Epson RS Series Maintenance Manual Download

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RS3 RS4 Maintenance 3. Covers

RS series Maintenance Rev.3

3. Covers

All procedures for removing and installing covers in maintenance are described in this
chapter.

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.

■

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.

Name

Quantity

Note

Maintenance

parts

Gasket unit

1514477 (RS3-351C)
1548345 (RS4-551C)
Only for Cleanroom-model

Tools

Hexagonal wrench
(width across flats: 3 mm)

For M4 screw

Tightening torque: 0.9 N

⋅

m (9.2 kgf

⋅

cm)

Cross-point screwdriver

For bellows removal (Only for Cleanroom-model)
For M4 truss

Tightening torque: 0.9 N

⋅

m (9.2 kgf

⋅

cm)

Arm #1 side cover

Arm #1 under cover

J2 cover

User plate

Arm #1 side cover

Arm #1 cover

Base cover

Arm #2 maintenance cover

Arm #2 cover

Under cover

Cable plate

Summary of Contents for RS Series

Page 1: ...Original instructions Rev 3 ENM226R5366F Industrial Robot SCARA ROBOT RS series MAINTENANCE MANUAL ...

Page 2: ...RS series MAINTENANCE MANUAL Rev 3 ...

Page 3: ...RS series Maintenance Rev 3 i Industrial Robot SCARA ROBOT RS series Maintenance Manual Rev 3 Seiko Epson Corporation 2021 2022 ...

Page 4: ...ns described in the manuals This manual describes possible dangers and consequences that we can foresee Be sure to comply with safety precautions on this manual to use our robot system safety and correctly TRADEMARKS Microsoft Windows and Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries Other brand and product names ar...

Page 5: ... contact your local government office 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 accu...

Page 6: ...r 7 1 2 or greater Turning ON OFF Controller When you see the instruction Turn ON OFF the Controller in this manual be sure to turn ON OFF all the hardware components For the Controller composition refer to the table above Shape of Motors The shape of the motors used for the Manipulator that you are using may be different from the shape of the motors described in this manual because of the specifi...

Page 7: ...F This manual describes the specifications and functions of the Manipulator The manual is primarily intended for people who design robot systems Technical information functions specifications etc required for the Manipulator installation and design Daily inspection of the Manipulator Status Code Error Code List PDF This manual contains a list of code numbers displayed on the controller and message...

Page 8: ...vi RS series Maintenance Rev 3 ...

Page 9: ...5 Matching Origins 13 2 6 Layout of Maintenance Parts 14 3 Covers 15 3 1 Arm 1 16 3 1 1 Standard model 17 3 1 2 Cleanroom model 17 3 2 Arm 2 18 3 2 1 Arm 2 Cover 18 3 2 2 Under Cover 19 3 2 3 Arm 2 Maintenance Cover 19 3 3 Connector Plate 20 3 4 Base Cover 21 3 5 User Plate 22 4 Cable Unit 23 4 1 Replacing Cable Unit 24 4 2 Wiring Diagrams 32 4 2 1 Signal Cable 32 4 2 2 Power Cable 34 4 2 3 User C...

Page 10: ...73 8 3 Replacing the Reduction Gear Unit 77 9 Bellows 78 10 Ball Screw Spline Unit Replacement 81 11 Lithium Battery 88 11 1 Replacing the Battery Unit Lithium Battery 90 11 2 Replacing the Battery Board 91 12 LED Lamp 92 13 Calibration 93 13 1 About Calibration 93 13 2 Calibration Procedure 94 13 3 Accurate Calibration of Joint 2 103 13 4 Calibration Procedure without using Calibration Wizard 105...

Page 11: ...RS Maintenance This volume contains maintenance procedures with safety precautions for RS series Manipulators ...

Page 12: ......

Page 13: ... check it while you are outside of the safeguarded area Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly Before operating the robot system make sure that both the Emergency Stop switches and safeguard switch function properly Operating the robot system when the switches do not function ...

Page 14: ...ided 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 must be added every 250 hours 750 hours 1500 hours and 3000 hours operation h hour Inspection Point Daily inspection Monthly inspection Quarterly inspection Biannual inspection Annual inspection Overhaul...

Page 15: ...bolts are not loose When the bolts are loose refer to 2 4 Tightening Hexagon Socket Head Bolts and tighten them to the proper torque Check looseness of connectors Check that connectors are not loose When the connectors are loose reattach it not to come off Visually check for external defects Clean up if necessary Check the appearance of the Manipulator and clean up if necessary Check the appearanc...

Page 16: ... parts parts replacement The time between overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on ambient temperature 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...

Page 17: ... the View 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 Dialog image EPSON RC 7 0 For the parts subject to overhaul refer to 14 Maintenance Parts List For details of replacement of each part refer to each section Please contac...

Page 18: ...verhaul timing SK 1A 5 2 Replacing the Joint 1 Reduction Gear Unit 6 2 Replacing the Joint 2 Reduction Gear Unit Joint 3 Ball screw spline unit At 100 km of operation 50 km for first greasing AFB Greasing the Ball Screw Spline Unit See below Joint 1 2 reduction gear units As a rough indication perform greasing at the same timing as overhaul However it may vary depending on ambient temperature usag...

Page 19: ...he lower limit manually while pressing the brake release switch 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 the end effector Move the shaft to the lower limit manually while by selecting EPSON RC 7 0 menu Tools Robot Manager Jog Teach Be sure to keep enough space and prevent the end effector hitting ...

Page 20: ...t manager and move the shaft to the origin position Be careful not to hit peripheral equipment 8 After moving to the origin position reciprocate the shaft The reciprocating operation is a low power mode operation program that performs from the upper limit to the lower limit Run for about 5 minutes to spread the grease over the shaft 9 Turn OFF the controller End of the spline nut Figure RS3 351 10...

Page 21: ...switch is being pressed because the shaft may be lowered by the weight of the end effector Move the shaft to the upper limit manually while by selecting EPSON RC 7 0 menu Tools Robot Manager Jog Teach Be sure to keep enough space and prevent the end effector hitting any peripheral equipment Brake release switch Clamp band Lower bellows Brake release switch Illustration RS3 351C 3 Loosen the clamp ...

Page 22: ...s cut 10 Fix the lower bellows Move the shaft to the upper limit Insert the bellows mounted part until it touches the cylinder part of the cover Fit the rubber sheet Be sure to fit the rubber sheet so that no space is made between the bias cut Fix with the clamp band 11 After fitting move the shaft up and down several times and rotate Joint 4 Make sure that the bellows can expand and contract smoo...

Page 23: ...ce 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 Origins A...

Page 24: ...D lamp Joint 4 motor Cable unit 2 Z belt U1 belt Battery board Arm 2 cover Lithium battery Joint 1 reduction gear unit Joint 3 brake Signal cable Power cable Figure RS3 351S Arm 1 cover Joint 2 motor J2 belt Joint 4 reduction gear unit Joint 3 motor Ball screw spline unit Cable unit 1 Cleanroom model Bellows Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket Figure RS3 351C ...

Page 25: ...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 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 exi...

Page 26: ... cause the 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 When mounting Arm 1 cover be sure to check the air tubes and cables are secured as in the figure below Be careful not to squash the air tubes and cables with the cover If the maintenance wind...

Page 27: ... 1 Standard model For arm 1 under cover 4 M4 8 For arm 1 side cover 4 M4 15 For the arm 1 cover 4 M4 12 For arm 1 side cover 4 M4 15 J2 cover 4 M4 8 Truss 3 1 2 Cleanroom model Spacer Gasket Spacer Gasket Gasket Gaskets and spacers are installed to Cleanroom model ...

Page 28: ...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 1 Move the Arm 2 to the 180 degree For the arm position refer to the figure in 3 1 Arm 1 2 Remove the Arm 1 side cover on the Joint 2 side For details refer to 3 1 Arm 1 3 Remove the Arm 2 cover mounting bolt...

Page 29: ...e the under cover completely If it is not necessary to remove the cover completely move the shaft to the lower limit and lower the under cover Then perform maintenance or inspection When bellows are installed to the manipulator remove or pull down the lower bellows and then remove the under cover For bellows removal refer to 9 Bellows Standard model Cleanroom model 3 M4 10 Gasket 3 M4 10 A gasket ...

Page 30: ...fere with the plate mounting and do not bend these cables forcibly to push them into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables observe the cable locations aft...

Page 31: ...ate and disconnect the connectors Unscrew the bolts securing the base cover to remove the base cover Standard model Cleanroom model 8 M4 10 Base cover 6 M4 10 Connector plate 4 M4 8 4 M4 8 6 M4 10 Gasket Gasket Spacer Spacer Base cover 8 M4 10 Gasket Spacer Connector plate Gaskets and spacers are installed to the Cleanroom model ...

Page 32: ...Covers 22 RS series Maintenance Rev 3 3 5 User Plate Unscrew the user plate mounting bolts and remove the plate Standard model Cleanroom model 4 M4 8 4 M4 8 Gasket Spacer A gasket and spacer are installed to Cleanroom model ...

Page 33: ...stances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous and may result in electric shock and or malfunction of the robot system Be sure to remove the Manipulator with two or more people The Manipulator weight is as follows Be careful not to get hands fingers or feet caught and or hav...

Page 34: ... all joints and axes Name Quantity Note Maintenance parts Cable unit 1 Each manipulator model Refer to 14 Maintenance parts Battery Unit Lithium battery 3 2117879 Tools Hexagonal wrench width across flats 3 mm 1 For M4 screw Hexagonal wrench width across flats 4 mm 1 For M5 screw Hexagonal wrench width across flats 5 mm 1 For M6 screw Spanner width across flats 5 mm 1 For D sub connector removal N...

Page 35: ... 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 and or contact failure Damaged cables disconnection or contact failure is extremely haza...

Page 36: ...innest one first Cable 12 Remove the Arm 1 cover For details refer to 3 1 Arm 1 13 Cut off two wire ties bundling the cables Wire tie 14 Disconnect the ground wire 15 Pull out the tubes and cables upward in order of size with the thinnest one first Be careful about the connectors not to be caught 16 Remove the Arm 1 side cover and Arm 1 under cover For details refer to 3 1 Arm 1 17 Connect the spa...

Page 37: ... the Connector plate For details refer to 3 3 Connector plate 23 Remove the Base cover For details refer to 3 4 Base cover 24 Remove the D sub connector from the plate securing the cables 25 Remove three air tubes Cut off two wire ties bundling the cables Wire tie 26 Pull out the cable unit 2 and air tubes Be careful about the connector not to be caught ...

Page 38: ...r both ends of the cables with plastic bags The photo shows the one end covered with plastic bags The plastic bags prevent grease adhesion to the ends of connectors air tubes during the cable drawing 3 Insert the cables to the Joint 1 from the base side Be careful about the cable direction Refer to the connector label in Step 1 Insert the connectors in order of size with the largest one first and ...

Page 39: ...ubes and ground wire downward and secure them to the cable mounting plate with the wire tie When bundling the cables untangle the cables and put Arm 1 to the position of 90 degree end of the arm faces to the other side to the J1 motor Wire tie 9 Install the ground wire 10 Mark the position of the cable unit 2 using a permanent marker Arm 2 side Ground wire 600mm rough 150 Air tube 3 rough XU11 XU2...

Page 40: ...und wire 16 Connect the connectors Connectors X21 X22 X23 X30 XB22 XB23 X221 X231 XU10 XU20 Connector 17 Remove the spare battery from XB12 18 Secure the cables with the wire tie 19 Install the ground wire to the connector plate D sub cable Air tube Brake release switch 20 Connect the D sub cable connectors XU11 XU21 and air tubes connected to the inner side of connector plate 21 Put the cable uni...

Page 41: ...d Arm 2 maintenance cover without the cables being stuck For details refer to 3 2 Arm 2 26 Mount the Arm 1 cover Arm 1 side cover and Arm 1 under cover For details refer to 3 1 Arm 1 27 Install the Base cover For details refer to 3 4 Base Cover 28 Connect the connector and install the connector plate For derails refer to 3 3 Connector Plate 29 Perform the calibration of all axis ...

Page 42: ...RS3 RS4 Maintenance 4 Cable Unit 32 RS series Maintenance Rev 3 4 2 Wiring Diagrams 4 2 1 Signal Cable For the colors and symbols of the cables refer to 4 2 2 Power Cable Continues to the next page ...

Page 43: ...RS3 RS4 Maintenance 4 Cable Unit RS series Maintenance Rev 3 33 Continued from the previous page ...

Page 44: ...intenance 4 Cable Unit 34 RS series Maintenance Rev 3 4 2 2 Power Cable Continues to the next page Code Cable color Code Cable color B Black P Pink BR Brown R Red G Green V Violet L Blue W White O Orange Y Yellow ...

Page 45: ...RS3 RS4 Maintenance 4 Cable Unit RS series Maintenance Rev 3 35 Continued from the previous page ...

Page 46: ...e Code Cable color Code Cable color B Black R Red BR Brown V Violet G Green W White L Blue Y Yellow The following table shows the types of the cable unit Environment Model name Code Note S RS3 351 1514474 RS4 551 1547166 C RS3 351 1514475 Waterproof connector D sub RS4 551 1548346 ...

Page 47: ...per connection of the connectors may result in improper function of the robot system For details on the connections refer to 4 2 Wiring Diagrams When mounting the cover be careful not to allow the cables to interfere with the cover mounting and do not bend these cables forcibly to push them into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact ...

Page 48: ...ector has a unique number Each connector has a different shape Do not disconect the battery connectors X61 X62 X63 Otherwise the calibration must be executed M C Cable Installation 1 Connect new M C cable connectors to those of the Cable Unit Connect to the connectors of the Cable Unit with the same number 2 Mount the Connector Plate For details refer to 3 3 Connector Plate 3 Connect the power cab...

Page 49: ...er source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and ...

Page 50: ...13 g When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts Joint 1 motor Removal 1 Turn ON the Controller 2 Move the Manipulator Joint 1 to the origin 3 Turn OFF the Controller 4 Remove the connector plate For details refer to 3 3 Connector Plate 5 Disconnect the following connectors Connectors X10 X20 X30 X111 X121 X131 Hold the clip to remove Con...

Page 51: ...nit from the base Unscrew the bolts securing the Joint 1 motor plate and pull it upward to remove 4 M4 15 Joint 1 motor unit Washer 9 Remove the pulley from the Joint 1 motor 2 M5 8 set screw M5 Brass bushing Pulley 10 Remove the motor plate from the Joint 1 motor 4 M4 15 washer Motor plate ...

Page 52: ...the Joint 1 motor unit to secure the unit loosely Make sure that the gear grooves of the belt are fit into those of the pulleys completely Put the motor cable facing toward the other side of Joint 1 When securing the motor unit make sure the 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 J1 belt Pul...

Page 53: ...y board Connector X61 6 Mount the base cover For the details refer to 3 4 Base Cover 7 Connect the following connectors Connectors X10 X20 X30 X111 X121 X131 8 Mount the connector plate For details refer to 3 3 Connector Plate 9 Perform the calibration of Joint 1 For details refer to 13 Calibration ...

Page 54: ...exagon Socket Head Cap Bolts WARNING When removing the Manipulator from the base table 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 RS3 351 approx 17 kg 38 lb RS4 551 approx 19 kg 42 lb When removing the Manipulator from the base table support the Manipula...

Page 55: ...l out the Cable unit 1 except air tubes from the base side When pulling out the cables first pull out the air tubes from the Arm 1 side the other side to the cables And pull out from smaller connectors in order from the base side Wire tie Do not try to pull out the cables forcibly Otherwise connectors may be stuck disconnected or connector pins may fall off 8 Remove the Arm 1 12 M6 20 9 Remove the...

Page 56: ...ev 3 10 Remove the J1 ring falling off prevention screws and remove the J1 ring 12 M4 30 J1 flange J1 ring 2 M2 6 J1 ring falling off prevention screw O ring S90A Reduction gear unit 11 Remove the J1 flange with Metallic pipe Be sure to keep the O ring S90A ...

Page 57: ...alling off prevention screw O ring S90A Reduction gear unit 4 Set the J1 ring and secure the J1 ring falling off prevention screws Item Bolt type Number of bolts Tightening torque Joint 1 reduction gear unit M4 30 12 6 0 N m 61 2 kgf cm M6 15 8 22 0 N m 224 3 kgf cm 5 Set the O ring to the O ring S65A groove in the Base 16 M4 20 O ring S65A 6 Mount the reduction gear unit to the base Be sure to ke...

Page 58: ...ove the J1 motor unit Follow the steps in 5 1 Replacing Joint 1 Motor Removal 1 8 4 M4 15 J1 Motor unit Washer J1 belt 2 Remove the J1 belt J1 belt Installation 1 Mount the J1 belt to the pulley of the Joint 1 side 2 Mount the J1 motor unit Follow the steps in 5 1 Replacing Joint 1 Motor Installation 3 9 ...

Page 59: ...er source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and ...

Page 60: ...Length about 800 mm 1 For belt tension Wiping cloth 1 For wiping grease Material Wire tie 4 Grease Grease SK 1A 6 g When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts Joint 2 motor Removal 1 Remove the Arm 1 cover For details refer to 3 1 Arm 1 2 Remove the Arm 1 under cover For details refer to 3 1 Arm 1 3 Disconnect the following connectors Co...

Page 61: ...nit from the Arm 1 Unscrew the bolts securing the Joint 2 motor plate and pull the plate upward to remove 4 M4 15 Washer Joint 2 motor unit 6 Remove the pulley from the Joint 2 motor 2 M5 8 set screw M5 brass bushing Pulley 7 Remove the motor plate from the Joint 2 motor 4 M5 12 Motor plate ...

Page 62: ...to prevent damage to the motor shaft Then tighten both set screws 2 M5 8 set screw M5 brass bushing Pulley Motor shaft end face Pulley end face 3 Set the J2 belt around the pulley of the Joint 2 motor unit and secure the unit loosely Make sure the gear grooves of the belt are fit into those of the pulleys completely Set the motor cable facing toward the other side to J2 axis When securing the unit...

Page 63: ...Then pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right J2 belt tension 100N 10 2 kgf Force gauge 5 Insert the cables to Arm 1 6 Connect the connectors Connectors X21 X221 XB22 7 Mount the Arm 1 cover For details refer to 3 1 Arm 1 8 Mount the Arm 1 under cover For details refer to 3 1 Arm 1 9 Perform the calibration of Joint 2 For det...

Page 64: ... SK 1A 12 g When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts Joint 2 reduction gear unit Removal 1 Remove the Arm 1 cover For details refer to 3 1 Arm 1 2 Remove the Arm 1 under cover For details refer to 3 1 Arm 1 3 Disconnect the connectors Connectors X30 X23 XB23 X231 XU10 XU20 Hold the clip to remove 4 Put the cables over the J2 Wire tie 5...

Page 65: ...e Joint 2 motor unit toward the Joint 2 side 4 M4 5 Washer Joint 2 motor unit J2 belt Pulley 13 Remove the screws secured with nuts Nut 14 Use the holes and rotate the Arm 2 to remove the screws 16 M3 20 15 Pull out the cables except air tube to downward from Joint 1 Pull out cables in order of size smaller cables first Do not try to pull out the cables forcibly Otherwise connectors may be stuck d...

Page 66: ... RS series Maintenance Rev 3 16 Remove the J2 flange Be sure to keep the O ring S71A 16 M3 20 J2 flange O ring S71A 17 Remove the reduction gear unit Be sure to keep the O ring S53A 11 M3 25 1 M3 30 Nut O ring S53A Reduction gear unit ...

Page 67: ...p the O ring Item Bolt type Number of bolts Tightening torque Joint 2 reduction gear unit M3 25 11 3 0 N m 30 5 kgf M3 30 1 M3 20 16 4 Set the O ring S53A to the O ring groove in the J2 flange 16 M3 20 J2 flange O ring S53A 5 Mount the J2 flange Be sure to keep the O ring 6 Insert the cables to the Arm 7 Mount the Arm 2 16 M3 20 8 Mount J2 ring 2 M4 15 M4 20 J2 ring 9 Insert the air tube to Arm 2 ...

Page 68: ...the ground wire Wire tie 12 Along both sides of the motor insert the cables and tube in the Arm 1 13 Connect the connector 14 Mount the Arm 1 under cover and J2 cover For details refer to 3 1 Arm 1 15 Secure the Joint 2 motor and mount the cover Follow the steps in 6 1 Replacing Joint 2 Motor Installation 4 8 ...

Page 69: ...0 3 Push the metal pipe for the cable 4 Remove the J2 belt J2 belt Installation 1 Mount the J2 belt 2 Pull out the pipe for cables to the upper part of the arm Follow the steps in 6 2 Replacing Joint 2 Reduction Gear Unit Installation 8 10 3 Install the Joint 2 motor unit Follow the steps in 6 1 Replacing Joint 2 Motor Installation 3 6 4 Follow the steps in 6 2 Replacing Joint 2 Reduction Gear Uni...

Page 70: ...power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor a...

Page 71: ...ure by following the removal steps from 1 to 4 When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 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 Be careful of the shaft fallin...

Page 72: ... Z pulley from the Z belt Pull the Joint 3 motor unit upward to remove Pulley Z belt Joint 3 motor unit 11 Remove the brake unit from the Joint 3 motor unit Joint 3 motor unit 2 M5 8 Brake unit 12 Unscrew the screws securing the pulley to the Joint 3 motor Press the pulley toward the plate Remove the brake hub Remove the pulley and motor plate There is a brass bushing in one of the set screw holes...

Page 73: ...he pulley to the position touching the hub Put the one of the set screws and the flatly chamfered surface of motor shaft to touch vertically Insert the bushing into the other screw Secure the bushing to prevent damage from the motor shaft 4 Install the brake to the Joint 3 motor Align the position of the disk on the brake and the hub When the brake disk is not aligned connect the connector X32 Pre...

Page 74: ...ten remove screws Put the M4 wrench to the Joint 3 motor unit near its mounting plate And pass a suitable cord or string around the motor unit Then pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure Make sure that the brake cables do not touch the pulley 4 M4 15 washer Z belt tension 75N 7 7 kgf Force gauge Joint 3 Motor unit M4 wrench 9 Connect th...

Page 75: ...t before the replacement procedure following the removal steps When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts Z belt Removal 1 Remove the Joint 3 motor Follow the steps in 7 1 Replacing Joint 3 Motor Removal 1 10 2 Remove the Z belt Remove the volts securing the spline plate Hold up the spline plate and pull out the Z belt upward 3 M4 12 was...

Page 76: ...al Wire tie 3 A brake is mounted on the motor of Joint 3 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 Note that the brake will not work during the replacement procedure Move the shaft down to its lower limit before the replacement procedure following the removal steps When tighteni...

Page 77: ... of the motor shaft to touch vertically Insert the bushing into the other screw to prevent the damage from the motor shaft 3 Install the electromagnetic brake to the brake plate 2 M3 8 Brake plate 4 Install the brake to the Joint 3 motor Align the position of the disk on the brake and the hub When the brake disk is not aligned connect the connector X32 Press the brake release switch and release th...

Page 78: ...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 79: ...s refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 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 Be careful of the shaft falling while the brake release switch is being pressed because the shaft may be lowered by the w...

Page 80: ...n gear unit Remove the set screw Rotate the pulley until the screws fit into the holes Maintenance window Joint 4 motor unit Remove two set screws 12 Remove the Joint 4 motor 2 M4 15 Joint 4 reduction gear unit Joint 4 motor If the motor cannot be removed easily put a washer between the motor and reduction gear and use the motor mounting screws to press the motor equally from the reduction gear si...

Page 81: ...ws Close the maintenance windows Maintenance window Joint 4 motor unit 3 Place the Joint 4 motor unit in the arm so that the motor cable faces toward the right side of arm 3 M4 15 washer Joint 4 motor unit 4 Place the U belt around the U pulley so that the gear grooves of the belt are fit into those of the pulley completely U pulley U belt Joint 4 motor unit 5 Loosely secure the Joint 4 motor unit...

Page 82: ...ing a force gauge or similar tool to apply the specified tension shown in the figure 4 M4 15 washer U belt tension 120 N 12 2 kgf Force gauge Joint 4 motor unit M4 wrench 7 Connect the connectors X341 X41 XB34 8 Re bundle the cables in their original positions with a wire tie removed in step 7 Do not allow unnecessary strain on the cables 9 Install the Arm 2 cover For details refer to 3 2 Arm 2 10...

Page 83: ...lowing the removal steps 1 4 When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts U 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 Be careful of the shaft falling while the brake release...

Page 84: ...Pulley Z belt Joint 3 motor unit 11 Loosen the U belt Loosen the four bolts securing the Joint 4 motor unit Slide the Joint 4 motor unit toward the end of arm 3 M4 15 washer Joint 4 motor unit 12 Remove the Joint 4 motor unit from Arm 2 First remove the bolts securing the Joint 4 motor unit Next remove the U pulley from the U belt Pull out the Joint 4 motor unit to remove U pulley U belt Joint 4 m...

Page 85: ...o Arm 2 Check that the motor unit can be moved by hand and it will not tilt when pulled If the units are secured too loose or too tight the belt will not have the proper tension 6 Apply the proper tension to the U belt and then secure the Joint 4 motor unit Hexagonal wrench Stubby type makes it easier to tighten remove the screws To do so pass a suitable cord or string around the Joint 4 intermedi...

Page 86: ...tring around the Joint 4 intermediate shaft unit near its mounting plate Then pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right Make sure the brake cable not to touch the pulley 4 M4 15 washer Z belt tension 75N 7 7 kgf Force gauge Joint 3 Motor unit M4 wrench 11 Connect the connectors Connector X331 X31 X32 X341 X41 XB33 XB34 12 Re b...

Page 87: ...r unit Removal 1 Remove the Joint 4 motor unit from Arm 2 and remove the motor Follow the steps in 8 1 Replacing Joint 4 Motor Removal 1 12 2 Remove the reduction gear unit Remove the U pulley and remove the Joint 4 reduction gear unit from U axis plate 3 M4 20 4 M3 15 Joint 4 reduction gear unit U axis plate U pulley Joint 4 reduction gear unit Installation 1 Mount the reduction gear unit At this...

Page 88: ...ce parts Bellows 100 mm 1 1510547 Tools Cross point screwdriver 1 For clamp band removal Material Liquid gasket 1 Bellows Removal 1 Remove the end effector 2 Remove the wires and tubes from the end effector 3 Turn ON the controller Stop motor excitation MOTOR OFF 4 Remove the mechanical stop Bellows Clamp band big Clamp band small Mechanical stop 5 Loosen the cramp band securing above and below th...

Page 89: ...ows 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 Be careful not to misplace the clamp bands The clamp band has two sizes small and large Attach the mounting part of the bellows until the end touches the cylindrical part of the cover Bellows cover side Attach the rubber sheet Be sure to attach the rubber shee...

Page 90: ...heet so that no space is made between the bias cut Bias cut Then secure them with clamp bands Bellows Bearing case Mechanical stop 8 After completing the attachment of the bellows move the shaft up down by hand several times and rotate Joint 4 Make sure that the bellows can expand and contract smoothly without any excessive force 9 Turn OFF the Controller and peripheral equipment 10 Attach the end...

Page 91: ...wer 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 moto...

Page 92: ...emoval steps from 1 to 3 When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 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 Be careful of the shaft falling while the b...

Page 93: ...or unit Pulley Z belt Joint 3 motor unit 12 Loosen the U belt Loosen four bolts securing the Joint 4 motor Slide the Joint 4 motor unit toward the arm end 3 M4 15 washer Joint 4 motor unit 13 Remove the Joint 4 motor unit from Arm 2 First remove the bolts securing the Joint 4 motor Next remove the U pulley from the U belt and pull out the Joint 4 motor unit Joint 4 motor unit U belt U pulley 14 Re...

Page 94: ... Replacement 84 RS series Maintenance Rev 3 15 Remove the under cover For details refer to 3 2 Arm 2 16 Remove the nut mounting screws of the ball screw spline shaft on the underside of Arm 2 4 M4 12 17 Pull the ball screw spline unit out of Arm 2 ...

Page 95: ...under cover For details refer to 3 2 Arm 2 4 Loosely secure the spline plate to Arm 2 Secure the spline plate to Arm 2 after moving the shaft up and down several times U belt 3 M4 12 washer Spline plate Z belt 5 Place the Joint 4 motor unit back to Arm 2 3 M4 15 washer Joint 4 motor unit 6 Set the U belt around the U pulley so that the gear grooves of the belt are fit into those of the pulleys com...

Page 96: ...specified tension shown in the figure 4 M4 15 washer Z belt tension 120 N 12 2 kgf Force gauge Joint 4 Motor unit M4 wrench 9 Place the Joint 3 motor unit back to Arm 2 so that the motor cable faces toward the right side of arm 4 M4 15 washer Joint 3 motor unit 10 Put the Z belt around the Z pulley so that the gear grooves of the belt are fit into those of the pulleys completely Pulley Z belt Join...

Page 97: ...X331 X31 X32 X341 X41 Connector XB33 XB34 14 Re bundle the cables in their original positions with a wire tie removed in Removal step 8 Do not allow unnecessary strain on the cables 15 If the position of the lower limit mechanical stop was changed for area limit secure it to the proper position 16 Grease the shaft For details refer to 10 1 Greasing the Ball Screw Spline Unit 17 Install the Arm 2 c...

Page 98: ... leakage explosion or inflammation and may cause serious safety problems Improper Handling Forced Discharge Deformation by Pressure Short circuit Polarity Positive Negative Heating 85 C or more Soldering the terminal of the lithium battery directly Battery Charge Disassembly Incorrect Installation Exposing to Fire When disposing of the battery consult with the professional disposal services or com...

Page 99: ... warnings of voltage reduction occur the calibration for all joints is not necessary You need to perform calibration if the position moves from the originals after replaced the battery Always use the lithium battery and battery board designated by us Refer to 14 Maintenance Parts List Be careful of the battery polarity to connect it correctly Name Quantity Note Maintenance parts Battery unit Lithi...

Page 100: ...ation must be executed again 4 Cut off the wire tie banding the cables of lithium battery X60A X60B Wire tie Battery board J1 cable plate 5 Cut off the wire tie banding the lithium battery Remove the battery Battery unit lithium battery Installation 1 Mount the new lithium battery to the battery board 2 Fix the cable of lithium battery and connector cable connecting to battery board with wire tie ...

Page 101: ...r plate and base cover For details refer to 3 3 Connector Plate and 3 4 Base Cover 3 Disconnect the following connectors from the battery board Connectors X60 X61 X62 X63 X64 Battery board X61 X62 X63 X64 X60B X60A 4 Loosen the screws securing the battery board and remove the battery board Battery board 5 Cut the wire tie securing the battery and remove the battery Battery board Installation 1 Mou...

Page 102: ...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 Name Quantity Note Maintenance parts LED Lamp 1 1661726 Tools Hexagonal wrench width across flats 3 mm 1 For M4 screw When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon So...

Page 103: ...ing 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 safeguarded area is extremely haza...

Page 104: ...to be calibrated accurately Execute the procedure in Calibration Using Right Left Arm Orientations to accurately calibrate Joint 2 For details refer to 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 The reference point a point to identify the position of t...

Page 105: ...RS series Maintenance Rev 3 95 2 Confirm the warning message and click the Yes button 3 Move the joint to calibrate manually to approximate zero position Joint 1 90 deg as shown in the dialog After moving the joint click the Next button ...

Page 106: ...0 pulse position of Joint 3 upper limit position in motion range The height of Joint 3 depends on manipulator model Standard model Cleanroom model Upper limit 0 pulse Turn the shaft flat surface to the inner side of Arm RS3 351S 48 5 mm RS4 551S 45 5 mm RS3 351C 74 5 mm RS4 551C 73 5 mm 0 pulse position of Joint 4 position where the flat surface or groove in mechanical stop on the shaft faces towa...

Page 107: ...3 97 4 Click the Yes button to reset the encoder 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 7 Click the Jog button to display the Jog Teach dialog ...

Page 108: ...3 8 Jog the end effector to approximate reference point in the Jog Teach dialog for rough calibration Then click the OK button 9 Click the Next button 10 The manipulator moves to the reference point Click the Execute button Input JUMP P0 z 0 Point selected in step 6 ...

Page 109: ...ance 13 Calibration RS series Maintenance Rev 3 99 11 Confirm the message and click the Yes button 12 After the manipulator moves to the reference point click the Next button 13 Jog to the accurate reference position ...

Page 110: ...n click the OK button Position Joint 2 only and move Joint 3 to around 0 pulse 15 Click the Next button 16 Execute the procedures 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 ...

Page 111: ...RS3 RS4 Maintenance 13 Calibration RS series Maintenance Rev 3 101 ii Jog to the accurate reference position iii Jog to the accurate reference position and adjust the position Click the OK button ...

Page 112: ...bration 102 RS series Maintenance Rev 3 iv Click the Next button 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 113: ...t on the end of the shaft to make the center of the shaft clear Decide a target point and mark a cross on it so that you can easily verify the center of the shaft after switching the arm pose between right and left Calibration jig at the end of the shaft Example Target point The center of the shaft After removing the end effector and performing the calibration install the end effector and move the...

Page 114: ... from right to lefty click the Free All button 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 H...

Page 115: ...ibrating Joint 4 you must calibrate Joint 3 and 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 perform the calibration using the point data currently registered Confirm the point data number P...

Page 116: ... 0 pulse position of Joint 3 upper limit position in motion range The height of Joint 3 depends on manipulator model Standard model Cleanroom model Upper limit 0 pulse Turn the shaft flat surface to the inner side of Arm RS3 351S 48 5 mm RS4 551S 45 5 mm RS3 351C 74 5 mm RS4 551C 73 5 mm 0 pulse position of Joint 4 position where the flat surface or groove in mechanical stop on the shaft faces tow...

Page 117: ... 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 Tools Command Window Joint 1 calib 1 Joint 2 calib 2 Joint 3 calib 3 Joi...

Page 118: ...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 1 Calib 1 Joint 2 Calib 2 Joint 3 ...

Page 119: ...97639 R13B030501 7 3 Timing Belt Joint 1 1510524 R13B030216 Width 15 mm Length 270 mm 5 3 Joint 2 1510525 R13B030217 Width 10 mm Length 246 mm 6 3 Joint 3 1510526 R13B030218 Width 9 mm Length 246 mm 7 2 Joint 4 1510527 R13B030219 Width 12 mm Length 339 mm 8 2 Battery Board 2126750 R13B041203 No lithium battery Installed in Base 11 2 Battery Unit 2117879 R13ZA00600 300 Spare lithium battery ER17330...

Page 120: ...2640100 As a rough indication perform the overhaul parts replacement before reaching 20 000 operation hours of the Manipulator The operation hours can be checked in Controller Status Viewer dialog Motor On Hours For details refer to 2 2 Overhaul Parts Replacement Regarding purchase of grease Due to the chemicals regulations of individual countries the UN GHS we are requesting our customers to purc...

Page 121: ... 2 1 Bellows 1510547 R13B030705 9 Gasket Unit 1514477 R13B031240 RS3 351 3 1548345 R13B031254 RS4 551 Liquid gasket KE3497W For purchasing the liquid gasket please contact the supplier of your region 9 As a rough indication perform the overhaul parts replacement before reaching 20 000 operation hours of the Manipulator The operation hours can be checked in Controller Status Viewer dialog Motor On ...

Page 122: ...RS3 RS4 Maintenance 14 Maintenance Parts List 112 RS series Maintenance Rev 3 ...

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