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Maintenance  4. Cable 

 

LS20  Rev.4 

75 

4. Cable 

 

WARNING 

■

 

Do not insert or pull out the motor connectors while the power to the robot system 

is turned ON.    Inserting or pulling out 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, pull out 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 pull out 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  and may result in 

electric shock and/or malfunction of the robot system. 

 

 

CAUTION 

■

 

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 function of the robot system. 

 

4.1  Replacing Cable Unit 

Since the power is supplied to each motor from the lithium battery installed on the battery 
board via the battery connector, the position data will not be lost when the Controller is 
turned OFF.  When the battery connectors are disconnected, the position data will be lost, 
and EPSON RC+ will display an error when the Controller is turned ON. 

If the error occurs, execute the calibration of all joints and axes. 
For details of the calibration, refer to 

Maintenance:

 

13. Calibration. 

 

 

 

Name 

Quantity 

Note 

Maintenance 

parts 

Cable unit 

1 

LS20-804*: 1646486 
LS20-A04*: 1646485 

Battery Unit   

1 

2167689 

(Lithium battery for replacement 

A set of 3 batteries) 

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 

- 

 

Summary of Contents for LS20

Page 1: ...Rev 4 EM179R3533F SCARA ROBOT LS20 series MANIPULATOR MANUAL ...

Page 2: ...MANIPULATOR MANUAL LS20 series Rev 4 ...

Page 3: ...LS20 Rev 4 i SCARA ROBOT LS20 series Manipulator Manual Rev 4 Copyright 2016 2017 SEIKO EPSON CORPORATION All rights reserved ...

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: ... Shape 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 ...

Page 8: ...vi LS20 Rev 4 ...

Page 9: ...s and Installation 27 3 1 Environmental Conditions 27 3 2 Base Table 28 3 3 Mounting Dimensions 29 3 3 1 LS20 804 29 3 3 2 LS20 A04 31 3 4 Unpacking and Transportation 33 3 4 1 Precautions for Transportation 33 3 4 2 Transportation 34 3 5 Installation Procedure 35 3 5 1 Standard Model 35 3 5 2 Cleanroom Model 36 3 6 Connecting the Cables 37 3 7 User Wires and Pneumatic Tubes 38 3 8 Relocation and ...

Page 10: ... the Manipulator for Joints 1 and 2 58 5 4 Standard Motion Range 58 Maintenance 1 Safety Maintenance 61 2 General Maintenance 62 2 1 Maintenance Inspection 62 2 1 1 Schedule for Maintenance Inspection 62 2 1 2 Inspection Point 63 2 2 Overhaul Parts Replacement 64 2 3 Greasing 66 2 4 Tightening Hexagon Socket Head Cap Bolts 68 2 5 Matching Origins 68 2 6 Layout of Maintenance Parts 69 3 Covers 70 3...

Page 11: ...25 8 4 Replacing the Reduction Gear Unit 126 8 5 Checking the Timing Belt Tension 128 9 Bellows 129 10 Ball Screw Spline Unit 131 10 1 Greasing the Ball Screw Spline Unit 131 10 1 1 Standard model S type 132 10 1 2 Cleanroom model 133 10 2 Replacing the Ball Screw Spline Unit 135 11 Lithium Battery 138 11 1 Replacing the Battery Unit Lithium Battery 140 11 2 Replacing the Resolver Board 141 11 3 R...

Page 12: ...TABLE OF CONTENTS x LS20 Rev 4 ...

Page 13: ...Setup Operation This volume contains information for setup and operation of the LS20 series Manipulators Please read this volume thoroughly before setting up and operating the Manipulators ...

Page 14: ......

Page 15: ...ations 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 in...

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: ...line 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 Calculation example 110 N 11 2 kgf load is placed at 400 mm from the end of the spline nut Moment M F L 1...

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

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: ...Stop 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 restorat...

Page 21: ...istance 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 LS20 804 LS20 A04 Accel Setting 100 100 Speed Setting 100 100 Load kg 20 20 Weight Setting 20 20 Joint 1 Stop position E Stop signal Input position Target position Motion s...

Page 22: ...The shaft cannot be rotated by hand until the solenoid brake applied to the shaft is released Move the shaft while pressing the brake release switch Joint 3 Joint 4 brake release switch Joint 1 rotating Joint 2 rotating Joint 3 up and down Joint 4 rotating Arm 1 Arm 2 Shaft Figure LS20 804S Base The brake release switch affects both Joints 3 and 4 When the brake release switch is pressed in emerge...

Page 23: ...he Z axis height ACCELS setting value by Z axis height and tip load Z axis height mm Tip load 5 kg or less 10 kg or less 15 kg or less 20 kg or less 0 Z 100 10000 or less 10000 or less 10000 or less 9000 or less 100 Z 200 7000 or less 5500 or less 200 Z 300 7500 or less 5000 or less 3500 or less 300 Z 420 5500 or less 3500 or less 2500 or less Z axis height 0 Origin point Z If the Manipulator is o...

Page 24: ...hile 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 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 bel...

Page 25: ...Setup Operation 1 Safety LS20 Rev 4 13 Location Label G C A D B C G Opposite side E Opposite side F Figure LS20 804S ...

Page 26: ...s therefore it has high resistance to environment and hardly breaks down It mounts the resolver board and battery inside the manipulator therefore the calibration is not required when you disconnect the M C cable Large Capacity It supports the U axis allowable moment up to 0 45 kg m2 It stably handles large loads by optimized control based on the each load Tact Time Improvement by High speed Motio...

Page 27: ...oad 20 20 kg 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 Payload Arm length Environment Joint 3 stroke Model Number 20 kg 800 mm Standard 420 mm LS20 804S Cleanroom 390 mm LS20 804C 1000 mm Standard 420 mm LS20 A04S Cl...

Page 28: ...ser connector 15 pin D sub connector LED lamp CE label User connector 9 pin D sub connector Fittings white for ø4 mm pneumatic tube KC KCs Mark The brake release switch affects both Joints 3 and 4 When the brake release switch is pressed in emergency mode the brakes for both Joints 3 and 4 are released simultaneously While the LED lamp is on the current is being applied to the manipulator Performi...

Page 29: ...Setup Operation 2 Specifications LS20 Rev 4 17 LS20 804S Standard Model ...

Page 30: ...cations 18 LS20 Rev 4 LS20 804C Cleanroom Model 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: ...Setup Operation 2 Specifications LS20 Rev 4 19 LS20 804C Cleanroom Model ...

Page 32: ...D sub connector LED lamp CE label User connector 9 pin D sub connector Fittings white for ø4 mm pneumatic tube KC KCs Mark 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 the current is being applied to the manipulator Performing any work with...

Page 33: ...Setup Operation 2 Specifications LS20 Rev 4 21 LS20 A04S Standard Model ...

Page 34: ...cations 22 LS20 Rev 4 LS20 A04C Cleanroom Model 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 35: ...Setup Operation 2 Specifications LS20 Rev 4 23 LS20 A04C Cleanroom Model ...

Page 36: ...method All joints AC servo motor Motor energy consumption Joint 1 750 W Joint 2 600 W Joint 3 400 W Joint 4 150 W Option Installation environment Cleanroom 3 Joint 3 down force 250 N Installed wire for customer use 15 pin D sub 9 pin D sub Installed pneumatic tube for customer use 2 pneumatic tubes ø6 mm 0 59 MPa 6 kgf cm2 86 psi 2 pneumatic tubes ø4 mm 0 59 MPa 6 kgf cm2 86 psi Environmental requ...

Page 37: ...t and the exhaust tube with vinyl tape so that the joint is airtight If the exhaust flow is not sufficient dust particle emission may exceed the specified maximum level Cleanliness level Class ISO 4 ISO14644 1 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 Recommended...

Page 38: ...model properly Improper setting of the Manipulator model may result in abnormal or no operation of the Manipulator and or cause safety problems If an MT label is attached to the rear of a Manipulator the Manipulator has custom specifications The custom specifications may require a different configuration procedure check the custom specifications number described on the MT label and contact us when...

Page 39: ...ct 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 ...

Page 40: ...ensions 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 be secured on the floor or wall to prevent it from moving The Manipulator must be installed horizontally When using a leveler to adjust the height of t...

Page 41: ...unting 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 obstacles In addition leave enough space for other cables so that they are not bent ...

Page 42: ...Setup Operation 3 Environments and Installation 30 LS20 Rev 4 Cleanroom Model LS20 804C Center of Joint 3 Maximum space Motion range Area limited by mechanical stop Base mounting face 390 ...

Page 43: ...Setup Operation 3 Environments and Installation LS20 Rev 4 31 3 3 2 LS20 A04 Standard Model LS20 A04S Center of Joint 3 Maximum space Motion range Area limited by mechanical stop Base mounting face ...

Page 44: ...Setup Operation 3 Environments and Installation 32 LS20 Rev 4 Cleanroom Model LS20 A04C Center of Joint 3 Maximum space Motion range Area limited by mechanical stop Base mounting face ...

Page 45: ...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 secure it to the delivery equipment or pass a belt through the eyebolt to hang the Manipulator and then attach the hands on the shaded area in the figure below bottom of the Arm 1 and the base If carrying the Manipulator without using the belt have ...

Page 46: ...move 4 Use the wire tie to fix the band for hoisting to the Arm 1 Set the band at the shaded area in the figure below so that the band cannot move 5 Pass the belts through the eyebolts 6 Hoist the Manipulator slightly so that it does not fall Then remove the bolts securing the Manipulator to the delivery equipment or pallet 7 Hoist the Manipulator attaching the hands on the shaded area so that it ...

Page 47: ...ttings 3 5 1 Standard Model CAUTION Install the 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 LS20 804 approx 47 kg 103 6 lb LS20 A04 approx 50 kg 110 2 lb 1 Secure the base to the base table with four bolts Use bolts with specifications conforming to ISO898 1 ...

Page 48: ...2 Secure the Manipulator 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 ...

Page 49: ... and may result in electric shock and or improper function of the robot system Grounding the manipulator is done by connecting with the controller Ensure that the 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 s...

Page 50: ...J9 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 2 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 ...

Page 51: ... 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 hoisting...

Page 52: ... 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 Insert the bolt to the screw hole on the arm and tie the bolt with the metal duct using a string If fixing the arm using the shaft fix it with adequate strength not to deform the spline For d...

Page 53: ...p 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 and rotate by hand because the solenoid brake is applied to the joint while power to the robot system is turned OFF This pre...

Page 54: ...ctor 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 Figure LS20 804S From the base mounting face 4 M4 depth 10 4 M4 depth...

Page 55: ...load 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 LS20 series is 10 kg at the default rating 20 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 th...

Page 56: ...of camera M 1kg W 1kg L2 450 mm LM 550 mm Joint 2 Automatic speed setting by Weight 140 120 100 80 60 40 20 0 5 10 15 20 kg Weight setting LS20 A0 LS20 80 80 65 120 120 100 75 55 The percentage in the graph is based on the speed at rated weight 10 kg as 100 Automatic acceleration deceleration setting by Weight 160 140 120 100 80 60 40 20 LS20 A0 LS20 80 0 5 10 15 20 kg Weight setting 140 110 100 8...

Page 57: ...fficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable moment of inertia of load for a LS20 series Manipulator is 0 05 kg m2 at the default rating and 0 45 kg m2 at the maximum When the moment of inertia of the load exceeds the rating change the setting of the moment of inertia parameter of the Inertia command After the setting is changed the maximum ...

Page 58: ...hange 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 gravity Rotation center Eccentric quantity 200 mm or less Eccentric Quantity Eccentric quantity of load on the shaft The eccentric quan...

Page 59: ...of inertia of the entire load is calculated by the sum of each part a b and c Work piece b Work piece c End effector a Joint 3 shaft Rotation center Moment of inertia of end effector a Moment of inertia of work piece b Moment of inertia of work piece c Whole moment of inertia The methods for calculating the moment of inertia for a b and c are shown below Calculate the total moment of inertia using...

Page 60: ...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 61: ...n 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 When moving the Manipulator horizontally while the shaft is being lowered it may cause over shoot at the time of final positioning Automatic acceleration deceleration vs Joint 3 position The percentage in th...

Page 62: ...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 63: ...ckwise pulse value is defined as the negative Y X 0 pulse B B A A A Max Motion Range B Max Pulse Range LS20 804 132 deg 152918 808278 pulse LS20 A04 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 64: ...ulse LS20 A04S LS20 804C Cleanroom model 390 mm 263578 pulse LS20 A04C For the Cleanroom model LS20 804C LS20 A04C 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 65: ...ponding 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 upper limit mechanical stop Mechanical stop of Joint 1 Fixed M...

Page 66: ...from the bottom of Arm 1 Joint 1 Mechanical Stops a b LS20 804 LS20 A04 Setting Angle 122 deg 122 deg Pulse Value 444188 pulse 444188 pulse b a Views from the top of Arm 1 Joint 2 Mechanical Stops a b LS20 804 LS20 A04 Setting Angle 135 deg 135 deg Pulse Value 307200 pulse 307200 pulse 1 Turn OFF the Controller 2 Install a hexagon socket head cap bolt into the hole corresponding to the setting ang...

Page 67: ...the mechanical stop and the motion range you set Example Using LS20 804S The angle of Joint 1 is set from 110 degrees to 110 degrees The angle of Joint 2 is set from 125 degrees to 125 degrees Execute the following commands from the Command Window MOTOR ON Turns ON the motor CP ON Enters low power mode SPEED 5 Sets at low speeds PULSE 400498 0 0 0 Moves to the min pulse position of Joint 1 PULSE 4...

Page 68: ... by hand while pressing the button 3 Turn OFF the Controller 4 Loosen the lower limit mechanical stop screw 2 M5 6 set screw 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 t...

Page 69: ...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 check wheth...

Page 70: ...otion 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 that the cen...

Page 71: ...Maintenance This volume contains maintenance procedures with safety precautions for LS20 series Manipulators ...

Page 72: ......

Page 73: ...urses 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 74: ...g 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 75: ... 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 11 Lithium Battery and Boards Inspection While the Power is ON Manipulator is operating Inspect...

Page 76: ...en overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on usage condition and degree of the load such as when operated with the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator For the EPSON RC 7 0 Ver 7 2 x or later firmware Ver 7 2 x x or later the recommended replacement time for ...

Page 77: ...ntroller 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 distribut...

Page 78: ...e gets on your skin Wash the area thoroughly with soap and water Greasing part Greasing Interval Grease Refer to Maintenance Joint 1 Reduction gear units Overhaul timing SK 1A 5 Joint 1 Joint 2 SK 2 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...

Page 79: ...ease is discolored or becomes dry Normal grease Discolored grease Perform greasing at 50 km of operation for the first time of greasing 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 grease on the ball screw spline unit can be checked in the Maintenance dialog box of the EPSON RC 7 0 For details refer to the following manual Robot Con...

Page 80: ...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 have been r...

Page 81: ...4 motor Z belt U belt Joint 2 motor Joint 2 reduction gear unit Joint 1 reduction gear unit Joint 1 motor Joint 3 motor Figure LS20 804S Joint 4 reduction gear unit Lithium battery Battery board Control Board Resolver Board Cleanroom model with optional bellows For the Cleanroom model the following parts are added to the Standard model Bellows Clamp Band Bellows Clamp Band Figure LS20 804C ...

Page 82: ...onnect 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 pull out 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 c...

Page 83: ... 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 Maintenance 9 Bellows Be ca...

Page 84: ...Cover completely When you can work maintenance inspection without removing the cover completely move the shaft to the lower limit and lower the Arm Bottom Cover Truss 4 M4 10 When bellows are installed to the manipulator remove or pull down the lower bellows and then remove the arm bottom cover For bellows removal refer to Maintenance 9 Bellows 3 3 Arm 1 Cover Unscrew the Arm 1 cover mounting bolt...

Page 85: ...o 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 plate Be sure to place the cables back to their original locations Unscrew the Connector Plate mounting bolts and remove...

Page 86: ...lt 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 Plate mou...

Page 87: ...ot system CAUTION 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 o...

Page 88: ... 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 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 str...

Page 89: ...to the Connector Plate Air tube D sub cable Ground Wire Mounting screws for the D sub cable are very small Be careful not to lose them To remove the air tube push the ring of the fittings and then pull the tube ø6 2 ø4 2 7 Pull out the signal connector X20 from the resolver board Ferrite core Wire tie Signal connector 8 Cut off the wire tie binding the cables in the Base side Remove the ferrite co...

Page 90: ... it Arm 2 side Saddle Silicone sheet Clip band Ferrite core 15 Remove the nut of the rotary fitting Remove the rotary fitting from the Duct Plate Pull out the cables from the Duct Plate Nut 2 M4 10 Ground wire Rotary fittings Duct Plate 16 Remove the rotary fitting from the metal duct The rotary fitting is directly screwed in the metal duct Loosen the screws to remove the fitting Cut off the wire ...

Page 91: ...te For the details refer to Maintenance 3 6 User Plate 8 Connect the connectors Connectors X21 X31 X41 X22 X32 X33 X35 X42 X221 X231 X241 9 Mount the ground wire in the Arm side to the Arm 2 10 Bind the cables with a clip band in their original position as before removed in the removal step 14 Wrap the cables in the silicon sheet for protection Bind the cables with the nylon clip and the saddle In...

Page 92: ...Maintenance 4 Cable 80 LS20 Rev 4 4 2 Wiring Diagrams 4 2 1 Signal Cable ...

Page 93: ...U BR 5 5 B7 4V L 6 4V L 6 4V L 6 6 A8 4W O 7 4W O 7 4W V B8 fGND Y G 8 fGND Y G 8 fGND Y G X131 X131 No Color No Color X231 X231 A5 3U GY 1 3U GY 1 3U GY No Color No Color B5 3V V 2 3V V 2 3V V 1 3U GY 1 3U R A6 3W SK 3 3W SK 3 3W O 2 3V V 2 3V W B6 fGND Y G 4 fGND Y G 4 fGND Y G 3 3W O 3 3W B A9 5 5 4 C G Y G 4 C G Y G 6 6 5 5 6 6 X241 X241 Color No Color No Color White 1 4U BR 1 4U R Black 2 4V ...

Page 94: ... G W 6 G W 6 G W 7 R W 7 R W 8 R W 8 R W 9 V W 9 V W 10 V W 10 V W 11 L BR 11 L BR 12 L BR 12 L BR 13 Y BR 13 Y BR 14 Y BR 14 Y BR 15 G 15 G Color White Black Red Green Yellow Violet Brown Blue D sub 9pin D sub 9pin D sub 15pin D sub 15pin Y V BR L Abbreviation of the color Abbreviation W B R G The following table shows the types of the use cable Model name Model type Code LS20 804 Standard Cleanr...

Page 95: ... connectors are disconnected the position data will be lost and EPSON RC will display an error when the Controller is turned ON If the error occurs execute the calibration of all joints and axes For details refer to Maintenance 13 Calibration Name Quantity Note Maintenance parts M C Cable 1 3 m 1646521 5 m 1646522 10 m 1646523 Tools Hexagonal wrench width across flats 3 mm 1 For M4 screw Torque wr...

Page 96: ...ot 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 result in damage to the cables disconnection an...

Page 97: ...ble to the Connector Plate For details refer to Maintenance 3 5 Connector Sub Plate 2 Connect the connectors Connect to the Cable Unit with the same number 3 Install the ferrite core removed in the removal step 5 to the signal cable 4 Mount the Connector Plate For details refer to Maintenance 3 4 Connector Plate 5 Install the ferrite core removed in the removal step 3 to the power cable 6 Connect ...

Page 98: ...eplacement 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 cause a posit...

Page 99: ...K 1A Joint 1 motor Removal 1 Remove the Connector Plate For details refer to Maintenance 3 4 Connector Plate 2 Disconnect the connector from Resolver board Connector X111 Hold the claw to remove Connector X10 3 Remove the Arm 1 cover For details refer to Maintenance 3 3 Arm 1 cover 4 Remove the Arm 1 mounting bolt in the Joint 1 side and remove the Arm 1 8 M6 20 plane washer 5 Remove the screws mo...

Page 100: ...remove M5 15 screws on the front side remove the plate on the front side of the base and insert the wrench from the front and loosen the screws Metal pipe Torque wrench Long hexagonal bit General hexagonal wrench After loosening the screws rotate the motor to pull out If the motor is hard to pull out pull the motor while rotating the Arm 1 slowly Pull out while rotating 8 Remove the waveform gener...

Page 101: ...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 on the motor mounting surface and assemble the top plate 6 M5 15 To insert the motor turn it slowly from side to side by hand and push in 4 Mount the Joint 1 unit on the Base 8 M8 25 Secure the Joint 1 motor ca...

Page 102: ...width across flats 2 5 mm 1 For M5 set screw width across flats 3 mm 1 For M4 screw width across flats 4 mm 1 For M5 screw width across flats 5 mm 1 For M6 set screw width across flats 6 mm 1 For M8 screw Cross point screwdriver 2 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 Grease Grease SK 1A Joint 1 Reductio...

Page 103: ...g 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 The other side 3 Face the convex side of the circul...

Page 104: ...ts Tightening torque Joint 1 reduction gear unit M5 16 10 0 N m 102 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 80 g 7 Mount the spacer to the reduction gear unit Hexagon socket head cap bolts 4 M4 15 Tightening torque 5 5 N m 56 1 kgf cm Hexagon socket head cap bolts 8 M5 40 Tightening torque 10 0 N m 102 kgf...

Page 105: ...eplacement 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 cause a posit...

Page 106: ...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 simultaneously Be careful of the shaft falling and rotating while the brake ...

Page 107: ...it to the new one If the Manipulator is operated while the cap is not installed the motor may be damaged due to entering of the foreign materials into the rotating part of the motor sensor and interference of the rotating part and the cables cap 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 The O ring will ...

Page 108: ...rator properly Improper installation of the waveform generator will result in improper function of the Manipulator 3 Apply grease between the waveform generator and motor flange Grease volume 38 g SK 1A 4 Mount the Joint 2 motor unit on the Arm 2 To insert the motor slowly move the Arm 2 by hand and push in Do not push in the motor forcibly Push the motor while moving the Arm 2 slowly 4 M5 20 Join...

Page 109: ...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 2 moves the connector for the other joint might be connected to the Joint 2 motor Check the connector conne...

Page 110: ...6484 Hexagonal wrench width across flats 2 5 mm 1 For M5 set screw width across flats 3 mm 1 For M4 screw width across flats 4 mm 1 For M5 screw Cross point screwdriver 2 1 For M4 screw Torque wrench 1 Nippers 1 For cutting wire tie Spatula 1 For apply grease Wiping cloth 1 For wiping grease Flange 1 For wiping grease Bolt Material Wire tie Grease Grease SK 1A The brakes are mounted on the Joints ...

Page 111: ...d 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 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 M5 30 B 8 M5 45 8 M5 plain washer...

Page 112: ...r 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 The other side 3 Face the convex side of the circular spline down and then fit it into the flexsp...

Page 113: ... Bolt type Qty Tightening torque Joint 2 reduction gear unit M4 4 5 5 N m 56 1 kgf cm M5 8 10 0 N m 102 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 Grease volume 38 g SK 1A Inside the flexspline Grease volume 90 g SK 1A 7 Set ...

Page 114: ...rming 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 a posi...

Page 115: ...llowing the removal 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 ...

Page 116: ...hile avoiding the belt Joint 3 Motor Motor Plate 4 M5 15 Z belt When replacing the motor of the Joint 3 remove the cap from the old motor and install it to the new one If the Manipulator is operated while the cap is not installed the motor may be damaged due to entering of the foreign materials into the rotating part of the motor sensor and interference of the rotating part and the cables cap 9 Lo...

Page 117: ...de of the Z belt Joint 3 Motor Motor Plate 4 M5 15 Z belt When replacing the motor of the Joint 3 remove the cap from the old motor and install it to the new one If the Manipulator is operated while the cap is not installed the motor may be damaged due to entering of the foreign materials into the rotating part of the motor sensor and interference of the rotating part and the cables cap 3 Loosely ...

Page 118: ...nt put the bolt back to its original position and fix it with the nut 5 Connect the connectors X231 X31 6 Install the clip band removed in the removal step 5 bind the cables and then fix them Do not allow unnecessary strain on the cables 7 Install the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 8 Check if the Joint 3 moves in a Jog motion by operating from EPSON RC menu Tools ...

Page 119: ... 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 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 car...

Page 120: ...holes will be used again when installing the Z belt Be careful not to lose them Joint 3 Motor Unit 3 M5 20 washer for slotted hole 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 Joint 3 Motor Motor Plate 4 M5 15 Z belt 10 Remove the screws for...

Page 121: ... Z belt between the motor plate of the Joint 3 motor unit and the brake plate Motor Plate Z belt Brake Plate 4 Mount the Joint 3 motor to the motor plate while aligning the hub to the brake disc Install the motor so that the pulley will be inside of the Z belt Joint 3 Motor Motor Plate 4 M5 15 Z belt 5 Temporarily fix the Joint 3 motor unit to the Arm 2 Make sure that the teeth of the timing belt ...

Page 122: ...onic tension meter For details refer to Maintenance 7 4 Checking the Timing Belt Tension 6 4 Repeat the steps 6 1 through 6 3 until you get appropriate tension 6 5 After the adjustment put the bolt back to its original position and fix it with the nut 7 Connect the connectors X231 X31 8 Mount the User Plate For details refer to Maintenance 3 6 User Plate 9 Bind the cables with new wire ties at the...

Page 123: ...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 simultaneously Be careful of the shaft falling and rotating ...

Page 124: ...e 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 Joint 3 Motor Motor Plate 4 M5 15 Z belt 9 Remove the brake from the brake plate Brake 3 M3 8 10 Loosen the screws of the brake hub and remove the brake hub from the pulley shaft of the Joint 3 motor unit There is a brass bushing on one of the set screws Be careful ...

Page 125: ...rake disc Before aligning the hub set the motor so that the pulley will be inside of the Z belt Joint 3 Motor Motor Plate 4 M5 15 Z belt When the brake disc is not aligned manually adjust the position by following the steps below 1 Connect the connector X32 2 Press the brake release switch to release the brake 3 Adjust the brake disk manually so that the hole is at the center 4 Apply the proper te...

Page 126: ...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 LS20 Z belt 2 5 17 367 2 Strum the belt and measure tension Measurement failure may occur if the microphone touches the belt during measurement NOTE ...

Page 127: ...rming 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 a posi...

Page 128: ...oval 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 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 si...

Page 129: ...ing the motor shaft Reduction Gear Unit 2 M4 12 After loosening the screw mount the cover to the hole Pull the motor upward to remove When replacing the motor of the Joint 4 remove the cap from the old motor and install it to the new one If the Manipulator is operated while the cap is not installed the motor may be damaged due to entering of the foreign materials into the rotating part of the moto...

Page 130: ...for fixing the motor shaft Reduction Gear Unit 2 M4 12 3 Fix the motor shaft to the reduction gear unit Remove the cover of the hole for fixing the motor shaft and then tighten the screw to fix the motor shaft to the reduction gear unit After fixing the shaft mount the cover for the hole When replacing the motor of the Joint 4 remove the cap from the old motor and install it to the new one If the ...

Page 131: ...tor 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 4 moves the connector for other joint might be connected to the Joint 4 motor Check the connector connection 8 Execute the calibration of Joint 4 For details on the calibration method ...

Page 132: ...screwdriver 2 1 For M3 M4 screws Torque wrench 1 Nippers 1 For cutting wire tie Ultrasonic tension meter 1 Refer Unitta U 508 Material Wire tie For binding cables A brake is mounted on the motor of Joints 3 and 4 to prevent the shaft from moving down 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 i...

Page 133: ... Cover 5 Remove the clip band bundling the motor cables Cut off the wire tie fixing the cable to the belt tensioner At this point do not cut off the wire tie fixing the cable to the duct plate Control Board Clip Band User Plate Belt tensioner Duct Plate 6 Disconnect the following connectors Connectors X31 X35 X231 X41 X42 X241 Hold the claw to remove 7 Remove the User Plate For details refer to Ma...

Page 134: ...e screws temporarily so that the spline plate can be moved by hand Fix the spline plate with the screws while pushing the front side of the Arm 2 and the right side face Faces to push the spline plate 4 Loosely secure the Joint 3 motor unit to the Arm 2 Make sure the teeth of the timing belt are engaged with those of the pulley Joint 3 Motor Unit 3 M5 20 washer for slotted hole At this point make ...

Page 135: ...7 1 Loosen the nut and turn the bolt Push in the Joint 4 motor unit plate slowly 7 2 After fixing the Joint 4 motor unit turn the bolt to leave from the plate 7 3 Check the tension using the ultrasonic tension meter For details refer to Maintenance 8 5 Checking the Timing Belt Tension 7 4 Repeat the steps 7 1 through 7 3 until you get appropriate tension 7 5 After the adjustment put the bolt back ...

Page 136: ...Maintenance 8 Arm 4 124 LS20 Rev 4 12 Execute the calibration for Joint 3 4 For details on the calibration method refer to Maintenance 13 Calibration ...

Page 137: ...m 4 LS20 Rev 4 125 8 3 Replacing the Brake The Joint 4 of LS20 series uses the brake equipped motor If the brake needs to be replaced replace the motor For details refer to Maintenance 8 1 Replacing Joint 4 Motor NOTE ...

Page 138: ...imit before the replacement procedure following the removal steps Joint 4 Reduction Gear Unit Removal 1 Remove the Joint 4 motor unit from the Arm 2 For details refer to the Installation steps in Maintenance 8 2 Replacing the Timing Belt 2 M4 12 Joint 4 Motor Joint 4 Reduction Gear Unit Screw hole for fixing the motor shaft 2 Remove the Joint 4 motor from the reduction gear unit Remove the screws ...

Page 139: ... 4 motor to the reduction gear unit Fix the motor shaft to the reduction gear unit Remove cover of the hole for fixing the motor shaft and loosen the screw to fix the motor shaft to the reduction gear unit After fixing the shaft mount the cover to the hole 2 M4 12 Joint 4 Motor Joint 4 Reduction Gear Unit Screw hole for fixing the motor shaft 4 Mount the Joint 4 motor unit to the Arm 2 For details...

Page 140: ...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 Model Belt Unit mass M g 1 mm width 1 m length Width W mm Span S mm LS20 U belt 2 5 30 357 2 Strum the belt and measure tension Measurement failure may occur if the microphone touches the belt during measurement NOTE ...

Page 141: ...rance or take the necessary countermeasures to prevent dust emission before removing the bellows Name Quantity Note Maintenance parts Bellows 1 1499591 Tools Cross point screwdriver 1 For clamp band removal Bellows Clamp band Bellows 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 excitation MOTOR OFF 4 Lo...

Page 142: ...rough the 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 cov...

Page 143: ... 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 t...

Page 144: ...the 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 145: ...release switch 6 Wipe off the old grease from the upper part of the shaft and then apply new grease Directly fill the grooves on the shaft inside the bellows with 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 the lower limit manually while pressing the b...

Page 146: ... bellows move the shaft to its lower limit To attach the lower bellows move the shaft to its upper limit To move the shaft up down press and hold the brake release switch Attach the mounting part of the bellows until it touches the cylindrical part of the cover Then secure them with clamp bands ...

Page 147: ... Unit AFB grease Proper quantity 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 release switch is applied to both Joints 3 and Joint 4 When the brake release switch is pressed the respective brakes of the Join...

Page 148: ... Spline Unit 136 LS20 Rev 4 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 U belt ...

Page 149: ...ails refer to Maintenance 7 1 Replacing Joint 3 Motor s Maintenance 8 1 Replacing Joint 4 Motor s 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 cables a...

Page 150: ... 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 WARNING Use meticulous care when handling the lithium battery Improper handling of the lithium battery as mentioned below is extremely hazardous may result in heat generation leakage explosion or inflammation and may cause serious s...

Page 151: ...irmware Ver 7 2 x x or later the recommended replacement time for the battery can be checked in the Maintenance dialog box of the EPSON RC 7 0 For details refer to the following manual Robot Controller RC90 Maintenance 6 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 p...

Page 152: ...o the following procedures Battery 3 Resolver Board Resolver Plate MC Signal Cable Wire Tie Signal Cable Battery Plate Connecter Plate 4 Cut off the wire tie binding the lithium batteries to the battery plate 5 Bind new batteries to the battery plate with a new wire tie 6 Disconnect one connector of the old three batteries and connect a new one 7 Disconnect the other old batteries connector and co...

Page 153: ... 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 execute the calibration Resolver Board Removal 1 Turn OFF the controller 2 Remove the resolver plate from the connector plate Truss screw 4 M4 10 4 M4 10 3 Disconnect three batteries connectors and the cable connector Conn...

Page 154: ... resolver plate so that the heat dissipation sheet does not come off and then fix them Hexagon socket head cap bolts 4 M3 4 3 Connect the connectors to the resolver board Connecter M C Signal X10 X20 Battery Connecter X10 M C Signal X20 4 Connect the three batteries connectors to the resolver board 5 Mount the resolver plate to connector plate Truss screw 4 M4 10 4 M4 10 6 Turn ON the Controller 7...

Page 155: ...or details refer to Maintenance 3 1 Arm Top Cover 3 Disconnect the connector X35 4 Remove the Control board Control Board 3 M3 8 Pan head screw Small Control Board Installation 1 Mount a new Control board Be careful of the board direction 2 Connect the connector X35 3 Mount the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 4 Turn ON the controller ...

Page 156: ...wer source Performing any replacement with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Name Quantity Note Maintenance parts LED Lamp 1 2077258 Tools Cross point screwdriver 1 For wire removal LED Lamp Removal 1 Remove the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 2 Disconnect the X1 and X2 terminals from the LED...

Page 157: ... and Design 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 t...

Page 158: ...e the procedure in Calibration Using Right Left Arm Orientations to accurately calibrate Joint 2 For details 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 bat...

Page 159: ...he System Configuration dialog ii Select Robots Robot to display Calibration 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 zero position as shown in the dialog After moving the joint click the Next button ...

Page 160: ... 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 LS20 804S LS20 A04S LS20 804C LS20 A04C 0 pulse position of Joint 4 position where the flat surface of the shaft or the set screw of the bottom mechanical stop faces toward the tip of Arm 2 0 pulse Set Screws Flat Surface ...

Page 161: ...when 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 162: ...ick 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 163: ...1 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 164: ...S20 Rev 4 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 165: ...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 166: ...Maintenance 13 Calibration 154 LS20 Rev 4 iii Jog to the accurate reference position and adjust the position Click the OK button iv Click the Next button ...

Page 167: ...intenance 13 Calibration LS20 Rev 4 155 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 168: ...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 e...

Page 169: ...rom 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 value...

Page 170: ...d 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 positi...

Page 171: ... The height of Joint 3 depends on manipulator model LS20 804S LS20 A04S LS20 804C LS20 A04C 0 pulse position of Joint 4 position where the flat surface of the shaft or the set screw of the bottom mechanical stop faces toward the tip of Arm 2 0 pulse Set Screws Flat Surface 3 3 Connect EPSON RC to the Controller Select a robot to be calibrated Input as below in the Command Window and execute it Thi...

Page 172: ...rts 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 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 ...

Page 173: ...ly 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 1 Calib 1 Joint 2 Calib 2 Joint 3 Calib 3 Join...

Page 174: ...Joint 1 2 5 2 1489339 CO0557 1618362 CO0549 1618361 CO0546 Joint 2 1489339 CO0557 6 2 1618362 CO0549 Timing Belt Joint 3 1618727 Z 7 2 Joint 4 1618729 U 8 2 Solenoid Brake 1499588 Z axis 7 3 Brake Release Switch 2173869 Bellows 1499591 4 9 Ball Screw Spline LS20 S 1646487 420 mm 10 2 LS20 C 1646488 390 mm Battery 2167689 Lithium battery for replacement A set of 3 batteries 11 1 Resolver Board 1593...

Page 175: ...an 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 required for maintenance from the manufacturers listed in the table below as of April 2015 Regarding purchase of the grease please contact the following man...

Page 176: ...Maintenance 14 Maintenance Parts List 164 LS20 Rev 4 ...

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