Epson LS series Manipulator Manual Download

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Rev.10

EM16XR3299F

SCARA ROBOT

LS series

MANIPULATOR MANUAL

Summary of Contents for LS series

Page 1: ...Rev 10 EM16XR3299F SCARA ROBOT LS series MANIPULATOR MANUAL ...

Page 2: ...MANIPULATOR MANUAL LS series Rev 10 ...

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: ...ombinations of Controllers and software TYPE A Controller Software RC90 EPSON RC 5 0 LS3 401 LS6 602 RC90 Controller Firmware Version Ver 3 0 EPSON RC 5 0 Before Ver 5 4 0 Ver 5 4 1 or later OK OK Compatible All functions of the EPSON RC 5 0 and the Controller are available Compatible Connection is OK We recommend using EPSON RC 5 0 Ver 5 4 1 or later Controller firmware update cannot be executed ...

Page 8: ...serial No L6 00 LS6 602 RC90 controller firmware Ver 7 0 2 0 or later EPSON RC 7 0 Before Ver 7 0 1 Ver 7 0 2 or later OK OK Compatible All functions of the EPSON RC 7 0 and the Controller are available Compatible Connection is OK We recommend using EPSON RC 7 0 Ver 7 0 2 or later Manipulator serial No L6 01 or later LS6 502 LS6 602 LS6 702 RC90 controller firmware Ver 7 1 6 0 or later EPSON RC 7 ...

Page 9: ...or 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 Standard model Manipulator Unless special instruction is provid...

Page 10: ...viii LS Rev 10 ...

Page 11: ...S3 18 2 3 2 LS6 22 2 4 Specifications 26 2 5 How to Set the Model 28 3 Environments and Installation 29 3 1 Environmental Conditions 29 3 2 Base Table 30 3 3 Mounting Dimensions 31 3 3 1 LS3 31 3 3 2 LS6 33 3 4 Unpacking and Transportation 35 3 5 Installation Procedure 36 3 5 1 Standard Model 37 3 5 2 Cleanroom Model 38 3 6 Connecting the Cables 39 3 7 User Wires and Pneumatic Tubes 40 3 8 Relocat...

Page 12: ...62 5 4 Standard Motion Range 62 Maintenance 1 Safety Maintenance 65 2 General Maintenance 66 2 1 Maintenance Inspection 66 2 1 1 Schedule for Maintenance Inspection 66 2 1 2 Inspection Point 67 2 2 Overhaul Parts Replacement 68 2 3 Greasing 70 2 4 Tightening Hexagon Socket Head Cap Bolts 71 2 5 Matching Origins 72 2 6 Layout of Maintenance Parts 73 3 Covers 74 3 1 Arm Top Cover 75 3 2 Arm Bottom C...

Page 13: ...e Timing Belt Tension U1 U2 Belts 137 9 Bellows 138 10 Ball Screw Spline Unit 140 10 1 Greasing the Ball Screw Spline Unit 140 10 1 1 Standard model S type 141 10 1 2 Cleanroom model 142 10 2 Replacing the Ball Screw Spline Unit 143 11 Lithium Battery and Boards 146 11 1 Replacing the Battery Unit Lithium Battery 148 11 2 Replacing the Resolver Board 149 11 3 Replacing the Control Board 151 12 LED...

Page 14: ...TABLE OF CONTENTS xii LS Rev 10 ...

Page 15: ...Setup Operation This volume contains information for setup and operation of the LS series Manipulators Please read this volume thoroughly before setting up and operating the Manipulators ...

Page 16: ......

Page 17: ...tions 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 ins...

Page 18: ... 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 19: ...e 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 LS3 M 13 000 N mm LS6 M 27 000 N mm Example If 100 N load is applied at 200 mm from the end of the spline nut Moment M F L...

Page 20: ...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 21: ...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 22: ...eration makes the brakes work This will shorten the life of the brakes due to the worn friction plates Normal brake life About 2 years when the brakes are used 100 times day Do not turn OFF the Controller while the Manipulator is operating If you attempt to stop the Manipulator in emergency situations such as Safeguard Open make sure to stop the Manipulator using the Emergency Stop switch of the C...

Page 23: ...nipulator cannot stop immediately after the Emergency Stop switch is pressed The free running time angle distance of the Manipulator are shown below However remember that the values vary depending on following conditions Weight of the end effector Weight of work piece Operating pose Weight Speed Accel etc Conditions for Measurement LS3 401 LS6 602 Accel Setting 100 100 Speed Setting 100 100 Load k...

Page 24: ... the Emergency Stop switch of the Controller If the Manipulator is stopped by turning OFF the Controller while it is operating following problems may occur Reduction of the life and damage of the reduction gear unit Position gap at the joints In addition if the Controller was forced to be turned OFF by blackouts and the like while the Manipulator is operating make sure to check the following point...

Page 25: ... 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 LS3 401 LS6 502 602 702 Accel Setting 100 100 Speed Setting 100 100 Load kg 3 6 Weight Setting 3 6 Joint 1 Point where the emergency stop signal is input Start point of operation Target point Stop p...

Page 26: ...le pressing the brake release switch Joint 3 brake release switch Joint 1 rotating Joint 2 rotating Joint 3 up and down Joint 4 rotating Arm 1 Arm 2 Shaft Figure LS3 401S LS3 The brake release switch affects only Joint 3 When the brake release switch is pressed in emergency mode the brake for Joint 3 is released Be careful of the shaft while the brake release switch is pressed because the shaft ma...

Page 27: ...height mm Tip load 1 kg or less 2 kg or less 3 kg or less __ 0 Z _ 50 25000 or less 25000 or less 22500 or less _ 50 Z 100 22500 or less 15000 or less 100 Z 150 17500 or less 10000 or less LS6 Z axis height mm Tip load 2 kg or less 4 kg or less 6 kg or less __ 0 Z _ 50 25000 or less 25000 or less 25000 or less _ 50 Z 100 15000 or less 100 Z 150 17500 or less 12500 or less 150 Z 200 15000 or less 1...

Page 28: ...Warning Label NOTE A Before loosening the base mounting screws hold the arm and secure it tightly with a band to prevent hands or fingers from being caught in the Manipulator B Do not enter the operation area while the Manipulator is moving The robot arm may collide against the operator This is extremely hazardous and may result in serious safety problems C Hazardous voltage exists while the Manip...

Page 29: ...Setup Operation 1 Safety LS Rev 10 15 LS3 C A D B C E Opposite side Figure LS3 401S LS6 C Arm Top Cover A D B C E Opposite side Figure LS6 602S ...

Page 30: ...rdly 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 12 kg m2 LS6 0 05 kg m2 LS3 It stably handles large loads by optimized control based on the each load Tact Time Improvement by High speed Motion It improves the tact time of long r...

Page 31: ...ment 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 Models Payload Arm length Environment Joint 3 stroke Model Number 3 kg 400 mm Standard 150 mm LS3 401S Cleanroom 120 mm LS3 401C 6 kg 500 mm Standard 200 mm LS6 502S Cleanroom 170 m...

Page 32: ...r ø6 mm pneumatic tube Fittings white for ø6 mm pneumatic tube User connector 15 pin D sub connector LED lamp CE label The brake release switch affects only Joint 3 When the brake release switch is pressed in emergency mode the brake for Joint 3 is released While the LED lamp is on the current is being applied to the manipulator Performing any work with the power ON is extremely hazardous and it m...

Page 33: ...ations LS Rev 10 19 Standard Model LS3 401S shaft diameter Max ø11 through hole mechanical stop diameter Conical hole Ø3 90 1 mm flat Detail view from A 90 or more Space for cables indicates the stroke margin by mechanical stop ...

Page 34: ...ications 20 LS Rev 10 Cleanroom Model LS3 401C The following figures show the additional parts and specifications for Cleanroom model when compared with the Standard model in appearance Upper bellows Exhaust port Lower bellows ...

Page 35: ... LS Rev 10 21 Cleanroom Model LS3 401C indicates the stroke margin by mechanical stop 90 or more Space for cables φ16 h7 shaft diameter Max ø11 through hole φ30 mechanical stop diameter Conical hole Ø3 90 1 mm flat Detail view from A ...

Page 36: ...neumatic tube User connector 15 pin D sub connector LED lamp CE label 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 the power ON is extremely hazardous and it may resul...

Page 37: ...Setup Operation 2 Specifications LS Rev 10 23 Standard Model LS6 2S indicates the stroke margin by mechanical stop Detail view from A ...

Page 38: ...fications 24 LS Rev 10 Cleanroom Model LS6 2C The following figures show the additional parts and specifications for Cleanroom model when compared with the Standard model in appearance Upper bellows Exhaust port Lower bellows ...

Page 39: ...Setup Operation 2 Specifications LS Rev 10 25 Cleanroom Model LS6 2C indicates the stroke margin by mechanical stop Detail view from A ...

Page 40: ...lse Joint 4 0 001927 deg pulse 0 001465 deg pulse Hand Shaft diameter ø 16 mm ø 20 mm Through hole ø 11 mm ø 14 mm Mounting hole 120 120 mm 135 120 mm Free choice of either hole 150 150 mm 4 M8 Weight cables not included 14 kg 31 lb 50 17 kg 37 5 lb 60 17 kg 37 5 lb 70 18 kg 39 7 lb Driving method All joints AC servo motor Motor energy consumption Joint 1 200 W Joint 2 100 W 200 W Joint 3 100 W Jo...

Page 41: ...rm cover interior together A crack or other opening in the base unit can cause loss of negative air pressure in the outer part of the arm which can cause increased dust emission Seal the exhaust port 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 ISO...

Page 42: ... 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 whe...

Page 43: ... 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 an...

Page 44: ...2 9 For dimensions refer to Setup Operation 3 3 Mounting Dimensions The plate for the Manipulator mounting face should be 20 mm thick or more and made of steel to reduce vibration The surface roughness of the steel plate should be 25 μm or less The table must 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 ...

Page 45: ...ces in addition to the space required for mounting the Manipulator Controller and peripheral equipment Space for teaching Space for maintenance and inspection Ensure a space to open the covers and plates for maintenance Space for cables The minimum bend radius of the power cable is 90 mm When installing the cable be sure to maintain sufficient distance from obstacles In addition leave enough space...

Page 46: ...Setup Operation 3 Environments and Installation 32 LS Rev 10 Cleanroom Model LS3 401C Center of Joint 3 Maximum space Motion range Area limited by mechanical stop Base mounting face ...

Page 47: ...02S a Arm 1 Arm 2 length mm 500 600 700 b Arm 1 length mm 225 325 425 c Arm 2 length mm 275 d Joint 1 motion angle deg 132 e Joint 2 motion angle deg 150 f Motion range 138 1 162 6 232 0 g Motion range at the rear 425 6 492 5 559 4 h Angle of the Joint 1 mechanical stop deg 2 8 i Angle of the Joint 2 mechanical stop deg 4 2 j Mechanical stop area 121 8 142 5 214 0 k Mechanical stop area at the rea...

Page 48: ...S6 702C a Arm 1 Arm 2 length mm 500 600 700 b Arm 1 length mm 225 325 425 c Arm 2 length mm 275 d Joint 1 motion angle deg 132 e Joint 2 motion angle deg 150 f Motion range 138 1 162 6 232 0 g Motion range at the rear 425 6 492 5 559 4 h Angle of the Joint 1 mechanical stop deg 2 8 i Angle of the Joint 2 mechanical stop deg 4 2 j Mechanical stop area 121 8 142 5 214 0 k Mechanical stop area at the...

Page 49: ...fall Be careful not to get hands or fingers caught The arm is secured with a wire tie Leave the wire tie secured until you finish the installation so as not to get hands or fingers caught To carry the Manipulator have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure bottom of Arm 1 and bottom of the base by hand...

Page 50: ...interference with buildings structures utilities other machines and equipment that may create a trapping hazard or pinch points Oscillation resonance may occur during operation depending on rigidity of the installation table If the oscillation occurs improve rigidity of the table or change the speed or acceleration and deceleration settings ...

Page 51: ...18 kg 39 7 lb 1 Secure the base to the base table with four bolts Use bolts with specifications conforming to ISO898 1 Property Class 10 9 or 12 9 Tightening torque 32 0 N m 326 kgf cm 10 mm 4 M8 25 Screw Hole depth 20 mm or more Spring Washer Plane Washer LS6 only 2 Using nippers cut off the wire tie binding the shaft and arm retaining bracket on the base Wire tie Bolt M4 20 Bolt M4 20 LS6 only 3...

Page 52: ...y 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 53: ...mely hazardous 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 s...

Page 54: ... connectors on both ends of the cables are connected Pneumatic Tubes Max Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter Inner Diameter 0 59 MPa 6 kgf cm2 86 psi 2 ø 6 mm ø 4 mm 1 ø 4 mm ø 2 5 mm Fittings for ø6 mm and ø4 mm outer diameter pneumatic tubes are supplied on both ends of the pneumatic tubes Fitting black or blue for ø4 mm pneumatic tube Detail view from A Detail view from B A...

Page 55: ...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 56: ...ower on all devices and unplug the cables Remove the mechanical stops if using them to limit the motion range of Joints 1 and 2 For details on the motion range refer to Setup Operation 5 2 Motion Range Setting by Mechanical Stops 2 Cover the arm with a sheet so that the arm will not be damaged Tie the lower end of the shaft and arm and the base and arm together with the wire tie Be careful not to ...

Page 57: ...tions Do not move the upper limit mechanical stop on the lower side of the shaft Otherwise when Jump motion is performed the upper limit mechanical stop may hit the Manipulator and the robot system may not function properly Use a split muff coupling with an M4 bolt or larger to attach the end effector to the shaft Brake release switch LS3 Joint 3 cannot be moved up down by hand because the solenoi...

Page 58: ...tor turn ON the Controller and move the joint up down or rotate the joint while pressing the brake release switch This button switch is a momentary type the brake is released only while the button switch is being pressed The respective brakes for Joints 3 and 4 are released simultaneously Be careful of the shaft while the brake release switch is being pressed because the shaft may be lowered by th...

Page 59: ...v 10 45 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 LS3 From the base mounting face LS6 From the base mounting face ...

Page 60: ...th loads exceeding LS3 3 kg LS6 6 kg Always set the Weight parameters according to the load Setting a value that is smaller than the actual load may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable weight capacity end effector and work piece in LS series is LS3 1 kg at the default rating 3 kg at the maximum LS6 2...

Page 61: ...end of the LS3 series arm 180 mm away from the rotation center of Joint 2 with a load weight of 1 kg M 1 L2 175 LM 225 WM 1 2252 1752 1 653 1 7 round up W WM 1 1 7 2 7 Enter 2 7 for the Weight Parameter Shaft Weight of camera M 1kg W 1kg L2 175 mm LM 225 mm Joint 2 Automatic speed setting by Weight LS3 140 120 100 80 60 40 20 0 1 2 3 kg Weight setting The percentage in the graph is based on the sp...

Page 62: ...80 60 40 20 0 1 2 3 kg Weight setting The percentage in the graph is based on the acceleration deceleration at rated weight 3 kg as 100 90 110 100 60 LS6 140 120 100 80 60 40 20 0 1 2 3 4 5 6 kg Weight setting The percentage in the graph is based on the acceleration deceleration at rated weight 6 kg as 100 100 80 75 70 65 105 ...

Page 63: ...han the actual moment of inertia may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable moment of inertia of load for a LS series Manipulator is LS3 0 005 kg m2 at the default rating and 0 05 kg m2 at the maximum LS6 0 01 kg m2 at the default rating and 0 12 kg m2 at the maximum When the moment of inertia of the lo...

Page 64: ...m Always set the eccentric quantity parameter according to the eccentric quantity Setting a value that is smaller than the actual eccentric quantity may cause errors excessive shock insufficient function of the Manipulator and or shorten the life cycle of parts mechanisms The acceptable eccentric quantity of load in LS series is 0 mm at the default rating and LS3 100 mm LS6 150 mm at the maximum W...

Page 65: ...nel Tools Robot Manager You may also execute the Inertia command from the Command Window Automatic acceleration deceleration setting by Inertia eccentric quantity LS3 The percentage in the graph is based on the acceleration deceleration at rated eccentricity 0 mm as 100 120 100 80 60 40 20 0 50 75 100 mm Eccentricity setting 60 40 25 100 LS6 The percentage in the graph is based on the acceleration...

Page 66: ... 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 the basic formulas a Moment of inertia of a rectangular parallelepiped h b L Mass m Rectangular parallelepiped s center of gr...

Page 67: ...Joint 3 up and down Adjust the position of Joint 3 for the Manipulator motion after considering the relation between the current position and the destination position The upper limit of Joint 3 during horizontal motion using Jump command can be set by the LimZ command Automatic acceleration deceleration vs Joint 3 position LS3 120 100 80 60 40 20 0 50 100 150 mm Shaft height Figures on the graph a...

Page 68: ...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 69: ...e value is defined as the negative Y X 0 pulse B B A A A Max Motion Range B Max Pulse Range LS3 132 deg 95574 505174 pulse LS6 152918 808278 pulse 5 1 2 Max Pulse Range of Joint 2 The 0 zero pulse position of Joint 2 is the position where Arm 2 is in line with Arm 1 With the 0 pulse as a starting point the counterclockwise pulse value is defined as the positive and the clockwise pulse value is def...

Page 70: ...LS6 2S Standard model 200 mm 245760 pulse LS6 2C Cleanroom model 170 mm 208896 pulse For the Cleanroom model LS3 401C LS6 2C 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 count...

Page 71: ...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 72: ...ponding to the angle that you want to set Install the bolts for the mechanical stop to the following position Views from the bottom of Arm 1 a b Joint 1 Mechanical Stops a b LS3 Setting Angle 110 deg 110 deg Pulse Value 455112 pulse 45512 pulse LS6 Setting Angle 115 deg 115 deg Pulse Value 746383 pulse 91023 pulse Views from the top of Arm 1 b a Joint 2 Mechanical Stops a b LS3 LS6 Setting Angle 1...

Page 73: ...s the positions of the minimum and maximum pulse range Make sure that the arm does not hit the mechanical stops Check the position of the mechanical stop and the motion range you set Example Using LS3 401S 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 t...

Page 74: ...the shaft by hand while pressing the button 3 Turn OFF the Controller 4 Loosen the lower limit mechanical stop screw M3 10 A mechanical stop is mounted on both the top and bottom of Joint 3 However only the position of the lower limit mechanical stop on the top can be changed Do not remove the upper limit mechanical stop on the bottom because the calibration point of Joint 3 is specified using the...

Page 75: ...sing 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 whethe...

Page 76: ...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 77: ...Maintenance This volume contains maintenance procedures with safety precautions for LS series Manipulators ...

Page 78: ...64 ...

Page 79: ...rses Do not enter the operating area while the power is ON Entering the operating area with the power ON is extremely hazardous and may cause serious safety problems as the Manipulator may move even it seems to be stopped When you check the operation of the Manipulator after replacing parts be sure to check it while you are outside of the safeguarded area Checking the operation of the Manipulator ...

Page 80: ... trouble and ensuring safety Be sure to perform the maintenance inspections in accordance with the schedule 2 1 Maintenance Inspection 2 1 1 Schedule for Maintenance Inspection Inspection points are divided into five stages daily monthly quarterly biannual and annual The inspection points are added every stage If the Manipulator is operated for 250 hours or longer per month the inspection points m...

Page 81: ... 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 82: ...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 83: ...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 17 Maintenance Parts List For details of replacement of each part refer to the Maintenance section Please contact the distribut...

Page 84: ... 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 at the same timing as overhaul However it may vary depending on usage condition and degree of the load such as when operate...

Page 85: ...t Tightening Torque Refer below for the set screw M3 2 0 0 1 N m 21 1 kgf cm Set Screw Tightening Torque M4 4 0 0 2 N m 41 2 kgf cm M4 2 4 0 1 N m 26 1 kgf cm M5 8 0 0 4 N m 82 4 kgf cm M5 3 9 0 2 N m 40 2 kgf cm M6 13 0 0 6 N m 133 6 kgf cm M8 32 0 1 6 N m 326 16 kgf cm M10 58 0 2 9 N m 590 30 kgf cm M12 100 0 5 0 N m 1 020 51 kgf cm The bolts aligned on a circumference should be fastened in a cr...

Page 86: ...ed in the Controller After replacing the parts it is necessary to match these origins For calibration the pulse values for a specific position must be recorded in advance Before replacing parts select easy point pose data from the registered point data to check the accuracy Then follow the steps below to display the pulse values and record them Execute the following command from the Command Window...

Page 87: ...se switch Ball screw spline unit Joint 3 motor Cable unit Z belt U1 belt Joint 2 motor Arm cover U2 belt Joint 3 brake LED lamp Power cable Signal cable Joint 4 motor Palgen Intermediate pulley Control board Resolver board Figure LS3 401S 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 LS...

Page 88: ...o 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 B...

Page 89: ...over 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 careful for user wires and tubes when removing the cover 4 M4 12 Truss 4 M4 8 Arm Top Cover Arm Top Cover Installation Put the arm top cover to the arm and secure with the Arm Top Cover mounting bolts After securing the Arm Top Cover ma...

Page 90: ... 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 the plate The fittings position and size of the Connector Plate are different...

Page 91: ...d 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 mounting bolts and remove the plate The fittings position and size of the...

Page 92: ...he 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 m...

Page 93: ... 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 LS3 401 1668313 LS6 502 1675508 LS6 602 1668314 LS6 702 1675509 Battery Unit 1 R13B060007 Lithium battery for replacement A set of 3 batteries Tools Hexagonal wrench width across flats 3 mm 1 For M4 screw width across flats 4 mm 1 For M5 screw...

Page 94: ...s 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 and or contact failure Damaged cables disconnection or contact...

Page 95: ...connectors from thee controller 4 Remove the Connector Plate For details refer to Maintenance 3 3 Connector Plate 5 Remove the following that connected to the Connector Plate and Connector Sub Plate Air tube D sub cable Connector X121 X131 6 Remove the ground wire that secured on the base side cable fixing plate 7 Pull out the signal connector from the resolver board Remember the cable layout for ...

Page 96: ...and pull out the cables from the User Plate 16 Remove the nut that secures the cable duct fittings to the Base Remove the signal connector X20 connected to the resolver board at the back side and pull out the cables from the Base Base side Ground Wire Cable Mounting Plate Arm 2 side Nut 2 M4 10 Ground wire ...

Page 97: ...e removal step 8 6 Connect the air tube and the D sub cable to the User Plate 7 Mount the User Plate For the details refer to Maintenance 3 5 User Plate 8 Connect the connectors X21 X31 X41 X22 X32 X33 X35 X221 X231 X241 9 Mount the ground wire in the Arm side to the Z motor plate 10 Bind the cables with a wire tie in their original position as before removed in the removal step 15 11 Mount the Co...

Page 98: ...e 84 LS Rev 10 4 2 Wiring Diagrams 4 2 1 Signal Cable LS3 Cable color Pink Red Violet White Yellow Code P R V W Y Cable color Black Brown Green Blue Orange Code B BR G L O Resolver Board Control Board Brake Switch Brake ...

Page 99: ...aintenance 4 Cable LS Rev 10 85 LS6 Cable color Pink Red Violet White Yellow Code P R V W Y Cable color Black Brown Green Blue Orange Code B BR G L O Resolver Board Control Board Brake Switch Brake Brake ...

Page 100: ...Maintenance 4 Cable 86 LS Rev 10 4 2 2 Power Cable LS3 LS6 Cable color Pink Red Violet White Yellow Code P R V W Y Cable color Black Brown Green Blue Light green Orange Code B BR G L LG O ...

Page 101: ...v 10 87 4 2 3 User Cable LS3 LS6 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 use cable Model type Code Standard Cleanroom 1668313 ...

Page 102: ...tion data will be lost and EPSON RC will display an error when the Controller is turned ON If the signal cable of the motor X10 or the signal cable which is connected to the resolver board X20 is disconnected during cable replacement execute calibration For details refer to Maintenance 13 Calibration Name Quantity Note Maintenance parts M C Cable 1 3 m R12B020453 5 m R12B020454 10 m R12B020455 Too...

Page 103: ...ions 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 and or contact failure Damaged cables disconnection or cont...

Page 104: ...ate 2 Connect the connectors Connect to the Cable Unit with the same number 3 Mount the Connector Plate For details refer to Maintenance 3 3 Connector Plate 4 Connect the power cable and signal cable connectors to the controller 5 Turn ON the Controller 6 If the connector falls off from the battery board execute the calibration for all axes For details refer to Maintenance 13 Calibration ...

Page 105: ...ng any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder will cause...

Page 106: ...e and remove the arm There is an O ring between the Joint 1 unit and the arm Be sure to keep the O ring 4 Remove the screws mounting the Joint 1 flange on the Base LS3 8 M4 12 LS6 6 M5 15 5 Hold up the Joint 1 unit and remove the connector X10 from the resolver board 6 LS3 Loosen the motor mounting screws on the Joint 1 motor flange and remove the motor unit There is an O ring in the assembly posi...

Page 107: ...t screw holes Be sure to keep the bushing A Brass Bushing LS3 M4 LS6 M5 B Set Screw LS3 2 M4 6 LS6 2 M5 6 Set Screw Brass Bushing Waveform Generator Joint 1 Motor 8 Only LS6 Remove the motor mounting screws and then remove the motor flange and O ring LS3 does not have a motor flange 4 M4 12 Joint 1 Motor Motor Flange O ring NOTE ...

Page 108: ...5 6 CAUTION See the figure above for the orientation of the waveform generator Be sure to install the waveform generator properly Improper installation of the waveform generator will result in improper function of the Manipulator 3 LS3 Set an O ring on the motor mounting surface and assemble the motor with the Joint 1 flange LS6 Set an O ring on the motor flange and assemble the motor with the Joi...

Page 109: ...ats 3 mm 1 For M4 screw Torque wrench 1 Nippers 1 Spatula 1 For apply grease Wiping cloth 1 For wiping grease Flange 1 For wiping grease Bolt Screw M4 2 About 20 mm in length For flexspline removal Grease Grease SK 1A Joint 1 Reduction Gear Unit Removal 1 Remove the Joint 1 motor unit Follow the removal steps in Maintenance 5 1 Replacing Joint 1 Motor 2 Remove the reduction gear unit from the Join...

Page 110: ...and then fit it into the flexspline 4 Match the screw holes on the inner ring of the cross roller bearing unit and the through holes of the circular spline 5 Secure the reduction gear flange to the circular spline Loosely fasten all bolts in a crisscross pattern so that the bolts will be fastened evenly Then using a torque wrench tighten each bolt securely in a crisscross pattern at the torque spe...

Page 111: ...intenance 5 Arm 1 LS Rev 10 97 6 Apply grease SK 1A inside the flexspline Grease volume LS3 19 g LS6 37 g 7 Mount the Joint 5 motor Follow the installation steps in Maintenance 5 1 Replacing Joint 1 Motor ...

Page 112: ...ng any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft when replacing the motors The shock may shorten the life cycle of the motors and encoder and or damage them Never disassemble the motor and encoder A disassembled motor and encoder will cause...

Page 113: ...re the replacement procedure following the removal steps Joint 2 Motor Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment LS3 The brake release switch affects only Joint 3 When the brake release switch is pressed the Joint 3 brake is released Be ...

Page 114: ...rom 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 Remove the waveform generator from the Joint 2 motor There is a brass bushing in one of the set screw holes Be sure to kee...

Page 115: ... Waveform Generator CAUTION See the figures above for the orientation of the waveform generator Be sure to install the waveform generator properly Improper installation of the waveform generator will result in improper function of the Manipulator 3 Apply grease between the waveform generator and motor flange Grease volume LS3 4 g SK 2 LS6 6 g SK 1A 4 Mount the Joint 2 motor unit on the Arm 2 To in...

Page 116: ...ctors X221 X21 7 Bind the cables with a wire tie in their original positions as before removed in the removal step 6 Do not allow unnecessary strain on the cables 8 Mount the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 9 Execute the calibration for Joint 2 For details refer to Maintenance 13 Calibration ...

Page 117: ...m 1 For M3 screw width across flats 3 mm 1 For M4 screw Torque wrench 1 Spatula 1 For apply grease Wiping cloth 1 For wiping grease Flange 1 For wiping grease Bolt Screw M3 Length about 20 mm 2 For removing the flexspline Material Wire tie Grease Grease SK 2 LS3 SK 1A LS6 LS3 A brake is mounted on the Joint 3 motor to prevent the shaft from lowering down due to the weight of the end effector while...

Page 118: ...of the Joint 3 and Joint 4 are released simultaneously Be careful of the shaft falling and rotating while the brake release switch is being pressed because the shaft may be lowered by the weight of an end effector 3 Turn OFF the Controller 4 Remove the 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 sc...

Page 119: ... CAUTION Never adjust loosen or tighten the mounting bolts between the flexspline and cross roller bearing unit If the mounting bolts are adjusted the flexspline and cross roller bearing unit must be aligned by the maker of the reduction gear unit 2 Fit the O rings into the grooves on both sides of the new circular spline Make sure that the rings do not come out of the grooves Convex side Grooves ...

Page 120: ...e torque specified in the table below A Arm 2 Reduction Gear Unit Arm 1 C O ring B Item Bolt type Tightening torque Joint 2 reduction gear unit M3 2 35 N m 24 kgf cm Be careful not to apply too much force since it may damage the parts 6 Apply grease between the motor flange and waveform generator and next inside the flexspline Grease volume Between the motor flange and waveform generator LS3 4 g S...

Page 121: ...orming 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 pos...

Page 122: ...e the replacement procedure following 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 LS3 The brake release switch affects only Joint 3 When the brake release switch is pressed the Joint 3 brake is released Be c...

Page 123: ...nt 3 motor from the Joint 3 motor unit Joint 3 Motor 2 M4 12 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 11 Loos...

Page 124: ...f the motor shaft Insert a bushing into the other set screw hole to prevent damage to the motor shaft 2 Mount the Joint 3 motor on the Z plate Pass the pulley through the Z belt and fit the brake disk to the hub Secure the motor cables facing to back of the Arm Joint 3 Motor Z Belt Z Plate Pulley 2 M4 12 When replacing the motor of the Joint 3 remove the cap from the old motor and install it to th...

Page 125: ...n with the tension meter refer to Maintenance 7 4 Checking the Timing Belt Tension Z Belt 5 Mount the control board For details refer to Maintenance 11 3 Replacing the Control Board 6 Connect the connectors X231 X241 X31 X35 X41 7 Mount the User Plate For details refer to Maintenance 3 5 User Plate 8 Bind the cables with a wire tie in their original positions as before removed in the removal step ...

Page 126: ...tatus MOTOR OFF Move the shaft down to its lower limit before the replacement procedure following the removal steps Z belt Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment LS3 The brake release switch affects only Joint 3 When the brake release...

Page 127: ...the Arm 2 column At this point do not cut off a wire tie in the duct fittings outlet that binds the cables to the User Plate 8 Disconnect the following connectors Connectors X31 X32 X231 Hold the claw to remove 9 Remove the User Plate For details refer to Maintenance 3 5 User Plate 10 Remove the screws for the Joint 3 motor unit and pull out the Joint 3 motor unit 3 M4 15 Washer Joint 3 Motor Unit...

Page 128: ...motor unit can be moved by hand and it will not tilt when pulled If the unit is secured too loose or too tight the belt will not have the proper tension 6 Apply the proper tension to the Z belt and then secure the Joint 3 motor unit Pass a suitable cord or string around the Joint 3 motor unit near its mounting plate Then pull the cord using a force gauge or similar tool to apply the specified tens...

Page 129: ...Maintenance 7 Arm 3 LS Rev 10 115 11 Install the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 12 Execute the calibration of Joint 3 For details refer to Maintenance 13 Calibration ...

Page 130: ...e motor is in OFF status MOTOR OFF Move the shaft down to its lower limit before the replacement procedure following the removal steps Joint 3 brake Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment LS3 The brake release switch affects only Join...

Page 131: ... Remove the Joint 3 motor from the Joint 3 motor unit Joint 3 Motor 2 M4 12 7 Remove the brake from the brake plate Brake 2 M3 8 8 Loosen the screws of pulley and brake hub and remove them from the Joint 3 motor There is a brass bushing in one of the set screw holes Be sure to keep the bushing Joint 3 Motor M5 8 Set Screw M5 Bushing Pulley Brake Hub M5 8 Set Screw ...

Page 132: ...ey Motor Plate LS6 Tighten one of the set screws vertically on the flat face of the motor shaft Insert a bushing into the other set screw hole to prevent damage to the motor shaft 3 Mount the Joint 3 motor unit to the Z plate Align the position of the disk on the brake and the hub When the brake disk is not aligned manually adjust the position after connecting the connector X32 and pressing the br...

Page 133: ...Maintenance 7 Arm 3 LS Rev 10 119 5 Mount the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 6 Execute the calibration of Joint 3 For details refer to Maintenance 13 Calibration ...

Page 134: ... 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 LS3 Z belt 1 9 9 127 LS6 Z belt 1 9 10 212 2 Strum the belt and measure tension Measurement failure may occur if the microphone touches the belt during measurement NOTE ...

Page 135: ...rforming 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 p...

Page 136: ...e power to the Controller is OFF or while the motor is in OFF status MOTOR OFF LS6 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 its lower limit before the replacement procedure following the removal steps Join...

Page 137: ...lts securing the Joint 4 motor on the motor plate and pull out the motor Joint 4 Motor Unit 3 M4 12 Washer Motor Plate 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 motor sensor and in...

Page 138: ...he unit is secured too loose or too tight the belt will not have the proper tension Make sure the gear grooves of the belt are fit into those of the pulleys completely 5 Apply the proper tension to the U1 belt and secure the Joint 4 motor unit Pass a suitable cord or string around the Joint 4 motor unit near its mounting plate Then pull the cord using a force gauge or similar tool to apply the spe...

Page 139: ...fer to Maintenance 11 3 Replacing the Control Board 9 Bind the cables with a wire tie in their original positions as before removed in removal step 5 Do not allow unnecessary strain on the cables 10 Mount the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 11 Execute the calibration of Joint 4 For details on the calibration method refer to Maintenance 13 Calibration ...

Page 140: ...0 4 0 75 kgf S N L6 01 or later and Controller firmware Ver 7 1 6 0 or later CAUTION The belt must be installed with proper tension otherwise the following problems may occur If falling below the lower limit Jumping of the belt gears position gap If exceeding the upper limit Abnormal noise or vibration oscillation decline in the life of driving parts LS3 A brake is mounted on the Joint 3 motor to ...

Page 141: ...and rotating while the brake release switch is being pressed because the shaft may be lowered by the weight of an end effector 3 Turn OFF the Controller 4 Remove the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 5 Remove the control board For details refer to Maintenance 11 3 Replacing the Control Board Control Board Special Power Supply 6 Remove one screw that mounts the specia...

Page 142: ...t 4 Motor Unit 12 Remove the screws securing the Joint 4 intermediate shaft unit Pull out the Joint 4 intermediate shaft unit and U1 belt 3 M4 12 Washer Joint 4 Intermediate Shaft Unit U1 belt 13 Remove the screws mounting the spline plate Hold up the spline plate and pull out the Z belt and U2 belt 3 M4 12 Spline Plate Z belt U2 belt ...

Page 143: ... belts are fit into those of the pulleys completely Joint 4 Intermediate Shaft Unit U1 belt U2 belt Pulley Large Pulley Small 5 Loosely secure the Joint 4 intermediate shaft unit Make sure the unit can be moved by hand and it will not tilt when pulled If the unit is secured too loose or too tight the belt will not have the proper tension 6 Apply the proper tension to the U2 belt and then secure th...

Page 144: ...wn in the figure on the right U1 belt tension LS3 39 N 4 0 0 5 kgf LS6 a 39 N 4 0 0 5 kgf LS6 b 58 N 5 9 0 5 kgf 3 M4 12 Washer Force Gauge Joint 4 Motor Unit To check belt tension with the tension meter refer to Maintenance 8 4 Checking the Timing Belt Tension U1 U2 Belts 10 Put the Joint 3 motor unit back in the arm 3 M4 15 Washer Joint 3 Motor Unit 11 Pass the brake cable and special power supp...

Page 145: ...efer to Maintenance 7 4 Checking the Timing Belt Tension Z Belt 14 Remove the control board For details refer to Maintenance 11 3 Replacing the Control Board 15 Connect the following connectors Connector X31 X32 X35 X41 X231 X241 16 Mount the User Plate For details refer to Maintenance 3 5 User Plate 17 Bind the cables with a wire tie in their original positions as before removed in the removal st...

Page 146: ... Joint 4 motor Follow the removal steps in Maintenance 8 2 1 U2 Belt Joint 4 Motor Unit 3 M4 12 Washer 2 Remove the Joint 4 intermediate shaft unit Follow the removal steps in Maintenance 8 2 1 U2 Belt Joint 4 Intermediate Shaft Unit 3 M4 12 Washer U1 belt 3 Remove the U1 belt ...

Page 147: ... proper tension to the U2 belt and then secure the Joint 4 intermediate shaft unit Pass a suitable cord or string 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 U1 belt tension LS3 69 N 7 0 0 5 kgf LS6 a 69 N 7 0 0 5 kgf LS6 b 102 N 10 4 0 5 kgf 3 M4 12 Plain W...

Page 148: ...9 N 7 0 0 5 kgf LS6 b 102 N 10 4 0 5 kgf 3 M4 12 Washer Force Gauge Joint 4 Motor Unit To check belt tension with the tension meter refer to Maintenance 8 4 Checking the Timing Belt Tension U1 U2 Belts 6 Connect the connector X241 X41 7 Bind the cables with a wire tie in their original position as before removed in the removal step 5 8 Remove the User Plate For details refer to Maintenance 3 5 Use...

Page 149: ...6 series Joint 4 brake Removal 1 Turn ON the Controller 2 Push down the shaft to its lower limit while pressing the brake release switch Be sure to keep enough space and prevent the end effector hitting any peripheral equipment The brake release switch is applied to both Joint 3 and 4 When the brake release switch is pressed the respective brake for Joints 3 and 4 are released simultaneously Be ca...

Page 150: ...he rubber cap Insert 9 mm to the brake If the cap is inserted 10 mm or more the rotation part touches the rubber cap and may result in malfunctions Rubber Cap Rubber Cap Rotator part Brake Hub 4 Connect the connector X42 5 Re bundle the cables in their original positions with a wire tie removed in step 6 Do not allow unnecessary strain on the cables 6 Install the Arm Top Cover For details refer to...

Page 151: ...th 1 m length Width W mm Span S mm LS3 U1 belt 1 3 10 45 U2 belt 1 3 16 92 LS6 a U1 belt 1 3 10 54 U2 belt 1 3 15 170 LS6 b U1 belt 2 0 10 54 U2 belt 2 0 15 170 2 Strum the U2 belt and measure tension Measurement failure may occur if the microphone touches the belt during measurement 3 LS6 only Remove the rubber plug from the hole on the Arm 2 4 Strum the U1 belt and measure tension For LS6 insert...

Page 152: ... as the room in front of the clean room s entrance or take the necessary countermeasures to prevent dust emission before removing the bellows Name Quantity Note Maintenance parts Bellows 1 LS3 401C R13B030704 LS6 2C R13B030708 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...

Page 153: ...brake release switch is being pressed because the shaft may be lowered by the weight of an end effector 2 Pass the shaft through 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 ...

Page 154: ...line unit etc the Manipulator cannot operate properly because a mismatch exists between the origin stored in each motor and its corresponding origin stored in the Controller After replacing the parts it is necessary to match these origins The process of aligning the two origins is called Calibration Refer to Maintenance 13 Calibration to perform the calibration 10 1 Greasing the Ball Screw Spline ...

Page 155: ...he upper part of the shaft directly fill the grooves on it by hand Wipe off excess grease from the shaft 6 Turn ON the Controller 7 Move the shaft to its lower limit by hand while pressing the brake release switch 8 Wipe off the old grease from the lower part of the shaft and then apply new grease to it When applying the new grease to the lower part of the shaft directly fill the grooves on it by ...

Page 156: ... by hand Wipe off excess grease from the shaft 6 Shaft 7 Clamp Band Lower Part of the Shaft 7 Loosen the clamp band on the bellows and then move the bellows downward 8 Move the shaft to the lower limit manually while pressing the brake release switch 9 Wipe off the old grease from the lower part of the shaft and then apply new grease Directly fill the grooves on the shaft inside the bellows with g...

Page 157: ...ension 98 N 10 kgf 74 N 7 5 kgf Suitable cord Length about 1000 mm 1 For belt tension Wiping cloth 1 For wiping grease Spline shaft Material Wire tie 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 LS3 The brake release ...

Page 158: ... Joint motor unit Joint 4 motor unit Joint 4 intermediate pulley U belt Follow the U2 belt removal steps in Maintenance 8 2 Replacing the Timing Belt 8 Remove three screws mounting the spline plate 3 M4 12 LS3 4 M4 10 LS6 4 M4 12 9 Remove four screws mounting the spline nut 10 Pull out the following toward the Arm 2 upper side Ball screw spline unit Z belt U2 belt ...

Page 159: ...ey U1 belt U2 belt Z belt Follow the U2 belt installation steps in Maintenance 8 2 Replacing the Timing Belt 4 Mount the Arm Top Cover and Arm Bottom Cover For details refer to Maintenance 3 Covers 5 Grease the shaft For details refer to Maintenance 10 1 Greasing the Ball Screw Spline Unit 6 For the Cleanroom model mount the bellows For details refer to Maintenance 9 Bellows 7 Mount the end effect...

Page 160: ...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 sa...

Page 161: ...re 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 perfor...

Page 162: ...Battery Mounting Screw Cable Support 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 Mount the battery plate to the cable support Battery plate mounting screw 1 M3 5 7 Disconnect one connector of the old three batteries and connect a new one 8 Disconnect the other old batteries connector and connect new ones ...

Page 163: ...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 Connector Plate For details refer to Maintenance 3 3 Connector Plate 3 Disconnect three batteries connectors and the M C signal connector 3 4 3 4 4 Remove the screws flat head screw 4 on the...

Page 164: ... the resolver board into the Base Secure the board to the side face of the Base with the screws flat head screws 4 Be careful not to remove the hear transfer sheet while inserting the resolver board Secure the resolver board so that the Base side face and resolver board hold the hear transfer sheet between them 4 Connect the three batteries connectors and M C signal connector 4 3 4 3 5 Mount the C...

Page 165: ...r 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 166: ...may result in electric shock and or malfunction of the robot system Name Quantity Note Maintenance parts LED Lamp 1 R13A030000200 Tools Cross point screwdriver 1 For wire removal Nippers 1 Material Wire tie 1 LED Lamp Removal 1 Remove the Arm Top Cover For details refer to Maintenance 3 1 Arm Top Cover 2 Remove the User Plate For details refer to Maintenance 3 5 User Plate 3 Disconnect the X1 and ...

Page 167: ...gn Precautions Before operating the robot system make sure that no one is inside the safeguarded area The robot system can be operated in the mode for teaching even when someone is inside the safeguarded area The motion of the Manipulator is always in restricted low speeds and low power status to secure the safety of an operator However operating the robot system while someone is inside the safegu...

Page 168: ...o Maintenance 13 3 Accurate Calibration of Joint 2 When calibrating Joint 4 you must calibrate Joint 3 and 4 at the same time You cannot calibrate Joint 4 alone because of the structure of the Manipulator If Err9716 or 5016 Power supply failure of the absolute encoder Replace the battery Check the robot internal wiring occurs apply the procedure of 13 4 Calibration Procedure without using Calibrat...

Page 169: ... 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 Following steps use images of EPSON RC 5 0 dialogs 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 170: ...here Arms 1 and 2 are in a straight line Regardless of the Joint 1 direction 0 pulse 0 pulse position of Joint 3 upper limit position in motion range The height of Joint 3 depends on manipulator model 0 pulse position of Joint 4 position where the flat surface or groove in the up down mechanical stop on the shaft faces toward the tip of Arm 2 Groove Flat surface 0 pulse ...

Page 171: ...hen the Controller starts up 5 Reboot the Controller This window will disappear when the Controller starts up 6 Select the reference point to use for calibration and click the Next button Select a point from the current points to use for checking the accuracy 7 Click the Jog button to display the Jog Teach dialog ...

Page 172: ...ck 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 173: ...9 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 174: ...S Rev 10 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 175: ...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 176: ...Maintenance 13 Calibration 162 LS Rev 10 Jog to the accurate reference position and adjust the position Click the OK button iii Click the Next button ...

Page 177: ...aintenance 13 Calibration LS Rev 10 163 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 178: ...ight figure and attach it on the end of the shaft to make the center of the shaft clear Decide a target point and mark a cross on it so that you can easily verify the center of the shaft after switching the arm pose between right and left Calibration jig at the end of the shaft Example Target point The center of the shaft After removing the end effector and executing the calibration install the en...

Page 179: ...om 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 180: ... 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 positio...

Page 181: ... position in motion range The height of Joint 3 depends on manipulator model 0 pulse position of Joint 4 position where the flat surface or groove in the up down mechanical stop on the shaft faces toward the tip of Arm 2 Groove Flat surface 0 pulse 3 3 Connect EPSON RC to the Controller Select a robot to be calibrated Input as below in the Command Window and execute it This example uses robot 1 ro...

Page 182: ...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 183: ...y 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 Joint...

Page 184: ...t 3 R13B030233 Z 7 2 Joint 4 R13B030234 U1 8 2 R13B030235 U2 Solenoid Brake R13B030509 Z 7 3 Brake Release Switch R13Z702640100 Bellows LS3 401C R13B030704 4 9 Ball Screw Spline LS3 401S R13B010228 150 mm 10 2 LS3 401C R13B010229 120 mm Battery R13B060007 Lithium battery for replacement A set of 3 batteries 11 1 Resolver Board R13B040501 11 2 Control Board R13B040502 11 3 LED Lamp R13A030000200 12...

Page 185: ...00 Timing Belt Joint 3 R13B030236 Z 7 2 Joint 4 1674797 U1 8 2 1674798 U2 Solenoid Brake R13B030509 Z 7 3 R13B030502 U 7 4 Brake Release Switch R13Z702640100 Bellows LS6 2C R13B030708 5 9 Ball Screw Spline LS6 2S R13B010231 200 mm 10 2 LS6 2C R13B010232 170 mm Battery R13B060007 Lithium battery for replacement A set of 3 batteries 11 1 Resolver Board R13B040501 11 2 Control Board R13B040502 11 3 L...

Page 186: ... 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 manufacturers If there is anything unclear please contact our suppliers Product name Manufacturer URL THK AFB LF ...

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Epson LS series, Manipulator Manual

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