Epson LS20 User Manual

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Rev.1 EM158R3027F

LS20 series

SCARA ROBOT

MANIPULATOR MANUAL

MANIPULATOR MANUAL LS

20 series Rev.1

SCARA ROBOT

LS20 series Manipulator Manual

Rev.1

LS20 Rev.1 i

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

Malfunctions caused by customers’ unauthorized disassembly.

Damage due to improper adjustments or unauthorized repair

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

1. If the Manipulator or associated equipment is used outside of the usage conditions and product specifications described in the manuals, this w

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.

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 Manipulator and its optional parts are shipped to our customers only after being subjected to the strictest q uality controls, tests, and inspections to ce rtify 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):

Warnings, Cautions, Usage:

arranty is void.

attempts.

ii LS20 Rev.1

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

LS20 Rev.1 iii

Toyoshina Plant Robotics 6925 Toyoshin a Tazawa, Azumino JAPAN

TEL

: +81-(0)263-72-1530

FAX

: +81-(0)263-72-1495

North & South America

Epson America, Inc.

Factory Automation/Robotics 18300 Central Avenue Carson, CA 907 46 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 D Germany

TEL

: +49-(0)-2159-538-1391

FAX

: +49-(0)-2159-538-3170

E-MAIL

: robot.infos@epson.de

China

Epson (China) Co., Ltd.

Factory Automation Division 7F, Jinbao Building No. 89 Dongcheng District, Beijing China, 100005

TEL

: +86-(0)-10-8522-1199

FAX

: +86-(0)-10-8522-1120

Taiwan

Epson T ai wan Technology & T ra ding Ltd.

Factory Automation Division 14F, No.7, Song Ren Road, Taipei 110 Taiwan, ROC

TEL

: +886-(0)-2-8786-6688

FAX

: +886-(0)-2-8786-6677

MANUFACTURER

SUPPLIERS

Solutions Operations Division

-shi, Nagano, 399-8285

-Hahn-Str.4

-40670 Meerbusch

, Jinbao Street,

iv LS20 Rev.1

Korea

Epson Korea Co., Ltd.

Marketing T eam 27F DaeSung D Seobusaet Korea

TEL

: +82-(0)-2-3420-6692

FAX

: +82-(0)-2-558-4271

Southeast Asia

Epson Singapore Pte. Ltd.

Factory Automation System 1 HarbourFront Place, #03 HarbourFront Tower One, Singapore 098633

TEL

: +65-(0)-6586-5696

FAX

: +65-(0)-6271-3182

India

Epson India Pvt. Ltd.

Sales & Marketing (Factory Automation) 12th Floor, The Millenia, Tower A, No. 1, Murphy Road, Ulsoor, Bangalore, India 560008

TEL

: +91-80-3051-5000

FAX

: +91-80-3051-5005

Japan

Epson Sales Japan Corporation

Factory Automation Systems Department Nishi Nishishinjuku Japan

TEL

: +81-(0)3-5321-4161

(Robot Business)

-Polis A, 606

-gil, Geumcheon-gu, Seoul, 153-803

-02,

-Shinjuku Mitsui Bldg. 6-24-1 , Shinjuku-ku, Tokyo 160-8324

LS20 Rev.1 v

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)

vi LS20 Rev.1

Label

Controller

Software

EPSON

RC+

Before Reading This Manual

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

Structure of Control System

The LS 20 series Manipulators can be used with the following combinations of Controllers and software.

Robot Controller RC90 with the following label attached.

Turning ON/OFF Controller

RC90 EPSON RC+ 7.0 Ver.7.1.4 or later

When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to turn ON/OFF all the hardware components. For the Controller composition, refer to the table above.

Shape of Motors

The shape of the motors used for the Manipulator that you are using may be different from the shape of the motors described in this manual because of the specifications.

Setting by Using Software

This manual contains setting procedures by using software. They are marked with the following icon.

Figures in this Manual

The figures of manipulators indicated in this manual are basically Standard-model Manipulator. Unless special instruction is provided, the specifications of Standard-model and Cleanroom-model are the same.

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.

LS20 Rev.1 vii

viii LS20 Rev.1

Setup & Operation

1. Safety 3

1.1 Conventions................................................................................................ 3

1.2 Design and Installation Safety .................................................................... 4

1.2.1 Strength of Ball Screw Spline ......................................................... 5

1.3 Operation Safety ........................................................................................ 6

1.4 Emergency Stop ......................................................................................... 8

1.5 Emergency Movement Without Drive Power ........................................... 10

1.6 ACCELS Setting for CP Motions .............................................................. 11

1.7 Manipulator Labels ................................................................................... 12

2. Specifications 14

2.1 Features of LS20 series Manipulators ..................................................... 14

2.2 Model Number .......................................................................................... 15

2.3 Part Names and Outer Dimensions ......................................................... 16

2.3.1 LS20-804* ..................................................................................... 16

2.3.2 LS20-A04* .................................................................................... 20

2.4 Specifications ........................................................................................... 24

2.5 How to Set the Model ............................................................................... 26

3. Environments and Installation 27

TABLE OF CONTE NT S

3.1 Environmental Conditions ........................................................................ 27

3.2 Base Table ................................................................................................ 28

3.3 Mounting Dimensions ............................................................................... 29

3.3.1 LS20-804* ..................................................................................... 29

3.3.2 LS20-A04* .................................................................................... 31

3.4 Unpacking and Transportation ................................................................. 33

3.4.1 Precautions for Transport ation ........................................................ 33

3.4.2 Transpor tati on ................................................................................. 34

3.5 Installation Procedure ............................................................................... 35

3.5.1 Standard-Model ............................................................................ 35

3.5.2 Cleanroom-Model ......................................................................... 36

3.6 Connecting the Cables ............................................................................. 37

3.7 User Wires and Pneumatic Tube s............................................................ 38

3.8 Relocation and Storage ............................................................................ 39

3.8.1 Precautions for Relocation and Storage ...................................... 39

3.8.2 Relocation ..................................................................................... 40

4. Setting of End Effectors 41

4.1 Attaching an End Effector ......................................................................... 41

4.2 Attaching Cameras and Valv es ................................................................ 42

4.3 Weight and Inertia Settings ...................................................................... 43

4.3.1 Weight Setting .............................................................................. 43

4.3.2 Inertia Setting ............................................................................... 45

LS20 Rev.1 ix

TABLE OF CONTENTS

4.4 Precautions for Auto Acceleration/Deceleration of Jo int #3..................... 49

5. Motion Range 50

5.1 Motion Range Setting by Pulse Range (for All Joints) ............................. 50

5.2 Motion Range Setting by Mechanical Stops ............................................ 53

5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate

5.4 Standard Motion Range ........................................................................... 58

Maintenance

5.1.1 Max. Pulse Range of Joint #1 ...................................................... 51

5.1.2 Max. Pulse Range of Joint #2 ...................................................... 51

5.1.3 Max. Pulse Range of Joint #3 ...................................................... 52

5.1.4 Max. Pulse Range of Joint #4 ...................................................... 52

5.2.1 Setting the Mechanical Stops of Joints #1 an d #2 ....................... 54

5.2.2 Setting the Mechanical Stop of Joint #3 ....................................... 56

System of the Manipulator ( for Joi nts #1 and #2) ................................... 58

1. Safety Maintenance ................................................................... 61

2. General Maintenance ................................................................. 62

2.1 Maintenance Inspection ........................................................................... 62

2.1.1 Schedule for Maintenance Inspection .......................................... 62

2.1.2 Inspection Point ............................................................................ 63

2.2 Overhaul ................................................................................................... 64

2.3 Greasing ................................................................................................... 65

2.4 Tightening Hexagon Socket Head Cap Bolts .......................................... 66

2.5 Matching Origins ...................................................................................... 66

2.6 Layout of Maintenance Parts ................................................................... 67

3. Covers ........................................................................................ 68

3.1 Arm Top Cover ......................................................................................... 69

3.2 Arm Bottom Cover .................................................................................... 70

3.3 Arm #1 Cover ........................................................................................... 70

3.4 Connector Plate ....................................................................................... 71

3.5 Connector Sub Plate ................................................................................ 72

3.6 User Plate................................................................................................. 72

4. Cable .......................................................................................... 73

4.1 Replacing Cable Unit ............................................................................... 73

4.2 Wiring Diagrams ....................................................................................... 78

4.2.1 Signal Cable ................................................................................. 78

4.2.2 Power Cable ................................................................................. 79

4.2.3 User Cable ................................................................................... 80

4.3 Replacing M/C Cable ............................................................................... 81

x LS20 Rev.1

TABLE OF CONTENTS

5. Arm #1 ........................................................................................ 84

5.1 Replacing Joint #1 Motor ......................................................................... 85

5.2 Replacing Joint #1 Reduction Gear Unit .................................................. 88

6. Arm #2 ........................................................................................ 91

6.1 Replacing Joint #2 Motor ......................................................................... 92

6.2 Replacing Joint #2 Reduction Gear Unit .................................................. 96

7. Arm #3 ...................................................................................... 100

7.1 Replacing Joint #3 Motor ....................................................................... 101

7.2 Replacing the Timing Be lt ...................................................................... 105

7.3 Replacing the Brake ............................................................................... 109

7.4 Checking the Timing Belt Tension .......................................................... 113

8. Arm #4 ...................................................................................... 114

8.1 Replacing Joint #4 Motor ....................................................................... 115

8.2 Replacing the Timing Be lt ...................................................................... 119

8.3 Replacing the Brake ............................................................................... 123

8.4 Replacing the Reduction Gear Unit ....................................................... 124

8.5 Checking the Timing Belt Tension .......................................................... 126

9. Bellows ..................................................................................... 127

10. Ball Screw Spline Unit ............................................................ 129

10.1 Greasing the Ball Screw Sp li ne U nit .................................................... 129

10.1.1 Standard-model (S type) .......................................................... 130

10.1.2 Cleanroom-model ..................................................................... 131

10.2 Replacing the Ball Screw Spline Unit ................................................... 133

11. Lithium Battery ........................................................................ 136

11.1 Replacing the Battery Unit (Lithium Battery ) ........................................ 138

11.2 Replacing the Resolver Board .............................................................. 139

11.3 Replacing the Control Board ................................................................ 141

12. LED Lamp .............................................................................. 142

13. Calibration .............................................................................. 143

13.1 About Calibration .................................................................................. 143

13.2 Calibration Procedure ........................................................................... 144

13.3 Accurate Calibration of Joint #2 ........................................................... 154

13.4 Calibration Procedure without using Calibration Wizard ..................... 156

14. Maintenance Parts List ........................................................... 160

LS20 Rev.1 xi

TABLE OF CONTENTS

xii LS20 Rev.1

Setup & Operation

This volume contains infor mation for setup and operation of the LS20

Please read this volume operating the Manipulators.

series Manipulators.

thoroughly before setti ng up and

associated instructions are not followed

death caused by electric shock exists if the associated

or physical damage to equipment and facilities exists if the

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 properly.

This symbol indicates that a danger of possible serious injury or instructions are not followed properly.

This symbol indicates that a danger of possible harm to people

CAUTION

associated instructions are not followed properly.

LS20 Rev.1 3

Setup & Operation 1. Safety

Personnel who design and/or construct the robot system with this product must read the safety requirements before designing and/or constructing the robot system. Designing and/or constructing the robot system without understanding the safety requirements is extremely hazardous, may res severe equipment damage to the robot system, and may cause serious safety problems.

■

The Manipulator and the Controller must be used within the environmental conditions described in their respective manuals. designed and manufactur ed strict ly for use in a norma l indoor env iron ment. 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 seriou

■

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 problems.

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 lev el as tho se w ho have co mplet ed the tr aini ng 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:

■

Safety chapter in the EPSON RC+ User’s Guide to understand the

WARNING

ult in serious bodily injury and/or

s safety problems.

Further precautions for installation are mentioned in the chapter Setup & Operation: 3. Environments and Installation. Please read this chapter carefully to understand safe installation procedures before installing the robots and robotic equipment.

This product has been

safety

4 LS20 Rev.1

Setup & Operation 1. Safety

End of spline nut F

1.2.1 Strength of Ball Screw Spline

If a bending load exceeding the allowable limit is placed on the ball screw spline, the spline may be deformed or broken and not function normally. If the load exceeding the allowance is placed, the ball screw spline needs to be replaced. The allowable load depends on distance that the load is placed. Calculate the value by referring to the following.

[Allowable bending moment]

M=50,000 N

Calculation example: 110 N (11.2 kgf) load is placed at 400 mm from the end of the spline nut

[Moment]

M=F

∙L＝

∙

110·400＝44,000 N∙mm

LS20 Rev.1 5

Setup & Operation 1. Safety

Please carefully read the the the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and/or sever 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 t o

■

Before operating the robot system, make sure that no one is inside the safeguarded area. even when someone is in side the safeguarded area. The motion of the Manipulat or is always in restricted (low speeds and low power) status to secure the safety of an operator. 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. the Manipulator moves abnormally is extremely hazardous and may result in serious bodily injury and/o r severe equipment damage to the robot system.

To shut off power to the robot system, pull out the power plug from the power source. NOT connect it direct ly 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.

■

Do not insert or pull out the motor connectors w hile the power t o the robot system is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in ele ctr ic sho c k and/or ma lfunc tion o f the robot system.

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

■

EPSON RC+ User’s Guide before operating the robot system. Operating

Safety-related Requirements in the Safety chapter of

e equipment

be stopped.

WARNING

■

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

The robot system can be operated in the mode for teaching

However, operating the robot system

Continuing the operation while

turned ON. Inserting or pulling out the motor co n nectors w ith the p ow er ON i s

6 LS20 Rev.1

Setup & Operation 1. Safety

Whenever possible, only one person should operate the robot system. necessary to operate t he r obot sy st em with mor e th a n one per s on, e nsure that al l people involved com mu ni cat e with each other as to what t hey are doing and take all necessary safety pr ecaut ions.

Joint #1, #2, and #4: If the joints are operate d they may get damaged early because the bearings are likely to cause oil film shortage in such situation. To prevent early breakdown, move the joints larger than 50 degrees

Joint #3: If the up the maximum stroke for fi ve to ten times a day.

Oscillation (resonance) may (Speed: effector load. Oscillation arises from natural oscillation frequency of the Arm and can be controlled by follow ing measures.

■

If it is

CAUTION

■ repeatedly with t he oper ating ang le less tha n 5 degr ees ,

for about five to ten t imes a day.

-and-down motion of the hand is less than 1 0 mm, move t he joint a hal f of

■

occur continuously in low speed Manipulator motion

approx. 5 to 20%) depending on combination of Arm orientation and end

Changing Manipulator speed Changing the teach point s Changing the end effe c t or load

LS20 Rev.1 7

Setup & Operation 1. Safety

1.4 Emergency Stop

If the Manipulator moves abnormally during operation, immediately press the Emergency Stop switch. Pressing the Emergency Stop switch immediately changes the manipulator to deceleration motion and stops it at the maximum deceleration speed.

However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator is running normally. Pressing the Emergency Stop switch locks the brake and it may cause wear on the friction plate of the brake, resulting in the short life of the brake.

Normal brake life cycle: About 2 years (when the brakes are used 100 times/day) To place the 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.

Do not turn OFF the Controller while the Manipulator is operating. If you attempt to stop the Manipulator in emergency situations such as “Safeguard Open”, make sure to stop the Manipulator using the E-Stop of the Controller.

If the Manipulator is stopped by turning OFF the Controller while it is operating, following problems may occur. Reduction of the life and damage of the reduction gear unit Position gap at the joints In addition, if the Controller was forced to be turned OFF by blackouts and the like while the Manipulator is operating, make sure to check the following points after power restoration. Whether or not the reduction gear is damaged Whether or not the joints are in their proper positions

If there is a position gap, perform calibration by referring to the Maintenance 16. Calibration in this manual.

Before using the Emergency Stop switch, be aware of the followings.

- The Emergency Stop (E-STOP) switch should be used to stop the Manipulator only

in case of emergencies.

- To stop the Manipulator operating the program except in emergency, use Pause (halt)

or STOP (program stop) commands. Pause and STOP commands do not turn OFF the motors. Therefore, the brake does not function.

- For the Safeguard system, do not use the circuit for E-STOP.

For details of the Safeguard system, refer to the following manuals.

EPSON RC+ User’s Guide

2. Safety - Installation and Design Precautions - Safeguard System

Safety and Installation

2.6 Connection to EMERGENCY Connector

8 LS20 Rev.1

Setup & Operation 1. Safety

Conditions for Measurement

LS20-804*

LS20

-A04*

Accel Setting

100

Speed Setting

100

Load [kg]

Weight Setting

Joint #1

Stop position

E-Stop signal Input position

Target position

Motion start

position

Joint #2

To check brake problems, refer to the following manuals.

Manipulator Manual Maintenance

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

Safety and Installation

5.1.1 Manipulator - Inspection While the Power is ON (Manipulator is operating)

Free running distance in emergency

The operating Manipulator cannot stop immediately after the Emergency Stop switch is pressed. The free running time/angle/distance of the Manipulator are shown below. However, remember that the values vary depending on following conditions.

Weight of the end effector Weight of work piece Operating pose Weight Speed Accel etc.

LS20 Rev.1 9

Controller RC90

Manipulator LS20-804* LS20-A04*

Free running time

Free running angle

Free running distance Joint #3 [mm] 110

Joint #1 + Joint #2 [sec.] 0.65 0.7 Joint #3 [sec.] 0.3 Joint #1 [deg.] 65 70 Joint #2 [deg.] 50 50 Joint #1 + Joint #2 [deg.] 115 120

Setup & Operation 1. Safety

Joint #3 / Joint #4

brake release switch

Joint #1

(rotating)

Joint #2

(rotating)

Joint #3

(up and down)

Joint #4

(rotating)

Arm #1

Arm #2

−

Shaft

（Figure: LS20-804S）

Base

NOTE

1.5 Emergency Movement Without Drive Power

When the system is placed in emergency mode, push the arm or joint of the Manipulator by hand as shown below:

Arm #1 Push the arm by hand. Arm #2 Push the arm by hand. Joint #3 The joint cannot be moved up/down by hand until the solenoid

brake applied to the joint has been released. Move the joint up/down while pressing the brake release switch.

Joint #4 The shaft cannot be rotated by hand until the solenoid brake

applied to the shaft is released. Move the shaft while pressing the brake release switch.

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

10 LS20 Rev.1

Z position

(mm)

Tip load (kg)

5 kg or less

10 kg or less

15 kg or less

20 kg or less

0 > Z >= - 100

10000 or less

9000 or less

- 100 > Z >= - 200

7000 or less

5500 or less

- 200 > Z >= - 300

7500 or less

5000 or less

3500 or less

- 300 > Z >= - 420

5500 or less

3500 or less

2500 or less

-axis height

(Origin point)

NOTE

1.6 ACCELS Setting for CP Motions

To make the Manipulator move in CP motion, see the following and set ACCELS properly according to the motion area, load, and Z-axis height.

Improper setting may cause following problems. Reduction of the life and damage of the ball screw spline

Set ACCELS as follows according to the Z-axis height.

ACCELS setting value by Z-axis position and tip load

10000 or less

Setup & Operation 1. Safety

If the Manipulator is operated in CP motion with the wrong set values, make sure to check the following point. Whether the ball screw spline shaft is deformed or bent

LS20 Rev.1 11

Setup & Operation 1. Safety

to prevent hands or fingers from being

collide against the operator. This is

ly hazardous and may result in

Hazardous voltage exists while the

sling work and operate a crane and a forklift.

shaft falling and rotating

1.7 Manipulator Labels

The following labels are attached near 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:

Labels NOTE

Before loosening the base mountin g screws, hold the arm and secure it tight ly with a band

caught in the Manipulator.

Do not enter the operation area while the Manipulator is moving. The robot arm may

extreme serious safety problems.

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

You can catch your hand or fingers between the shaft and cov er when bringing your hand close to moving parts.

* Manipulators with bellows do not have this label for no danger of your hand or fingers being caught.

Only authorized personnel should perform 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.

Be careful of the while the brake release switch is pressed because the shaft may be lowered by the weight of the end effector.

12 LS20 Rev.1

Setup & Operation 1. Safety

(Opposite side)

Labels NOTE

(Figure: LS20-804S)

LS20 Rev.1 13

Setup & Operation 2. Specifications

2. Specifications

2.1 Features of LS20 series Manipulators

The LS20 series Manipulators are advanced manipulators pursuing high speed and high cost-performance. The features of the LS20 series Manipulators are as follows:

Resolver for the Position Detect or

It includes no electrical components; therefore it has high resistance to environment and hardly breaks down.

It mounts the resolver board and battery inside the manipulator; therefore the calibration is not required when you disconnect the M/C cable.

Large Capacity

It supports the U-axis allowable moment up to 0.45 kg·m It stably handles large loads by optimized control based on the each load.

Tact Time Improvement by High-speed Motion

It improves the tact time of delicate movements by acceleration/deceleration speed optimized for each payload and stop short technology.

14 LS20 Rev.1

Environment

: Standard

: Cleanroom

Joint #3 stroke

: 390 mm : Cleanroom-Model (with bellows)

Arm length

: 800 mm

Payload

Standard

420 mm

LS20-804S

Standard

420 mm

LS20-A04S

Cleanroom

390 mm

LS20-A04C

2.2 Model Number

LS20-80 4 S

: 420 mm : Standard-Model

A0 : 1 0 00 mm

20 : 20 kg

Setup & Operation 2. Specifications

Environment

Cleanroom-model

This model has additional features that reduce dust emitted by the Manipulator to enable use in clean room environments.

For details on the specifications, refer to Setup & Operation: 2.4 Specifications.

Payload Arm length Environment Joint #3 stroke Model Number

800 mm

20 kg

Cleanroom 390 mm LS20-804C

1000 mm

LS20 Rev.1 15

Setup & Operation 2. Specifications

Joint #3 / Joint #4

Brake release switch

Arm #1

Arm #2

Base

Shaft

MT label

(only for custom

specification)

Signature label

(Serial No.

of Manipulator)

Signal cable

Power cable

Fittings (blue) for ø4 mm pneumatic tube

Fittings (blue) for ø6 mm pneumatic tube

Fittings (white) for

ø6 mm

pneumatic tube

User connector (15-pin D-sub connector)

LED lamp

CE label

User connector (9-pin D-sub connector)

Fittings (white) for ø4 mm

pneumatic tube

KC Mark

NOTE

2.3 Part Names and Outer Dimensions

2.3.1 LS20-804*

LS20-804S (Standard-Model)

- The brake release switch affects both Joints #3 and #4. When the brake release switch is pressed in emergency mode, the brakes for both Joints #3 and #4 are released simultaneously.

- While the LED lamp is on, the current is being applied to the manipulator. 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.

16 LS20 Rev.1

LS20-804S (Standard-Model)

Setup & Operation 2. Specifications

LS20 Rev.1 17

Setup & Operation 2. Specifications

Upper bellows

Lower bellows

Exhaust port

LS20-804C (Cleanroom-Model)

The following figures show the additional parts and specifications for Cleanroom-model when compared with the Standard-model in appearance.

18 LS20 Rev.1

LS20-804C (Cleanroom-Model)

Setup & Operation 2. Specifications

LS20 Rev.1 19

Setup & Operation 2. Specifications

Joint #3 / Joint #4

Brake release switch

Arm #1

Arm #2

Base

Shaft

MT label

(only for custom

specification)

Signature label

(Serial No.

of Manipulator)

Signal cable

Power cable

Fittings (blue) for ø4 mm pneumatic tube

Fittings (blue) for ø6 mm pneumatic tube

Fittings (white) for ø6 mm pneumatic tube

User connector (15-pin D-sub connector)

LED lamp

CE label

User connector (9-pin D-sub connector)

Fittings (white) for ø4 mm pneumatic tube

KC Mark

NOTE

2.3.2 LS20-A04*

LS20-A04S (Standard-Model)

- The brake release switch affects both Joints #3 and #4. When the brake release switch is pressed in emergency mode, the brakes for both Joint #3 and Joint #4 are released simultaneously.

- While the LED lamp is on, the current is being applied to the manipulator. Performing any work

with the power ON is extremely hazardous and it may result in electric shock and/or improper function of the robot system. Make sure to turn OFF the controller power before the maintenance work.

20 LS20 Rev.1

LS20-A04S (Standard-Model)

Setup & Operation 2. Specifications

LS20 Rev.1 21

Setup & Operation 2. Specifications

Upper bellows

Lower bellows

Exhaust port

LS20-A04C (Cleanroom-Model)

The following figures show the additional parts and specifications for Cleanroom-model when compared with the Standard-model in appearance.

22 LS20 Rev.1

LS20-A04C (Cleanroom-Model)

Setup & Operation 2. Specifications

LS20 Rev.1 23

Setup & Operation 2. Specifications

Item

LS20-804*

LS20-A04*

Arm #1, #2

800 mm

1000 mm

Arm #1

350 mm

550 mm

Arm #2

450 mm

Joints #1, #2

9940 mm/s

11250 mm/s

Joint #3

2020 mm/s

Joint #4

1400 deg/s

Joints #1, #2

± 0.025 mm

Joint #3

± 0.01 mm

Joint #4

± 0.01 deg.

Rated

10 kg

Max.

20 kg

Joint #4 allowable Rated

0.05 kg·m2

Max.

0.45 kg·m2

Joints #1

0.000275 deg/pulse

Joint #2

0.000439 deg/pulse

Joint #3

0.00148 mm/pulse

Joint #4

0.001046 deg/pulse

Shaft diameter

ø 25 mm

Through hole

ø 18 mm

200 × 200 mm

4 × ø16

Weight (cables not included)

47 kg : 103.6 lb

50 kg : 110.2 lb

Driving metho d

All joints

AC servo motor

Joint #1

750 W

Joint #2

600 W

Joint #3

400 W

Joint #4

150 W

Option

Installation environment

Cleanroom *3

Joint #3 down force

250 N

Installed wire for customer use

15 pin: D-sub, 9 pin: D-sub

tube for customer use

2 pneumatic tubes (ø6 mm) : 0.59 Mpa (6 kgf/cm2 : 86 psi)

2 pneumatic tubes (ø4 mm) : 0.59 Mpa (6 kgf/cm2 : 86 psi)

Ambient relative humidity

10 to 80% (no condensation)

Noise level *4

Aeq

= 70 dB (A)

Applicable Controller

RC90

SPEED

1 to (5) to100

ACCEL *5

1 to (10) to 120

SPEEDS

1 to (50) to 2000

ACCELS

1 to (200) to 10000

FINE

0 to (1250) to 65000

WEIGHT

0,450 to (10,450) to 20,450

CE Mark

NFPA 79 (2007 Edition)

2.4 Specifications

Arm length

Max. operating speed *1

Repeatability

Payload (Load)

moment of inertia *2

Resolution

Hand

Mounting hole

Motor energy consumption

Installed pneumatic

Environmental requirements

Assignable Value ( ) Default values

Ambient Temp. 5 to 40 degrees C (with minimum temperature variation)

Safety standard

24 LS20 Rev.1

EMC Directive, Machinery Directive, RoHS Directive

KC Mark / KCs Mark

ANSI/RIA R15.06-2012

Item

LS20-804S

LS20-A04S

LS20-804C

LS20-A04C

Joint #1

± 132 deg

Joint #2

± 152 deg

Joint #3

420 mm

390 mm

Joint #4

± 360 deg

Joint #1

− 152918 to 808278

Joint #3

−283853 to 0

−263578 to 0

Joint #4

± 344064

Max. motion range

Setup & Operation 2. Specifications

Max. pulse range

Joint #2

± 345885

*1: In the case of PTP command.

Maximum operating speed for CP command is 2000 mm/s on horizontal plane.

*2: In the case where the center of gravity is at the center of Joint #4.

If the center of gravity is not at the center of Joint #4, set the parameter using Inertia command.

*3: The exhaust system in the Cleanroom-model Manipulator draws air from the base interior and arm cover

interior together. A crack or other opening in the base unit can cause loss of negative air pressure in the outer part of the arm, which can cause increased dust emission. Do not remove the maintenance cover on the front of the base. Seal the exhaust port and the exhaust tube with vinyl tape so that the joint is airtight. If the exhaust flow is not sufficient, dust particle emission may exceed the specified maximum level.

Cleanliness level : Class ISO 4 (ISO14644-1)

Exhaust System : Exhaust port diameter : Inner diameter: ø12 mm / Outer diameter: ø16 mm

Exhaust tube : Polyurethane tube

Outer diameter: ø12 mm (Inner diameter:ø8 mm) or Inner diameter ø16mm Recommended exhaust flow rate : approx. 1000 cm

/s (Normal)

*4: Conditions of Manipulator during measurement as follows:

Operating conditions : Under rated load, 4-joints simultaneous motion, maximum speed, maximum

acceleration, and duty 50%.

Measurement point : In front of the Manipulator, 1000 mm apart from the motion range, 50 mm above

the base-installed surface.

*5: In general use, Accel setting 100 is the optimum setting that maintains the balance of acceleration and

vibration when positioning. Although values larger than 100 can be set to Accel, it is recommended to minimize the use of large values to necessary motions since operating the manipulator continuously with the large Accel setting may shorten the product life remarkably.

LS20 Rev.1 25

Setup & Operation 2. Specifications

When you need to change the setting of the Man ipulator model, be s ure to set the Manipulator model properly. result in

or no operation of the Manipulator and/or cause safety

problems.

NOTE

2.5 How to Set the Model

The Manipulator model for your system has been set before shipment from the factory. It is normally not required to change the model when you receive your system.

■

CAUTION

If an MT label is attached to the rear of a Manipulator, the Manipulator has custom specifications. The custom specifications may require a different configuration procedure; check the custom specifications number described on the MT label and contact us when necessary.

The Manipulator model can be set from software. Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide.

abnormal

Improper setting of the Manipulator model may

26 LS20 Rev.1

Setup & Operation 3. Environments and Installation

Item

Conditions

Ambient temperature *

5 to 40 deg C (with minimum temperature variation)

First transient burst noise

2 kV or less

· Keep away from sources of electric noise.

Use an earth leakage breaker on the AC power cable of the the electric shock and circuit breakdown caused by an unexpected water leak. Prepare the earth leakage brake that pertains the controller you are using. For details, refer to the contr oller manual.

CAUTION

When cleaning the M anip ulator, do not rub it strongly w ith alcoho l or may lose luster on the coated face.

NOTE

3. Environments and Installation

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:

Ambient relative humidity 10 to 80% (no condensation)

Electrostatic noise 6 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 shocks or vibrations.

WARNING

Manipulators are not suitable for operation in harsh environments such as painting areas, etc. When using Manipulators in inadequate environments that do not meet the above conditions, please contact us.

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

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

Special Env iron ment a l Conditions

The surface of the Manipulator has general oil resistance. However, if your requirements specify that the Manipulator must withstand certain kinds of oil, please consult your distributor. Rapid change in temperature and humidity can cause condensation inside the Manipulator. If your requirements specify that the Manipulator handles food, please consult your distributor to check whether the Manipulator gives damage to the food or not. The Manipulator cannot be used in corrosive environments where acid or alkaline is used. In a salty environment where the rust is likely to gather, the Manipulator is susceptible to rust.

■

Controller to avoid

benzene. It

LS20 Rev.1 27

Setup & Operation 3. Environments and Installation

LS20

Max. Reaction torque on the horizontal plate

1000

Max. Horizontal reaction force

7500

Max. Vertical reaction force

2000

Power Cable

Connector

Signal Cable

Connector

M/C Cables

(Unit : mm

)

To ensure safety, a safeguard must be inst alled For details on the

NOTE

3.2 Base Table

A base table for anchoring the Manipulator is not supplied. P lease make or obtain the base table for your Manipulator. The shape and size of the base table differs depending on the use of the robot system. For your reference, we list some Manipulator table requirements here.

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

The threaded holes required for mounting the Manipulator base are M12. Use mounting bolts with specifications conforming to ISO898-1 property class: 10.9 or 12.9. For dimensions, refer to Setup & Operation: 3.3 Mounting Dimensions.

WARNING

The plate for the Manipulator mounting face should be 20 mm thick or more and made of steel to reduce vibration. T he surface roughness of the steel plate should be 25 μm or less.

The table must be secured on the floor or wall to prevent it from moving.

The Manipulator must be installed horizontally.

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

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

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.

■

safeguard, refer to the EPSON RC+ User’s Guide.

for the robot system.

28 LS20 Rev.1

Center of Joint #3

Maximum space

Motion range

Area limited by mechanical stop

Base mounting face

3.3 Mounting Dimensions

The maximum space described in figures shows that the radius of the end effector is 60 mm or less. If the radius of the end effector exceeds 60 mm, define the radius as the distance to the outer edge of maximum space. If a camera or solenoid valve extends outside of the arm, set the maximum range including the space that they may reach.

Be sure to allow for the following extra spaces in addition to the space required for mounting the Manipulator, Controller, and peripheral equipment.

Sp ace for teachin g Sp ace for mainten ance an d inspection

(Ensure a space to open the covers and plates for maintenance.)

Sp ace for cables

The minimum bend radius of the power cable is 90 mm. When installing the cable, be sure to maintain sufficient distance from obstacles. In addition, leave enough space for

other cables so that they are not bent forcibly. Leave approximately 150 mm at the back of the Manipulator for battery replacement. Ensure distance to the safeguard from the maximum motion range is more than 100 mm.

3.3.1 LS20-804*

Setup & Operation 3. Environments and Installation

Standard-Model: LS20-804S

LS20 Rev.1 29

Setup & Operation 3. Environments and Installation

Center of Joint #3

Maximum space

Motion range

Area limited by mechanical stop

Base mounting face

390

Cleanroom-Model: LS20-804C

30 LS20 Rev.1

Setup & Operation 3. Environments and Installation

Center of Joint #3

Maximum space

Motion range

Area limited by mechanical stop

Base mounting face

3.3.2 LS20-A04*

Standard-Model: LS20-A04S

LS20 Rev.1 31

Setup & Operation 3. Environments and Installation

Center of Joint #3

Maximum space

Motion range

Area limited by mechanical stop

Base mounting face

Cleanroom-Model: LS20-A04C

32 LS20 Rev.1

Setup & Operation 3. Environments and Installation

■

Only authorized personnel forklift. When extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

Using a cart or similar equipment, transport the Manipulator in the same manner as it was delivered.

After Manipulator

■

The arm is installation so as not to

■

To carry the Manipulator, through the eyebolt to hang the Manipulator, shaded area in the figure the Manipulator without using the belt, have at least When holding the bottom of the base by hand, be very careful not to get your hands or fingers caught.

■

Do not hold the may damage the

Resin duct

Metal duct

LS20-804* : approx. 47 kg :103.6 lb. LS20-A04* : approx. 50

kg :110.2 lb.

Figure : LS20-804S

■

Stabilize the Manipulator with your hands when hoist

■

When transporting the Manipulator for a long distance, secure it to the equipment directly so t hat t he M ani pulator never falls. If necessary, pack the Manipulator in the same style as

3.4 Unpacking and Transportation

3.4.1 Precautions for Tr ansport ation

THE INSTALLATION SHALL BE PREFORMED BY QUALIFIED INSTALLATION

PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL

CODES.

should perform sling work and operate a crane and a

WARNING

■

these operations are performed by unauthorized personnel, it is

CAUTION

■

removing the bolts securing the Manipulator to the delivery equipment, the

can fall. Be careful not to get hands or fingers caught.

secured with a wire tie. Leav e the wire tie secure d until y ou finish the

get hands or fingers caught.

secure it to the delivery equipment or pass a belt

and then attach the hands on the

below (bottom of the Arm #1 and the base). If carrying

two workers to work on it.

metal duct and the resi n duct when carrying the Manipulator. It

LS20 Rev.1 33

ing it.

delivery

it was delivered.

Setup & Operation 3. Environments and Installation

Arm #1 Band fixing position

Arm Lock

3.4.2 Transportation

Transport the Manipulator following the instructions below: (1) Attach the eyebolts to the upper back side of the Arm.

(2) Turn the Arm #1 to face the front. (3) Fix the Arm #1 using the arm lock so that it cannot move. (4) Use the wire tie to fix the band for hoisting to the Arm #1. Set the band at the

shaded area in the figure below so that the band cannot move.

(5) Pass the belts through the eyebolts. (6) Hoist the Manipulator slightly so that it does not fall. Then, remove the bolts

securing the Manipulator to the delivery equipment or pallet.

(7) Hoist the Manipulator attaching the hands on the shaded area so that it can keep

the balance. Then, move it to the base table.

34 LS20 Rev.1

■

The utilities, other pinch points.

Oscillation (resonance) may installation table. If the oscillation occurs, improve rigidity of the table or change the speed or acceleration

Install the Manipulator w ith The Manipulator weigh feet caught and/or have e quipment damage

(1)

Secure the base to the base table with four bo

Use bolts ISO898

Tightening

18.5 mm

Screw Hole (depth

mm or more)

4-M12×40

Spring Washer

Plane Washer

(2)

Using nippers, cut off the wire tie binding the shaft and arm retaining bracket on the base.

2-M10

×60

Arm lock

(3)

Remove the arm lock.

NOTE

3.5 Installation Procedure

Manipulator must be installed to avoid interference with buildings, struct ures,

machines and equipment that may create a trapping hazard or

■

CAUTION

3.5.1 Standard-Model

■

LS20-804* : approx. 47 kg :103.6 lb. LS20-A04* : approx. 50 kg :1 10.2 lb.

and deceleration sett ings.

Setup & Operation 3. Environments and Installation

occur during operation depending on rigidity of the

two or more people.

ts are as follows. Be careful not to get hands, fingers, or

d by a fall of the Manipulator.

lts.

with specifications conforming to

-1 Property Class: 10.9 or 12.9. torque: 73.5 N∙m (750 kgf∙cm)

LS20 Rev.1 35

Setup & Operation 3. Environments and Installation

(4)

Remove the bolts securing the wire ties removed in step (2).

Wire tie

3.5.2 Cleanroom-Model

(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) Refer to the installation procedure of each Manipulator model and install the

Manipulator.

(6) Connect an exhaust tube to the exhaust port.

36 LS20 Rev.1

To shut off power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it direct ly to a factory power source.

■

Before equipment, Performing any replacement procedure with the power ON is extremely hazardous and may result in

■

Be sure to connect cables. (Do not forcibl cables, disconnection, and/or c onta ct contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

■

Grounding the manipulator is done by c onnecting w it h the cont roller. Ensure that the wire is improperly connect ed t o gr ound, it may result in the fire or electric sh ock.

When connecting the Manipulator to 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 serious safety probl Controller used. For details on the connection, refer to the If the G series Manipulator or E2 series Manipulator is connected to the Controller for the

Power connector

Signal connector

Connect the power cable and the signal connector of the M/C cable to the Controller as shown below.

3.6 Connecting the Cables

■

performing any replacement procedure, turn OFF the Controller and related

and then pull out the power plug from the power source.

to the robot system, pull out the power plug from the power

electric shock and/or malfunction of the robot system.

Setup & Operation 3. Environments and Installation

WARNING

CAUTION

put heavy objects on the cables. Do not bend or pull the cables

y.) The unnecessary strain on the cables may result in damage to the

failure. Damaged cables, disconnection, or

controller is grounded and the cables are correctly connected. If the ground

■

the cables properly. Do not allow unnecessary strain on the

ems. The connection method varies with the

Controller manual.

PS series (ProSix), it may result in malfunction of the Manipulator .

For the Manipulator of Cleanroom-model, use it with an exhaust system. For details, refer to Setup & Operation: 2.4 Specifications.

Cable Connections

LS20 Rev.1 37

Setup & Operation 3. Environments and Installation

Only authorized or certified personnel should be allowed to perform wiring. Wiring by unauthorized malfunction of the robot system.

Rated Voltage

Allowable Current

Wires

Nominal Sectional Area

Note

Do not apply the current mor e t han 1A to the manipulator.

Maker

Standard

Suitable Connector

DA-15PF-N

(Solder type)

Clamp Hood

DA-C8-J10-F2-1R

(Connector setscrew: #4-40 NC)

DE-9PF-N

Clamp Hood

DE-C8-J9-F2-1R

(Connector setscrew: #4-40 NC)

Max. Usable Pneumatic Pressure

Pneumatic T ubes

Outer Diameter × Inner Diameter

Fitting (white) for ø4 mm pneumatic tube

Fitting (blue) for ø6 mm pneumatic tube

User connector (15-pin D-sub connector)

Fitting (white) for ø6 mm pneumatic tube

Detail view from A

Detail view from B

LS20-804*

Brake release switch

Fitting (blue) for ø6 mm pneumatic tube

Fitting (blue) for ø4 mm pneumatic tube

Exhaust port (Cleanroom-model only)

Fitting (blue) for ø4 mm pneumatic tube

User connector (9-pin D-sub connector)

Fitting (white) for ø4 mm pneumatic tube

Fitting (white) for ø6 mm pneumatic tube

3.7 User Wires and Pneumatic Tubes

■

or uncertified personnel may result in bodily injury and/or

CAUTION

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

Electrical Wires

WARNING

AC/DC30 V 1 A

0.211 mm2

Twist pair

Unshielded

■

15 pin

Suitable Connector

JAE

(Solder type)

9 pin

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

Pneumatic Tubes

0.59 MPa (6 kgf/cm2 : 86 psi)

Fittings for ø6 mm and ø4 mm (outer diameter) pneumatic tubes are supplied on both ends of the pneumatic tubes.

ø 6 mm × ø 4 mm

ø 4 mm × ø 2.5 mm

38 LS20 Rev.1

■

Only authorized personnel forklift. When extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

Before relocating the Mani pul at or, to prevent hands or finger s from

■

When removing the anchor bolts, support the Manipulator to prevent falling. Removing the anchor bol and then get hands, fingers, or feet caught.

■

To Manipulator to the deliv ery the main cable fitting, and the bottom of the bottom of the base by hand, be very careful not to get hands or fingers c aught.

■

Stabilize the Manipulator with your hands when hoist extremely hazardous and may r esult in fall of the Manipulator.

3.8 Relocation and Storage

3.8.1 Precautions for R eloc ati on and Storage

Observe the following when relocating, storing, and transporting the Manipulators.

The installation shall be performed by qualified installation personnel and should conform to all national and loca l codes.

WARNING

■

these operations are performed by unauthorized personnel, it is

Setup & Operation 3. Environments and Installation

should perform sling work and operate a crane and a

fold the arm and secure it tight ly with a wire tie

being caught in the M anipulator .

ts without support may result in a fall of the Manipu lator,

CAUTION

carry the Manipulator, have two or more people to work on it and secure the

equipment or hold the bot tom o f Arm #1, the bottom of

base by hand. W hen holding the

ing it. Unstable hoisting is

When transporting the Manipulator for a long distance, secure it to the delivery equipment so that the Ma nip ulat or cannot fall. If necessary, pack the Manipulator in the same way as it was delivered.

When the Manipulator is used for a robot system again after long-term storage, perform a test run to verify t hat it w or ks prop er ly, and then operate it thorough ly.

Transport and st ore the Manipulator in the range o f -25°C to +55°C. Humidity within 10% to 90% is recommended. When condensation occurs on the Manipulator during transport or storage, turn

ON the power only after the condensation dries. Do not shock or shake the Manip ul at or dur ing transport.

LS20 Rev.1 39

Setup & Operation 3. Environments and Installation

Install

The Manipulator

weigh

fingers, or feet caught

and/or have equipment da ma ge

Wire tie

Example of Arm Retaining Posture

NOTE

3.8.2 Relocation

■

CAUTION

(1) Turn OFF the power on all devices and unplug the cables.

(2) Cover the arm with a sheet so that the arm will not be damaged.

or relocate the Manipulator with two or more people.

ts are as follows. Be careful not to get hands,

d by a fall of the Manipulator.

LS20-804* : approx. 47 kg :103.6 lb. LS20-A04* : approx. 50 kg :110.2 lb.

Remove the mechanical stops if using them to limit the motion range of Joints #1 and #2. For details on the motion range, refer to Setup & Operation: 5.2 Motion Range Setting by Mechanical Stops.

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

For details on strength of the ball screw spline, refer to Setup & Operation: 1.2.1 Strength of Ball Screw Spline.

(3) Hold the bottom of Arm #1 by hand to unscrew the anchor bolts.

Then, remove the Manipulator from the base table.

40 LS20 Rev.1

If you use an end effector equipped with a gripper or chuck, connect wires and/or pneumatic when the wires and as the work piece is released w hen the Emergency Stop switch is pressed. I/O by power disconnect ion, the robot system

- Attach For the shaft dimensions,

Setup

& Operation:

- Do not move the upper limit mechanical stop on the lower side of the shaft. Otherwise, when

is performed, the upper limit mechanical stop may hit

the Manipulator, and the r

- Use a split muff coupling with an M4 bolt or larger to attach the end effector to the shaft.

- Joint #3 by hand because the solenoid brake is applied to the joint while power This prevents t

hitting peripheral equipment in the case that the shaft is lowered the effector when the

is disconnected during operation, or when the motor is turned OFF even though the

To move Joint #3 up/down or rotate Joint #4 while attaching an end effector move the joint up/down or rotate the joint while pressing

Brake release switch

The shaft may be lowered by the weight of the end effector.

This button switch The respective brakes for Joints #3 and #4 are released simultaneously.

- Be careful of the

pressed

because

4. Setting of End Effectors

4.1 Attaching an End Effector

Users are responsible for making their own end effector(s). Before attaching an end effector, observe these guidelines.

■

tubes properly so that the gripper does not release the work piece

power to the robot system is turned OFF. Improper connection of the

CAUTION

outputs are configured at the factory s o that t hey are auto mat ically shut off (0)

Shaft

/or pneumatic tubes may damage the robot system and/or work piece

an end effector to the lower end of the shaft.

2. Specifications.

Setup & Operation 4. Setting of End Effectors

Emergency Stop switch, or the safety features of the

and the overall dimensions of the Manipulator, refer to

“Jump motion”

obot system may not function properly.

Brake release switch

and #4 cannot be moved up/down and rotate

to the robot system is turned OFF.

he shaft from

end effector is rotated by the weight of the end

power

power is turned ON.

, turn ON the Controller and

LS20 Rev.1 41

the brake release switch.

switch is a momentary-type; the brake is released only while the button

is being pressed.

shaft falling and rotating while the brake release switch is

the shaft may be lowered by the weight of the end effector.

and

Setup & Operation 4. Setting of End Effectors

- When

interfere

with

the outer diameter of the end effector, the size of the

work piece

system layout, pay

attention to the interference area of the end effector.

(Figure: LS20-804S)

From the base mounting face

4 × M4

depth 10

4 × M4

depth 10

2 × M4

depth 10

Layouts

you operate the manipulator with an end effector, the end effector may

the Manipulator because of

, or the position of the arms. When designing your

4.2 Attaching Cameras and Valves

The bottom of the Arm #2 has threaded holes as shown in the figure below. U se these holes for attaching cameras, valves, and other equipment. [Unit: mm]

42 LS20 Rev.1

The total weight of the end effector and the work piece must

. The kg Always set the Weight parameters according to the load. Setting a value that is smaller than the actual load may cause errors, excessive shock, insufficient function of the Manipulator,

Enter a value into the [Load inertia:] text box on the [Inertia] panel (

[Robot

When you attach the equipment near When you attach the equipment to the end of Arm #2:

W WM = M (LM)2/(L2)2

W M L L L

: : : : :

EPSON

RC+

4.3 Weight and Inertia Settings

To ensure optimum Manipulator performance, it is important to make sure that the load (weight of the end effector and work piece) an d moment of inertia of the load are within the maximum rating for the Manipulator, and that Joint #4 does not become eccentric. If the load or moment o f inertia exceeds the rating or if the load becomes eccentric, follow the steps below, “4.3.1Weight Setting” and “4.3.2 Inertia Setting” to set parameters. Setting parameters makes the PTP motion 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 larger than the default setting.

CAUTION

4.3.1 Weight Setting

■

LS20 series Manipulators are not designed to work with loads exceeding 20

Setup & Operation 4. Setting of End Effectors

not exceed 20 kg

and/or shorten the life cyc le of parts/mechanisms.

The acceptable weight capacity (end effector and work piece) in LS20 series is 10 kg at the default rating / 20 kg at the max i mum. When the load (weight of the end effector and work piece) exceeds the rating, change the setting of Weight parameter. After the setting is changed, the maximum acceleration/deceleration speed of the robot system at PTP motion corresponding to the “Weight Parameter” is set automatically.

Load on the Shaft

The load (weight of the end effector and work piece) on the shaft can be set by Weight parameter.

[Tools] -

anager]). (You may also execute the Inertia command from the [Comm and Window].)

Load on the Arm

When you attach a camera or other devices to the arm, calculate the weight as the equivalent of the shaft. Then, add this to the load and enter the total weight to the Weight parameter.

Equivalent Weight Formula

Arm #2:

equivalent weight

weight of camera etc. length of Arm #1

length of Arm #2

distance from rotation center of Joint #2 to center of gravity

LS20 Rev.1 43

of camera etc.

= M (L1)2/(L1+L2)2

Setup & Operation 4. Setting of End Effectors

A “1

away from the rotation center of Joint #2) with a load weight of “1 kg”.

M=1 L L W

(round up)

W+W

Enter

Shaft

Weight of camera M=1kg

W=1kg

L2=450

LM=550 mm

Joint #2

140 120 100

80 60 40 20

5 10

20 (kg)

Weight setting

(%)

LS20-A0 LS20-80

120

100

The percentage in the graph is based on the speed at rated weight (10 kg) as 100%.

160 140 120 100

80 60 40 20

(%)

LS20-A0 LS20-80

20 (kg)

Weight setting

140

110

100

120

130

150

* The percentage in the graph is

based on the acceleration / deceleration at rated weight

kg” camera is attached to the end of the LS20 series arm (550

=450

=550

=1 × 5502 / 4502 = 1.494  1.5

=1+1.5=2.5

“2.5” for the Weight Parameter.

Automatic speed setting b y Weight

Automatic acceleration/ deceleration setting by Weight

44 LS20 Rev.1

The must be work with inertia parameter to t he correct mome nt of inertia. Setting a value that is smaller than the actual moment of inertia may cause errors, excessi function of the Manipulator, and/ or shor t en t he life cycle of parts/mechanisms

Enter a value into the [Load inertia:] text box on the [Inertia] panel (

[Robot

0 0.10 0.20 0.30 0.40 (kg･m2)

Moment of inertia setting

120 100

80 60 40 20

(%)

115

12.8

7.4

100

EPSON

RC+

CAUTION

Setup & Operation 4. Setting of End Effectors

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 end effector) attached to the shaft, the moment of inertia of load must be considered.

■

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

0.45 kg·m2 or less. The LS20 series Manipulators are not designed to

”. When the Manipulator operates with additional objects (such as an

a moment of inertia exceeding 0.45 kg·m2. Always set the moment of

ve shock, insufficient

The acceptable moment of inertia of load for a LS20 series Manipulator is 0.05 kgm2 at the default rating and 0.45 kgm

at the maximum. When the moment of inertia of the load exceeds the rating, change the setting of the moment of inertia parameter of the Inertia command. After the setting is changed, the maximum acceleration/deceleration speed of Joint #4 at PTP motion corresponding to the “moment of inertia” value is set automatically.

Moment of inertia of load on t he s haft

The moment of inertia of load (weight of the end effector and work piece) on the shaft can be set by the “moment of inertia” parameter of the Inertia command.

[Tools] -

anager]). (You may also execute the Inertia command from the [Comm and Window].)

Automatic acceleration/ deceleration setting of Joint #4 by Inertia (moment of inertia)

LS20 Rev.1 45

Setup & Operation 4. Setting of End Effectors

The 20 eccentric quantity

Always set the eccentric quantity parameter according to the eccentric quantity. Setting a value that is smaller than the actual function of the Manipulator, and/ or shor t en t he life cycle of parts/mechanisms

Position of load’s center of gravity

Rotation center

Eccentric quantity (200 mm or les s)

Eccentric Quantity

Enter a value into the [Eccentricity:] text box on the [Inertia] panel (

[Robot

* The percentage in the graph is

based on the acceleration / deceleration at rated eccentricity (0 mm) as 100%.

120 100

80 60 40 20

0 50 100 150 200 (mm)

Eccentricity setting

(%)

100

EPSON

RC+

Eccentric Quantity and t he I ner t ia Sett ing

■

eccentric quantity of load (weight of the end ef fect or and wor k piece) must be

0 mm or less. The LS20 series Manipulators are not designed to work with

exceeding 200 mm.

CAUTION

eccentric quantity may cause er r or s, excessive shock, insufficient

The acceptable eccentric quantity of load in LS20 series is 0 mm at the default ratin g and 200 mm at the maximum. When the eccentric quantity of load exceeds the rating, change the setting of eccentric quantity parameter of Inertia command. After the setting is changed, the maximum acceleration/deceleration speed of the Manipulator at PTP motion corresponding to the “eccentric quantity” is set automatically.

Eccentric quantity of load on t he shaft

The eccentric quantity of load (weight of the end effector and work piece) on the shaft can be set by “eccentric quantity” parameter of Inertia command.

[Tools] -

anager]). (You may also execute the Inertia command from the [Comm and Window].)

Automatic acceleration/ deceleration setting by Inerti a ( ecc ent r i c quantity)

46 LS20 Rev.1

Setup & Operation 4. Setting of End Effectors

Work piece (b)

Work piece (c)

End effector (a)

Joint #3 shaft

Rotation center

Moment of inertia

of end effector (a)

Moment of inertia

of work piece (b)

Moment of inertia

of work piece (c)

Whole moment

of inertia

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).

The methods for calculating the moment of inertia for (a), (b), and (c) are shown below. Calculate the total moment of inertia using the basic formulas.

LS20 Rev.1 47

Setup & Operation 4. Setting of End Effectors

Mass (

Rectangular parallelepiped

’s center of gravity

Rotation center

+ m × L2

b2 + h2

+ m × L2

r 2

Mass (m)

Cylinder’s center of gravity

Rotation center

r 2+ m × L2

Sphere’s center of gravity

Mass (m)

Rotation center

(a) Moment of inertia of a rectangular parallelepiped

(b) Moment of inertia of a cy linder

48 LS20 Rev.1

Setup & Operation 4. Setting of End Effectors

* The percentage in the graph is

based on the acceleration / deceleration at the upper-limited

120 100

80 60 40 20

0 - 100 - 200 - 300 - 400 (mm)

Height of the shaft

(%)

(-150, 100)

(-313, 24)

(0, 100)

LS20-804*

420, 24)

* The percentage in the graph is

based on the acceleration / deceleration at the upper-limited

120 100

80 60 40 20

0 - 100 - 200 - 300 - 400 (mm)

Height of the shaft

(%)

(-100, 100)

(-317, 24)

(0, 100)

(-420,

24)

LS20-A04*

NOTE

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3

When you move the Manipulator in horizontal PTP motion with Joint #3 (Z) at a high position, the motion time will be faster. When Joint #3 gets below a certain point, then auto acceleration/deceleration is used to reduce acceleration/deceleration. The higher the position of the shaft is, the faster the motion acceleration/deceleration is. However, it takes more time to move Joint #3 up and down. Adjust the position of Joint #3 for the Manipulator motion after considering the relation between the current position and the destination position. The upper limit of Joint #3 during horizontal motion using Jump command can be set by the LimZ command.

When moving the Manipulator horizontally while the shaft is being lowered, it may cause over-shoot at the time of final positioning.

Automatic acceleration/ deceleration vs. Joint #3 position

LS20 Rev.1 49

Setup & Operation 5. Motion Range

When setting up the motion range for safety, both the pulse range and mechanical stops mu st always be set at the same time.

Mechanical

stop

Rectangular range setting

Pulse range

Motion range

Mechanical

stop

The pulse range can be set on the [Range] panel shown by selecting [Tools] Manager]. (You may also execute the Range command from the [Command Window].)

EPSON

RC+

NOTE

5. Motion Range

■

CAUTION

The motion range is preset at the factory as explained in Setup & Operation: 5.4 Standard Motion Range. That 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 joints)

2. Setting by mechanical stops (for Joints #1 to #3)

3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the Manipulator (for Joints #1 and #2)

When the motion range is changed due to layout efficiency or safety, follow the descriptions in 5.1 to 5.3 to set the range.

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

Pulses are the basic unit of Manipulator motion. The motion range of the Manipulator is controlled by the pulse range between the pulse lower limit and upper limit of each joint. Pulse values are read from the encoder output of the servo motor.

For the maximum pulse range, refer to the following sections. The pulse range must be set inside of the mechanical stop range.

5.1.1 Max. Pulse Range of Joint #1

5.1.2 Max. Pulse Range of Joint #2

5.1.3 Max. Pulse Range of Joint #3

5.1.4 Max. Pulse Range of Joint #4.

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.

-[Robot

50 LS20 Rev.1

Setup & Operation 5. Motion Range

+X 0 pulse

+ B

- B

+ A

- A

A: Max. Motion Range

B: Max. Pulse Range

- B

+ B

0 pulse

- A

+ A

A: Max. Motion Range

B: Max. Pulse Range

5.1.1 Max. Pulse Range of Joint #1

The 0 (zero) pulse position of Joint #1 is the position where Arm #1 faces toward the positive (+) direction on the X-coordinate axis. When the 0 pulse is a starting point, the counterclockwise pulse value is defined as the positive (+) and the clockwise pulse value is defined as the negative (-).

LS20-804* LS20-A04*

±132 deg. - 152918 ~ 808278 pulse

5.1.2 Max. Pulse Range of Joint #2

The 0 (zero) pulse position of Joint #2 is the position where Arm #2 is in-line with Arm #1. With the 0 pulse as a starting point, the counterclockwise pulse value is defined as the positive (+) and the clockwise pulse value is defined as the negative (-).

LS20-804*

± 152 deg.

± 345885 pulse

LS20-A04*

LS20 Rev.1 51

Setup & Operation 5. Motion Range

Upper limit: 0 pulse

: +X 0 ± 344064 pulse

Clockwise (-value)

Counterclockwise (+value)

NOTE

5.1.3 Max. Pulse Range of Joint #3

The 0 (zero) pulse position of Joint #3 is the position where the shaft is at its upper limit. The pulse value is always negative because Joint #3 always moves lower than the 0 pulse position.

Joint #3 Stroke Lower Limit Pulse

LS20-804S

Standard-model 420 mm

-283853 pulse

LS20-A04S LS20-804C

Cleanroom-model 390 mm

-263578 pulse

LS20-A04C

For t he Cleanroom-model (LS20-804C/LS20-A04C), the motion range set with the Joint #3 mechanical stop cannot be changed.

5.1.4 Max. Pulse Range of Joint #4

The 0 (zero) pulse position of Joint #4 is the position where the flat near the end of the shaft faces toward the end of Arm #2. With the 0 pulse as a starting point, the counterclockwise pulse value is defin ed as the positive (+) and the clockwise pulse value is defined as the negative (-).

52 LS20 Rev.1

Setup & Operation 5. Motion Range

Mechanical stop of Joint #2 (Fixed)

Mechanical stop of Joint #1 (Adjustable)

Mechanical stop of Joint #3 (Lower limit mechanical stop)

(Do not move the upper limit mechanical stop.)

Mechanical stop of Joint #1 (Fixed)

Mechanical stop of Joint #2 (Adjustable)

5.2 Motion Range Setting by Mechanical Stops

Mechanical stops physically limit the absolute area that the Manipulator can move. Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for

the mechanical stop settings. Install the bolts in the holes corresponding to the angle that you want to set.

Joints #3 can be set to any length less than the maximum stroke.

LS20 Rev.1 53

Setup & Operation 5. Motion Range

Views from the bottom of A r m #1

Joint #1 Mechanical Stops

LS20-A04*

Setting Angle

122 deg

Pulse Value

444188 pulse

Views from the top of A r m #1

Joint #2 Mechanical Stops

LS20-A04*

Setting Angle

135 deg

Pulse Value

307200 pulse

(1) Turn OFF the

(2) Install a hexagon socket head cap bolt into the hole corresponding to the setting angle, and

Hexagon socket head cap

bolt (fully threaded)

The number

of bolts

Recommended

tightening torque

(3) Turn ON the

5.2.1 Setting the Mechanical Stops of Joints #1 and #2

Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for the mechanical stop settings. Install the bolts in the holes corresponding to the angle that you want to set.

Install the bolts for the mechanical stop to the following position.

LS20-804*

Controller.

tighten it.

Joint

1 2

M10 × 65 M10 × 50

1 bolt /

one side

Controller.

54 LS20 Rev.1

13.0 N⋅m (132.7 kgf⋅cm)

Setup & Operation 5. Motion Range

(4) Set the pulse range corresponding to the new Be sure to set the pulse range

Example:

Execute the following command

(5) Move the arm by hand until it touches the mechanical stops, and make sure that the arm does not hit

(6) O and

Make sure that the arm does not hit the mechanical

stops.

Example

Execute the following command

The Pulse command (Go Pulse command) moves

at the same time. Specify safe positions after considering motion of not only the joints whose pulse range have been changed, but also other joints

In this example, Joint #1 is moved to the

(pulse value:

327680

If the arm

s or if an error occurs after the arm hits the

mechanical stops

reset the pulse range to a narrower setting or extend the

position

RC+

EPSON

RC+

NOTE

positions of the mechanical stops.

inside the positions of the mechanical stop range.

Using LS20-804S

The angle of Joint #1 is set from –110 degrees to +110 degrees. The angle of Joint #2 is set from

125 degrees to +125 degrees.

s from the [Command W indow] .

>JRANGE 1, >JRANGE 2,-

-400498, 400498 ' Sets the pulse range of Joint #1 284445, 284445 ' Sets the pulse range of Joint #2

>RANGE ' Checks the setting using Range

-400498, 400498, -284445, 284445, -283853

, 0, -344064, 344064

any peripheral equipment during operation.

perate the joint changed at low speeds until it reaches the positions of the minimum

maximum pulse range.

(Check the position of the mechanical stop and the motion range you set.)

: Using LS20-804S

The angle of Joint #1 is set from -110 degrees to +110 degrees.

EPSON

The angle of Joint #2 is set from

s from the [Command W indow] .

125 degrees to +125 degrees.

>MOTOR ON ' Turns ON the motor >CP ON ' Enters low-power mode >SPEED 5 ' Sets at low speeds >PULSE -400498,0,0,0 ' Moves to the min. pulse positio n of Joint #1 >PULSE 400498,0,0,0 ' Moves to the max. pulse positio n of Joint #1 >PULSE 327680,-284445,0,0 ' Moves to the min. pulse positi on of Joint #2 >PULSE 327680,284445,0,0 ' Moves to the max. pulse position of Joi nt #2

all joints to the specified positions

center of its motion range

) when checking Joint #2.

is hitting the mechanical stop

, either

s of the mechanical stops within the limit.

LS20 Rev.1 55

Setup & Operation 5. Motion Range

(1)

Turn ON the Controller and turn OFF the motors using the Motor OFF command.

(2)

Push up the shaft while pressing the brake release switch.

Do not push the shaft up to its upper limit or it will be difficult for the arm top cover to be removed. Push the shaft up to a position where the Joint #3 mechanical stop can be changed.

Lower limit mechanical stop screw 2-M5×6 set screw + 2-M5 bush Brake release switch

Shaft

When you press the end effector.

(3)

Turn OFF the

(4)

Loosen the lower limit mechanical stop screw (

A mechanical stop is mounted on both the top and the position of the lower limit mechanical stop on the top can be changed. Do not remove the upper limit mechanical stop on the bottom because the calibration point of Joint #3 is specified

(5)

The upper end of the shaft maximum stroke. Move the lower limit mechanical stop down by the length you want to limit the stroke. For example, when the lower limit mechanical stop is set at “ stroke, the lower limit Z coordinate value is to “

”, move the lower limit mechanical stop down calipers to measure the distance when adjusting

Measure this distance.

(6)

Firmly tighten the lower limit mechanical stop Recommended tightening torque:

(7)

Turn ON the

NOTE

5.2.2 Setting the Mechanical Stop of Joint #3

This method applies only to the Standard-model manipulator (LS20-**4S). For t he Cleanroom-model ( stop cannot be changed.

Be sure to hold the shaft by hand while pressing the button.

LS20-**4C), the motion range set with the Joint #3 mechanical

the brake release switch, the shaft may lower due to the weight of

Controller.

2-M5×6 set screw).

bottom of Joint #3. However, only

using the stop.

defines the

420 mm”

“-420”. To change the value

-100 “320 mm”. Use

56 LS20 Rev.1

the mechanical stop.

screw (2-M5×6 set screw).

3.9 N⋅m (39.8 kgf⋅cm)

Controller.

Setup & Operation 5. Motion Range

(8)

Move

then

check the lower

Otherwise, the joint

(9)

Calculate the lower limit pulse

shown below

and set the value. T

he lower limit Z coordinate

value

** For the Joint #3 resolution,

Enter the

>JRANGE 3,X,0 ' Sets the pulse range of Joint #3

(10)

Using th e

Joint # 3 to the lower li mit

position of the pu lse range at low speed.

than

the pulse range, Joint #3

When

the error occurs, either change

or extend the position

of the mechanical stop within the limit.

If it is difficult to check whether Joint #3 hits a mechanical stop, turn OFF the Controller and lift the arm top cover to check the condition causing the problem from the side.

Enter the value

>MOTOR ON >SPEED 5 >PULSE 0,0,

those for Joint #3 are “0”.

even when lowering

Joint #3.)

RC+

NOTE

Joint #3 to its lower limit while pressing the brake release switch, and

limit position. Do not lower the mechanical stop too far

may not reach a target position.

value of the pulse range using the formula

he result of the calculatio n is always negative because t

is negative.

Lower limit of pulse (pulse)

= lower limit Z coordinate value (mm) / Resolution (

mm/pulse)

refer to the section Setup & Operation 2.4 Specifications.

EPSON

Execute the following command from the [Command Window]. calculated value in X.

Pulse command (Go Pulse command), move

If the mechanical stop range is less

will hit the mechanical stop and an error will occur.

the pulse range to a lower setting

EPSON

Execute the following commands from the [Command Window]. calculated in Step (9) in X.

' Turns ON the motor

' Sets low speed

X,0 ' Moves to the lower limit-pulse position of Joint #3.

(In this example, all pulses except Substitute these “0s” with the other pulse values specifying position where there is no interference

LS20 Rev.1 57

Setup & Operation 5. Motion Range

Set the XYLim setting on the [XYZ Limits] panel shown by selecting [Tools]-[Robot Manager]. (You may also execute the XYLim command from the [Command Window].)

EPSON

RC+

5.3 Setting the Cartesian (Rectangular) Range in the XY

Coordinate System of the Manipulator (for Joints #1 and #2)

Use this method to set the upper and lower limits of the X and Y coordinates. This setting is only enforced by software. Therefore, it does not change the physical

range. The maximum physical range is based on the position of the mechanical stops.

5.4 Standard Motion Range

The following “motion range” diagrams show the standard (maximum) specification. When each Joint motor is under servo control, the center of Joint #3’s (shaft’s) lowest point moves in the areas shown in the figure.

“Area limited by mechanical stop” is the area where the center of Joint #3’s lowest point can be moved when each joint motor is not under servo control.

“Mechanical stop” sets the limited motion range so that the center of Joint #3 cannot move beyond the area mechanically.

“Maximum space” is the area that contains the farthest reach of the arms. If the maximum radius of the end effector is over 60 mm, add the “Area limited by mechanical stop” and “radius of the end effector”. The total value is specified as the maximum area.

For the motion area figures, refer to Setup & Operation 3.3 Mounting Dimensions.

58 LS20 Rev.1

Maintenance

This volume contains mai ntenance pr ocedures wit h safety precautions for LS20 seri es Manipulators.

Do not maintenance procedure strictly as described in this manual. Improper removal of parts or robot system but also serious safety problems.

Keep away from the Manipulator while training courses.

is ON. Entering the operating area with the power ON is extremely hazardous and may cause serious safety problems as t he Manip ulator may move stopped

■

When you check the operation o f the Mani pulat or af t er replac ing p art s, be sure t o check it of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly.

■

Before switches and safeguard switch function properly. when the switches do not function properly is extremely hazardous and may result in serious bodily injur switches cannot fulfill the ir intended functions in an emergency.

To shut off power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it direct ly to a factory power source.

■

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

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 sy stem. 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 syst em.

Maintenance 1. Safety Maintenance

WARNING

■

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

improper maintenance may not only cause improper function of the

the power is ON if you have not taken the

Do not enter the operating area while the power

even it seems to be

while you are outside of the safeguarded area. Checking the operation

operating the robot system, make sure that both the Emergency Stop

Operating the robot system

y and/or serious damage to the robot system as the

to the robot system, pull out the power plug from the power

WARNING

LS20 Rev.1 61

performing any replacement procedure, turn OFF the Controller and

and then pull out the pow er plug from the power source.

Maintenance 1. Safety Maintenance

Be sure cables. (Do not forcibl cables, disconnection, and or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

Inspection Point

inspection

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)

√

20000 h

■

to connect the cables properly. Do not allow unnecessary strain on the

put heavy objects on the cables. Do not bend or pull the cables

y.) The unnecessary strain on the cables may result in damage to the

CAUTION

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 Maintenance Inspection

2.1.1 Schedule for Maintenance Inspection

Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and annual. The inspection points are added every stage. If the Manipulator is operated for 250 hours or longer per month, the inspection points must be added every 250 hours, 750 hours, 1500 hours, and 3000 hours operation.

/or contact failure. Damaged cables, disconnection,

h = hour

…

Daily

Inspect every day

…

√

Monthly

…

Quarterly

…

Biannual

…

Annual

…

Overhaul

…

62 LS20 Rev.1

Maintenance 2. General Maintenance

End effector mounting bolts

√ √ √ √ √

Manipulator mounting bolts

√ √ √ √ √

Each arm locking bolts

√ √ √ √ √

Bolts/screws around shaft

√

reduction gear units, etc.

plates etc.)

Manipulator cable unit

√ √ √ √

Manipulator

External cables

√ √ √ √

if necessary.

Tighten it if necessary.

Grease conditions

Refer to Maintenance: 2.3 Greasing.

Battery - Replace every 1.5 years

Inspection Point

Inspection Place

Daily

Monthly

Quarterly

Biannual

Annual

Check motion range

Each joint

√

are disconnected.

Manipulator)

to check whether backlash exists.

vibration occurs.

a gauge.

no sound, replace the brake.

2.1.2 Inspection Point

Inspection While the Pow er is O FF (M anipulator is not operating)

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

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.)

Bolts/screws securing motors,

√

Check looseness of connectors. If the connectors are loosen, push it securely or tighten.

Visually check for external def ects. Clean up if necessary.

Check for bends or improper location. Repair or place it properly

Check tension of timing belts.

External connectors on Manipulator (on the connector

External appearance of

Safeguard etc. √ √ √ √ √

Inside of Arm #2 √ √

Inspection While the Pow er is O N (M anipulator is operating)

√ √ √ √ √

Move the cables back and forth lightly to check whether the cables

Push each arm in MOTOR ON status

Check whether unusual sound or

Measure the accuracy repeatedly by

Turn ON and OFF the brake release switch and check the sound of the electromagnetic brake. If there is

LS20 Rev.1 63

External cables (including cable unit of the

Each arm √

Whole √ √ √ √ √

Whole √

Brake √ √ √ √ √

√ √

Maintenance 2. General Maintenance

Overhaul timing is based on an assumption that all joints are operated for equal distance. If a particular joint has a high duty or high load, it is recommended to overhaul all joints (as many as possible) before hours with the joint as a basis.

2.2 Overhaul

The parts for the manipulator joints may cause accuracy decline or malfunction due to deterioration of the manipulator resulting from long term use. In order to use the manipulator for a long term, it is recommended to overhaul the parts (parts replacement).

Although the degree of deterioration varies depending on usage condition and the load applied on the Manipulator, timing of the overhaul is 20,000 operation hours of the Manipulator as a rough indication.

The manipulator operation hours can be checked in [Controller Status Viewer] dialog

-[Motor On Hours].

(1) Select EPSON RC+ menu-[Tools]-[Controller] to open the [Controller Tools]

dialog.

(2) Click the <View Controller Status> button to open the [Browse For Folder] dialog. (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side.

For the parts subject to overhaul, refer to Maintenance 17. Maintenance Parts List. For details of replacement of each part, refer to the Maintenance section. Please contact our service center or distributors of your region for further information.

■

CAUTION

64 LS20 Rev.1

exceeding 20,000 operation

Keep enough grease in the Manipulator. Operating the Manipulator with insufficient the Manipulator required for the re

Greasing part

Greasing Interval

Grease

Refer to:

Joint #1

Reduction gear units

comes first

SK-1A

Maintenance: 5 Joint #1

Joint #2

Reduction gear units

SK-2

Maintenance: 6 Joint #2

whichever comes first

Grease with enough oil content

Grease with less oil content

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

with clean water, and then see a doctor

2.3 Greasing

The ball screw spline and reduction gear units need greasing regularly. Only use the

CAUTION

grease specified in the following table.

■

Maintenance 2. General Maintenance

grease will dama ge sliding p art s and/or result in insufficient function of

. Once the parts are damaged, a lot of time and money will be

pairs.

10,000 hours or 2 years, whichever

Joint #3 Ball screw spline shaft

6 months or 100 km of operation,

Grease discolors with temperature and gradually becomes black when the internal temperature of the reduction gear unit exceeds 80 degrees C. Grease functions normally as lubrication even if it is darkly discolored. However, grease does not exert lubricating effect when it contains less oil. In that case, grease the parts.

■

If grease gets into your eyes

: Flush them thoroughly

immediately.

If grease gets into your m out h

CAUTION

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

thoroughly.

If grease gets on your s kin

: Wash th e ar ea t hor oughly with soap and water.

AFB

Maintenance: 10. Gre asing the Ball Screw Spline Unit

LS20 Rev.1 65

Maintenance 2. General Maintenance

Bolt Tightening Torque

Refer below for the set screw.

2.0 N⋅m

(21 kgf⋅cm)

Set Screw

Tightening Torque

4.0 N⋅m

(41 kgf⋅cm)

2.5 N⋅m

(26 kgf⋅cm)

8.0 N⋅m

(82 kgf⋅cm)

3.9 N⋅m

(40 kgf⋅cm)

13.0 N⋅m

(133 kgf⋅cm)

32.0 N⋅m

(326 kgf⋅cm)

M10

58.0 N⋅m

(590 kgf⋅cm)

M12

100.0 N⋅m

(1,020 kgf⋅cm)

The bolts aligned on a circumference should be fastened in a crisscross pattern as shown in the figure below.

Bolt hole

Do not fasten all bolts securely at one time. Divide the number of times that the bolts are fastened into two or three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench so that the bolts are fastened with tightening torques shown in the table above.

Execute the following command from the [Command Window].

[Joint #3 Pulse value]

EPSON

RC+

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.

2.5 Matching Origins

After parts have been replaced (motors, reduction gear units, a brake, timing belts, a ball screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch exists between the origin stored in each motor and its corresponding origin stored in the Controller. After replacing the parts, it is necessary to match these origins.

For calibration, the pulse values for a specific position must be recorded in advance. Before replacing parts, select easy point (pose) data from the registered point data to check the accuracy. Then, follow the steps below to display the pulse values and record them.

>PULSE

PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls pls [Joint #4 Pulse value] pls

66 LS20 Rev.1

Power cable

Cable unit

Signal cable

Brake release

switch

LED lamp

Ball screw

spline unit

Joint #4 motor

Z belt

U belt

Joint #2 motor

Joint #2 reduction gear unit

Joint #1 reduction gear unit

Joint #1 motor

Joint #3 motor

(Figure: LS20-804S)

Joint #4 reduction gear unit

Lithium battery & Battery board

Bellows

Clamp Band

Bellows

Clamp Band

(Figure: LS20-804C)

2.6 Layout of Maintenance Parts

Standard-model

Maintenance 2. General Maintenance

Cleanroom-model (w i th opt ional bel l ows)

For the Cleanroom-model, the following parts are added to the Standard-model.

LS20 Rev.1 67

Maintenance 3. Covers

Do not insert or pull out the motor c onnect ors whil e the power to the ro bot syst em is turned ON. Inserting or pulling out the motor connectors extremely hazardous and may result move abn robot system.

■

To shut off 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 equipment, Performing any replacement procedure with the power ON is extremely hazardous and may result in

■

Be careful not to get any foreign substances in pins during maintenance. foreign substances exist in them is extremely shock

Arm

Bottom Cover

Connector Plate

Connector Sub Plate

Arm Top Cover

(Figure: LS20-804S)

Arm 1 Cover

3. Covers

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

■

with the power ON is

in serious bodi ly injury as the Man ipulator may

ormally, and also may result in electric shock and/or malfunction of the

to the robot system, pull out the power plug from the power

WARNING

performing any replacement procedure, turn OFF the Controller and related

and then pull out the power pl ug from the power source.

electric shock and/or malfunction of the robot syst em.

the Manipulator, connectors, and

Turning ON the power to the robot system when any

hazardous and may result in electric

and/or malfunction of the robot system.

68 LS20 Rev.1

Do not remove the arm top cover result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or cont act failure is ext remel y hazardous and may result in electric shock and/or improper function of the robot sys t em.

■

When installing the cover, b cover mounting and do 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 syste When

after removing the cover.

Be sure to

Unscrew the Arm Top Cover mounting bolts, and then lift the

When bellows are installed to the manipulator, remove the upper bellows and then remove the Arm Top Cover. For bellows removal, refer to

Maintenance 9. Bellows

Be careful for user t

Truss: 4-M4×14

Truss: 10-M4×10

Arm Top Cover

Put the arm top cover to the arm and secure with the Arm Top Cover mounting bolts.

After touch

When bellows are installed to the manipulator, Install the upper bellows and then install the Arm Top Cover. For bellows installation, refer to

NOTE

3.1 Arm Top Cover

Maintenance 3. Covers

CAUTION

Arm Top Cover Removal

■

he cover.

forcibly. Removing the cover forcibly may

e careful not to allow the cables to interfere with the

not bend these cables forcibly to push them into the

routing the cables, observe the cable locations

place the cables back to their original locat ions.

cover.

wires and tubes when removing

M4 Truss Tightening torque: 0.45 N⋅m

Arm Top Cover Installation

securing the Arm Top Cover, make sure that the lower limit mechanical stop is not

ing the cylindrical part of the Arm Top Cover.

LS20 Rev.1 69

Maintenance 9. Bellows.

Maintenance 3. Covers

Unscrew the and

Be careful of the effector not be removed from the shaft.

When you replace the need to remove the end effector to remove the Arm Bottom Cover completely.

When you can work (maintenance, inspection) without removing the shaft C

Truss: 4-M4×10

When bellows are installed to the manipulator, remove or pull down the lower bellows and then remove the arm bottom cover. For bellows removal, refer to Maintenance 9.

Bellows

Unscrew the Arm #1 cover mounting bolts and remove the cover.

Arm #1 covers are on the top and bottom of the Arm #1. Top and bottom covers are in the same shape.

4-M4×12 Double sems

NOTE

3.2 Arm Bottom Cover

then remove the cover. M4 Truss Tightening torque: 0.45 N⋅m

to the lower limit and lower the Arm Bottom

over.

Arm Bottom Cover mounting bolts

end effector. When the end

is installed, the Arm Bottom Cover may

ball screw spline unit, you

cover completely, move the

3.3 Arm #1 Cover

M4 double sems Tightening torqu e: 0.45 N⋅m

70 LS20 Rev.1

Do not remove the connector plate forcibly may result in dam age t o t he 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, b with the plate mounting and d the cover. U and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may r esult in electric shock and/or improper the robot system. When

after removing the

connector plate

8-M4×10

Connector Plate

GOOD: Curved

BAD: Bended

NOTE

3.4 Connector Plate

Maintenance 3. Covers

CAUTION

■

forcibly. Removing the connector plate

e careful not to allow the cables to interfere

o not bend these cables forcibly to push them into

nnecessary strain on cables may result in da mage to the cables, dis con necti on,

function of

routing the cables, observe the cable locations

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

Unscrew the Connector Plate mounting bolts and remove the plate.

When mounting the Connector Plate, be careful of the following.

Prevent the air tube from bending sharply inside the manipulator. Also, do not block the air flow.

If there is a kink in the air tube, air flow is blocked while the manipulator is operating and may cause a trouble.

Put the air tubes along the wall as shown in the picture.

LS20 Rev.1 71

Maintenance 3. Covers

Do not remove the connector sub plate 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, b interfere 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 extreme the robot system. When

after removing the

connector sub plate

4-M4×8

Connector Sub Plate

User Plate

(1) Remove

(2) Unscrew the User Plate mounting bolts remove the plate.

2-M4×10

(1) Put the U

(2) Mount the Arm Top Cover.

Refer to Maintenance: 3.1 Arm Top Cover.

3.5 Connector Sub Plate

■

CAUTION

with the plate mounting and do not bend these cables forcibly to push

ly hazardous and may result in electric shock and/or improper function of

routing the cables, observe the cable locations

forcibly. Removing the connector sub

e careful not to allow the cables to

. Be sure to place the cables back to their original locat io ns .

Unscrew the Connector Sub Plate mounting bolts and remove the plate.

3.6 User Plate

Removal

User Plate Installation

Refer to Maintenance: 3.1 Arm Top Cover.

the Arm Top Cover.

and

ser Plate to the arm and secure using the mounting bolts.

72 LS20 Rev.1

Do not insert or pull out the motor connectors while t he power to the r obot system is turned ON. Inserting or pulling out the motor connectors extremely hazardous and may result may move abnormally, and also may result i n the robot system.

■

To shut off power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it direct ly to a factory power source.

■

Before performing any replacement procedure, turn OFF the Controller and related equipment, 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 g pins during maintenance. foreign substances exist in them is extremely

and may result in

Be sure to connect the cables properly. cables. (Do not forcibl 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.

Name

Quantity

Note

LS20-A04*: 1646485

2167689 Hexagonal wrench

width across flats: 3 mm

For M4 screw

Spanner

width across flats: 5 mm

For D-sub connector removal

Nut screwdriver

width across flats: 5 mm

For D-sub connector removal

Torque wrench

Nippers

For cutting wire tie

Material

Wire tie

4. Cable

WARNING

CAUTION

■

in serious bodily injury as the Manipulator

to the robot system, pull out the power plug from the power

and then pull out the pow er plug from the power source.

et any foreign substances in the Manipulator, connectors, and

Turning ON the power to the robot system when any

lectric shock and/or malfunct ion of the robot system.

■

put heavy objects on the cables. Do not bend or pull the cables

y.) The unnecessary strain on the cables may result in damage to the

Do not allow unnecessary strain on the

Maintenance 4. Cable

with the power ON is

electric shock and/ or malfunct io n o f

hazardous

4.1 Replacing Cable Unit

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

If the error occurs, execute the calibration of all joints and axes. For details, refer to Maintenance: 13. Calibration.

Cable unit 1

Maintenance

parts

Battery Unit 1

Tools

LS20-804*: 1646486

(Lithium battery for replacement A set of 3 batteries)

LS20 Rev.1 73

Maintenance 4. Cable

Cable unit

(Figure: LS20-804S

)

If the connectors have been disconnected during the unit, b block diagrams. Improper connection of the connectors may result in improper robot system. For details on the conne ctions, refer to

■

When installing the cover, b cover mounting and do cover. 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

after removing the cover.

Be sure to

■

NOTE

■

replacement of the cable

e sure to reconnect the connectors to their proper positions. Refer to the

function of the

Maintenance: 4.2 Wir ing Diagrams.

e careful not to allow the cables to interfere with the

not bend these cables forcibly to push them into the

Unnecessary strain on cables may result in damage to the cables,

CAUTION

routing the cables, observe the cable locations

place the cables back to their original locat ions.

Do not allow unnecessary strain on the

put heavy objects on the cables. Do not bend or pull the cables

y.) The unnecessary strain on the cables may result in damage to the

mproper function of the ro bot system.

Brakes are mounted on the Joints #3 and #4 to prevent the shaft from moving down due to the weight of the end effector while the power to the Controller is OFF or the motor is in OFF status (MOTOR OFF).

74 LS20 Rev.1

Move the shaft down to its lower limit before the replacement procedure following the removal steps.

Maintenance 4. Cable

Cable Removal

(1) Turn ON the Controller and change the motor to OFF status (MOTOR OFF).

(2) Press and hold space and prevent the

The brake release switch is applied to both Joints #3 and Joint #4. When the brake release switch is pressed, the respective brakes of the Joint #3 and Joint #4 are released simultaneously. Be careful of the

being

pressed

(3) Turn OFF

and disconnect the power cable and signal cable connectors

from thee controller

(4) Remove the For details, refer to

(5) Remove the

(6) Remove the following that connected to the Connector Plate. Air tube, D

Mounting screws for To remove the air tube, push the ring of the fittings and then pull the tube. (ø6×2, ø4×2)

(7) Pull out the signal connector X20 from the resolver board.

Ferrite core

Wire tie

Signal connector

(8) Cut off the wire tie binding the cables in the Base side. Remove the ferrite core. The part will be used again. Be careful not to lose it. R

the cables

correctly after replacement (9) Remove

For details, refer to

(10)

Remove the User Plate. For details, refer to

(11) Disconnect 1

(12)

Disconnect the D Mounting screws for the D Press the ring on the fitting Remember

NOTE

Unit

the brake release switch to let the shaft down. Be sure to keep enough

end effector hitting any peripheral equipment.

shaft falling and rotating while the brake release switch is

because the shaft may be lowered by the weight of the end effector.

the Controller

Connector Plate.

Maintenance: 3.4 Connector Plate.

Connector.

Connector X121, X131

-sub cable, Ground Wire

the D-sub cable are very small. Be careful not to lose them.

emember the cable layout for reconnecting

the Arm Top Cover.

Maintenance: 3.1 Arm T op Cover.

Maintenance: 3.6 User Plate.

1 connectors on the Arm side.

Connecter: X21, X31, X41, X22, X32, X33, X35, X42, X221, X231, X241

-sub cable and air tube from the User Plate.

-sub cable are very small. Be sure to keep the screws.

LS20 Rev.1 75

the cable layout for reconnecting the disconnected parts after replacement.

s to pull out the air tube. (ø6×2, ø4×2)

Maintenance 4. Cable

(13) Remove the ground wire from the

(14) Cut off the wire tie binding the cables in the Arm side. Remove the

Removed parts will be used again. Be careful not to lose them. Cables are wrapped in a silicon sheet for protection.

The sheet will be reused when installing the cable unit.

Arm #2 side

Saddle

Silicone sheet

Clip band

Ferrite core

(15) Remove the nut of the rotary fitting. Remove the rotary fitting from the cables from the

Nut

2-M4×10

Ground wire

Rotary fittings

Duct Plate

(16) Remove the rotary The rotary fitting is directly screwed in the metal duct. Loosen the screws to remove

the fitting. Cut off the wire tie fixing the cable

Metal duct

Rotary fitting

Wire tie

Remove the signal connector X20 connected to the resolver

NOTE

Arm #2.

following parts.

Nylon clip, saddle, ferrite core

Be careful not to lose it.

Duct Plate. Pull out the

Duct Plate.

fitting from the metal duct.

s, and then pull out the cables from the metal duct.

76 LS20 Rev.1

board.

Maintenance 4. Cable

Cable Installation

(1) Pass the new cables through the cable duct unit. Turn the fitting to secure the cables. Secure the signal connector

(2) Pass the cables in the

and turn the

fittings to secure the cables.

(3) Connect the following to the Connector Plate.

(

Connect the

( Install the ferrite core. F

at the upper side

of the metal duct

(6) Connect the

(7) Mount the For the details, refer to

(8) Connect the connectors

Connectors X21, X31, X41, X22, X32, X33, X35, X42, X221, X231, X241.

(9) Mount the ground wire in the Arm side to the

(10)

Bind the cables with a

removed in the

removal step (1 W B Install the ferrite core.

(11)

Mount the Connector Plate. For the details, refer to

(12)

Place For

(13)

Connect the power cable and signal cable connectors to the controller

(14)

Turn ON the Controller.

(15)

Execute the calibration for all joints but the Joint If the connector falls off from the battery board, execute For

NOTE

Unit

X20 to the resolver board.

Duct Plate side through the Duct Plate and nut

Air tube, D-sub cable, ground wire

connectors.

Connectors X121, X131

5) Bind the cables with a wire tie as removed in the removal step (8).

ix the short flexible tube shipped with the cable unit with the wire tie

air tube and the D-sub cable to the User Plate.

User Plate.

Maintenance: 3.6 User Plate. .

Arm #2.

clip band in their original position as before

4).

rap the cables in the silicon sheet for protection.

ind the cables with the nylon clip and the saddle.

Maintenance: 3.4 Connector Plate.

and secure the Arm Top Cover without the cables being stuck.

details, refer to Maintenance: 3.1 Arm Top Cover.

#1.

the calibration for all axes.

details, refer to Maintenance: 13 Calibration.

LS20 Rev.1 77

Maintenance 4. Cable

4.2 Wiring Diagrams

4.2.1 Signal Cable

78 LS20 Rev.1

Maintenance 4. Cable

X111 X111

No. Color No. Color No. Color

A1 1U R 1 1U R 1 1U R

B1 1V W 2 1V W 2 1V W

A2 1W B 3 1W B 3 1W B

B2 fGND Y/G 4 fGND Y/G 4 fGND Y/G

5 5

6 6

X121 X121 X221 X221

No. Color No. Color No. Color No. Color

A3 2U R 1 2U R 1 2U B 1 2U B 1 2U R

B3 2V W 2 2V W 2 2V W 2 2V W 2 2V W

A4 2W B 3 2W B 3 2W R 3 2W R 3 2W B

B4 fGND Y/G 4 fGND Y/G 4 fGND Y/G 4 C.G. Y/G 4 C.G. Y/G

A7 4U BR 5 4U BR 5 4U BR 5 5

B7 4V L 6 4V L 6 4V L 6 6

A8 4W O 7 4W O 7 4W V

B8 fGND Y/G 8 fGND Y/G 8 fGND Y/G

X131 X131

No. Color No. Color X231 X231

A5 3U GY 1 3U GY 1 3U GY No. Color No. Color

B5 3V V 2 3V V 2 3V V 1 3U GY 1 3U R

A6 3W SK 3 3W SK 3 3W O 2 3V V 2 3V W

B6 fGND Y/G 4 fGND Y/G 4 fGND Y/G 3 3W O 3 3W B

A9 5 5 4 C.G. Y/G 4 C.G. Y/G

6 6 5 5

6 6

X241 X241

Color No. Color No. Color

White 1 4U BR 1 4U R

Black 2 4V L 2 4V W

Red 3 4W V 3 4W B

Green 4 C.G. Y/G 4 C.G. Y/G

Yellow 5 5

Violet 6 6

Sky Blue

Pink

Brown

Blue

Orange

Gray

VSKP

Abbreviation of the color

Abbreviation

Joi nt#1t

Y/G

Joi nt#2tJoi nt#3t

Joi nt#4t

BASE

ARM2

CONTOROLLER

4.2.2 Power Cable

LS20 Rev.1 79

Maintenance 4. Cable

No. Color No. Color

1 L/W 1 L/W 2 L/W 2 L/W 3 Y/W 3 Y/W 4 Y/W 4 Y/W 5 G/W 5 G/W 6 G/W 6 G/W 7 R/W 7 R/W 8 R/W 8 R/W 9 G 9 G

No. Color No. Color

1 L/W 1 L/W 2 L/W 2 L/W 3 Y/W 3 Y/W 4 Y/W 4 Y/W 5 G/W 5 G/W 6 G/W 6 G/W 7 R/W 7 R/W 8 R/W 8 R/W

9 V/W 9 V/W 10 V/W 10 V/W 11 L/BR 11 L/BR 12 L/BR 12 L/BR 13 Y/BR 13 Y/BR 14 Y/BR 14 Y/BR 15 G 15 G

Color White Black

Red

Green

Yellow

Violet

Brown

Blue

D-sub 9pin

D-sub 15pin

Abbreviation of the color

Abbreviation

Model name

Model type

Code

4.2.3 User Cable

The following table shows the types of the use cable.

LS20-804* Standard / Cleanroom 1646486

LS20-A04* Standard / Cleanroom 1646485

80 LS20 Rev.1

10 m: 1646523

Hexagonal wrench

width across flats: 3 mm

For M4 screw

Torque wrench

Nippers

For cutting wire tie

M/C cable

(Figure: LS20-804S)

NOTE

4.3 Replacing M/C Cable

If the error occurs, execute the calibration of all joints and axes. For details, refer to Maintenance: 13. Calibration.

Maintenance 4. Cable

Maintenance

parts

Tools

Name Quantity Note

M/C Cable 1

3 m: 1646521 5 m: 1646522

LS20 Rev.1 81

Maintenance 4. Cable

If the connectors have been unit, b block diagrams. Improper connection of the connectors may result in improper robot system. For details on th

■

after removing the cover.

Be sure to

■

M/C Cable Removal

(1) Turn OFF

(2) Disconnect the power cable and signal cable connectors from the controller

(3) Remove the ferrite core on the The part will be used again. Be careful not to

lose it.

Ferrite core

Power cable

(4) Remove the Connector Plate.

Do not pull the plate forcibly.

Signal Cable : 1 connector

Power Cable : 3 connectors

NOTE

■

CAUTION

disconnected during the replacement of the cable

e sure to reconnect the connectors to their proper positions. Refer to the

function of the

e connections, refer to Mai ntenance: 4.2 Wiring Diagrams.

e careful not to allow the cables to interfere with the

not bend these cables forcibly to push them into the

routing the cables, observe the cable locations

place the cables back to their original locat ions.

Do not allow unnecessary strain on the

put heavy objects on the cables. Do not bend or pull the cables

y.) The unnecessary strain on the cables may result in damage to the

may result in electric shock and/or

the Controller.

power cable.

For details, refer to Maintenance: 3.4 Connector Plate.

82 LS20 Rev.1

Maintenance 4. Cable

(

Remove the ferrite core on the signal cable. The part will be used again. Be careful not to

lose it.

Ferrite core

Signal cable

(

Disconnect E

Each

(

Remove the Connector Sub Plate.

M/C Cable Installation

(

Install the Connector Sub Plate with the new M/C Cable to the (

Connect the connectors. (Connect to the Cable Unit with the same number.)

(

Install the ferrite core removed in the removal step (5) to the signal cable.

(

Mount (5)

Install the ferrite core removed in the removal step (3) to the power cable.

(6) Connect the power cable and signal cable connectors to the controller

(7) Turn ON the

(

If the connector falls off from the battery board, execute

the connectors.

ach connector has a unique number.

connector has a different shape.

7) For details, refer to Maintenance: 3.5 Connector Sub Plate.

1) For details, refer to Maintenance: 3.5 Connector Sub Plate.

the Connector Plate.

Connector Plate.

For details, refer to Maintenance: 3.4 Connector Plate.

8) For details, refer to Maintenance: 13 Calibration.

LS20 Rev.1 83

Controller.

the calibration for all axes.

Maintenance 5. Arm #1

■

To shut off power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it direct ly to a factory power source.

■

Before related equipment, 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 apply excessive shock to the motor shaft when replacing motor damage them.

■

Never disassemble the motor and encoder. will cause a positional gap and cannot be used

(Figure: LS20-804S)

Joint #1 reduction gear unit

Joint #1 motor

5. Arm #1

■

with the power ON is

in serious bodily injury as the Manipulator

electric shock and/ or malfunct io n o f

to the robot system, pull out the power plug from the power

WARNING

CAUTION

performing any replacement procedure, turn OFF the Controller and

and then pull out the pow er plug from the power source.

■

s. The shock may shorten the life cycle of the motors and encoder and/or

A disassembled motor and enco der

again.

After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch exists between the origin stored in each motor and its corresponding origin stored in the Controller. After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”.

the

Refer to Maintenance: 13. Calibration to execute the calibration.

84 LS20 Rev.1

parts

width across flats: 2.5 mm

For M5 set screw

width across flats: 4 mm

For M5 screw

width across flats: 5 mm

For M6 screw

width across flats: 6 mm

For M8 screw

Cross-point screwdriver (#2)

For M4 screw

Torque wrench

Wiping cloth

For wiping grease

Grease

Grease (SK-1A)

Joint Removal

(1) Remove the For details, refer to

(2) Disconnect the connector (3) Remove the Arm #1 cover.

(4)

Remove the Arm #1 mounting bolt in the Joint #1 side and remove

8-M6×20 + plane washer

(

Remove the screw the B

8-M8×25

(

Hold Base

The Joint Arm to the following page for replacement steps.

5.1 Replacing Joint #1 Motor

Name Quantity Note

Maintenance 5. Arm #1

Maintenance

Tools

#1 motor

AC Servo Motor (750 W) 1 1646493

Hexagonal wrench

Connector Plate.

Maintenance: 3.4 Connector Plate.

from Resolver board.

Connector: X111 (Hold the claw to remove.) Connector: X10

For details, refer to Maintenance: 3.3 Arm #1 cover.

the Arm 1.

s mounting the Top plate on

ase.

up the Joint #1 unit and remove from the

#1 motor can be replaced while the

#1 and the Top plate are mounted. Refer

LS20 Rev.1 85

Maintenance 5. Arm #1

(7) Loosen the motor mounting #1

There is a the motor the

6-M5×15

Joint #1 Motor Unit

The When removing the motor with the Top plate mounted, use the torque wrench with the

long hexagonal bit, or lengthen the general hexagonal wrench by using the metal pipe to loosen the

To remove base and insert the wrench from the front and loosen the screws.

Metal pipe

Torque wrench

Long hexagonal bit

General hexagonal wrench

After loosening the screws, rotate the motor to pull out. If th the motor while rotating the Arm #1 slowly.

Pull out while rotating

(

Remove the wave #1 motor.

There is a brass bushing in one of the set screw holes.

2-M5×8 Set Screw

M5 Brass Bushing

Waveform Generator

Joint #1 Motor

(9) Remove the motor mounting screws and then remove the motor flange and O

4-M5×18 + Plane Washer

Joint #1 Motor

Motor Flange

O-

ring

NOTE

motor flange and remove the motor unit

O-ring.

motor can be removed while the Arm #1 and the Top plate are mounted.

screws on the Joint

n O-ring in the assembly position of and Joint #1 flange. Be sure to keep

screws.

M5×15 screws on the front side, remove the plate on the front side of the

e motor is hard to pull out, pull

form generator from the Joint

Be sure to keep the bushing.

-ring.

86 LS20 Rev.1

Epson LS20 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

WARRANTY

TRADEMARKS

NOTICE

INQUIRIES

SERVICE CENTER

MANUFACTURER

SUPPLIERS

For Customers in the European Union

Before Reading This Manual

Setup & Operation

1. Safety 3

2. Specifications 14

3. Environments and Installation 27

TABLE OF CONTE NT S

4. Setting of End Effectors 41

5. Motion Range 50

Maintenance

Setup & Operation

1. Safety

1.1 Conventions

1.2 Design and Installation Safety

1.2.1 Strength of Ball Screw Spline

1.3 Operation Safety

1.4 Emergency Stop

1.5 Emergency Movement Without Drive Power

1.6 ACCELS Setting for CP Motions

1.7 Manipulator Labels

2. Specifications

2.1 Features of LS20 series Manipulators

2.2 Model Number

2.3 Part Names and Outer Dimensions

2.3.1 LS20-804*

2.3.2 LS20-A04*

2.4 Specifications

2.5 How to Set the Model

3. Environments and Installation

3.1 Environmental Conditions

3.2 Base Table

3.3 Mounting Dimensions

3.3.1 LS20-804*

3.3.2 LS20-A04*

3.4 Unpacking and Transportation

3.4.1 Precautions for Tr ansport ation

3.4.2 Transportation

3.5 Installation Procedure

3.5.1 Standard-Model

3.5.2 Cleanroom-Model

3.6 Connecting the Cables

3.7 User Wires and Pneumatic Tubes

3.8 Relocation and Storage

3.8.1 Precautions for R eloc ati on and Storage

3.8.2 Relocation

4. Setting of End Effectors

4.1 Attaching an End Effector

4.2 Attaching Cameras and Valves

4.3 Weight and Inertia Settings

4.3.1 Weight Setting

Load on the Shaft

Load on the Arm

Automatic speed setting b y Weight

Automatic acceleration/ deceleration setting by Weight

4.3.2 Inertia Setting

Moment of Inertia and the Inertia Setting

Moment of inertia of load on t he s haft

Automatic acceleration/ deceleration setting of Joint #4 by Inertia (moment of inertia)

Eccentric Quantity and t he I ner t ia Sett ing

Eccentric quantity of load on t he shaft

Automatic acceleration/ deceleration setting by Inerti a ( ecc ent r i c quantity)

Calculating the Moment of Inertia

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3

Automatic acceleration/ deceleration vs. Joint #3 position

5. Motion Range

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

5.1.1 Max. Pulse Range of Joint #1

5.1.2 Max. Pulse Range of Joint #2