applied to both Joints 3 and Joint 4 When the brake release switch is pressed the respective brakes of the Joint 3 and Joint 4 are released simultaneously Be careful of the shaft falling and rotating while the brake rel...

Page 120: ...nt 3 Motor Unit 9 Remove the Joint 3 motor from the motor plate and pull out the Z belt The belt is placed around the pulley To remove the Joint 3 motor tilt the motor slightly and pull it upward while avoiding the belt 10 Remove the screws for the spline plate Holding the spline plate upward pull out the Z belt Z belt Spline Plate 3 M4 15 ...

Page 121: ...by hand and it will not tilt when pushed by tensioner If the unit is secured too loose or too tight the belt will not have the proper tension 6 Apply the proper tension to the Z belt and then secure the Joint 3 motor unit Install the tensioner in front of the Joint 3 motor unit Rotate the hexagonal bolt of the tensioner and push the plate to apply the specified tension Z belt tension 69 N 7 0 0 5 ...

Page 122: ... to Maintenance 3 1 Arm Top Cover 11 Check if the Joint 3 moves in a Jog motion by operating from EPSON RC menu Tools Robot Manager Jog Teach If the Manipulator oscillates with MotorON and the following errors are detected Error 5041 Motor torque output failure in low power state Error 4241 Over speed during low power mode was detected or when the joint other than Joint 3 moves the connector for t...

Page 123: ... to its lower limit before the replacement procedure following the removal steps 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 is applied to both Joints 3 and Joint 4 When the brake release switch is pr...

Page 124: ...tor slightly and pull it upward while avoiding the belt Joint 3 motor 4 M4 15 Washer 7 Remove the brake from the brake plate Brake 3 M3 8 8 Loosen the screws of brake hub and remove it from the pulley of the Joint 3 motor There is a brass bushing in one of the set screw holes Be sure to keep the bushing Joint 3 Motor M5 8 Set Screws M3 Bushing Brake Hub M3 4 Set screws ...

Page 125: ...tor M5 8 Set Screws M3 Bushing Brake Hub M3 4 Set screws 3 Mount the Joint 3 motor to the motor plate while aligning the hub to the brake disc Before aligning the hub set the motor so that the pulley will be inside of the Z belt Be sure to fix the motor cable so that it faces opposite side of the brake support Joint 3 motor Electromagnetic brake Pulley Motor plate When the brake disc is not aligne...

Page 126: ...ustment put the bolt back to its original position and fix it with the nut To check belt tension with the tension meter refer to Maintenance 7 4 Checking the Timing Belt Tension Z Belt 5 Mount the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 6 Check if the Joint 3 moves in a Jog motion by operating from EPSON RC menu Tools Robot Manager Jog Teach If the Manipulator oscillates w...

Page 127: ...e tension meter refer to the instruction manual of the tension meter Joint 3 Belt tension check 1 Enter appropriate setting values to the sonic tension meter Model Belt Unit mass M g 1 mm width 1 m length Width W mm Span S mm LS10 B Z belt 2 5 17 303 2 Strum the belt and measure tension Measurement failure may occur if the microphone touches the belt during measurement NOTE ...

Page 128: ...e Performing any replacement 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 cause...

Page 129: ...is OFF or while the motor is in OFF status MOTOR OFF Move the shaft down to its lower limit before the replacement procedure following the removal steps Joint 4 motor 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 is ...

Page 130: ...on the motor plate and pull out the motor The belt is placed around the pulley Tilt the motor unit slightly and pull it out Joint 4 Motor Unit 3 M4 15 Washer Motor Plate 9 Remove the pulley from the Joint 4 motor There is a brass bushing in one of the set screw holes Be sure to keep the bushing 2 M4 8 Set Screw Bushing Pulley 2 M4 70 Spacer Motor Plate 10 Remove the motor plate from the Joint 4 mo...

Page 131: ...place the Joint 4 motor unit in the upper face of the Arm 2 Joint 4 Motor Unit 3 M4 15 Washer Motor Plate 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 Make sure the gear grooves of the belt are fit into those of the pulleys compl...

Page 132: ...Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 10 Check if the Joint 4 moves in a Jog motion by operating from EPSON RC menu Tools Robot Manager Jog Teach If the Manipulator oscillates with MOTOR ON and the following errors are detected Error 5041 Motor torque output failure in low power state Error 4241 Over speed during low power mode was detected or when the joint other than J...

Page 133: ...sion belt tension 102 N 10 4 0 5 kgf Suitable cord Length about 800 mm 1 For belt tension CAUTION The belt must be installed with proper tension otherwise the following problems may occur If falling below the lower limit Jumping of the belt gears position gap If exceeding the upper limit Abnormal noise or vibration oscillation decline in the life of driving parts A brake is mounted on the motor of...

Page 134: ...he 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 control board and the plate 2 M2 16 Pan head screws Control Board Plate 4 M3 10 6 Cut off the wire tie binding the cables Do not cut off the wire tie that binds the cables to t...

Page 135: ...lightly and pull it out 3 M4 15 Washer Joint 4 Motor Unit 11 Remove the screws securing the Joint 4 intermediate shaft unit Pull out the Joint 4 intermediate shaft unit and U1 belt 3 M4 12 Washer Joint 4 Intermediate Shaft Unit U1 belt 12 Remove the screws mounting the spline plate Hold up the spline plate and pull out the Z belt and U2 belt 3 M4 15 Spline Plate Z belt U2 belt ...

Page 136: ...e shaft unit set the U2 belt in the Arm 2 on the small pulley and put them on the Arm 2 upper surface Make sure the gear grooves of the belts are fit into those of the pulleys completely 3 M4 12 Washer Joint 4 Intermediate Shaft Unit U1 belt U2 belt Pulley Large Pulley Small 5 Loosely secure the Joint 4 intermediate shaft unit Make sure the unit can be moved by hand and it will not tilt when pulle...

Page 137: ...h the U1 belt around the pulley 3 M4 15 Washer Joint 4 Motor Unit U1 belt Pulley 8 Loosely secure the Joint 4 motor unit to the 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 9 Apply the proper tension to the U1 belt and secure the Joint 4 motor unit Pass a suitable cord or...

Page 138: ...ified tension For details refer to Maintenance 7 2 Replacing the Timing Belt Z belt tension 69 N 7 0 0 5 kgf Nut Plate Bolt Tensioner 13 1 Loosen the nut and turn the bolt Push in the Joint 3 motor unit 13 2 After fixing the Joint 3 motor unit turn the bolt to leave from the plate 13 3 Check the tension using the sonic tension meter For details refer to Maintenance 7 4 Checking the Timing Belt Ten...

Page 139: ...by operating from EPSON RC menu Tools Robot Manager Jog Teach If the Manipulator oscillates with MOTOR ON and the following errors are detected Error 5041 Motor torque output failure in low power state Error 4241 Over speed during low power mode was detected or when the joint other than Joint 4 moves the connector for other joint might be connected to the Joint 4 motor Check the connector connecti...

Page 140: ...Joint 4 motor unit Follow the removal steps in Maintenance 8 2 1 U2 Belt Joint 4 Motor Unit 3 M4 15 Washer 2 Remove the Joint 4 intermediate shaft unit Refer to the removal steps in Maintenance 8 2 1 U2 Belt Joint 4 Intermediate Shaft Unit 3 M4 12 Washer U1 belt 3 Remove the U1 belt ...

Page 141: ...tension to the U2 belt and then secure the Joint 4 intermediate shaft unit Install the tensioner in front of the Joint 4 motor unit Rotate the hexagonal bolt of the tensioner and push the plate to apply the specified tension U2 belt tension 102 N 10 4 0 5 kgf 3 1 Loosen the nut and turn the bolt Push in the Joint 3 motor unit 3 2 After fixing the Joint 3 motor unit turn the bolt to leave from the ...

Page 142: ... Then pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right U1 axial tension pulling force 114 N 11 6 0 5 kgf U1 belt tension 58 N 5 9 0 5 kgf 3 M4 15 Washer Force Gauge Joint 4 Motor Unit To check belt tension with the tension meter refer to Maintenance 8 4 Checking the Timing Belt Tension U1 U2 Belts 6 Connect the connectors Connectors ...

Page 143: ...R ON and the following errors are detected Error 5041 Motor torque output failure in low power state Error 4241 Over speed during low power mode was detected or when the joint other than Joint 4 moves the connector for other joint might be connected to the Joint 4 motor Check the connector connection 11 Execute the calibration of Joint 4 For details refer to Maintenance 13 Calibration ...

Page 144: ...ss flats 2 mm 1 For M2 5 screw Nippers 1 For cutting wire tie Material Wire tie 1 A brake is mounted on the motor of Joints 3 and 4 to prevent the shaft from moving down and rotating due to the weight of the end effector while the power to the Controller is OFF or while the motor is in OFF status MOTOR OFF Move the shaft down to its lower limit before the replacement procedure following the remova...

Page 145: ...pressed the respective brake for Joints 3 and 4 are released simultaneously Be careful of the shaft falling and rotating 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 Disconnect the connector Connector BR4 6 Cut off the wire t...

Page 146: ...ount the rubber cap Insert the rubber cap until the cable part of the brake If the cables get inside the rubber cap the cables may be disconnected Rubber Cap Rubber Cap Rotator part Brake Hub 4 Connect the connector Connector BR4 5 Re bundle the cables in their original positions with a wire tie removed in step 6 Do not allow unnecessary strain on the cables 6 Install the Arm Top Cover For details...

Page 147: ... tension meter refer to the instruction manual of the tension meter Joint 4 Belt tension check 1 Enter appropriate setting values to the sonic tension meter Belt Unit mass M g 1 mm width 1 m length Width W mm Span S mm U1 belt 2 5 10 70 U2 belt 2 5 21 250 2 Strum the belt and measure tension Measurement failure may occur if the microphone touches the belt during measurement NOTE ...

Page 148: ...r take the necessary countermeasures to prevent dust emission before replacing the bellows Name Qty Note Maintenance parts Bellows 1 170 mm 1765523 270 mm 1765524 Tools Cross point screwdriver 1 For clamp band removal Bellows Bellows Clamp band Clamp band Clamp band Bellows Removal 1 Remove the cables and tubes from the end effector 2 Remove the end effector 3 Turn ON the controller Stop motor exc...

Page 149: ...he bellows from the larger joint 3 Secure the cover side 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...

Page 150: ...ric 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 process of align...

Page 151: ... 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 ha...

Page 152: ...se 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 the 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 Directly fill the grooves on the shaft inside the bellows with...

Page 153: ...tension pulling force 114 N 11 6 0 5 kgf Suitable cord Length about 1000 mm 1 For belt tension Wiping cloth 1 For wiping grease Spline shaft Material Wire tie 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 any peripheral equipment The brake rel...

Page 154: ... intermediate pulley U1 belt U2 belt Z belt Follow the U2 belt removal steps in Maintenance 8 2 Replacing the Timing Belt 8 Remove three screws mounting the spline plate 3 M4 15 4 M5 15 9 Remove four screws mounting the spline nut 10 Pull out the following toward the Arm 2 upper side Ball screw spline unit Z belt U2 belt ...

Page 155: ...belt U2 belt Z belt Follow the U2 belt installation steps in Maintenance 8 2 Replacing the Timing Belt 4 Mount the Arm Top Cover and Arm Bottom Cover For details refer to Maintenance 3 Covers 5 Grease the shaft For details refer to Maintenance 10 1 Greasing the Ball Screw Spline Unit 6 For the Cleanroom model mount the bellows For details refer to Maintenance 9 Bellows 7 Mount the end effector cab...

Page 156: ...disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result...

Page 157: ...or will not operate Converter board Removal 1 Turn OFF the controller 2 Remove the Connector Plate For details refer to Maintenance 3 3 Connector Plate 3 Disconnect the connectors which are connected to the converter board Connectors CV11 CV12 CV13 Converter board 4 Remove the converter board from the mount base Binding head small screws 2 M3 cross point screwdriver Converter board 2 M3 Binding he...

Page 158: ...nt base Binding head small screws 2 M3 Converter board 2 M3 Binding head small screws 2 Connect the connectors to the converter board Connectors CV11 CV12 CV13 3 Mount the Connector Plate For details refer to Maintenance 3 3 Connector Plate 4 Turn ON the Controller 5 Make sure no errors occur in all joints ...

Page 159: ...r 3 Disconnect the connector Connector X51 4 Remove the Control board 2 M2 16 Pan head screw Control board Connector Control Board Installation 1 Mount a new Control board Be careful of the board direction Check the board direction by the connector position 2 Connect the connector Connector X51 3 Mount the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 4 Turn ON the controller ...

Page 160: ...ly hazardous and may result in electric shock and or malfunction of the robot system Name Qty Note Maintenance parts LED Lamp 1 2077258 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 For details refer to Maintenance 3 5 User Plate 3 Disconnect the X...

Page 161: ...ign Precautions Before operating the robot system make sure that 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 safeg...

Page 162: ...etails refer to Maintenance 13 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 occurs apply the procedure of 13 4 Calibration Procedure without ...

Page 163: ...rate manually to approximate zero position as shown in the dialog After moving the joint click the Next button 0 pulse position of Joint 1 position aligned with X axis in Robot coordinate system 0 pulse 0 pulse position of Joint 2 position where Arms 1 and 2 are in a straight line Regardless of the Joint 1 direction 0 pulse ...

Page 164: ... of Joint 3 depends on manipulator model Standard model Cleranroom model 0 pulse position of Joint 4 position where the flat surface on the shaft faces toward the tip of Arm 2 Flat surface 0 pulse 4 Click the Yes button to reset the encoder 5 Reboot the Controller This window will disappear when the Controller starts up ...

Page 165: ...ion LS10 B Rev 6 153 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 166: ...lick the OK button Before operating the robot open the Control Panel and click on the Motor ON button Move the end effector from the zero pulse position to the approximate reference point where rough calibration will be executed at by the jog motion Position gap may occur if the end effector is not moved by the jog motion 9 Click the Next button NOTE ...

Page 167: ...55 10 The 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 ...

Page 168: ...10 B Rev 6 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 169: ...dure 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 170: ...Maintenance 13 Calibration 158 LS10 B Rev 6 iii Jog to the accurate reference position and adjust the position Click the OK button iv Click the Next button ...

Page 171: ...ntenance 13 Calibration LS10 B Rev 6 159 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 172: ... right 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 executing the calibration install the ...

Page 173: ...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 point is now called P2 Specify point number P2 and click the Teach button in Jog Teach 9 Input the new Hofs valu...

Page 174: ...nd 4 at 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 execute the calibration using the point data currently registered Confirm the point data number P to reconstruct the correct manipulator posit...

Page 175: ...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 Cleranroom model 0 pulse position of Joint 4 position where the flat surface on the shaft faces toward the tip of Arm 2 Flat surface 0 pulse ...

Page 176: ... EPSON RC menu Tools Controller and click the Reset Controller button This window will be disappeared when the Controller starts up 4 Rough Calibration 4 1 Execute the following command from the menu Tools Command Window calpls 0 0 0 0 Manipulator does not move 4 2 Execute one of the following commands according to the joint you want to calibrate from the menu Tool Command Window Joint 1 calib 1 J...

Page 177: ...ed moves to the original position 5 6 Accurately align the joint being calibrated to the specified point using jog commands You must move Joint 3 and 4 to 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 ...

Page 178: ...0538A 1510528 CO0551A Joint 2 1653181 Supplied with Joint 2 reduction gear unit 6 2 1213267 CO0547A Timing Belt Joint 3 1758946 Z 7 2 Joint 4 1757386 U1 8 2 1757387 U2 Electromagnetic brake 1499588 Z axis Brake only 7 3 1750573 U axis Brake Power 7 4 Brake Release Switch 2117817 Bellows LS10 B 2C 1765523 4 9 LS10 B 3C 1765524 4 9 Ball Screw Spline LS10 B 2S 1765521 200 mm 10 2 LS10 B 3S 1765522 30...

Page 179: ...rcumference of the opening Circular spline A rigid ring shaped body with gear teeth on the inner circumference The circular spline has two more teeth than the flexspline does Splines are greased Be careful not to let grease adhere to clothes 2 Regarding purchase of grease Due to the chemicals regulations of individual countries the UN GHS we are requesting our customers to purchase the grease requ...

Page 180: ...Maintenance 14 Maintenance Parts List 168 LS10 B Rev 6 4 Bellows The bellows for LS10 B C are provided in a unit of two pieces The shape varies between the upper and lower bellows ...

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