EPSON C3-A601C, C3-A601S User Manual

C3 Manipulator

Rev.4 EM105R2013F

EPSON ProSix

C3 series

EPSON ProSix C3 series C3 Manipulator Rev. 4

EPSON ProSix

C3 series

C3 Manipulator

Rev. 4

C3 Rev.4 i

t

FOREWORD

Thank you for purchasing our robot products.

This manual contains the information necessary for the correct use of the manipulator.

Please carefully read this manual and other related manuals before installing the robot

system.

Keep this manual handy for easy access at all times.

WARRANTY

The robot and its optional parts are shipped to our customers only after being subjected to

the strictest quality controls, tests, and inspections to certify its compliance with our high

performance standards.

Product malfunctions resulting from normal handling or operation will be repaired free of

charge during the normal warranty period. (Please ask your Regional Sales Office for

warranty period information.)

However, customers will be charged for repairs in the following cases (even if they occur

during the warranty period):

1. Damage or malfunction caused by improper use which is not described in the manual,

2. Malfunctions caused by customers’ unauthorized disassembly.

or careless use.

3. Damage due to improper adjustments or unauthorized repair attempts.

4. Damage caused by natural disasters such as earthquake, flood, etc.

Warnings, Cautions, Usage:

1. If the robot or associated equipment is used outside of the usage conditions and produc

specifications described in the manuals, this warranty is void.

2. If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be

responsible for any malfunction or accident, even if the result is injury or death.

3. We cannot foresee all possible dangers and consequences. Therefore, this manual

cannot warn the user of all possible hazards.

ii C3 Rev.4

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 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.

INQUIRIES

Contact the following service center for robot repairs, inspections or adjustments.

If service center information is not indicated below, please contact the supplier office for

your region.

Please prepare the following items before you contact us.

- Your controller model and its serial number

- Your manipulator model and its serial number

- Software and its version in your robot system

- A description of the problem

SERVICE CENTER

C3 Rev.4 iii

MANUFACTURER & SUPPLIER

Japan & Others Suwa Minami Plant

Factory Automation Systems Dept. 1010 Fujimi, Fujimi-machi, Suwa-gun, Nagano, 399-0295

JAPAN TEL : +81-(0)266-61-1802 FAX : +81-(0)266-61-1846

SUPPLIERS

North & South America EPSON AMERICA, INC.

Factory Automation/Robotics

18300 Central Avenue

Carson, CA 90746

USA TEL : +1-562-290-5900 FAX : +1-562-290-5999 E-MAIL : info@robots.epson.com

Europe EPSON DEUTSCHLAND GmbH

Factory Automation Division

Otto-Hahn-Str.4

D-40670 Meerbusch

Germany TEL : +49-(0)-2159-538-1391 FAX : +49-(0)-2159-538-3170 E-MAIL : robot.infos@epson.de

iv C3 Rev.4

For Customers in the European Union

The crossed out wheeled bin label that can be found on your product indicates that this product and incorporated batteries should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health please separate this product and its batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner. For more details on available collection facilities please 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 accumulators and repealing Directive 91/157/EEC and legislation transposing and implementing it into the various national legal systems. For other countries, please contact your local government to investigate the possibility of recycling your product.

The battery removal/replacement procedure is described in the following manuals: Controller manual / Manipulator manual (Maintenance section)

C3 Rev.4 v

Before Reading This Manual

This section describes what you should know before reading this manual.

Structure of Control System

C3 Manipulators can be used with the following combinations of Controllers and software.

The operating methods and descriptions are different depending on which software you are

using. The following icons are put beside appropriate text as necessary. Use the

descriptions that pertain to the software you are using.

Controller

Name Structure

RC180 Controller EPSON RC+ 5.0

RC620

For details on commands, refer to “EPSON RC+ User’s Guide” or “On-line help”.

Control Unit

Drive Unit

EPSON RC+ 6.0 Ver. 6.0 or greater

Software

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.

Photos and Illustrations Used in This Manual

The appearance of some parts may differ from those on an actual product depending on

when it was shipped or the specifications. The procedures themselves, however, are

accurate.

vi C3 Rev.4

Setup & Operation

This volume contains information for setup and operation of the Manipulators.

Please read this volume thoroughly before setting up and operating the Manipulators.

1. Safety

Installation and transportation of robots and robotic equipment shall be performed by

qualified personnel and should conform to all national and local codes.

Please read this manual and other related manuals before installing the robot system or

before connecting cables.

Keep this manual handy for easy access at all times.

1.1 Conventions

Important safety considerations are indicated throughout the manual by the following

symbols. Be sure to read the descriptions shown with each symbol.

WARNING

Setup & Operation 1. Safety

This symbol indicates that a danger of possible serious injury

or death exists if the associated instructions are not followed

properly.

This symbol indicates that a danger of possible harm to people

caused by electric shock exists if the associated instructions are

not followed properly.

This symbol indicates that a danger of possible harm to people

CAUTION

or physical damage to equipment and facilities exists if the

associated instructions are not followed properly.

1.2 Design and Installation Safety

Only trained personnel should design and install the robot system. Trained personnel are defined as those who have taken robot system training and maintenance training classes held by the manufacturer, dealer, or local representative company, or those who understand the manuals thoroughly and have the same knowledge and skill level as those who have completed the training courses. To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to the Installation and Design Precautions in the Safety chapter of the EPSON RC+ User’s Guide.

The following items are safety precautions for design personnel:

■

Personnel who design and/or construct the robot system with this product must read the Safety chapter in the EPSON RC+ User’s Guide. Designing and/or

WARNING

constructing the robot system without understanding the safety requirements is extremely hazardous, and may result in serious bodily injury and/or severe equipment damage to the robot system.

C3 Rev.4 3

Setup & Operation 1. Safety

■

The Manipulator and the Controller must be used within the environmental conditions described in their respective manuals. This product has been designed and manufactured strictly for use in a normal indoor environment. Using the product in an environment that exceeds the specified environmental conditions may not only shorten the life cycle of the product but may also cause

WARNING

serious safety problems.

■

The robot system must be used within the installation requirements described in the manuals. Using the robot system outside of the installation requirements may not only shorten the life cycle of the product but also cause serious safety problems.

Further precautions for installation are mentioned in the chapter Setup & Operation

3. Environment and Installation. Please read this chapter carefully to understand safe installation procedures before installing the robots and robotic equipment.

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

WARNING

■

Please carefully read the Safety-related Requirements in the Safety chapter of the EPSON RC+ User’s Guide. Operating the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

■

Do not enter the operating area of the Manipulator while the power to the robot system is turned ON. Entering the operating area with the power ON is extremely hazardous and may cause serious safety problems as the Manipulator may move even if it seems to be stopped.

■

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 status (low speeds and low power) to secure the safety of an operator. However, operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly.

■

Immediately press the Emergency Stop switch whenever the Manipulator moves abnormally while the robot system is operated. Continuing the operating the robot system while the Manipulator moves abnormally is extremely hazardous and may result in serious bodily injury and/or severe equipment change to the robot system.

4 C3 Rev.4

■

Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source. Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

■

Before performing any replacement procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source.

WARNING

Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

■

Do not insert or pull out the motor connectors while the power to the robot system is turned ON. Inserting or pulling out the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

1.4 Emergency Stop

Setup & Operation 1. Safety

If the Manipulator moves abnormally during operation, immediately press the Emergency

Stop switch. The motor power will be turned OFF, and the arm motion by inertia will be

stopped with the electromagnetic brake and dynamic brake.

However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator

is running normally. Otherwise, the Manipulator may hit the peripheral equipment since

the operating trajectory while the robot system stops is different from that in normal

operation.

To place the robot system in emergency mode during normal operation, press the

Emergency Stop switch when the Manipulator is not moving.

Refer to the Controller manual for instructions on how to wire the Emergency Stop switch

circuit.

Free running distance in emergency

The operating Manipulator cannot stop immediately after the Emergency Stop switch is

pressed.

However, remember that the values vary depending on conditions such as the weight of

the end effector and work piece, WEIGHT/SPEED/ACCEL settings, operating pose, etc.

The free running time/angle/distance of the Manipulator are shown below.

Conditions of Measurement

ACCEL Setting

SPEED Setting

Load [kg]

WEIGHT Setting

100

3

C3 Rev.4 5

Setup & Operation 1. Safety

Robot controller RC180 / RC620

Free running

time

[sec.]

Free running

angle

[deg.]

Brake

Arm #1

Arm #2

Arm #3

Arm #4

Arm #5

Arm #6

Arm #1

Arm #2

Arm #3

Arm #4

Arm #5

Arm #6

Standard

J2, J3, J5 with brake

0.4

0.5 0.3

0.3

0.1

85

60

55

55 45

45

10

Option

All joint with brake

1.5 How to Move Arms the Electromagnetic Brake is Applied to

Standard: Brakes on Joints #2, #3, #5

While the electromagnetic brake is ON (such as in emergency mode), you can move

Arms #1, #4, #6 by pushing manually.

Option : Brakes on all joints

While the electromagnetic brake is ON (such as in emergency mode), you cannot move

any arm by pushing manually.

There are two methods to release the electromagnetic brake. Follow either method to

release the electromagnetic brake and move the arms manually.

1.5.1 Moving the arm using the brake release unit

Follow the method when you just unpack the delivered boxes or when the

Controller does not start up yet.

1.5.2 Moving the arm using the software

Follow the method when you can use the software.

6 C3 Rev.4

Setup & Operation 1. Safety

Arm Motion

J6−

J6+

Arm #5

Arm #4

J5+

J5−

Joint #5

Joint #4

J4−

J4+

Joint #2

J3−

J3+

J2+J2−

Arm #3

Joint #3

Arm #2

J1+

Arm #6

Joint #6

Arm #1 (Lower Arm)

Joint #1

Base

1.5.1 Moving the arm using the brake release unit

The C3 series has the Brake Release Unit as an option.

For details, refer to Setup & Option: 6 Options.

1.5.2 Moving the arm using the software

■

Normally, release the brake of a single joint at a time. Take extra care to release the brakes of two or more joints simultaneously from necessity. Releasing the brakes of two or more joints simultaneously may cause hands and fingers to be caught and/or equipment damage to or malfunction of the Manipulator as the arms of the Manipulator may move in unexpected directions.

J1−

■

Be careful of the arm falling when releasing the brake. While the brake is being released, the Manipulator’s arm falls by its own weight.

CAUTION

The arm falling may cause hands and fingers to be caught and/or may cause equipment damage to or malfunction of the Manipulator.

■

Before releasing the brake, be sure to keep the Emergency Stop switch handy so that you can immediately press the Emergency Stop switch. If you cannot immediately press the Emergency Stop switch, you have no means to stop the arms urgently when a wrong operation causes the arm to fall. The arm falling may cause equipment damage to and/or malfunction of the Manipulator.

C3 Rev.4 7

Setup & Operation 1. Safety

EPSON

RC+

After releasing the Emergency Stop switch, Execute the following commands.

[Command Window] EPSON RC+ 5.0 (RC180) / EPSON RC+ 6.0 (RC620)

>Reset

>Brake Off,[the number (from 1 to 6) corresponding to the arm whose brake will be

turned off]

Execute the following command to turn on the brake again. >Brake On,[The number (from 1 to 6) corresponding to the arm whose brake will be

turned on]

1.6 Precaution for Operation in Low Power Status

When the power mode is low, the Manipulator will operate at low speed and low torque.

However, comparatively high torque is generated under some circumstances so that the

Manipulator can support its own weight. The maximum torque of each joint in the low

power status is shown in the following table “Max. Joint Torque in Low Power Status”.

Even though the Manipulator is in the low power status, carefully operate the Manipulator

since a comparatively high joint torque may be generated. Be careful not to get hands or

fingers caught during operations. The Manipulator may also collide with peripheral

equipment and it may cause equipment damage to or malfunction of the Manipulator.

Max. Joint Torque in Low Power Status

#1 #2 #3 #4 #5 #6

102.28 102.28 33.51

CAUTION

Joint

Joint Torque

■

Carefully operate the Manipulator even though it is in the low power status. A comparatively high joint torque may be generated. The comparatively high joint torque may cause hands and fingers to be caught and/or may cause equipment damage to or malfunction of the Manipulator as it may collide with peripheral equipment.

[Unit: N·m]

10.31 10.31 7.98

8 C3 Rev.4

Setup & Operation 1. Safety

1.7 Manipulator Labels

The following labels are attached around the locations of the Manipulator where specific

dangers exist.

Be sure to comply with descriptions and warnings on the labels to operate and maintain

the Manipulator safely.

Do not tear, damage, or remove the labels. Use meticulous care when handling those

parts or units to which the following labels are attached as well as the nearby areas:

Location Label NOTE

Hazardous voltage exists while the Manipulator is ON.

(1)

(2)

To avoid electric shock, do not touch any internal electric parts.

Only authorized personnel should perform sling work and operate a crane and a forklift.

When these operations are performed by unauthorized personnel, it is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

(3)

(4)

(5)

C3 Rev.4 9

Setup & Operation 1. Safety

Location Label NOTE

(6)

(7)

Location of Labels

Be careful of the arm falling / rotation while the brake release button is being pressed.

* This label is on the Brake Release Box (Option).

(6)

(1)

Top V i e w

Front View

(3)

(1)

Lateral View

(4)

(2)

(1)

(5)

Back View

(1)

10 C3 Rev.4

2. Specifications

2.1 Features of Manipulators

Speed & Accuracy

Increases productivity with the balanced performance of best in class speed and

accuracy

Average cycle time (300 mm) 0.39 second (Speed 100 / Accel 100)

0.37 second (Speed 120 / Accel 120)

Repeatability ± 0.02 mm

Slim Body

High space efficiency

Manipulator volume only 1/44 of its motion range

Small elbow area (Joint #3) half of current model

Less interference with peripherals, walls and ceiling permits more compact

installation

Skillful Wrist

Setup & Operation 2. Specifications

Compact wrist (Joint #5) with wide motion range enables smooth movement and the

ability to work from many angles

Minimal interference with surroundings improves flexibility in hand design

2.2 Model Number

C3 – A 6 0 0 S R -UL

NOTE

For the Wall / Skewed mounting types, brakes are equipped on all joints.

)

UL specification

UL : UL compliant

□

: Non UL compliant

Type

□

: Table Top mounting

W : Wall mounting

R : Ceiling mounting

A : Skewed mounting

Environment

S : Standard model

C : Cleanroom model

Brake equipment

0 : Standard : Brakes on Joint #2, #3, #5

1 : Option : Brakes on all joints

Arm length

6 : 600 mm

C3 Rev.4 11

Setup & Operation 2. Specifications

−

A

r

2.3 Part Names and Motion Range of Each Arm

J6−

Arm #6

Joint #6

J6+

Arm #5

Upper Arm (Arms #3 to #6)

Arm #4

J5+

J5−

Joint #5

Joint #4

J4−

J4+

J3

LED Lamp

This lamp lights up while the motors are ON.

J3+

rm #3

Joint #3

J2+J2−

J1+

rm #2

Joint Motion

Joint #1 : The whole Manipulator revolves.

Joint #2 : The lower arm swings.

Joint #3 : The upper arm swing s.

Joint #4 : The wrist revolves.

Joint #5 : The wrist swings.

Joint #6 : The hand rotates.

Signal cable

(only for UL specification)

Power cable

MT label

(only for custom

specification)

UR label

Joint #2

Arm #1

(Lower Arm)

Joint #1

Base

User cable connecto (9-pin D-sub connector)

White

Black

Standard-model / Clean-room type

Fitting for ø4 mm pneumatic tube

Cover Exhaust port For ø8 mm pneumatic tube

J1−

CE label (only for CE specification)

Signature label

(Serial No. of Manipu lator)

NOTE

)

When the LED lamp is lighting or the controller power is on, the current is being applied

to the manipulator. Performing any work with the power ON is extremely hazardous and

it may result in electric shock and/or improper function of the robot system. Make sure

to turn OFF the controller power before the maintenance work.

12 C3 Rev.4

Setup & Operation 2. Specifications

2.4 Outer Dimensions

[Unit: mm]

Space for cables

*1:

*2:

Including the lamp

(Tolerance is optimum for ø6H7)

*1: Tolerance in this range

*2: Front and back

C3 Rev.4 13

Setup & Operation 2. Specifications

2.5 Standard Motion Range

[Unit: mm]

Motion range of P point*

Top Vi e w

*1

*2

*3

Joint #1 0 pulse position

P point*

Lateral viewFront View

Joints #4, #6 0 pulse position

P point*

Joints #3, #5 0 pulse position

Joint #2 0 pulse position

*5

CAUTION

*4

Motion range of P point*

* P point : Intersection of the rotation centers for Joint #4, #5, and #6

*1 : Joint #1 without mechanical stop (

*2 : P point from top with Joint #3 declining

*3 : P point from top with Joint #3 tilting up

*4 : P point from lateral with Joint #3 declining (51 deg. (Joint #2 center – P point center)

*5 : P point from lateral with Joint #3 tilting up (225 deg. (Joint #2 center – P point center)

Pay attention to the arm pose of the basic arms (Arms #1, #2, and #3) when

±180 deg.)

−51 deg. (Joint #1 center – P point center)

+225 deg. (Joint #1 center – P point center)

operating the Manipulator. Arm #5 moves keeping a constant angle regardless of the arm pose. Depending on the arm pose of the basic arms, the wrist may collide with the Manipulator. The collision may cause equipment damage to and/or malfunction of the Manipulator.

14 C3 Rev.4

2.6 Specifications

2.6.1 Specifications table

Item Specification

Model Number Mounting type Weight (not include the weight of cables

or shipping jigs) Driving method All joints

Joint #1 Joint #2

Max. operating

*1

speed

Repeatability Joint #1 ~ #6

Max. motion range

Max. pulse range

Resolution

Motor power consumption

Payload *2

Allowable moment

Joint #3 Joint #4 Joint #5 Joint #6

Joint #1

Joint #2 Joint #3 Joint #4 Joint #5

Joint #6

Joint #1

Joint #2

Joint #3

Joint #4 Joint #5 Joint #6 Joint #1 Joint #2 Joint #3 Joint #4 Joint #5 Joint #6 Joint #1 Joint #2 Joint #3 Joint #4 Joint #5 Joint #6 Rated

Max.

Joint #4

Joint #5

Joint #6

Setup & Operation 2. Specifications

C3

Table Top, Ceiling, Skewed mounting Wall mounting

27 kg (59.5 lb.)

AC servo motor

450 deg/s 450 deg/s 514 deg/s 553 deg/s 553 deg/s 720 deg/s

± 0.02 mm

± 170 deg

(± 180 deg without the mechanical stop)

± 30 deg

− 160 deg ~ + 65 deg

− 51 deg ~ + 225 deg

± 200 deg ± 135 deg ± 360 deg

± 4951609

(± 5242880 without the mechanical stop)

± 873814

− 4660338 + 1893263

− 1299798 + 5734400 ± 4700057 ± 3217222

± 6553600

0.00000429 deg /pulse

0.00000490 deg /pulse

0.00000531 deg /pulse

0.00000524 deg /pulse

0.00000686 deg /pulse 400 W 400 W 150 W

50 W 50 W 50 W

1 kg 3 kg

5 kg with arm downward positioning

4.41 N·m (0.45 kgf·m)

2.94 N·m (0.3 kgf·m)

C3 Rev.4 15

Setup & Operation 2. Specifications

Item Specification

Allowable moment of inertia (GD

Installed wire for customer use

Installed pneumatic tube for customer use *4

Environmental requirements

Equivalent continuous A-weighted sound pressure level

*6

Environment

Applicable Controller

Default values (Max. setting values)

Safety standard

2

/4) *3

*5

Joint #4 Joint #5 Joint #6

Ambient Temperature

Ambient relative humidity

Vibration

SPEED ACCEL SPEEDS ACCELS

FINE

WEIGHT

*1 In the case of PTP control

0.15 kgxm2

0.1 kgxm2

9 wires (D-sub)

4 pneumatic tubes,

Allowable pressure: 0.59Mpa

(6 kgf/cm

2

) (89 psi)

5 ~ 40 deg C

20 ~ 80 % (no condensation)

4.9 m⋅s2 (0.5 G) or less

LAeq = 76 dB (A) or under

Standard model

Cleanroom model

*7

& ESD

RC180, RC620

5 (100)

5, 5 (120, 120)

50 (2000)

200 (25000)

10000, 10000, 10000, 10000, 10000, 10000

(65535, 65535, 65535, 65535, 65535, 65535)

1, 0

UL1740 (Third Edition, Dated December 7,2007)

ANSI/RIA R15.06-1999 NFPA 79 (2007 Edition)

CSA/CAN Z434-03 (February 2003)

CE Marking − Machinery Directive,

Low Voltage Directive, EMC Directive

*2 When the setting payload is more than 3 kg and less than or equal to 5 kg, refer to the

section “Restrictions on payload exceeding 3 kg (more than 3 kg and less than or equal

to 5 kg)” in the Setup & Operation 4.3.1 WEIGHT Setting.

*3 In the case where the center of gravity is at the center of each arm. If the center of

gravity is not at the center of each arm, set the eccentric quantity using INERTIA

mmand.

*4 For details of the installed pneumatic tube for customer use, refer to the Setup &

Operation 3.6 User Wires and Pneumatic Tubes.

*5 For details of the environmental requirements, refer to the Setup & Operation 3.1

Environmental Conditions.

*6 Conditions of Manipulator at measurement are as follows:

Operating conditions: Under rated load, 6 arms simultaneous motion, maximum speed,

maximum acceleration, and duty 50%.

Measurement point: 1000 mm apart from the rear of Manipulator

16 C3 Rev.4

Setup & Operation 2. Specifications

*7: The exhaust system in the Cleanroom-model Manipulator draws air from the base

interior and arm cover interior.

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.

Do not remove the covers.

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 3 (ISO14644-1)

In previous criteria; Clean Class: 10 or its equivalent

Amount of Dust (0.1 µm diameter or larger) in

28317 cm

of the motion rang: 10 particles or less.)

Exhaust System : Fitting for ø8 mm pneumatic tube

Refer to Setup & Operation: 3.6 User Wires and Pneumatic Tubes.

60 L/min vacuum

Exhaust tube : Polyurethane tube

Outer diameter: ø8 mm (Inner diameter: ø5 to 6 mm)

3

(1cft) sample-air around the center

2.6.2 Option

C3 series has the options below. For details of options, refer to Setup& Operation: 6.

Options.

Brake release unit

Camera plate unit

PS compatible plate

Base side angled fittings

Base side fittings

2.7 How to Set the Model

The Manipulator model for your system has been set before the shipment from the factory.

It is normally not required to change the model when you receive your system.

■

When you need to change the setting of the Manipulator model, be sure to set the Manipulator model properly. Improper setting of the Manipulator model may

CAUTION

NOTE

)

result in abnormal or no operation of the Manipulator and/or cause safety problems.

If an MT label is attached to the side of a Manipulator, the Manipulator has custom

specifications. If the Manipulator has custom specifications, the methods for setting the

model may differ from those described below. Please contact us with the number on the

MT label.

The method for setting the Manipulator model depends on the software used.

Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide.

C3 Rev.4 17

Setup & Operation 3. Environment and Installation

3. Environment and Installation

Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes.

3.1 Environmental Conditions

A suitable environment is necessary for the robot system to function properly and safely.

Be sure to install the robot system in an environment that meets the following conditions:

Item Conditions

Ambient temperature* 5 deg C ~ 40 deg C

Ambient relative humidity 20 % ~ 80 % (no condensation)

First transient burst noise 2 kV or less (Power supply wire)

1 kV or les (Signal wire)

Electrostatic noise 4 kV or less

Environment · Install indoors.

· Keep away from direct sunlight.

· Keep away from dust, oily smoke, salinity, metal

powder or other contaminants.

· Keep away from flammable or corrosive solvents

and gases.

· Keep away from water.

· Keep away from shock or vibration.

· Keep away from sources of electric noise.

* The ambient temperature conditions are for the Manipulators only. For the Controller

the Manipulators are connected to, refer to the Controller manual.

NOTE

)

When using the Manipulators in inadequate environments that do not meet the above

conditions, please consult your distributor.

Be sure to transport and store the robot system in environments that meet the following

conditions:

Item Conditions

Ambient temperature 0 ~ 45 deg C

Ambient relative humidity 20 ~ 80 %

18 C3 Rev.4

Setup & Operation 3. Environment and Installation

3.2 Unpacking, Transportation, and Relocation

Using a cart or similar equipment, transport the Manipulator in the same conditions as it

was delivered. Observe the following when unpacking the Manipulator.

THE INSTALLATION SHALL BE MADE BY QUALIFIED INSTALLATION PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL CODES.

■

Only authorized personnel should perform sling work and operate a crane or forklift. When these operations are performed by unauthorized personnel, it is extremely hazardous and may result in serious bodily injury and/or severe

WARNING

equipment damage to the robot system.

■

Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is extremely hazardous and may results in serious bodily injury and/or severe equipment damage to the robot system as the fall of the Manipulator.

■

When removing the anchor bolts, support the Manipulator to prevent falling. Removing the anchor bolts without supporting the Manipulator may get hands, fingers, or feet caught as the Manipulator will fall.

CAUTION

■

To carry the Manipulator, have at least 2 people to work on it and secure the Manipulator to the delivery equipment or hold it by hand.

Do not hold the bottom of the base (the screened parts in the figure). Holding these parts by hand is extremely hazardous and may cause your hands and fingers to be caught.

■

Avoid excessive vibration or shock during Manipulator transporting. Excessive vibration or shock may cause equipment damage to and/or malfunction of the Manipulator.

During unpacking and relocation avoid applying external force to the arms and motors of

the Manipulator.

When transporting the Manipulator for a long distance, secure it to the delivery equipment

so that the Manipulator cannot fall. If necessary, pack the Manipulator in the same way

as it was delivered.

When condensation occurs on the Manipulator during transport or storage, turn ON the

power only after the condensation dries.

When using the Manipulator for the robot system again after long-term storage, perform a

test run to verify that the Manipulator works properly. Then, operate the Manipulator

thoroughly.

Manipulator weight : 27 kg (59.5 lb.)

DO NOT hold the bottom of the base by hand.

C3 Rev.4 19

Setup & Operation 3. Environment and Installation

Relocating

Follow the procedures described below when relocating the Manipulator.

(1) Turn OFF the power for all devices and unplug the power cable connector and signal

cable connector from the controller.

Do not unplug the M/C cable (power cable and signal cable) from the manipulator.

NOTE

Remove the mechanical stops if using them to limit the motion range.

)

For details on the motion range, refer to the Setup & Operation 5.2 Motion Range

Setting by Mechanical Stops.

(2) Unscrew the anchor bolts. Then, remove the Manipulator from the base table.

(3) Position the Manipulator as shown in the

figure. Then, secure the Manipulator to the

delivery equipment or have 2 or more people

to carry the Manipulator.

Recommend : Joint #2 +65 deg.

Joint #3 −51 deg.

Manipulator weight : 27 kg (59.5 lb.)

Do not hold the bottom of the base (the

screened parts in the figure). Holding these

parts by hand is extremely hazardous and may

cause your hands and fingers to be caught.

DO NOT hold the bottom of the base by hand.

Using Eyebolt

Check that the eyebolts are securely fastened before carrying the Manipulator.

After transporting the Manipulator, remove the eyebolts and keep them for future use.

The weight of the Manipulator is approx. 27 kg (59.5 lb). The eyebolts and wire must be

strong enough to withstand the weight.

or more

or less

Holes for eye bolt

2-M6 depth 12.5

Use the wire of 1000 mm or more to avoid contact with Manipulator.

If you use the eyebolts to lift up the Manipulator, be sure to use the bifilar wire of 1000

mm-long or more to avoid contact with the Arm #4 side cover.

However, the Manipulator can swing while lifting up even with the appropriate length of

wire, so be sure to handle it with care.

Take extra care if you use the wire of 240 mm-long or more to lift the Manipulator,

because the wire is likely to touch the Arm #4 side cover and break the Manipulator.

20 C3 Rev.4

3.3 Mounting Dimensions

Mounting Area

Be sure to have the following space available in addition to the space for mounting the

Manipulator, Controller, and peripheral equipment.

Space for teaching points

Space for maintenance and inspections

Space for cables

NOTE

)

The minimum bend radius of the power cable is 90 mm. When installing the cable, be

sure to maintain sufficient distance from obstacles. In addition, leave enough space for

other cables so that they are not bent forcibly.

Mounting Dimensions [Unit: mm]

Setup & Operation 3. Environment and Installation

(Reference through hole)

Space for cable

(Mounting hole)

C3 Rev.4 21

Setup & Operation 3. Environment and Installation

3.4 Installation

THE INSTALLATION SHALL BE MADE BY QUALIFIED INSTALLATION PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL CODES.

■

To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to the Installation and Design Precautions in the Safety chapter of the EPSON RC+ User’s Guide.

■

Install the Manipulator at a location with sufficient space so that a tool or a work piece on the end effector does not reach a wall or a safeguard when the Manipulator extends its arm fully while holding a work piece. Installing the Manipulator at a location with insufficient space is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system as a tool or a work piece may collide with a wall and a safeguard.

■

Anchor the Manipulator before turning ON the power to or operating the

WARNING

Manipulator. Turning ON the power to or operating the Manipulator that is not anchored is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system as the Manipulator may fall down.

CAUTION

■

Before installing and operating the Manipulator, make sure that all parts of the Manipulator are in place and have no external defects. Missing or defective parts may cause improper operation of the Manipulator. Improper operation of the Manipulator is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

■

The robot system must be installed to avoid interference with buildings, structures, utilities, other machines and equipment that may create a trapping hazard or pinch points.

Mounting bolt

There are 4 threaded holes for the Manipulator base. Use M8 mounting bolts

conforming to the strength, ISO898-1 property class: 12.9. For the dimensions, refer to

Setup & Operation 3.3 Mounting Dimensions.

Base table

A base table for anchoring the Manipulator is not supplied. Please make or obtain the

base table for your Manipulator. The shape and size of the base table will differ

depending on the use of the robot system. For your reference, we list some basic

Manipulator table requirements here.

The base table must not only be able to bear the weight of the Manipulator but also be able

to withstand the dynamic movement of the Manipulator when it operates at maximum

acceleration. Ensure that there is enough strength on the base table by attaching

reinforcing materials such as crossbeams.

22 C3 Rev.4

Setup & Operation 3. Environment and Installation

The torque and reaction force produced by the movement of the Manipulator are as

follows:

Max. Horizontal rotating torque : 500 N·m

Max. Horizontal reaction force : 800 N

Max. Vertical rotating torque : 600 N·m

Max. Vertical reaction force : 2500 N

The plate for the Manipulator mounting face should be 30 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 base table must be secured on the floor to prevent it from moving.

The Manipulator must be installed horizontally.

When using a leveler to adjust the height of the base table, use a screw with M16 diameter

or more.

Connector

If you are passing cables through the holes on the base table, see the figures below.

[unit : mm]

95

47

26

53

18

NOTE

)

Power Cable

Connector

M/C Cables

Signal Cable

Connector

Do not remove the M/C cables from the Manipulator.

For environmental conditions regarding space when placing the Controller on the base

table, refer to the Controller manual.

Cleanroom-model Manipulator

For the Cleanroom-model, follow the steps below before the installation.

(1) Unpack it outside of the clean room.

(2) Secure the Manipulator to delivery equipment such as a pallet with bolts so that the

Manipulator does not fall.

(3) Wipe off the dust on the Manipulator with a little alcohol or distilled water on a

lint-free cloth.

(4) Carry the Manipulator in the clean room.

(5) Secure the Manipulator to the base table.

(6) Connect an exhaust tube (ø 8 mm) to the exhaust port.

C3 Rev.4 23

Setup & Operation 3. Environment and Installation

3.5 Connecting the Cables

■

Before performing any replacement procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

■

Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source. Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

■

Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the

WARNING

cables forcibly.) The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

CAUTION

■

Before wiring, turn OFF the Controller and related equipment, and then pull up a warning sign (e.g. DO NOT TURN ON THE POWER.). Wiring with the power ON is extremely hazardous and may result in electric shock and/or malfunction 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.

■

When connecting the Manipulator and the Controller, make sure that the serial numbers on each equipment match. Improper connection between the Manipulator and Controller may not only cause improper function of the robot system but also safety problems. The connection method varies with the Controller used. For details on the connection, refer to the Controller manual.

■

Only authorized or certified personnel should be allowed to perform wiring. Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system.

Cleanroom-model Manipulator

For the Cleanroom-model, an exhaust system is necessary. For details, refer to Setup &

Operation: 2.6 Specifications.

Connect

Connect the power

connector and signal

connector of the M/C cables to the Controller.

24 C3 Rev.4

M/C power cable

M/C signal

Setup & Operation 3. Environment and Installation

r

3.6 User Wires and Pneumatic Tubes

■

Only authorized or certified personnel should be allowed to perform wiring.

CAUTION

Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system.

User electrical wires and pneumatic tubes are contained in the cable unit.

Electrical Wires

Rated Voltage

Allowable

Current

Wires

AC/DC30 V 1 A 24 0.211 mm2

Maker Standard

9 pin

Suitable Connector JAE Clamp Hood JAE

Pins with the same number, indicated on the connectors on both ends of the cables, are

connected.

Nominal Sectional

Area

Outer Diameter Note

ø8.3±0.3 mm

Shielded

DE-9PF-N (Solder type)

DE-C8-J9-F2-1R (Connector setscrew: #4-40 NC)

Pneumatic Tubes

Max. Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter × Inner Diameter

0.59 MPa (6 kgf/cm2 : 86 psi)

4 ø4 mm × ø2.5 mm

Tubes with the same number, indicated in details of A and B, are connected.

B

Detail of “B”

No.1 No.2 No.3 No.4

Detail of “A”

A

User cable connector (9-pin D-sub connector)

User cable connecto (9-pin D-sub connector)

No.1 : White

No.2 : White

No.3 : Black

No.4 : Black

Standard-model : Cover Clean-room type : Exhaust port ( For ø8 mm pneumatic tube)

Fitting for ø4 mm pneumatic tube

We prepare the part that can be mounted to the position shown in “Detail of B”.

C3 Rev.4 25

Setup & Operation 3. Environment and Installation

One Touch Fittings Kit (Set of four: M5-ø4 mm one touch fittings for tubes)

Straight Elbow

User Connector kit (Single: 9 pins D-sub connector)

26 C3 Rev.4

3.7 Checking the Basic orientation

After parts have been replaced (motors, reduction gear units, belts, 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.

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

At shipment, the following basic orientation is configured as origin.

After all setting is done, go through an origin return run and make sure the manipulator

moves to the right basic orientation.

To make the manipulator return to origin, select the [Tool]-[Robot Manager]-[Control

Panel] and click the <Home> button.

If the manipulator cannot be in the basic orientation after the origin return run (not like as

the figure below), refer to Maintenance 16. Calibration to calibrate the manipulator.

Setup & Operation 3. Environment and Installation

Basic orientation

C3 Rev.4 27

Setup & Operation 4. End Effectors

4. End Effectors

4.1 Attaching an End Effector

Create an end effector for your Manipulator that will attach to Arm #6. Before attaching

the end effector to the end of Arm #6, observe these guidelines.

■

If you use an end effector equipped with a gripper or chuck, connect wires and/or pneumatic tubes properly so that the gripper does not release the work piece when the power to the robot system is turned OFF. Improper connection of the wires and/or pneumatic tubes may damage the robot system and/or work piece

CAUTION

as the work piece is released when the Emergency Stop switch is pressed. I/O outputs are configured at the factory so that they are automatically shut off (0) by power disconnection, the Emergency Stop switch, or the safety features of the robot system.

Wrist Flange

Toleranc e in this range

A

Detail of “A”

Arm #6

Attach an end effector to the end of the Arm #6 using an M4 bolt.

Layouts

When you operate the Manipulator with an end effector, the end effector may interfere

with the Manipulator because of the outer diameter of the end effector, the size of the work

piece, or the position of the arms. When designing your system layout, pay close

attention to the interference area of the end effector.

Standard specification (Brakes on Joints #2, #3, #5)

When the end effector is mounted, the joint may rotate by the hand weight or inertia in

Emergency Stop status. The end effector may contact the manipulator body depending

on the diameter of end effector, size of part, or arm position. Be careful about the area of

interference of the end effector for the system layout.

Compatibility with PS series

To mount the end effector used in the PS series to the C3 series, we prepare the option –

PS Compatible Plate. For details of the option, refer to Setup & Operation: 6. Options.

28 C3 Rev.4

4.2 Attaching Camera and Valves

Decks are equipped to Arms #3 and #5 to enable the easy installation of air valve.

Deck

Setup & Operation 4. End Effectors

Deck

Rotation Center of the Upper

Space for cable

[Unit: mm]

For details of the payload exceeding 3 kg, refer to the section “Restriction on payload

exceeding 3 kg (more than 3 kg and less than or equal to 5 kg)” in the Setup & Operation

4.3.1 WEIGHT Setting.

To mount the camera, the camera plate unit is necessary.

We prepare the option – Camera Plate Unit. For details of the option, refer to Setup &

Operation: 6. Options.

C3 Rev.4 29

Setup & Operation 4. End Effectors

4.3 WEIGHT and INERTIA Settings

The WEIGHT and INERTIA commands are for setting the load parameters of the

Manipulator. These settings optimize the Manipulator motion.

WEIGHT Setting

The WEIGHT command is for setting the load weight. The more the load weight

increases, the more the speed and acceleration/deceleration for the Manipulator movement

are reduced.

INERTIA Setting

The INERTIA command is for setting the moment of inertia and the eccentricity of the

load. The more the moment of inertia increases, the more the acceleration and

deceleration of the Arm #6 are reduced. The more the eccentricity increases, the more

the acceleration and deceleration for the Manipulator movement are reduced.

To ensure optimum Manipulator performance, it is important to make sure that the load

(weight of the end effector and work piece) and moment of inertia of the load are within

the maximum rating for the Manipulator, and that Arm #6 does not become eccentric.

If the load or moment of inertia exceed the ratings or if the load becomes eccentric, follow

the steps in the Setup & Operation 4.3.1 WEIGHT Setting and 4.3.2 INERTIA Setting, to

set parameters.

Setting parameters makes the operation of the Manipulator optimal, reduces vibration to

shorten the operating time, and improves the capacity for larger loads. In addition, it

reduces persistent vibration produced when the moment of inertia of the end effector and

work piece is bigger.

The allowable weight for C3 Manipulators is up to 3 kg (5 kg*). However, the moment

and the moment of inertia should also be considered due to limitations for these factors.

If force is applied to the Manipulator instead of the weight, force on the Arms #4, #5, and

#6 should be within the values shown in the table “Allowable Moment and Moment of

Inertia for C3 Manipulators”.

* When the load of the Manipulator is more than 3 kg and less than or equal to 5 kg,

refer to the section “Restriction on payload exceeding 3 kg (more than 3 kg and less

than or equal to 5 kg)” in the Setup & Operation 4.3.1 WEIGHT Setting.

Allowable Moment and Moment of Inertia for C3 Manipulators

Arm Allowable Moment

*1

GD2/4 Allowable Moment of Inertia

#4 4.41 N·m (0.45 kgf·m) 0.15 kg·m2

#5 *2

4.41 N·m (0.45 kgf·m) 0.15 kg·m

2

#6 2.94 N·m (0.3 kgf·m) 0.1 kg·m2

*1 Gravitational unit

*2 The allowable moment and allowable moment of inertia of Arm #5 are calculated by

the distance from the Arm #5 rotation center (a + 65 mm). (Refer to the figure in the

“Critical Location of the Load on C3 Manipulators”).

30 C3 Rev.4

Setup & Operation 4. End Effectors

Critical Location of the Load on C3 Manipulators

Position of Load’s Center of Gravity

Arm #J6 Rotation Center

Flange

Arm #J5 Rotation Center

[Unit: mm]

Rotation Center

Distance from the Arm #J6

Distance from the Flange

When calculating the critical location of the load on the Arm #5 using the allowable

moment and allowable moment of inertia, the calculated value represents a distance from

the Arm #5 rotation center, not the distance from the flange. Therefore, to get a value of

the critical location of the load on Arm #5, subtract 65 (mm) from the calculated distance

from the Arm #5 rotation center as shown the example below.

Example: Calculate the critical location of the load on the Arm #5 (c) when a 2.5 kg load is

on the Arm #6 rotation center line (b = 0).

Allowable Moment of the Arm #5 (N·m) / Load (kg)

= Distance from the Arm #5 rotation center (m)

4.41 (N·m) / 9.8 / 2.5 (kg) = 0.18 → 0.18 (m) = 180 (mm)

c (mm) = Distance from the Arm #5 rotation center (mm) − 65 (mm)

c = 180 (mm) − 65 (mm) = 115 (mm)

C3 Rev.4 31

Setup & Operation 4. End Effectors

Moment

A moment is a necessary torque (holding torque) to counteract the gravity affecting the

load.

Design an end effector so that the eccentric quantity at the position where the load is

attached is within the allowable moment.

A maximum torque (T) is calculated by the following formula.

T = m (kg) × L (m) × g (m/s

m: Weight of load (kg)

L: Eccentric quantity of load (m)

g: Gravitational acceleration (m/s

Max. Eccentric Quantity of Load (Distance between the joint rotation center and the load’s center of gravity)

Axis WEIGHT 1 kg WEIGHT 2 kg WEIGHT 3 kg

#4

#5

200 mm 200 mm 150 mm

#6 200 mm

(The maximum eccentric quantity of load is restricted to 200 mm or less.)

4.3.1 WEIGHT Setting

■

Set the total weight of the end effector and the work piece to 3 kg or less. The C3 Manipulators can operate without limitations on the condition that the load of the Manipulator should be 3 kg or less. When the payload of the Manipulator is more than 3 kg and less than or equal to 5 kg, refer to the section “Restrictions on payload exceeding 3 kg (more than 3 kg and less than or equal

CAUTION

to 5 kg)” in the later part of this section for details. Always set the Weight parameters of the WEIGHT command 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.

2

)

2

)

150 mm 100 mm

L

Joint Rotation Center

T

The acceptable weight capacity (end effector and work piece) for C3 Manipulators is 1 kg

nominal rating and 3 (5) kg maximum*. When the load (weight of the end effector and

work piece) exceeds the rating, change the setting of the Weight parameter.

After the setting of the Weight parameter is changed, the maximum

acceleration/deceleration and speed of the robot system corresponding to the Weight

parameter is set automatically.

* When the payload of the Manipulator is more than 3 kg and less than or equal to 5 kg,

refer to the section “Restrictions on payload exceeding 3 kg (more than 3 kg and less

than or equal to 5 kg)” in the later part of this section for details.

32 C3 Rev.4

Setup & Operation 4. End Effectors

Setting method of Weight parameters

The method for setting Weight parameter varies with the software used.

EPSON

RC+

EPSON RC+ 5.0 (RC180) / EPSON RC+ 6.0 (RC620)

Enter into the [Weight:] text box on the [Weight] panel ([Tools]-[Robot Manager]).

You may also execute the Weight command from [Command Window].

Load on the Manipulators

The Manipulator can load valves or any other devices onto the following three points.

Top View

Load on the Fore – end of Arm #6

Arm #5 Deck

Arm #3 Deck

Deck detailed

approx.

Arm #5 Deck Arm #3 Deck

[Unit: mm]

When you attach the equipment to the decks on the upper arm, convert its weight into

equivalent weight assuming that the equipment is attached to the end of the Arm #6.

Then, this equivalent weight added to the load will be a Weight parameter.

C3 Rev.4 33

Setup & Operation 4. End Effectors

w

Calculate the Weight parameter by following the formula below and enter the value.

Weight Parameter Formula

Weight parameter = M

Mw

: Load on the fore-end of Arm #6 (kg)

W

: Equivalent weight of the Arm #3 deck (kg)

a

W

: Equivalent weight of the Arm #5 deck (kg)

b

W

= Ma (La)²/ (L)²

a

= Mb (Lb)²/ (L)²

W

b

M

: Weight of the air valve on the Arm #3 deck

a

M

: Weight of the camera on the Arm #5 deck

b

L

: Length of the upper arm (315 mm)

L

: Distance between the Joint #3 and the center of gravity of

a

the air valve on the Arm #3 deck (mm)

L

: Distance between the Joint #3 and the center of gravity

b

of the camera on the Arm #5deck (mm)

+ Wa + Wb

w

M

<Example> The fore-end of Arm #6 is 315 mm (L) away from the Joint #3.

Load on the fore-end of Arm #6 is 1 kg (M

Load on the Arm #3 deck is 1.5 kg (M

The deck is 0 mm (L

) away from Joint #3.

a

Load on the Arm #5 deck is 0.5 kg (M

The deck is 280 mm (L

) away from the Joint #3.

b

).

w

).

a

).

b

=1.5 × 02/3152=0

W

a

=0.5 × 2802/3152=0.395 → 0.4(round up)

W

b

M

+ W

w

=1 + 0 + 0.4=1.4

+ W

a

b

Enter “1.4” for the Weight parameter.

34 C3 Rev.4

Setup & Operation 4. End Effectors

Automatic speed setting by Weight parameter

Acceleration / Deceleration

Speed

Weight Parameter

* The percentage in the graph is based on the speed at rated weight (1 kg) as 100%.

* When the payload of the Manipulator is more than 3 kg and less than or equal to 5 kg,

refer to the section “Restrictions on payload exceeding 3 kg (more than 3 kg and less

than or equal to 5 kg)” in the later part of this section for details.

Restrictions on payload exceeding 3 kg

(more than 3 kg and less than or equal to 5 kg)

Although the maximum payload of the C3 Manipulator is 3 kg, you can increase up to 5

kg when you restrict the arm pose range of Arm #5 with arm downward positioning.

When the load is over 3 kg, the Arm #5 orientation must be within the angle indicated in

the following graph.

1

The graph shows the relation of the load weight and Arm #5 angle limit (A

vertical direction (direction of gravity). Note that the heavier load Arm #6 holds, the

smaller the angle limit becomes.

When the manipulator operates vertically to the operating surface, the limit of Arm #5 is

2

equivalent to the limit of operating angle (A

).

In addition, for the eccentric load, the angle limit is an angle of the line joining the center

of load and Arm #5 rotation axis with the vertical direction (B).

) measured in

The eccentric quantity of load should be within the allowable moment and the allowable

moment of inertia of Arms #4, #5, and #6.

C3 Rev.4 35

Setup & Operation 4. End Effectors

1

2

Relation of load weight and Arm #5 angle limit

Arm #5 Angle Limit

Arm #5 rotation axis

Arm #5

Arm #6

Load on Arm #6 End

Arm #4

Vertical direction

Load on Arm 6 end

: Arm #5 angle

A

from vertical direction

Operating surface

A

Plane

: Angle of operating

surface form plane

Arm #5

Arm #6

Angle limit for eccentric load Relation of Arm #5 angle and operating surface

Vertical direction

Arm #5 rotation axis

Gravity

Load on Arm #6 end

B

36 C3 Rev.4

y

4.3.2 INERTIA Setting

Moment of Inertia and the INERTIA Setting

The moment of inertia is defined as “the ratio of the torque applied to a rigid body and its

resistance to motion”. This value is typically referred to as “the moment of inertia”,

“inertia”, or “GD

attached to the Arm #6, the moment of inertia of load must be considered.

■

The moment of inertia of load (weight of the end effector and work piece) must be

0.1 kg·m

2

of inertia exceeding 0.1 kg·m

CAUTION

Always set the moment of inertia (INERTIA) parameter according to the moment of inertia. Setting a value that is smaller than the actual moment of inertia may cause errors, excessive shock, insufficient function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.

The acceptable moment of inertia of load in C3 Manipulator is 0.1 kgxm2 nominal rating and 0.1 kgxm

the setting of the moment of inertia using the INERTIA command. After the setting has

been changed, the maximum acceleration/deceleration speed of Arm #6 responding to

“moment of inertia” is set automatically.

Moment of inertia of load on Arm #6

The moment of inertia of load (weight of the end effector and work piece) on Arm #6 can

be set by the “moment of inertia (INERTIA)” parameter of the INERTIA command.

The method for setting the parameter varies with the software used.

EPSON

RC+

EPSON RC+ 5.0 (RC180) / EPSON RC+ 6.0 (RC620)

Enter into the [Load inertia:] text box on the [Inertia] panel ([Tools]–[Robot Manager]).

You may also execute the Inertia command from [Command Window].

Setup & Operation 4. End Effectors

2

”. When the Manipulator operates with objects such as an end effector

or less. The C3 Manipulators are not designed to work with moment

2

.

2

maximum. When the moment of inertia of load exceeds the rating, change

Eccentric Quantity and the INERTIA Setting

■

The eccentric quantity of load (weight of the end effector and work piece) must be 200 mm or less. The C3 Manipulators are not designed to work with eccentric quantity exceeding 200 mm.

.

CAUTION

Always set the eccentric quantity parameter according to the eccentric quantit 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 C3 Manipulators is 30 mm nominal rating and

200 mm maximum. When the eccentric quantity of load exceeds the rating, change the

setting of eccentric quantity parameter using the INERTIA command. After the setting

has been changed, the maximum acceleration/deceleration speed of Manipulator

corresponding to “eccentric quantity” is set automatically.

C3 Rev.4 37

Setup & Operation 4. End Effectors

Rotation Center

a

Flange

b

Position of Load’s Center of Gravity

a, b = Eccentric Quantity (200 mm or less)

To set the parameter, enter the larger value of “a” or “b”.

Eccentric Quantity

Eccentric quantity of load on Arm #6

The eccentric quantity of load (weight of the end effector and work piece) on Arm #6 can

be set by the “eccentric quantity” parameter of the INERTIA command.

Enter the larger value of “a” or “b” in the figure above to the [Eccentricity] text box.

The method for setting the parameter varies with the software used.

EPSON

RC+

EPSON RC+ 5.0 (RC180) / EPSON RC+ 6.0 (RC620)

Enter into the [Eccentricity:] text box on the [Inertia] panel ([Tools]–[Robot Manager]).

You may also execute the Inertia command from [Command Window].

Automatic acceleration/deceleration setting by INERTIA (eccentric quantity)

Eccentric Quantity

* The percentage in the graph is based on the acceleration/ deceleration at rated eccentricity (30 mm)

as 100%.

INERTIA (eccentric quantity) is affected by the load setting. When you configure the

load setting, refer to Setup & Operation 4.3: WEIGHT and INERTIA Settings and

determine it carefully.

38

C3 Rev.4

Setup & Operation 4. End Effectors

Calculating the Moment of Inertia

Refer to the following examples of formulas to calculate the moment of inertia of load

(end effector with work piece).

The moment of inertia of the entire load is calculated by the sum of each part (a), (b), and

(c).

Rotation Center

End Effector (a)

Work Piece (b)

Whole Moment

of Inertia

Moment of Inertia

=

of End Effector (a)

Moment of Inertia

+

of Work Piece (b)

Work Piece (c)

Moment of Inertia

+

of Work Piece (c)

The methods for calculating the moment of inertia for (a), (b), and (c) are shown on this

page or the next page. Find the whole moment of inertia using the basic formulas on the

next page.

C3 Rev.4 39

Setup & Operation 4. End Effectors

(a) Moment of inertia of a rectangular parallelepiped

Rectangular Parallelepiped’s Center of Gravity Rotation Center

Weight = m

L

h

(b) Moment of inertia of a cylinder

Cylinder’s Center of Gravity

Rotation Center

r

Weight = m

L

(c) Moment of inertia of a sphere

Rotation Center

b

Sphere’s Center of Gravity

m+ m × L

2

b

r

2

+ h2 12

2

40

2 5

2

+ m × L2

Weight = m

L

r

mr

C3 Rev.4

Setup & Operation 4. End Effectors

4.4 Precautions for Auto Acceleration/Deceleration

The speed and acceleration/deceleration of the Manipulator motion are automatically

optimized according to the values of WEIGHT and INERTIA and the Manipulator’s

postures.

WEIGHT Setting

The speed and acceleration/deceleration of the Manipulator are controlled according to the

load weight set by the WEIGHT command.

The more the load weight increases, the more the speed and acceleration/deceleration are

reduced to prevent residual vibration.

INERTIA Setting

The acceleration/deceleration of Arm #6 are controlled according to the moment of inertia

set by the INERTIA command. The acceleration/deceleration of the whole Manipulator

are controlled according to the eccentricity set by the INERTIA command. The more the

moment of inertia and eccentricity of the load increase, the more the

acceleration/deceleration are reduced.

Auto Acceleration/Deceleration According to Manipulator’s Posture

The acceleration/deceleration are controlled according to the Manipulator’s posture.

When the Manipulator extends its arms or when the movement of the Manipulator

produces vibration frequently, the acceleration/deceleration are reduced.

Set appropriate values for WEIGHT and INERTIA so that the Manipulator operation is

optimized.

C3 Rev.4 41

Setup & Operation 5. Motion Range

5. Motion Range

■

When setting up the motion range for safety, both the pulse range and

WARNING

mechanical stops must always be set at the same time. Failure to set both of them together may cause serious safety problems.

The motion range is preset at the factory as explained in the Setup & Operation 2.5

Standard Motion Range. This is the maximum motion range of the Manipulator.

There are three methods for setting the motion range described as follows:

1. Setting by pulse range (for all arms)

2. Setting by mechanical stops

3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the

Manipulator

Rectangular Range Setting

Mechanical

Stop

When the motion range is changed due to layout efficiency or safety, follow the

descriptions in 5.1 to 5.4 to set the range.

Motion Range

Pulse Range

5.1 Motion Range Setting by Pulse Range (for All Arms)

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 axis.

Pulse values are read from the encoder output of the servo motor.

The pulse range must be set inside of the mechanical stop range.

■

Do not set and/or use the Arm #4 with pulse range beyond the maximum value. The Arm #4 does not have a mechanical stop. The used of Arm #4 in motion

CAUTION

exceeding the maximum pulse range may cause inner wiring damage to and/or malfunction of the Manipulator.

Mechanical

Stop

You can check the inner wiring torsion by removing the Arm #3 cover.

Arm #3 cover

42 C3 Rev.4

t

NOTE

)

EPSON

RC+

Once the Manipulator receives an operating command, it checks whether the target

position specified by the command is within the pulse range before operating. If the

target position is out of the set pulse range, an error occurs and the Manipulator does not

move.

EPSON RC+ 5.0 (RC180) / EPSON RC+ 6.0 (RC620)

The pulse range can be set on the [Range] panel shown by selecting the [Tools]-[Robo

manager].

You may also execute the Range command from the [Command Window].

5.1.1 Max. Pulse Range of Arm #1

Counterclockwise pulse values are positive (+) and clockwise pulse values are negative (-).

Setup & Operation 5. Motion Range

(without mechanical stop)

Arm #1 0 pulse position

5.1.2 Max. Pulse Range of Arm #2

Counterclockwise pulse values are positive (+) and clockwise pulse values are negative (-).

Arm #2

0 pulse position

(without mechanical stop)

C3 Rev.4 43

Setup & Operation 5. Motion Range

5.1.3 Max. Pulse Range of Arm #3

Counterclockwise pulse values are positive (+) and clockwise pulse values are negative (-).

Arm #3 0 pulse position

5.1.4 Max. Pulse Range of Arm #4

From the angle of arm end, clockwise pulse values are positive (+) and counterclockwise pulse values are negative (-).

Arm #4

0 pulse position

CAUTION

■

Do not set and/or use the Arm #4 with pulse range beyond the maximum value. The Arm #4 does not have a mechanical stop. The used of Arm #4 in motion exceeding the maximum pulse range may cause inner wiring damage to and/or malfunction of the Manipulator.

You can check the inner wiring torsion by removing the Arm #3 head cover.

Arm #3 head cover

44 C3 Rev.4

5.1.5 Max. Pulse Range of Arm #5

Counterclockwise pulse values are positive (+) and clockwise pulse values are negative (-).

Arm #5 0 pulse position

5.1.6 Max. Pulse Range of Arm #6

From the angle of arm end, clockwise pulse values are positive (+) and counterclockwise pulse values are negative (-).

Arm #6

0 pulse position

Setup & Operation 5. Motion Range

5.2 Motion Range Setting by Mechanical Stops

Mechanical stops physically limit the absolute area that the Manipulator can move.

Be sure to turn OFF the Controller in advance.

Bolts are not provided, arrange for them by yourself.

Use a bolt conforming to the strength specified by ISO-898-1, property class: 12.9.

Re-specify the pulse range after changing the position of the mechanical stop.

For details on the pulse range setting, refer to the Setup & Operation 5.1 Motion Range

Setting by Pulse Range (for All Arms).

Be sure to set the pulse range without exceeding the pulse values corresponding to the

mechanical stop’s setting angles.

C3 Rev.4 45

Setup & Operation 5. Motion Range

5.2.1 Motion Range Setting of Arm #1

There are threaded holes corresponding to each angle on the Manipulator.

Normally a mechanical stop is equipped in [ b ].

[ a ] and [ c ] limit the one side of motion range.

a

If the motion range of Arm #1 is ±180 deg, remove the bolts below.

M8×15 hexagon socket head cap bolt

Tightening torque 3720 N·cm (380 kgf·cm)

Angle (deg.) Pulse (pulse) Bolt

a b c

−125 ±170 ±180

−3640889 ±4951609 ±5242880 −3640889

Applied

5.2.2 Motion Range Setting of Arm #2

There are threaded holes corresponding to each angle on

the Manipulator.

Normally there is no mechanical stop equipped.

(−160 deg. - +65 deg.)

[ d ] and [ e ] limit the one side of motion range.

M10×15 hexagon socket head cap bolt

Tightening torque 7350 N·cm (750 kgf·cm)

Applied (Normal) Not applied

d

b

c

+125

Applied

e

Angle (deg.) Pulse (pulse)

Bolt

d e - -

−143

−4165177

Applied Applied

5.2.3 Motion Range Setting of Arm #3

There are threaded holes corresponding to each angle on

the Manipulator.

Normally mechanical stops are equipped to [ g ] and [ h ].

(+225 deg. - −51 deg.)

M8×12 hexagon socket head cap bolt

Tightening torque 3720 N·cm (380 kgf·cm)

Angle (deg.) Pulse (pulse)

Bolt

f i g h

+201

+5122731

Applied Applied

+48

+1398102

−27

−688128

−160

−4660338

Not applied

(Normal)

g

h

+225

+5734400

Applied

(Normal)

+65

+1893263

Not applied

(Normal)

f

i

−51

−1299798

Applied

(Normal)

46 C3 Rev.4

Setup & Operation 5. Motion Range

5.3 Restriction of Manipulator Operation by Joint Angle Combination

To prevent the arms of the Manipulator from interfering each other, the Manipulator

operation is restricted in the specified motion range according to the joint angle

combination of the Arm #1, #2, and #3.

The Manipulator operation is restricted and the Manipulator stops when the joint angles of

the Arm are within the gray areas in the following figure.

Combination of Joint #1 and #2

Joint #2 Angle

Joint #1 Angle

Combination of Joint #2 and #3

Joint #3 Angle

Joint #2 Angle

The restriction to Manipulator operation is enabled:

- During CP motion command execution

- You attempt to execute the motion command for moving the Manipulator to a target

point (or pose) in the specified motion range.

The restriction to the Manipulator operation is disabled:

- The Arms of the Manipulator momentarily go through the specified motion range

during the PTP motion command execution even though the joint angles of the Arms

are in the gray areas of the figures above.

C3 Rev.4 47

Setup & Operation 5. Motion Range

t

5.4 Coordinate System

The origin point is located where the Manipulator base intersects with the rotation axis of

Joint #1.

For details on the coordinate system, refer to the EPSON RC+ Users Guide manual.

Table Top mounting Ceiling mounting Wall mounting Skewed mounting

+Y

+X

+Z

+X

+Z

+X

+Y

+X

+Y

+Z

+X

+Y

20 deg.

+Y

5.5 Setting the Cartesian (Rectangular) Range in the XY Coordinate System of the Manipulator

The Cartesian (rectangular) range in the XY coordinate system of the Manipulator is

specified by the limited Manipulator operation area and the XYLIM setting.

The limited Manipulator operation area is defined so that the end effector does not

interfere with the rear side of the Manipulator. The XYLIM setting is that you can set the

upper and lower limits of the X and Y coordinates.

The limited Manipulator operation area and XYLIM setting apply only to the software.

Therefore, these settings do not change the physical range. The maximum physical range

is based on the position of the mechanical stops.

These settings are disabled during a joint jogging operation. Therefore, be careful not to

allow the end effector to collide with the Manipulator or peripheral equipment.

The method for changing the XYLIM setting varies with the software used.

EPSON

RC+

EPSON RC+ 5.0 (RC180) / EPSON RC+ 6.0 (RC620)

Set the XYLIM setting on the [XYZ Limits] panel shown by selecting the [Tools]-[Robo

manager].

You may also execute the XYLim command from the [Command Window].

48 C3 Rev.4

6. Options

The C3 series has the options below.

6.1 Brake Release Unit

6.2 Camera Mounting Plate

6.3 PS Compatible Plate

6.4 Base Side Angled Fittings

6.5 Base Side Fittings

6.1 Brake Release Unit

With the electromagnetic brake is ON (such as in Emergency Stop status), you cannot

move the Arms #2, #3, #5 by hand. If the all joints have a brake, all arms don’t move.

You can move Arms by hand using the brake release unit while the controller power is

OFF or right after unpacking.

■

Before connecting/disconnecting the connector of Brake release unit, be sure to

WARNING

check the powers of the controller and break release unit are OFF.

Otherwise, it leads to the electrical shock or breakdown.

Setup & Operation 6. Option

CAUTION

■

Release a brake for each joint one by one. If you need to release some brakes at a time, take a great care. Because when some joints are released at a time, the arms may fall to unintended directions. This is extremely dangerous and may break the manipulator or catch your hand, fingers.

■

Take care of the arm downward motion when the brake is released. While you are pressing the brake release switch, the arm moves downward by its own weight. This is extremely dangerous and may break the manipulator or catch your hand, fingers.

Width 180 mm

Depth 150 mm

Height 87 mm

Weight (Cables are not included.) 1.7 kg

Cable to the Manipulator 2 m

Power cable length 2 m

Power cable (US) 100 V specification

Power cable (EU) 200 V specification

A

View from A

Power switch

C3 Rev.4 49

Power cable

Power lamp

Arm switches

Setup & Operation 6. Option

Precautions for use

■

After the brake release unit is disconnected, be sure to connect the external short connector. Otherwise, you cannot release the brakes.

■

Keep the external short connector. Otherwise you cannot release the brakes.

■

If you turn ON the brake release unit while the brake release switch is being pressed, an unintended arm may move downward. Before turning ON the brake release unit, make sure that the brake release switch is not pressed.

■

If you turn ON the brake release unit without the connector, it may lead to the short for the male pin used in the connector. Before turning ON the brake release unit, make sure that the connector is connected.

■

When you purchased several C3 series manipulators and use the brake release unit in the manipulator without the connection cable, you need to change the connection cable inside the manipulator. To skip this switching work, purchase the cable set for the brake release unit.

If you purchased the manipulator and connection cable together, the cable has been installed to the manipulator before shipment.

For additional external short connector or connection cable, please contact us.

CAUTION

NOTE

)

50 C3 Rev.4

(2)

(3)

How to connect the connection cable

If you purchased the manipulator and connection cable together, the cable has been

installed to the manipulator before shipment. This procedure is not necessary.

Setup & Operation 6. Option

(1) Turn OFF the controller.

(2) Remove the hiding plate.

2-M4×8

(3) Open the connector plate.

4-M4×8

For details, refer to Maintenance: 3.

Covers.

(4)

Pass the cable through the hole below

the hiding plate from the outside.

Connect the connection cable to the

connector plate.

2-M4×8

(5)

Take out the connector of internal cable

SW1.

Hiding plate

2-M4×8

Connector plate

4-M4×8

Connector plate

Connection cable

(6)

(7)

(8)

(9)

Disconnect the internal short connector.

Keep the short connector to the inside

Internal short connector

of base or somewhere not to lose.

Connect the connection cable and

internal cable SW1.

Connection

cable

Mount the connector plate. Be careful not to catch the cables.

4-M4×8

If the brake release unit is not used,

mount the external short connector.

To prevent the external short connector

from falling off, secure the two screws

External short connector

included with the connector.

Connector SW1

C3 Rev.4 51

Setup & Operation 6. Option

Mount the brake release unit

(1)

(2)

(3)

Turn OFF the controller.

Remove the external short connector.

Connect the brake release unit to the

connector of the connection cable.

Remove the brake release unit

External short connector

Connector of the connection cable

(1)

(2)

(3)

(4)

Turn OFF the brake release unit.

Remove the power cable of the brake release unit.

Disconnect the brake release unit from the connector of connection cable.

Connect the external short connector to the connector of connection cable.

52 C3 Rev.4

How to use the brake release unit

■

Be careful of the arm downward motion while you release the brakes. The arm will move downward by its own weight while you are pressing a brake release switch. This is extremely dangerous and may break the manipulator or catch your hand, fingers.

■

CAUTION

If the arm you released the brake moves strange or slower than normal, stop the

motion promptly and contact us. The brake release unit is possibly broken and if you keep operating the manipulator, it may lead to the brake of the manipulator or you will be caught by the hand or fingers.

Setup & Operation 6. Option

(2) Power switch

(1)

(2)

(3)

(4)

(5)

NOTE

)

Disconnect the external short connector.

Plug the power cable into the brake release unit.

Plug the power cable into the power supply plug.

Turn ON the brake release unit.

When the brake release unit is enabled, the power lamp lights up.

Press the arm switch J1 ~ J6 you want to move and then move the arm.

Press the switch again, then the brake will be released.

The brake will be enabled by pressing the switch once again.

Move the arm the brake is released by two persons or more (one presses the switch

and one moves the arm). The arm can be very heavy and needs the significant force

to move.

(1) Power cable

(3) Arm switches connector lock(2) Power lamp

C3 Rev.4 53

Setup & Operation 6. Option

A

r

6.2 Camera Plate Unit

To mount a camera to the C3 series manipulator, you need to mount the camera plate unit

first.

Appearance of arm end with camera

Camera

Camera plate unit

Parts included unit

A Camera adapter plate 1

B Camera mid plate 1

C Camera base plate 1

D Hexagon socket head screws

M4×12

E hexagon socket head screws

M4×20

F Plain washer for M4

(small washer)

To mount the camera plate unit

(1) Mount the camera base plate to the manipulator.

2-M4 × 20 + Plain washer for M4 (small washer)

(2) Mount the camera mid plate to the base plate.

6

: Camera adapter plate

2

D

B: Camera mid plate

C: Camera base plate

Mounting holes of

camera base plate

D

E

F

2-M4 × 12

(3) Mount the camera to the camera adapter plate.

(4) Mount the camera adapter plate and camera to the camera mid plate.

(5) Secure the cables at the position where they will not interfere with the manipulato

NOTE

)

NOTE

)

NOTE

)

The motion range and dimension of the manipulator with the camera installed may

vary depending on the mounting hole of camera mid plate. The details are

described in the table below.

According to the camera, the available mounting hole of adapter plate will be

different. The details are described below.

4-M4 × 12

motion.

When securing the cables, check if the cables bend radius is big enough and the

cables are not rubbing against each other while the manipulator moves. Otherwise,

the cables will be disconnected.

54 C3 Rev.4

Setup & Operation 6. Option

Dimension of the camera plate unit

3-M4 through hole (for securing cables)

4-M4 depth 5 (for securing cables)

Camera

4-M4 depth 8 * same hole on opposite side (for securing cables)

Dimensions X and Y will change depending on the position of camera mid plate and

camera size. Refer to the table below for the values.

Camera mid plate

The camera mid plate uses the mounting holes

A ~ D .

By using the different mounting holes, it can

be mounted to the camera base plate in the

different four positions.

Camera adapter plate

Each camera uses the different mounting holes.

Sony XC-ES30, HR50, HR70 : 1, 2, 4

Matrox Iris : 1, 2, 3, 5

JAI (Pulnix) CV-A1 : 6, 7

1

3

4

2

5

6

7

Mounting example

Using the mounting hole A Using the mounting hole C

E.g.) Camera: XC-ES30

C3 Rev.4 55

Setup & Operation 6. Option

Camera vs. Joint #5 motion range (reference values)

The Joint #5 motion range varies depending on the mounting position of camera mid plate

and the camera you are using.

The table below shows the motion range (reference values) based on the available cameras

for this option and the mounting positions of the camera mid plate. The values in the

table may vary depending on how to secure the cables.

By changing the Y position, you can extend the distance from the end effector mounting

surface to the camera. Also, you can attach the larger end effector. However, be careful

about the Joint #5 motion range that will be limited in this case.

（° = degree）

JAI (Pulnix) CV-A1

Sony XC-ES30, HR50, HR70

Matrox Iris −135° ~ +45° −135° ~ +30° −135° ~ +15° −135° ~ +10° 83 mm

Y

A B C D X

−135° ~ +60° −135° ~ +50° −135° ~ +35° −135° ~ +25° 72.5 mm

A B C D

57 mm 37 mm 17 mm 7 mm

Direction of the Joint #5 motion

56 C3 Rev.4

6.3 PS Compatible Plate

Using the PS compatible plate, you can mount the end effector used in the PS series to the

C3 series.

Parts included Unit

A PS compatible plate 1

B Dowel pin (M3 hole on one side) 1

C Hexagon socket head screw M4×12

Setup & Operation 6. Option

4

Dimensions of PS-compatible plate

Spot faced hole for M4 (at 90 ° pitch)

H7 depth 12

4-M4 depth 12 (at 90 ° pitch)

Insert dowel pin here

C: Hexagon socket head screw 4-M4×12

A: PS-compatible plate

B: Dowel pin (M3 hole on one side)

(° = degree)

To mount the PS compatible plate

(1)

Align the hole on the arm end flange (ø12H7) to the projection on the PS compatible plate (ø12h7).

(2) Insert the dowel pin from the PS compatible plate side and position the arm and PS

compatible plate. One side of the dowel pin has the M3 screw hole and you can

adjust the depth using M3.

NOTE

)

If you move the manipulator with the dowel pin inserted, the dowel pin will fall out.

Even so you want to move the manipulator, you need to secure the dowel pin with

glue.

(3) Secure the PS compatible plate with 4 hexagon socket head screws.

4-M4 × 12

C3 Rev.4 57

Setup & Operation 6. Option

A

6.4 Base Side Angled Fittings

Using the base side angled fittings to the C3 series manipulator base, you can mount the

manipulator in skewed position. The motion range expands with this mounting type

more than the normal ceiling mounting.

Mounting image using the base side angled fittings

For details of the mounting and precautions, refer to Setup & Operation: 3. Environment

and Installation.

Parts included Unit

A Base side angled plate (Left side) 1

B Base side angled plate (Right side) 1

C Base side plate (for Skewed mounting type) 2

D Pin 6

E Hexagon socket head screw M8 × 25 4

F Hexagon socket head screw M8 × 30 4

D

E

F F

B

D

CC

D

E

58 C3 Rev.4

Setup & Operation 6. Option

To mount the base side angled fittings

(1) Drive pins to the base side plate (for Skewed mounting type).

Protruding part of pins is approx. 2 ~ 5 mm.

(2) Drive pins to the base side angled plate (left & right sides).

Protruding part of pins is approx. 2 ~ 5 mm.

(3)

(4)

Create a base side angled fittings.

Fit the pins of the plate for Skewed mounting type in the step

(1) with the holes on the plate in the step (2) and secure with

the screws.

Hexagon socket head screw M8 × 30

Mount the base side angled fittings to the both sides of manipulator base.

Fit the pins drove in the step (2) with the holes on the base. Secure the fittings by

pressing it to the indicated direction in the figure below.

Left & Right side Hexagon socket heat screw 2- M8 × 25

Two pi ns Protruding part

2mm～5mm

Pin at each side Protruding part

2mm～5mm

Right side

NOTE

)

Base side angled fittings

2-M8×25

The shape of base side angled fittings is different for left and for right. Be sure to mount the correct fittings. Otherwise, the motion range of Arm #2 is limited in the backside.

C3 Rev.4 59

Setup & Operation 6. Option

Dimension of the manipulator with the base side angled fitting is installed

(Prepared hole ø8.5)

(Tolerance is ø6H 7)

Base plate thickness* 40mm or less

Position of base plate

* Base plate thickness

NOTE

)

We recommend that the base plate thickness is between 30 mm and 40mm. If the

thickness is more than 40 mm, the manipulator may contact the base plate when Arm #1

rotates, depending on the center cut dimension in the base plate.

The base plate securing the manipulator is prepared by users. The torque value and

reaction force generated in the manipulator motions are described in Setup & Operation:

3.4 Installation.

60 C3 Rev.4

A

6.5 Base Side Fittings

Using the base side fittings to the C3 manipulator base, you can mount the manipulator in

the place where limits the mounting height or use the open room for the base.

Mounting image using the base side fittings

For the information on how to mount and precautions, refer to Setup & Operation: 3.

Environment and Installation.

Parts included Unit

A Base side plate 2

B Pin 2

Hexagon socket head

C

screw M8 × 60

C

4

Setup & Operation 6. Option

B

C

To mount the base side plate

(1) Drive the pins to the base side plate.

Protruding part of pins is approx. 2 ~ 5 mm.

(2)

Mount the base side plate with the pins driven to the both sides of the base.

Fit the pins with the holes and secure the base side plate by pressing it from above to the base fixing part. (With the steps above, the both surfaces of base side fittings can be stable.)

Base fixing part

2-M8×60

Pin protruding part

2. Press toward this face from above

2mm～5mm

1. Insert pins into the holes

C3 Rev.4 61

Setup & Operation 6. Option

Dimension of the manipulator with the base side fittings installed

2-M10 (Prepared hole ø8.5)

62 C3 Rev.4

Setup & Operation 6. Option

←

f

Mounting example

Available screws

Size Recommended length

A M8 30 mm or more

B M10 15 mm + Base Plate or more

NOTE

)

Table Top mounting

The base side plate has a M10 screw hole. You can secure with a M10

screw or M8 screw by using a M10 prepared screw of ø8.5 to make a M8

screw hole on the mounting surface.

A: Securing from above

To secure from above, use the screw A in the table above.

When you install the manipulator for practical use, you need to insert the

screws in the right/left side from the same direction (above or below).

B: Secures

rom below

A: Secures

rom above

A: Secures

rom below

B: Secures

from above

Base Plate

(Floor)

Ceiling mounting

A: Secures

from above

← Base plate

(Ceiling)

A: Secures

from below

B: Secures

from above

B: Secures

from below

C3 Rev.4 63

Setup & Operation 6. Option

64 C3 Rev.4

Maintenance

This volume contains maintenance procedures with safety precautions for C3 series Manipulators.

1. Safety Maintenance

Please read this chapter, this manual, and other relevant manuals carefully to understand

safe maintenance procedures before performing any routine maintenance.

Only authorized personnel who have taken safety training should be allowed to maintain the robot system. Safety training is the program for industrial robot operators that follows the laws and regulations of each nation. The personnel who have taken safety training acquire knowledge of industrial robots (operations, teaching, etc.), knowledge of inspections, and knowledge of related rules/regulations. The personnel who have completed the robot system-training and maintenancetraining classes held by the manufacturer, dealer, or locally-incorporated company are allowed to maintain the robot system.

Do not remove any parts that are not covered in this manual. Follow the

■

maintenance procedure strictly as described in this manual. Improper removal of parts or improper maintenance may not only cause improper function of the robot system but also serious safety problems.

Maintenance 1. Safety Maintenance

WARNING

■

Keep away from the Manipulator while the power is ON if you have not taken the training courses. 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 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 properly is extremely hazardous and may result in serious bodily injury and/or serious damage to the robot system as the switches cannot fulfill their intended functions in an emergency.

■

To shut off power to the robot system, pull out the power plug from the power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source.

■

Before performing any replacement procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

C3 Rev.4 67

Maintenance 1. Safety Maintenance

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

CAUTION

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.

2. General Maintenance

This chapter describes maintenance inspections and procedures. Performing maintenance

inspections and procedures properly is essential for preventing trouble and ensuring safety.

Be sure to perform the maintenance inspections in accordance with the schedule.

2.1 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

must be added every 250 hours, 750 hours, 1500 hours, and 3000 hours operation.

1 month (250 h) √

2 months (500 h) √

3 months (750 h) √ √

4 months (1000 h) √

5 months (1250 h) √

6 months (1500 h) √ √ √

7 months (1750 h) √

8 months (2000 h) √

9 months (2250 h) √ √

10 months (2500 h) √

11 months (2750 h) √

12 months (3000 h) √ √ √ √

13 months (3250 h)

…

Daily

inspection

Inspect every day

…

Monthly

inspection

√

…

Inspection Point

Quarterly

inspection

…

Biannual

inspection

…

Annual

inspection

…

h = hour

68 C3 Rev.4

2.2 Inspection Point

2.2.1 Inspection While the Power is OFF (Manipulator is not operating)

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

Maintenance 2. General Maintenance

Check looseness or backlash of

bolts/screws.

Tighten them if necessary.

(For the tightening torque, refer to

Maintenance: 2.4 Tightening

Hexagon Socket Head Cap Bolts.)

Check looseness of connectors.

If the connectors are loosen, push it

securely or tighten.

Visually check for external defects.

Clean up if necessary.

Check for bends or improper

location. Repair or place it properly

if necessary.

Check tension of timing belts.

Tighten it if necessary.

Grease conditions Refer to Maintenance: 2.3 Greasing.

End effector mounting bolts √ √ √ √ √

Manipulator mounting bolts √ √ √ √ √

Each arm locking bolts √ √ √ √ √

Bolts/screws around shaft √

Bolts/screws securing motors,

reduction gear units, etc.

External connectors on

Manipulator (on the connector

plates etc.)

Manipulator cable unit √ √ √ √

External appearance of

Manipulator

External cables √ √ √ √

Safeguard etc. √ √ √ √ √

Base

Inside of Arms #1, 2, 3, 4

√ √ √ √ √

2.2.2 Inspection While the Power is ON (Manipulator is operating)

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

√

√ √

Check motion range Each joint √

Move the cables back and forth

lightly to check whether the cables

are disconnected.

Push each arm in MOTOR ON

status to check whether backlash

exists.

Check whether unusual sound or

vibration occurs.

Measure the accuracy repeatedly by

a dial gauge.

External cables

(including cable unit of the

Manipulator)

Each arm √

Whole √ √ √ √ √

Whole √

√ √

C3 Rev.4 69

Maintenance 2. General Maintenance

2.3 Greasing

The reduction gear units and bevel gear need greasing regularly. Only use the grease

specified in the following table.

■

Keep enough grease in the Manipulator. Operating the Manipulator with insufficient grease will cause the noise or damage sliding parts and/or result in insufficient function of the Manipulator. Once the parts are damaged, a lot of time and money will be required for the repairs.

If grease gets into your eyes, mouth, or on your skin, follow the instructions

■

below.

CAUTION

Greasing part Greasing Interval Grease Greasing method

If grease gets into your eyes

: Flush them thoroughly with clean water, and then see a doctor immediately.

If grease gets into your mouth

: If swallowed, do not induce vomiting. See a doctor immediately. : If grease just gets into your mouth, wash out your mouth with water

thoroughly.

If grease gets on your skin

: Wash the area thoroughly with soap and water.

Joint #1, 2, 3, 4

Joint #6 Bevel gear Once a year (every 8000 hours) SK-2 Follow the steps below.

* Under normal conditions, the reduction gear units shall be greased only when the motor is replaced. However, in

case of severe working conditions (such as high duty, high speeds, large payloads, etc.), the reduction gear units

must be greased every 10,000 hours.

Reduction gear units In the replacement of motor* SK-1A Please contact us.

Greasing Joint #6 bevel gear

Maintenance Parts and Tools

Maintenance Parts

Tools

Grease for reduction gear unit (

Screw M4×15 (length: 15 mm or more) 1 For unplugging

Wiping cloth

Name Quantity Note

SK-2) Proper quantity

1 For wiping grease

(1) Secure Arm #5 in the direction you can unplug easily.

(2) Insert the screw into the screw part of plug. M4 depth 5.

Screw : M4 length 15 mm or more (easy-to-unplug)

M4×15

Plug

(3) Hold the screw inserted in the step (2) and unplug.

(4) Apply the grease.

(2)

Grease amount : 2 g

(5) Insert the plug unplugged in the step (3) to the original

position.

(3)

To prevent the grease leaking or unplugging, be sure to

insert the plug all the way seated.

(6) Pull out the screw inserted in the step (2).

(4) Apply grease here

70 C3 Rev.4

Maintenance 2. General Maintenance

a

2.4 Tightening Hexagon Socket Head Cap Bolts

Hexagon socket head cap bolts are used in places where mechanical strength is required.

(A hexagon socket head cap bolt will be called a “bolt” in this manual.) These bolts are

fastened with the tightening torques shown in the following table.

When it is necessary to refasten these bolts in some procedures in this manual (except

special cases as noted), use a torque wrench so that the bolts are fastened with the

appropriate tightening torques as shown below.

Tightening Torque

Bolt

M3 2.5 N⋅m (25 kgf⋅cm)

M4 4.9 N⋅m (50 kgf⋅cm) M4 2.5 N⋅m (25 kgf⋅cm)

M5 9.8 N⋅m (100 kgf⋅cm) M5 3.9 N⋅m (40 kgf⋅cm)

M6 17.6 N⋅m (180 kgf⋅cm)

M8 37.2 N⋅m (380 kgf⋅cm)

M10 73.5 N⋅m (750 kgf⋅cm)

M12 127.4 N⋅m (1,300 kgf⋅cm)

Refer below for the set screw.

Set Screw Tightening Torque

We recommend that the bolts aligned on a circumference should be fastened in a crisscross

pattern as shown in the figure below.

5

Bolt hole

3

1

8

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

4

torque wrench so that the bolts are fastened with

tightening torques shown in the table above.

7

2

6

C3 Rev.4 71

Maintenance 2. General Maintenance

2.5 Layout of Maintenance Parts

Joint #5, #6 unit

Joint #3 Reduction Gear Unit

Joint #5 Timing belt

Joint #2 Reduction Gear Unit

Electromagnetic Brake

Lithium battery & Battery board

Joint #6 Motor

LED lamp

Joint #3 Timing belt

Join t#3 Electromagnetic Brake

Joint #2 Timing belt

Joint #5

Joint #2 Electromagnetic Brake

Joint #1 Motor

Joint #1

Reduction Gear Unit

Joint #1 Timing belt

Joint #6 Electromagnetic Brake

Joint #4

Electromagnetic Brake

Joint #4 Motor

M/C cable

Joint #1 Electromagnetic Brake

Joint #6 Timing belt

Joint #6 Motor

Joint #2 Motor

72 C3 Rev.4

A

3. Covers

■

WARNING

■

Tools

Maintenance 3. Covers

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

chapter.

Do not insert or pull out the motor connectors while the power to the robot system is turned ON. Inserting or pulling out the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

To shut off power to the robot system, pull out the power plug from the power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source.

Before performing any replacement procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

Be careful not to get any foreign substances in the Manipulator, connectors, and pins during maintenance. Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

Tools

rm #4 side cover

Arm #2 side cover

Arm #1 side cover

Name Quantity Note

Hexagonal wrench (width across flats: 2.5 mm)

Hexagonal wrench (width across flats: 3 mm)

Cross-point screwdriver

Arm #3 head cover

Arm #2 side cover

Arm #1 top cover

Connector plate

Connector sub plate

User plate

Arm #4 side cover

Arm #3

bottom cover

Arm #1 side cover

Base bottom cover

1

For M3 screw

For M4 screw

1

C3 Rev.4 73

Maintenance 3. Covers

3.1 Arm #1 Top Cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Unscrew the cover mounting bolts and remove the cover.

3-M4×10

Arm #1 top cover

3.2 Arm #1 Side Cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Unscrew the cover mounting bolts and remove the cover.

2-M4×15

2-M4×10

2-M4×15

2-M4×10

Arm#1 side cover

74 C3 Rev.4

3.3 Arm#2 Side Cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Unscrew the cover mounting bolts and remove the cover.

Maintenance 3. Covers

4-M4×10

Arm#2 side cover

3.4 Arm#3 Head Cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Unscrew the cover mounting bolts and remove the cover.

4-M4×10

Arm#3 head cover

C3 Rev.4 75

Maintenance 3. Covers

3.5 Arm #3 Bottom Cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Move the arm so that you can remove the Arm #3 bottom cover. Remove the screws (cross-recessed head truss screws) securing the cover and remove the cover.

4-M3×5 (Cross-recessed head truss screws)

Arm#3 bottom cover

76 C3 Rev.4

A

r

3.6 Arm#4 side cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Unscrew the cover mounting bolts and remove the cover.

6-M3×8

Maintenance 3. Covers

A

NOTE

)

6-M3×8

rm #4 side cover

To improve the manipulator performance, clearances of the Arm #4 side cover, Joint #5

motor pulley, and Joint #6 motor pulley have become smaller.

To avoid the interference of covers and pulleys, attach the Arm #4 side cover.

Arm #4 side cover

(Joint #6 motor pulley side)

Pressing direction

A′

Joint #6 motor

Pressing direction

Arm #4 side cove

(Joint #5 motor pulley side)

Joint #5 motor

A - A´ Cross section detail

C3 Rev.4 77

Maintenance 3. Covers

3.7 Base Bottom Cover

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Remove the screws (cross-recessed flat head machine screws) securing the cover and remove the cover. If you use the other screws than the screws indicated here, the screw head will protrude from the base surface and it will make it difficult to mount the manipulator firmly. We recommend using our attached screws or equivalent ones.

3.8 Connector Plate

Do not remove the connector plate forcibly. Removing the connector plate

■

forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

■

When installing the connector plate, be careful not to allow the cables to interfere

CAUTION

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 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 connector plate.

4-M3×5 (cross-recessed flat head machine screws)

Base bottom cover

Connector plate

4-M4×8

78 C3 Rev.4

3.9 Connector Sub Plate

Do not remove the connector sub plate forcibly. Removing the connector sub

■

plate forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

When installing the connector sub plate, be careful not to allow the cables to

■

CAUTION

interfere with the plate mounting and do not bend these cables forcibly to push them into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper 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 connector sub plate.

Maintenance 3. Covers

3.10 User Plate

■

When installing 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 failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

Unscrew the user plate mounting bolts and remove the user plate.

User plate

Connector sub plate

4-M4×8

×6

2-M3

C3 Rev.4 79

Maintenance 4. Cable Unit

4. Cable Unit

4.1 Replacing the Cable Unit

■

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.

■

Do not insert or pull out the motor connectors while the power to the robot system is turned ON. Inserting or pulling out the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

■

Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source. Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

WARNING

■

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.

■

Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

■

When installing 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 failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. When routing the cables, observe the cable locations after removing the cover. Be sure to place the cables back to their original locations.

80 C3 Rev.4

CAUTION

Maintenance 4. Cable Unit

■

When disconnecting the connectors during the replacement of the cable unit, be sure to reconnect the connectors to their proper positions. Improper connection of the connectors may result in improper function of the robot system. For details on the connections, refer to the Maintenance 10.3 Connector Pin

Assignments.

■

Carefully use alcohol and adhesive following respective instructions and also instructions below. Otherwise, it may cause a fire and/or safety problems.

- Never put alcohol or adhesive close to fire.

- Use alcohol or adhesive while ventilating the room.

- Wear protective gear including a mask, protective goggles, and oil-resistant

gloves.

- If alcohol or adhesive gets on your skin, wash the area thoroughly with soap and water.

- If alcohol or adhesive gets into your eyes or mouth, flush your eyes or wash out your mouth with clean water thoroughly, and then see a doctor immediately.

■

Wear protective gear including a mask, protective goggles, and oil-resistant gloves during grease up. If grease gets into your eyes, mouth, or on your skin, follow the instructions below.

If grease gets into your eyes : Flush them thoroughly with clean water, and

If grease gets into your mouth : If swallowed, do not induce vomiting. See a

If grease gets on your skin : Wash the area thoroughly with soap and

Maintenance Parts, Tools, and Material

Maintenance Parts

Grease (Krytox) Proper quantity R13B030304

Cable unit 1 R13B020036

Hexagonal wrench (width across flats: 2.5 mm) 1 For M3 screw

Hexagonal wrench (width across flats: 3 mm) 1 For M4 screw

Box wrench (width across flats: 5 mm) 1 For D-Sub connector

Tools

Long nose pliers 1

Cross-point screwdriver 1

Force gauge 1 For belt tension

Material

Wire tie (AB100) 18 Wire tie (AB150) 11 Wire tie (AB250) 3

then see a doctor immediately.

doctor immediately.

If grease just gets into your mouth, wash out your mouth with water thoroughly.

water.

Name Quantity Note

For removing

air connector

Nippers 1

Brush 1 For applying grease

Alcohol Proper quantity

C3 Rev.4 81

Maintenance 4. Cable Unit

Removal: Cable Unit

(1) Move the manipulator to the origin (0 pulse position).

(2) Turn OFF the controller power.

(3) Remove the covers and plates below.

For details, refer to Maintenance: 3. Covers.

Arm #4 side cover (Both sides) User plate

Arm #3 head cover Arm #3 bottom cover

Arm #2 side cover (Both sides) Arm #1 side cover (Both sides)

Arm #1 center cover Connector plate

When removing the user plate and connector plate, remove the parts below together.

D-sub 9-pin connector

Air tube × 4

(4) Disconnect the connectors inside the base.

Connector:

X010, X020, X030, X040, X050, X060,

LEDA, (BR010, BR011), BR020, BR030,

BR040, BT1, X11, X12, X13, X14, X15, X16

(5) Cut off the wire ties which bind the cables inside

Arm #3.

Remove the battery board inside Arm #1 and

disconnect the following connectors from the

battery board.

Connector:

X61, X62, X63, X64

(6) Remove the wire ties binding the cables.

Disconnect the connector of inside Arm #3.

Connector:

X71, X72, X041, X051, X061,

LEDB, (BR041), BR051,(BR061),

BT4, BT5, BT6, X141, X151, X161

(7) Disconnect the connector from the motors of Joint #2 and #3.

Connector: X021, X121, BR021, X031, X131, BT3, BR031

82 C3 Rev.4

(8) Remove the parts below from Arm #4.

Arm #4 cable fixing plate (2-M4×10)

Ground wire (M4×10)

(9) Cut off 4 wire ties of the Arm #4 cable fixing

plate.

- For binding the cables

- For fixing the coil plate

- For binding the special power supply

- For fixing the special power supply plate

(10) Remove the parts below from Arm #3.

Arm #3 cable fixing plate (2-M4×5)

Ground wire × 2 (2-M4×5)

(11) Cut off the 6 wire ties of Arm #3 cable fixing plate.

Maintenance 4. Cable Unit

(12)

Pull out the air tube alone toward Arm #2.

Pull out the cables below toward Arm #3.

Joint #5 motor cable, brake cable

Joint #6 motor cable, brake cable

Cable for installed wire for customer use

(X71, X72, X051, X061, X151, X161,

BR051, (BR061), BT5, BT6)

When pulling out cables, carefully treat cables and connectors.

Pull out the cables in the order of connector size, from smallest to largest.

(13) Cut off the 3 wire ties of Arm #2 and disconnect

2 ground wires (2-M4×5).

(14) Pull out the cable unit of Arm #3 toward Arm

#2.

Carefully treat cables ad connectors to prevent

damage to them.

Arm #3 side: Cable

Arm #2: Air tube

Ground wire

Wire tie

Arm #2 side: Cable unit

C3 Rev.4 83

Maintenance 4. Cable Unit

(15) Remove the Arm #2 cable fixing plate (2-M4×8).

There is no need to remove the fixing blot

completely.

Remaining the bolt in Arm #2 makes it easy to

mount the cable unit.

Pull out the cables toward Arm #1.

(16) Cut off 3 wire ties of Arm #1.

Disconnect 2 ground wires (2-M4×5).

(17) Remove the Arm #1 cable fixing plate (2-M4×5).

(18) Cut off 3 wire ties of Arm #1 cable fixing plate.

(19) Remove the parts below.

Base cable fixing plate (2-M4×8)

Ground wire (M4×5)

(20) Cut off 3 wire ties of base cable fixing plate.

Ground wire

Cable fixing plate

Wire tie

Pull out the cables in the base side toward Arm #1.

(21) Pull out the cable unit from the base.

84 C3 Rev.4

Installation: Cable Unit

Separate the cable unit. (1)

→

(2) Apply the grease inside of cable protection spring

(Krytox: 4 g)

Small-diameter spring : 0.5 g

Spring (Length: 130 mm) : 1 g × 2

Spring (Length: 230 mm) : 1.5 g

Maintenance 4. Cable Unit

(3) Secure the Arm #2 cable fixing plate and cable unit.

Plate and spring : Wire tie AB100

Cable unit and plate : Wire tie AB150

(4) Prepare to mount the cable unit to the manipulator.

Bind the cables. Be careful not to bind the ground wires together.

(Wire tie: AB100 × 6)

42

3

1

5

1. Connector

2. Connector

3. Connector

4. Connector

5. Connector

SW1, BR010, BR011, BR020,

BR030, BR040, LEDA

X121, X021, BR021

X131, X031, BR031, BT3

X71, X72

X141, X151, X101, X041, X051,

X061

C3 Rev.4 85

Maintenance 4. Cable Unit

(5) For the manipulator with all axes brakes:

insert the Joint #6 brake cable toward the direction

indicated in the right picture into the cable

protection spring and secure the Joint #6 motor

unit to Arm #4. (2-M4×15, 2-M4 washer)

(6) Insert the Joint #5 brake cable into the cable

protection spring toward the direction indicated in

the right picture. Loosely secure the Joint #5

motor unit to the opposite side from Arm #4.

(2-M4×15, 2-M4 washer)

(7) Insert the following connectors into the base side.

Signal cable: X010、X020、X030、X040、

LED-A、X050、X060

Power cable: X12、X13、X14、X15、X16

(8) Insert the cable unit into Arm #2 and then Arm

#3.

(9) Pass the air tube and ground wire of cable unit

through the cable protection spring

(Small-diameter) and take them out from Arm #4.

(10) Secure the Arm #3 cables.

Loosely bind the cables so that you can adjust their location afterward.

86 C3 Rev.4

[A] Bind 3 coils of cable protection spring in

Arm #2 side (130 mm) to the Arm #3 cable

fixing plate. (AB100)

[B] Loosely bind the cables using 2 wire ties

(AB150).

[C] Bind 3 cable protection springs

(Small-diameter) to the Arm #3 cable fixing

plate. (AB100)

[D] Loosely bind the cables sticking out from

Arm #4. (AB150)

Maintenance 4. Cable Unit

[A]

[B]

[C]

[D]

[E] Secure the Arm #3 cable fixing plate to Arm

#3. (2-M4×5)

[F] Secure 2 ground wires (2-M4×5).

Connect the connectors.

Connector: X71, X72, X041, X051, X061,

LEDB,

(BR041), BR051, (BR061),BT4,

BT5, BT6, X141, X151, X161

Bind the cables using 2 wire ties. (AB200)

(11) [A] Bind 3 cable protection springs

(Small-diameter) to the Arm #4 cable fixing

plate. (AB100)

[B] Loosely bind the cables. (AB150)

approx. 80 mm

[F]

[E]

[B]

[A]

(12) Secure the Arm #4 cable fixing plate to Arm #4. (2-M4×10)

C3 Rev.4 87

Maintenance 4. Cable Unit

)

(13) Secure the ground wire to Arm #4.

Secure the brake special power supply to th

Arm #4 cable protection plate. (AB150)

e

(14) Secure the cable protection spring (130 mm) to

Arm #2. (2-AB100)

(15) Loosely secure the cables to the cable binde

(AB150)

To avoid the cables from scratching against th

spring, put the cables up by 3 mm and secur

them.

(16) Secure 2 ground wires to Arm #2. (2-M4×5)

Connect the connector of the Joint #3 motor.

(17) Secure the Arm #2 cable fixing plate to Arm #2

(2-M4×8)

(18) Secure the cable protection spring (150 mm) to

Arm #1. (2-AB100)

(19) Loosely secure the cables to the cable binde

(AB150)

(20) Secure 2 ground wires to Arm #1. (2-M4×5)

r.

e

r.

(18)

(20)

.

(19)

(18)

(20)

(21)

(24

(24)

(21) Secure the Arm #1 cable fixing plate to Arm #1.

(2-M4×5)

(22) [A] Bind 3 coils of cable protection spring (230

mm) to the base cable fixing plat

e. (2

points: 2-AB100)

[B] Loosely secure the cables. (AB150)

(23) Connect the connector of the Joint #2 motor.

(24) [A] Bind 3 coils of cable protection spring (230

mm) to the base cable fixing plate. (AB100)

[B] Loosely secure the cables. (2 points:

2-AB150)

(25)

(26)-[B]

(26)-[A]

(29)

(28)-[A]

(28)-[B]

88 C3 Rev.4

EPSON C3-A601C, C3-A601S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

WARRANTY

TRADEMARKS

NOTICE

INQUIRIES

SERVICE CENTER

MANUFACTURER & SUPPLIER

SUPPLIERS

For Customers in the European Union

Before Reading This Manual

TABLE OF CONTENTS

Setup & Operation

Maintenance

Setup & Operation

1. Safety

1.1 Conventions

1.2 Design and Installation Safety

1.3 Operation Safety

1.4 Emergency Stop

1.5 How to Move Arms the Electromagnetic Brake is Applied to

1.5.1 Moving the arm using the brake release unit

1.5.2 Moving the arm using the software

1.6 Precaution for Operation in Low Power Status

1.7 Manipulator Labels

2. Specifications

2.1 Features of Manipulators

2.2 Model Number

2.3 Part Names and Motion Range of Each Arm

2.4 Outer Dimensions

2.5 Standard Motion Range

2.6 Specifications

2.6.1 Specifications table

2.6.2 Option

2.7 How to Set the Model

3. Environment and Installation

3.1 Environmental Conditions

3.2 Unpacking, Transportation, and Relocation

3.3 Mounting Dimensions

3.4 Installation

3.5 Connecting the Cables

3.6 User Wires and Pneumatic Tubes

3.7 Checking the Basic orientation

4. End Effectors

4.1 Attaching an End Effector

4.2 Attaching Camera and Valves

4.3 WEIGHT and INERTIA Settings

4.3.1 WEIGHT Setting

4.3.2 INERTIA Setting

4.4 Precautions for Auto Acceleration/Deceleration

5. Motion Range

5.1 Motion Range Setting by Pulse Range (for All Arms)

5.1.1 Max. Pulse Range of Arm #1

5.1.2 Max. Pulse Range of Arm #2

5.1.3 Max. Pulse Range of Arm #3

5.1.4 Max. Pulse Range of Arm #4

5.1.5 Max. Pulse Range of Arm #5

5.1.6 Max. Pulse Range of Arm #6

5.2 Motion Range Setting by Mechanical Stops

5.2.1 Motion Range Setting of Arm #1

5.2.2 Motion Range Setting of Arm #2

5.2.3 Motion Range Setting of Arm #3

5.3 Restriction of Manipulator Operation by Joint Angle Combination

5.4 Coordinate System

5.5 Setting the Cartesian (Rectangular) Range in the XY Coordinate System of the Manipulator

6. Options

6.1 Brake Release Unit

How to connect the connection cable

Mount the brake release unit

Remove the brake release unit

How to use the brake release unit

6.2 Camera Plate Unit

6.3 PS Compatible Plate

6.4 Base Side Angled Fittings

6.5 Base Side Fittings

Maintenance

1. Safety Maintenance