EPSON RS3-351C, RS3-351S User Manual

Rev.5 EM105R2014F

SCARA ROBOT

RS series

MANIPULATOR MANUAL

MANIPULATOR MANUAL RS series Rev.5

SCARA ROBOT

RS series Manipulator Manual

Rev.5

RS Rev.5 i

d

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 quality controls, tests, and inspections to certify its compliance

with our high performance standards.

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

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

warranty period information.)

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

during the warranty period):

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

or careless use.

2. Malfunctions caused by customers’ unauthorized disassembly.

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

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

Warnings, Cautions, Usage:

1. If the Manipulator or associated equipment is used outside of the usage conditions an

product specifications described in the manuals, this warranty is void.

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

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

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

cannot warn the user of all possible hazards.

ii RS Rev.5

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

RS Rev.5 iii

MANUFACTURER & SUPPLIER

TEL : +81-(0)266-61-1802

FAX : +81-(0)266-61-1846

Japan & Others

SEIKO EPSON CORPORATION

Suwa Minami Plant

Factory Automation Systems Dept.

1010 Fujimi, Fujimi-machi,

Suwa-gun, Nagano, 399-0295

JAPAN

SUPPLIERS

Factory Automation/Robotics

TEL : +1-562-290-5900

FAX : +1-562-290-5999

E-MAIL : info@robots.epson.com

Factory Automation Division

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

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

E-MAIL : robot.infos@epson.de

North & South America

Europe

EPSON AMERICA, INC.

18300 Central Avenue

Carson, CA 90746

USA

EPSON DEUTSCHLAND GmbH

Otto-Hahn-Str.4

D-40670 Meerbusch

Germany

iv RS Rev.5

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)

RS Rev.5 v

Before Reading This Manual

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

Structure of Control System

The RS series Manipulators can be used with the following combinations of Controllers and

software.

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

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

descriptions that pertain to the software you are using.

Controller

Name Structure

RC180 Controller EPSON RC+ 5.0 Ver.5.3 or greater

RC620

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

Control Unit

Drive Unit

Turning ON/OFF Controller

When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to

turn ON/OFF all the hardware components. For the Controller composition, refer to the

table above.

Shape of Motors

The shape of the motors used for the Manipulator that you are using may be different from

the shape of the motors described in this manual because of the specifications.

Software

EPSON RC+ 6.0 Ver. 6.0 or greater

Setting by Using Software

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

following icon.

EPSON

RC+

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,

Cleanroom-model, and Protected-model (IP54 / IP65) are the same.

vi RS Rev.5

Setup & Operation

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

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

1. Safety

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

qualified personnel and should conform to all national and local codes. Please read this

manual and other related manuals before installing the robot system or before connecting

cables.

Keep this manual handy for easy access at all times.

1.1 Conventions

Important safety considerations are indicated throughout the manual by the following

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

WARNING

Setup & Operation 1. Safety

This symbol indicates that a danger of possible serious injury or death exists if the associated instructions are not followed properly.

This symbol indicates that a danger of possible serious injury or death caused by electric shock exists if the associated instructions are not followed properly.

This symbol indicates that a danger of possible harm to people or physical damage to equipment and facilities

CAUTION

exists if the associated instructions are not followed properly.

RS Rev.5 3

Setup & Operation 1. Safety

1.2 Design and Installation Safety

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

The following items are safety precautions for design personnel:

■

Personnel who design and/or construct the robot system with this product must read the Safety chapter in the EPSON RC+ User’s Guide to understand 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 result in serious bodily injury and/or severe equipment damage to the robot system, and may cause serious safety problems.

WARNING

■

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

■

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

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

4 RS Rev.5

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

■

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

■

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

■

WARNING

Before operating the robot system, make sure that no one is inside the safeguarded area. The robot system can be operated in the mode for teaching even when someone is inside the safeguarded area. The motion of the Manipulator is always in restricted (low speeds and low power) status to secure the safety of an operator. However, operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly.

Setup & Operation 1. Safety

WARNING

CAUTION

■

Immediately press the Emergency Stop switch whenever the Manipulator moves abnormally while the robot system is operated.

■

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

■

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

■

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

■

Whenever possible, only one person should operate the robot system. If it is necessary to operate the robot system with more than one person, ensure that all people involved communicate with each other as to what they are doing and take all necessary safety precautions.

RS Rev.5 5

Setup & Operation 1. Safety

1.4 Emergency Stop

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

Stop switch. Stops the power supply to the motor, and the arm stops in the shortest

distance with the dynamic brake and mechanical brake.

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

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

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

operation.

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

Stop switch when the Manipulator is not moving.

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

circuit.

Free running distance in emergency

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

pressed.

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

remember that the values vary depending on following conditions.

Weight of the end effector Weight of work piece Operating pose

Weight Speed Accel etc.

Conditions for Measurement

Accel Setting 100

Speed Setting 100

Load [kg] 3

Weight Setting 3

Point where the emergency stop signal is input

Joint #1

Stop point

Joint #2

Start point of operation

Target point

Controller RC180 / RC620

Manipulator RS3-351*

Free running time

Free running angle

Free running distance Joint #3 [mm] 55

Joint #1 + Joint #2 [sec.] 0.4

Joint #3 [sec.] 0.2

Joint #1 [deg.] 50

Joint #2 [deg.] 30

Joint #1 + Joint #2 [deg.] 80

6 RS Rev.5

Setup & Operation 1. Safety

−

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

electromagnetic brake applied to the joint has been released.

Move the joint up/down while pressing the brake release

button.

Joint #4 ......... Rotate the shaft by hand.

Joint #1

(rotating)

−

+

Joint #2

(rotating)

−

Base

+

Arm #1

Arm #2

Joint #3

brake release button

NOTE

)

Base

Arm #1

Arm #2

+

Joint #3

(up and down)

−

Joint #4

(rotating)

Shaft

+

Be careful of the shaft while the brake release button is pressed,

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

RS Rev.5 7

Setup & Operation 1. Safety

1.6 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:

Label NOTE

A

B

C

D

E

Before loosening the base mounting screws, hold the arm and secure it tightly with a band to prevent hands or fingers from being caught in the Manipulator.

Hazardous voltage exists while the 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 Arm #1 when bringing your hand close to moving parts.

玉掛け、クレーン作業、フォークリフトの運転作業などは、有資格作業者により、行ってください。無資格作業者による作業は、非常に危険で重傷や重大な損害の可能性があります。

F

ブレーキ解除スイッチを押している間は、ハンドの自重による下降・回転に注意してください。

G

H

8 RS Rev.5

Setup & Operation 1. Safety

Location of Labels

C

D

H

Top

Side

Front

C

E

F

B (Both sides)

C

A

G

Bottom

RS Rev.5 9

Setup & Operation 2. Specifications

2. Specifications

2.1 Features of RS series Manipulators

The RS series Manipulators provides “Operation-oriented layout” with high-performance,

high speed, high accuracy, space saving, and flexible installation.

The features of the RS series Manipulators are as follows:

Space Saving

Compactness achieved by using a ductless design

Small body and wide motion range

Ceiling mounting realizes the cylindrical motion range.

- Operation area: approx. 160 % (compared with Scara robot of same arm length)

- Max. inscribed : approx. 250 % (compared with Scara robot of same arm length)

Great flexibility for peripheral equipments installation

Access to ALL directions

Operation efficiency improvement

The shortcut motion with inward movement

2.2 Model Number

RS3-35 1 S -UL

Environment

Cleanroom-model

This model has additional features that reduce dust emitted by the Manipulator to enable

use in clean room environments.

UL specification

UL : UL compliant

□

: Non UL compliant

Environment

S : Standard

C : Cleanroom & ESD (Anti-static)

Joint #3 stroke

: 130 mm

1

: 100 mm (with bellows)

Arm length

35 : 350 mm

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

10 RS Rev.5

−

2.3 Part Names and Outer Dimensions

Standard-model: RS3-351S

Setup & Operation 2. Specifications

Signal Cable

Fitting (white)

for ø 6 mm pneumatic tube

Signal Cable

Fitting (white)

for ø4 mm pneumatic tube

Base

Arm #1

Power Cable

User Connector

(15-pin D-sub Connector)

Fitting (white)

for ø4 mm

Joint #1

(rotating)

−

Joint #2

(rotating)

pneumatic tube

Power Cable

+

Arm #1

Arm #2

Fitting (black)

for ø 6 mm pneumatic tube

Base

Arm #2

User Connector

CE label

MT label (only for custom specification)

Signature

(Serial No. of Manipulator)

UR label

Joint #3

(up and down)

+

−

Joint #4

(rotating)

(15-pin D-sub Connector)

Shaft

+

NOTE

- When the brake release button is pressed in emergency mode, the Joints #3 brake will be

Fitting (black)

for ø 6 mm pneumatic tube

Fitting (white)

for ø 6 mm pneumatic tube

Joint #3 and #4 brake release button

label

released.

)

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

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

hazardous and it may result in electric shock and/or improper function of the robot

system. Make sure to turn OFF the controller power before the maintenance work.

RS Rev.5 11

Setup & Operation 2. Specifications

g

90 or more Space for cables

← Manipulator installation position

(*) indicates the stroke margin by mechanical stop.

1 mm flat cuｔ

Ø3,90°

Conical hole

Max.ø11 through hole ø16h7 shaft diameter

ø30 mechanical stop diameter

Enlarged view from A

(Original orientation of Joint #3, #4)

Reference through hole

(View from the top of the base)

through hole

For manipulator mounting

ø11 spot facing

depth 6.5

throu

h hole

12 RS Rev.5

Setup & Operation 2. Specifications

Cleanroom-model: RS3-351C

The following figures show the special parts for Cleanroom-model (Table Top mounting). These parts are different in appearance from Standard-model.

Bellows

Exhaust port

Plate cover (For Anti-static)

Bellows

RS Rev.5 13

Setup & Operation 2. Specifications

g

90 or more Space for cables

← Manipulator installation position

(*) indicates the stroke margin by mechanical stop.

throu

h hole

1 mm flat cuｔ

Ø3,90°

Conical hole

Max.ø11 through hole ø16h7 Shaft diameter

ø30 Mechanical stop diameter

Enlarged view from A

(Original orientation of Joint #3, #4)

(View from the top of the base)

Reference through hole

For Manipulator mounting

through hole

Ø11 spot facing

depth 6.5 （from back side）

14 RS Rev.5

Setup & Operation 2. Specifications

2.4 Specifications

Item RS series

Arm #1, #2 350 mm

Arm length

Max. operating speed *1

Repeatability

Payload (Load)

Joint #4 allowable moment of inertia *2

Max. motion range

Max. pulse range (pulse)

Resolution

Hand diameter

Mounting hole

Weight (cables not included)

Driving method

Motor power consumption

Option Environment Cleanroom *3 & ESD Joint #3 down force 150 N Installed wire for customer use 15 wires: D-sub / 15 pin connectors

Installed pneumatic tube for customer use

Environmental requirements

Ambient temperature Ambient relative

humidity Noise level *4 LAeq = 70 dB (A) Applicable Controller RC180, RC620

Arm #1 175 mm Arm #2 175 mm Joints #1, #2

6237 mm/s Joints # 3 1100 mm/s Joint #4 2600 deg/s Joints #1, #2

± 0.01 mm Joints # 3 ± 0.01 mm Joint #4 ± 0.01 deg Rated Max. Rated Max. Joint #1 Joint #2

Joint #3

Joint #4

Joint #1 Joint #2

Joint #3

Joint #4 Joint #1 Joint #2 Joint #3 Joint #4 Mounting Hollow

1 kg

3 kg

0.005 kg⋅m

0.05 kg⋅m

± 225 deg

RS3-351S: 130 mm

RS3-351C: 100 mm

± 720 deg

− 2560000 to + 5973334 pulse

± 4177920 pulse

RS3-351S: − 1479112 pulse to 0 pulse

RS3-351C: − 1137778 pulse to 0 pulse

± 3145728 pulse

0.0000527 deg/pulse

0.0000538 deg/pulse

0.0000879 mm/pulse

0.000229 deg/pulse ø 16 mm ø 11 mm 6-M6 17 kg: 38 lb (Common to Standard & Cleanroom-model) AC servo motor

Joint #1 Joint #2 Joint #3 Joint #4

400 W 200 W 150 W 100 W

2 pneumatic tubes (ø 6 mm): 0.59 Mpa (6 kgf/cm2 : 86 psi) 1 pneumatic tube (ø 4 mm): 0.59 Mpa (6 kgf/cm 5 to 40°C (with minimum temperature variation)

10 to 80% RH (no condensation)

2

: 86 psi)

RS Rev.5 15

Setup & Operation 2. Specifications

Item RS series

Assignable Value

( ) Default values

MTBF

SPEED ACCEL *5 SPEEDS ACCELS FINE WEIGHT

1 to (5) to100 1 to (10) to 120 1 to (50) to 2000 1 to (200) to 25000 0 to (10000) to 65000 0,175 to (1,175) to 3,175 3 years

UL1740 (Third Edition, Dated December 7, 2007) ANSI/RIA R15.06-1999

Safety standard

NFPA 79 (2007 Edition) CSA/CAN Z434-03 (February 2003) CE Marking − Machinery Directive, Low Voltage Directive, EMC Directive

*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 3 (ISO14644-1)

In previous criteria; Clean Class: 10 or its equivalent

Amount of Dust (0.1 µm diameter or larger) in 28317 cm

3

(1cft) sample-air around the center of the motion rang: 10 particles or less.)

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 or larger Recommended exhaust flow rate: approx. 1000 cm

3

/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. However, you may require an operation with high acceleration to shorten the cycle time by decreasing the vibration at positioning. In this case, set Accel to larger than 100. If you specify a larger Accel value, the frequency of the overload error and over heat may rise during continuous operation. The use of large Accel setting is recommended only for necessary motions.

16 RS Rev.5

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.

■

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

CAUTION

NOTE

)

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

If an MT label is attached to the 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.

Setup & Operation 2. Specifications

RS Rev.5 17

Setup & Operation 3. Environments and Installation

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:

Item Conditions

Ambient temperature *1 5 to 40°C (with minimum temperature variation)

Ambient relative humidity 10 to 80% (no condensation)

First transient burst noise 2 kV or less

Electrostatic noise 6 kV or less

· Install indoors

· Keep away from direct sunlight

· Keep away from dust, oily smoke, salinity,

metal powder or other contaminants

Environment

· Keep away from flammable or corrosive solvents

and gases

· Keep away from water

· Keep away from shocks or vibrations

· Keep away from sources of electric noise

NOTE

)

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.

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

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

3.2 Base Table

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

base table for your Manipulator. The shape and size of the base table differs depending

on the use of the robot system. For your reference, we list some Manipulator table

requirements here.

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

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

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

attaching reinforcing materials such as crossbeams.

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

follows:

Max. Reaction torque on the horizontal plate : 500 Nm

Max. Horizontal reaction force : 1200 N

Max. Vertical reaction force : 1100 N

The threaded holes required for mounting the Manipulator base are M6. 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.

18 RS Rev.5

Setup & Operation 3. Environments and Installation

The plate for the Manipulator mounting face should be 20 mm thick or more and made of

steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or

less.

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

The Manipulator must be installed horizontally.

When using a leveler to adjust the height of 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.

RC180 Controller

M/C Signal Cable

M/C Power Cable

[unit : mm]

WARNING

NOTE

)

RS series Manipulator

(Figure: RS3-351S)

47

Power Cable

Connector

26

53

Signal Cable

Connector

18

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

The M/C cables are installed to the Manipulator body and can not be removed. Never try

to remove the M/C cables.

In case that the base table has no maintenance window*, it needs to remove the

Manipulator from the base table for the maintenance. When designing the base table,

consider this point. (* Refer to next page.)

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

table, refer to the Controller manual.

■

To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to the EPSON RC+ User’s Guide.

RS Rev.5 19

Setup & Operation 3. Environments and Installation

Base Table – Design Example

The following is an example for designing the base table of RS3 Manipulator.

During the operation of RS3 in the maximum acceleration/deceleration speed, the base table must be steady enough to prevent the vibration from transmitting to RS3.

Maintenance window

Operating height

Space for Con troller

Joint #1 Center of rotation

: Make space for the Arm #1 cover

to remove

Adjustable bolt

X

Y

AA

Wight of table : approx. 250 kg

Material for the flame : Iron pipe: □ 100 × 50 mm 3.2 mm thick

Adjustable bolt : M36

8

Geometrical moment of inertia : Ix = 10.3 × 10

(A-A) Iy = 10.3 × 10

mm4

8

mm4

- Set low aspect ratio of the base table height and width

- Put center of gravity lower position by installing the Controller on the bottom of the base table.

- Reinforce the open part with joist or similar material to minimize the part.

- The condition depends on the table height, width, the position of joist, and the center of gravity.

20 RS Rev.5

3.3 Mounting Dimensions

The maximum space described in figures shows that the radius of the end effector is 50

mm or less. If the radius of the end effector exceeds 50 mm, define the radius as the

distance to the outer edge of maximum space.

If a camera or electromagnetic 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.

space for teaching

space for maintenance and inspection

Ensure a space to open the arm #1 cover, rear side cover and the maintenance

cover for maintenance.

space for cables

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

cable, be sure to maintain sufficient distance from obstacles. In addition, leave

enough space for other cables so that they are not bent forcibly.

Setup & Operation 3. Environments and Installation

Ensure distance to the safeguard from the maximum motion range is more than 50 mm.

Center of Joint#3

Maximum range

Y

X

RS3-351*

Arm #1 Length 175 mm Joint #1 Motion range

Arm #2 Length 175 mm Joint #2 Motion range

± 225 degree

RS Rev.5 21

Setup & Operation 3. Environments and Installation

3.4 Unpacking and Transportation

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

■

Only authorized personnel should perform sling work and operate a crane and a forklift. When these operations are performed by unauthorized personnel, it is

WARNING

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 removing the bolts securing the Manipulator to the delivery equipment, the Manipulator can fall. Be careful not to get hands or fingers caught.

■

The arm is secured with a wire tie. Leave the wire tie secured until you finish the installation so as not to get hands or fingers caught.

CAUTION

■

To carry the Manipulator, have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand. When holding the bottom of the base by hand, be very careful not to get your hands or fingers caught.

■

Stabilize the Manipulator with your hands when hoisting it.

■

When transporting the Manipulator for a long distance, secure it to the delivery equipment directly so that the Manipulator never falls. If necessary, pack the Manipulator in the same style as it was delivered.

RS3-351S : approx. 17 kg : 38 lb.

22 RS Rev.5

3.5 Installation

■

The robot system must be installed to avoid interference with buildings,

CAUTION

(1)

structures, utilities, other machines and equipment that may create a trapping hazard or pinch points.

3.5.1 Standard-model

■

Install the Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. RS3-351S: approx. 17 kg : 38 Ib. (except cables)

■

When installing the Manipulator to the ceiling, support the Manipulator, and then secure the anchor bolts. Removing the support without securing the anchor bolts properly is extremely hazardous and may result in fall of the Manipulator.

Unpack the Manipulator with retaining the

arm posture.

Setup & Operation 3. Environments and Installation

(2) Secure the base to the wall with 6 bolts.

NOTE

)

Intensity of the bolts should be equivalent

to ISO898-1 Property Class 10.9 or 12.9.

Screw hole (Depth: 12 mm

or more)

6-M6×20

RS Rev.5 23

Setup & Operation 3. Environments and Installation

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.

24 RS Rev.5

3.6 Connecting the Cables

■

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

■

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

■

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

WARNING

CAUTION

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

■

Grounding the manipulator is done by connecting with the controller. Ensure that the controller is grounded and the cables are correctly connected. If the ground wire is improperly connected to ground, it may result in the fire or electric shock.

■

When connecting the Manipulator 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 problems. The connection method varies with the Controller used. For details on the connection, refer to the Controller manual. If the Manipulator G series, E2 series or RS series is connected to the Controller for the PS series (ProSix), it may result in malfunction of the Manipulator.

Setup & Operation 3. Environments and Installation

When the Manipulator is a Cleanroom-model, use it with an exhaust system.

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

Cable Connections

Connect the power connector and signal connector of the M/C cables to the Controller.

Controller RC180

Manipulator RS series

(Figure: RS3-351S)

RS Rev.5 25

M/C Signal cable

M/C Power cable

Setup & Operation 3. Environments and Installation

3.7 User Wires and Pneumatic Tubes

■

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

CAUTION

Electrical Wires

Pneumatic Tubes

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

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

Rated Voltage

Allowable

Current

Wires Nominal Sectional Area Outer Diameter Note

AC/DC30 V 1 A 15 0.211 mm2

Maker Standard

15 pin

Suitable Connector JAE Clamp Hood JAE

DA-15PF-N (Solder type)

DA-C8-J10-F2-1R (Connector setscrew: #4-40 NC)

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

connected.

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

0.59 MPa (6 kgf/cm2 : 86 psi)

ø8.3±0.3 mm

2

1

ø6 mm × ø4 mm

ø4 mm × ø2.5 mm

Shielded

NOTE

)

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

of the pneumatic tubes.

User connector (15-pin D-sub connector）

Fitting (white)

for ø4 mm pneumatic tube

User connector

(15-pin D-sub connector）

Fitting (black)

for ø6 mm pneumatic tube

Fitting (white)

for ø4 mm pneumatic tube

Fitting (black)

for ø6 mm pneumatic tube

Fitting (white)

for ø6 mm pneumatic tube

Joint #3 break release switch

for ø4 mm pneumatic tube

The Joint #4 (rotating) motion range is ±720 degrees. Be careful not to let the

wires/tubes caught in the end effector.

26 RS Rev.5

3.8 Relocation and Storage

3.8.1 Precautions for Relocation and Storage

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

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

■

Only authorized personnel should perform sling work and operate a crane and a forklift. When these operations are performed by unauthorized personnel, it is

WARNING

extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

■

Before relocating the Manipulator, fold the arm and secure it tightly with a wire tie to prevent hands or fingers from being caught in the Manipulator.

■

When removing the anchor bolts, support the Manipulator to prevent falling. Removing the anchor bolts without support may result in a fall of the Manipulator, and then get hands, fingers, or feet caught.

Setup & Operation 3. Environments and Installation

CAUTION

■

To carry the Manipulator, have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand. When holding the bottom of the base by hand, be very careful not to get your hands or fingers caught.

RS3-351S : approx. 17 kg : 38 lb.

■

Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is extremely hazardous and may result in fall of the Manipulator.

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

When the Manipulator is used for a robot system again after long-term storage, perform a test run to verify that it works properly, and then operate it thoroughly.

Transport and store the Manipulator in the range of -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 Manipulator during transport.

RS Rev.5 27

Setup & Operation 3. Environments and Installation

3.8.2 Relocation procedure

■

Install or relocate the Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. RS3-351S : approx. 17 kg: 38 lb.

■

WARNING

When removing the Manipulator from the ceiling, support the Manipulator, and then remove the anchor bolts. Removing the anchor bolts without supporting is extremely hazardous and may result in fall of the Manipulator.

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

(2) Hold the bottom of Arm #1 by hand to unscrew the anchor bolts. Then, remove the

Manipulator.

28 RS Rev.5

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.

■

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

CAUTION

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

Shaft

- Attach an end effector to the lower end of the shaft.

For the shaft dimensions, and the overall dimensions of the Manipulator, refer to Setup

& Operation: 2. Specifications.

Setup & Operation 4. Setting of End Effectors

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

Otherwise, when “Jump motion” is performed, the upper limit mechanical stop may hit

the Manipulator, and the robot system may not function properly.

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

shaft.

Brake release button

- Joint #3 cannot be moved up/down by hand

because the electromagnetic brake is applied

while power to the robot system is turned

OFF.

This prevents the shaft from hitting peripheral

equipment in the case that the shaft is lowered

by the weight of the end effector when the

power is disconnected during operation, or

when the motor is turned OFF even though

the power is turned ON.

When attaching an end effector, turn ON the

Controller. Move Joint #3 up/down while

pressing the brake release button.

Brake release button

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

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

switch is being pressed.

- Be careful of the shaft falling and rotating while the brake release button is being

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

RS Rev.5 29

Setup & Operation 4. Setting of End Effectors

t

4.2 Attaching Cameras and Air valves

Arm #2 has threaded holes as shown in the figure below. Use these holes for attaching

cameras, air valves, and other equipment.

[Unit: mm]

NOTE

)

- When cameras and air valves are attached, it can limit the motion range by wires and

pneumatic tubes. Take extra care when designing and attaching.

- The Joint #4 (rotating) motion range is ±720 degrees. Be careful not to let the

wires/tubes caught in the end effector.

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) and 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 of 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 that the default setting.

CAUTION

4.3.1 Weight Setting

■

The total weight of the end effector and the work piece must not exceed 3 kg. The RS series Manipulators are not designed to work with loads exceeding 3 kg. Always set the Weight parameters according to the load. Setting a value that is smaller than the actual load may cause errors, excessive shock, insufficient function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.

The acceptable weight capacity (end effector and work piece) in RS series is 1 kg at the

default rating and 3 kg at the maximum. When the load (weight of the end effector and

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

After the setting is changed, 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.

EPSON

RC+

30 RS Rev.5

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

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

Setup & Operation 4. Setting of End Effectors

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

When you attach the equipment near Arm #2:

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

W

: equivalent weight

M

: weight of camera etc.

L

: length of Arm #1

1

L

: length of Arm #2

2

L

: distance from rotation center of Joint #2 to center of gravity of camera etc.

M

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

W

M

= M (LM)2/(L2)2

W

M

<Example> A “0.5 kg” camera is attached to the end of the RS series arm (450 mm

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

M = 0.5

= 175

L

2

L

= 250

M

W

= 0.5 × 2502/1752 = 1.02 → 1.1 (round up)

M

W + W

= 1 + 1.1 = 2.1

M

Enter “2.1” for the Weight Parameter.

100

* The percentage in the graph

is based on the speed at

rated weight (1 kg) as 100%.

(%)

Automatic speed setting by Weight

140

120

100

80

60

40

20

0 0.5 1 1.5 2 2.5 3 (kg)

Weight setting

Automatic acceleration/deceleration setting by Weight

(%)

140

120

100

80

70

60

* The percentage in the graph

is based on the acceleration

/ deceleration at rated weight

(1 kg) as 100%.

50

40

20

0 0.5 1 1.5 2 2.5 3 (kg)

Weight setting

RS Rev.5 31

Setup & Operation 4. Setting of End Effectors

t

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”,

2

“inertia”, or “GD

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

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

■

The moment of inertia of the load (weight of the end effector and work piece) must be 0.05 kg

2

wm

or less. The RS series Manipulators are not designed to

work with a moment of inertia exceeding 0.05 kg

CAUTION

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

The acceptable moment of inertia of load for a RS series Manipulator is 0.005 kgwm2 at the

2

default rating and 0.05 kgwm

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 the shaft

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.

EPSON

RC+

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

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

wm

2

.

32

(%)

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

140

120

100

80

100

70

60

40

20

0 0.50 1.00 1.50 2.00 2.50 3.00 3.50 (kg･m2) Moment of inertia setting

RS Rev.5

CAUTION

Setup & Operation 4. Setting of End Effectors

Eccentric Quantity and the Inertia Setting

■

The eccentric quantity of load (weight of the end effector and work piece) must be 100 mm or less. The RS series Manipulators are not designed to work with eccentric quantity exceeding 100 mm. Always set the eccentric quantity parameter according to the eccentric quantity. Setting a value that is smaller than the actual eccentric quantity may cause errors, excessive shock, insufficient function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.

The acceptable eccentric quantity of load in RS series is 0 mm at the default rating and

100 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.

Rotation center

Position of load’s center of gravity

Eccentric quantity (100 mm or less)

Eccentric Quantity

Eccentric quantity of load on the 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.

EPSON

RC+

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

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

Automatic acceleration/deceleration setting by Inertia (eccentric quantity)

120

(%)

100

80

60

100

70

* The percentage in the graph is based

on the acceleration/deceleration at

rated eccentricity (0 mm) as 100%.

40

30

20

0 25 50 75 100 (mm) Eccentricity setting

RS Rev.5

33

Setup & Operation 4. Setting of End Effectors

Calculating the Moment of Inertia

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

(end effector with work piece).

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

(c).

Rotation center

Joint #3 shaft

End effector (a)

Work piece (b)

Whole moment

of inertia

Moment of inertia

=

of end effector (a)

Moment of inertia

+

of work piece (b)

Work piece (c)

Moment of inertia

+

of work piece (c)

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

Calculate the total moment of inertia using the basic formulas.

(a) Moment of inertia of a rectangular parallelepiped

Rotation center

Rectangular parallelepiped’s center of gravity

Mass (m)

2

+ h2

b

m+ m

12

× L

2

34

L

h

(b) Moment of inertia of a cylinder

Cylinder’s center of gravity

Rotation center

Mass (m)

b

r

L

2

r

m+ m

2

× L

2

RS Rev.5

Setup & Operation 4. Setting of End Effectors

(c) Moment of inertia of a sphere

Sphere’s center of gravity

Rotation center

2 5

2

+ m × L2

L

r

Mass (m)

m r

4.4 Preca

utions for Auto Acceleration/Deceleration of Joint #3

When you move the Manipulator in horiz

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. (Refer to the figure below.) 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 af

ter considering the relation between the current position and the destination

position.

The upper limit of Jo

e LimZ command.

th

int #3 during horizontal motion using Jump command can be set by

Automatic acceleration/deceleration vs. Joint #3 position

120

(%)

100

80

60

40

20

ontal PTP motion with Joint #3 (Z) at a high

* The percentage in the graph is

based on the acceleration /

deceleration at the upper-limited

position of Joint #3

50

0 -20 -60 -100 -140 (mm)

Height of the shaft

NOTE

)

When moving the Manipulator horizontally while the shaft is being lowered, it may cause

o

ver-shoot at the time of final positioning.

RS Rev.5

35

Setup & Operation 5. Motion Range

5. Motion Range

■

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

CAUTION

mechanical stops must always be set at the same time.

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 #3)

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

Manipulator (for Joints #1 and #2)

Rectangular range setting

Mechanical

stop

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

descriptions in 5.1 to 5.3 to set the range.

Motion range

Pulse range

5.1 Motion Range Setting by Pulse Range

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.

Mechanical

stop

NOTE

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

)

EPSON

RC+

36 RS Rev.5

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.

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

Setup & Operation 5. Motion 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 (-).

0 pulse

View from

this point

A : Max. motion range : ± 225 °

B : Max. pulse range : − 2560000 to +5973334 pulse

5.1.2 Max. Pulse Range of Joint #2

The 0 (zero) pulse position of Joint #2 is where Arm #2 overlaps straight with Arm #1 as

shown in the figure below. 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 (-).

View from

this point

A : Max. motion range : ± 225 °

B : Max. pulse range : − 4177920 to + 4177920 pulse

RS Rev.5

37

Setup & Operation 5. Motion Range

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.

Upper limit: 0 pulse

Type

RS3-351S 130 mm − 1479112 pulse

RS3-351C 100 mm − 1137778 pulse

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 defined as the positive (+) and the clockwise pulse value is defined as the negative (-).

Joint #3 stroke Lower limit pulse value

NOTE

)

0 pulse ± 3145728 pulse

View from

this point

The Joint #4 (rotating) motion range is ±720 degrees.

38 RS Rev.5

Setup & Operation 5. Motion Range

s

A

5.2 Motion Range Setting by Joint #3 Mechanical Stops

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

(2) Remove the Arm #2 cover (4-M4×10).

(3) Push up the shaft while pressing the brake

release button.

NOTE

)

(4) Turn OFF the Controller.

(5) Loosen the lower limit mechanical stop screw (M3×10).

NOTE

)

(6) The upper end of the shaft defines the maximum

When you press the brake release button, the shaft may lower due to the weight of the end effector. Be sure to hold the shaft by hand while pressing the button.

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

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 “130 mm” stroke, the lower limit Z

coordinate value is “−130”. To change the

value to “−100”, move the lower limit

mechanical stop down “30 mm”. Use calipers

to measure the distance when adjusting the

mechanical stop.

Lower limit mechanical

top

M3×10

Measure this distance.

Brake release switch

Shaft

(7) Firmly tighten two lower limit mechanical stop screws (M3×10).

Recommended tightening torque: 245 N⋅cm (25 kgf⋅cm)

(8) Turn ON the Controller.

(9) Move Joint #3 to its lower limit while pressing the brake release button, and then

check the lower limit position. Do not lower the mechanical stop too far.

Otherwise, the joint may not reach a target position.

RS Rev.5

39

Setup & Operation 5. Motion Range

(10) Calculate the lower limit pulse value of the pulse range using the formula shown below

and set the value.

The result of the calculation is always negative because the lower limit Z coordinate

value is negative.

** For the Joint #3 resolution,

EPSON

RC+

(11) Use the Pulse command (Go Pulse command), and move Joint #3 to the lower limit

NOTE

)

EPSON

RC+

Lower limit of pulse (pulse)

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

refer to the section Setup & Operation 2.4 Specifications.

Execute the following command from the [Command Window]. Enter the

calculated value in X.

>JRANGE 3,X

position of the pulse range at low speed.

If the mechanical stop range is less than the pulse range, Joint #3 will hit the

mechanical stop and an error will occur. When the error occurs, either change the

pulse range to a lower setting or extend the position of the mechanical stop within the

limit.

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

Execute the following commands from the [Command Window]. Enter the value

calculated in Step (10) in X

>MOTOR ON ' Turns ON the motor

>SPEED 5 ' Sets low speed >PULSE 0,0,X

,0 ' Sets the pulse range of Joint #3

.

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

(In this example, all pulses except those for Joint #3 are “0”. Substitute these “0s” with the other pulse values specifying a position where there is no interference even when lowering Joint #3.)

mm/pulse)

check the condition causing the

40 RS Rev.5

Setup & Operation 5. Motion Range

t

)

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.

EPSON

RC+

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

Manager].

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

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.

Max range

Motion range

Center of Joint #3

Type

(unit: mm n : Joint #3 range to hit upper mechanical stop m : Joint #3 stroke p : Joint #3 range to hit lower mechanical stop

RS Rev.5 41

42 RS Rev.5

Maintenance

This volume contains maintenance procedures with safety precautions for RS3 series Manipulators.

1. Safety Maintenance

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

safe maintenance procedures before performing any routine maintenance.

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

When removing the arm from the Manipulator, for such as replacing the reduction gear unit, it must be done by two or more personnel.

For removing the Arm #1 cover, in case that the maintenance window is not installed to the base table, it needs to remove the Manipulator from the base table. Removing the Manipulator must be done by two or more personnel.

Maintenance 1. Safety Maintenance

WARNING

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

■

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

■

Keep away from the Manipulator while the power is ON if you have not taken the training courses. Do not enter the operating area while the power is ON. Entering the operating area with the power ON is extremely hazardous and may cause serious safety problems as the Manipulator may move even it seems to be stopped.

■

When you check the operation of the Manipulator after replacing parts, be sure to check it while you are outside of the safeguarded area. Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly.

■

Before operating the robot system, make sure that both the Emergency Stop switches and safeguard switch function properly. Operating the robot system when the switches do not function properly is extremely hazardous and may result in serious bodily injury and/or serious damage to the robot system as the switches cannot fulfill their intended functions in an emergency.

RS Rev.5 45

Maintenance 1. Safety Maintenance

■

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

■

Before performing any replacement procedure, turn OFF the Controller and

WARNING

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

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

■

cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on the cables may result in damage to the

CAUTION

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

2. General Maintenance

This chapter describes maintenance inspections and procedures. Performing maintenance

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

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

2.1 Schedule for Maintenance Inspection

Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and

annual. The inspection points are added every stage.

If the Manipulator is operated for 250 hours or longer per month, the inspection points

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

Inspection Point

1 month (250 h) √

2 months (500 h) √

3 months (750 h) √ √

4 months (1000 h) √

5 months (1250 h) √

6 months (1500 h) √ √ √

7 months (1750 h) √

8 months (2000 h) √

9 months (2250 h) √ √

10 months (2500 h) √

11 months (2750 h) √

12 months (3000 h) √ √ √ √

13 months (3250 h)

…

Daily

inspection

Inspect every day

…

Monthly

inspection

√

…

Quarterly

inspection

h = hour

Biannual

inspection

…

Annual

inspection

…

46 RS Rev.5

2.2 Inspection Point

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

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

Maintenance 2. General Maintenance

Check looseness or backlash of

bolts/screws.

Tighten them if necessary.

(For the tightening torque, refer to

Maintenance: 2.4 Tightening

Hexagon Socket Head Cap Bolts.)

Check looseness of connectors.

If the connectors are loosen, push it

securely or tighten.

Visually check for external defects.

Clean up if necessary.

Check for bends or improper

location. Repair or place it properly

if necessary.

Check tension of timing belts.

Tighten it if necessary.

Grease conditions Refer to Maintenance: 2.3 Greasing.

End effector mounting bolts √ √ √ √ √

Manipulator mounting bolts √ √ √ √ √

Each arm locking bolts √ √ √ √ √

Bolts/screws around shaft √

Bolts/screws securing motors,

reduction gear units, etc.

External connectors on

Manipulator (on the connector

plates etc.)

Manipulator cable unit √ √ √ √

External appearance of

Manipulator

External cables √ √ √ √

Safeguard etc. √ √ √ √ √

Inside of Arm #2 √ √

√ √ √ √ √

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

√

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

Check motion range Each joint √

Move the cables back and forth

lightly to check whether the cables

are disconnected.

Push each arm in MOTOR ON

status to check whether backlash

exists.

Check whether unusual sound or

vibration occurs.

Measure the accuracy repeatedly by

a gauge.

External cables

(including cable unit of the

Manipulator)

Each arm √

Whole √ √ √ √ √

Whole √

√ √

RS Rev.5 47

Maintenance 2. General Maintenance

2.3 Greasing

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

grease specified in the following table.

■

Keep enough grease in the Manipulator. Operating the Manipulator with insufficient grease will damage sliding parts and/or result in insufficient function of

CAUTION

Greasing part Greasing Interval Grease Refer to:

the Manipulator. Once the parts are damaged, a lot of time and money will be required for the repairs.

Joint #3 Ball screw spline shaft

Joint #1

Joint #2

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

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

must be greased every 10,000 hours.

Reduction gear units In the replacement of motor* SK-1A

First time: after 50 km operation

2nd or more: after 100 km operation

Maintenance: 10.1 Greasing the Ball

AFB

Screw Spline Unit

Maintenance:

5.2 Replacing the Joint #1 Reduction

Gear Unit

6.2 Replacing the Joint #2 Reduction

Gear Unit

■

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

If grease gets into your eyes

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

immediately.

If grease gets into your mouth

CAUTION

: If swallowed, do not induce vomiting. See a doctor immediately.

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

thoroughly.

If grease gets on your skin

: Wash the area thoroughly with soap and water.

48 RS Rev.5

Maintenance 2. General Maintenance

a

2.4 Tightening Hexagon Socket Head Cap Bolts

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

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

fastened with the tightening torques shown in the following table.

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

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

appropriate tightening torques as shown below.

Tightening Torque

Bolt

Refer below for the set screw.

M3 245 N⋅cm (25 kgf⋅cm)

M4 490 N⋅cm (50 kgf⋅cm) M4 245 N⋅cm (25 kgf⋅cm)

M5 980 N⋅cm (100 kgf⋅cm) M5 392 N⋅cm (40 kgf⋅cm)

M6 1,760 N⋅cm (180 kgf⋅cm)

M8 3,720 N⋅cm (380 kgf⋅cm)

M10 7,350 N⋅cm (750 kgf⋅cm)

M12 12,740 N⋅cm (1,300 kgf⋅cm)

Set Screw Tightening Torque

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

pattern as shown in the figure below.

5

Bolt hole

3

1

8

Do not fasten all bolts securely at one time.

Divide the number of times that the bolts are

fastened into two or three and fasten the bolts

securely with a hexagonal wrench. Then, use

4

torque wrench so that the bolts are fastened with

tightening torques shown in the table above.

7

2

6

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.

EPSON

RC+

RS Rev.5 49

Execute the following command from the [Command Window].

>PULSE

PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value]

pls [Joint #4 Pulse value] pls

Maintenance 2. General Maintenance

2.6 Layout of Maintenance Parts

RS3-***S : Standard-model

Power cable

Signal cable

Lithium battery

Battery board

Joint #1 motor

Joint #1 reduction gear unit

Cable unit 1

LED lamp

Arm #2 cover

Ball screw spline unit

Joint #3 motor

Z belt

Joint #3 brake

RS3-***C : Cleanroom-model

Gasket

J1 belt

U1 belt

Gasket

Cable unit 2

Arm #1 cover

Joint #2 motor

J2 belt

Joint #2 reduction gear unit

Joint #4 motor

Joint #4 reduction gear unit

Brake release switch

(Figure: RS3-351S)

Gasket

Bellows

Gasket

(Figure: RS3-351C)

50 RS Rev.5

3. Covers

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

■

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

■

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

■

Before performing any replacement procedure, turn OFF the Controller and related

WARNING

Maintenance Parts and Tools

Maintenance

parts

Tools

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

■

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

Name Quantity Note

Gasket unit 1 R13B031240 Only for Cleanroom-model

Hexagonal wrench

(width across flats: 3 mm)

Cross-point screwdriver 1

1 For M4 screw

For bellows removal

For M4 truss

Maintenance 3. Covers

Only for Cleanroom-model

Arm #1 cover

Arm #1 side cover

J2 cover

User plate

Arm #2 maintenance cover

Arm #1 under cover

Under cover

Cable plate

Base cover

Arm #1 side cover

Arm #2 cover

RS Rev.5 51

Maintenance 3. Covers

3.1 Arm #1

The following covers are mounted to Arm #1.

Arm #1 cover × 1

Arm #1 under cover × 1

J2 cover × 2

Arm #1 side cover × 2

Remove the bolt (or screw) securing the cover to remove the cover.

■

When installing the cover, do not allow the cables to interfere with the cover mounting or bend these cables forcibly to push them into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection,

CAUTION

and/or contact failure that cause the electric shock and/or improper function of the robot system. When routing the cables, observe the cable locations after removing the cover. Be sure to place the cables back to their original locations.

When mounting Arm #1 cover to both RS3-351S (Standard-model) and RS3-351C

(Cleanroom-model), be sure to check the air tubes and cables are secured as in the figure

below. Be careful not to squash the air tubes and cables with the cover.

If the maintenance window is not designed in the base table, the Arm #1 cover can not be

removed. It needs to remove the Manipulator from the base table for the maintenance

work.

Be sure to remove the Manipulator form the base table by two or more personnel.

For details, refer to Setup & Operation 3. Environments and Installation.

52 RS Rev.5

Maintenance 3. Covers

3.1.1 RS3-351S (Standard-model)

For the arm #1 cover: 4-M4×12

For arm #1 side cover: 4-M4×15

For arm #1 under cover: 4-M4×8

J2 cover:

4-M4×8 (Truss)

For arm #1 side cover: 4-M4×15

3.1.2 RS3-351C (Cleanroom-model)

Spacer

Gasket

Spacer

Gaskets and spacers are installed to RS3-351C (Cleanroom-model).

RS Rev.5 53

Maintenance 3. Covers

3.2 Arm #2

3.2.1 Arm #2 Cover

■

When installing the cover, be careful not to allow the cables to interfere with the cover mounting and do not bend these cables forcibly to push them into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or

CAUTION

Arm Top Cover Removal

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

(1) Move the Arm #2 to the 180 degree.

For the arm position, refer to the figure in Maintenance 3.1 Arm #1.

(2) Remove the Arm #1 side cover on the Joint #2 side.

For details, refer to Maintenance 3.1 Arm #1.

(3) Remove the Arm #2 cover mounting bolt and hold the cover up.

RS-351S (Standard-model) RS-351C (Cleanroom-model)

4-M4×10

Gasket

Arm Top Cover Installation

54 RS Rev.5

(1) Set the arm top cover to the arm and secure with the mounting bolts.

Gaskets are installed to the RS-351C (Cleanroom-model).

(2) Mount the Arm #1 side cover.

For details, refer to Maintenance 3.1 Arm #1.

Maintenance 3. Covers

d

3.2.2 Under Cover

Unscrew the under cover mounting bolts, and then pull the cover downward to remove it.

NOTE

)

The under cover may not be removed from the shaft because the end effector is installed.

If it is necessary to remove the cover completely (for replacement of the ball screw spline

unit etc.), remove the end effector.

When the ball screw spline unit need to be replaced, remove the end effector and remove

the under cover completely.

If it is not necessary to remove the cover completely, move the shaft to the lower limit, an

lower the under cover. Then, perform maintenance or inspection.

When bellows are installed to the manipulator, remove or pull down the lower bellows an

then remove the under cover. For bellows removal, refer to Maintenance 9. Bellows.

RS3-351S (Standard-model) RS3-351C (Cleanroom-model)

Gasket

3-M4×10

A gasket is installed to RS3-351C (Cleanroom-model).

3-M4×10

3.2.3 Arm #2 Maintenance Cover

Unscrew the bolts securing the Arm #2 maintenance cover, and then pull the cover

downward to remove it.

RS3-351S (Standard-model) RS3-351C (Cleanroom-model)

Gasket

4-M4×8

Gasket is installed to the RS3-351C (Cleanroom-model)

4-M4×8

RS Rev.5 55

Maintenance 3. Covers

3.3 Connector Plate

■

Do not remove the connector plate forcibly. Removing the connector plate forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

■

When installing the connector plate, be careful not to allow the cables to interfere with the plate mounting and do not bend these cables forcibly to push them into

CAUTION

RS3-351S (Standard-model) RS3-351C (Cleanroom-model)

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

Unscrew the connector plate mounting bolts and remove the plate.

8-M4×10

Spacer

Gasket

8-M4×10

A gasket and spacer are installed to RS3-351C (Cleanroom-model).

56 RS Rev.5

×

3.4 Base Cover

Before removing the base cover, remove the connector plate and disconnect the

connectors.

Unscrew the bolts securing the base cover to remove the base cover.

RS3-351S (Standard-model) RS3-351C (Cleanroom-model)

Maintenance 3. Covers

Connector plate

4-M4×8

Base cover

6-M4×10

8-M4×10

Connector plate

4-M4×8

Base cover

6-M4×10

Spacer

Gasket

Spacer

Gasket

Spacer

Gasket

8-M4

10

Gaskets and spacers are installed to the RS3-351C (Cleanroom-model).

RS Rev.5 57

Maintenance 3. Covers

3.5 User Plate

Unscrew the user plate mounting bolts and remove the plate.

RS-351S (Standard-model) RS3-351C (Cleanroom-model)

4-M4×8

A gasket and spacer are installed to RS3-351C (Cleanroom-model).

Gasket

Spacer

4-M4×8

58 RS Rev.5

4. Cable Unit

■

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

■

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

■

WARNING

CAUTION

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

■

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

■

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

Maintenance 4. Cable Unit

RS Rev.5 59

Maintenance 4. Cable Unit

4.1 Replacing Cable Unit

Since the power is supplied to each motor from the lithium battery installed on the battery

board via the battery connector, the position data will not be lost when the Controller is

turned OFF. When the battery connectors are disconnected, the position data will be lost,

and EPSON RC+ will display an error when the Controller is turned ON.

If the error occurs, execute the calibration of all joints and axes.

Maintenance parts, Tools and Materials

Name Quantity Note

Maintenance

parts

Tools

Material

Cable unit 1

Grease for cable (GPL-224) 10 g R13B030304

Battery Unit (Lithium battery) 3 R13ZA00600300

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

Hexagonal wrench (width across flats: 4 mm) 1 For M5 screw

Hexagonal wrench (width across flats: 5 mm) 1 For M6 screw

Spanner (width across flats: 5 mm) 1 For D-sub connector removal

Nut screwdriver (width across flats: 5 mm) 1 For D-sub connector removal

Nippers 1 For cutting wire tie

Alcohol

Wiping cloth 1 For wiping grease

Wire tie 20

Proper

quantity

Each manipulator model

(Refer to Maintenance:

14. Maintenance parts)

For wiping grease

Cable unit 2

Cable unit 1

(Figure: RS3-351S)

60 RS Rev.5

CAUTION

Maintenance 4. Cable Unit

■

If the connectors have been disconnected during the replacement of the cable unit, be sure to reconnect the connectors to their proper positions. Refer to the block diagrams. Improper connection of the connectors may result in improper function of the robot system. For details on the connections, refer to Maintenance: 4.2 Wiring Diagrams.

■

When installing the cover, be careful not to allow the cables to interfere with the cover mounting and do not bend these cables forcibly to push them into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. When routing the cables, observe the cable locations after removing the cover. Be sure to place the cables back to their original locations.

■

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

Cable unit Removal

(1) Turn OFF the Controller.

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

(3) Remove the Arm #2 cover.

For details, refer to Maintenance 3.2 Arm #2.

(4) Cut off the wire ties bundling cables.

Wire tie

(5) Connect the spare batteries to connector XB13, XB14 (in Arm #2 side).

- The position of motors of Joints #3 and #4 are stored by the battery in the base.

Connect the batteries to prevent the position data from losing.

(6) Disconnect the connectors.

Connectors X31, X32, X33, X41, XB33, XB34, X331, X341

(7) Remove the user plate, and it draws it out forward.

For details, refer to Maintenance 3.5 User Plate.

RS Rev.5 61

Maintenance 4. Cable Unit

A

(8) Disconnect the air tubes, ground wire, connecter of

the D-sub cable (XU11, XU21), and connector of the

brake release switch from the user plate.

Press the ring on the fitting and pull out the air tube.

(ø6×2, ø4×1)

ir tube

D-sub cable

NOTE

)

(9) Remove the ground wire from the cable mounting jig.

(10) Remove the Arm #2 maintenance cover.

(11) Draw out the cables connected to the motor side

(12) Remove the Arm #1 cover.

Be sure to remember the cable location to connect

them to the original position.

Cut off two wire ties bundling the cables.

For details, refer to Maintenance 3.2 Arm #2.

forward in order of size with the thinnest one first.

For details, refer to Maintenance: 3.1 Arm #1.

(13) Cut off two wire ties bundling the cables.

(14) Disconnect the ground wire.

Brake release switch

Cable

Wire tie

(15) Pull out the tubes and cables upward in order of size with the thinnest one first.

(Be careful about the connectors not to be caught.)

(16)

(17) Connect the spare batteries to connector XB12 (in Arm #2 side).

(18) Push the cables and tubes drawn out before and pull out the connectors from the hole

Remove the Arm #1 side cover and Arm #1 under cover.

For details, refer to Maintenance 3.1 Arm #1.

- The position of motor of Joint #2 is stored by the battery in the base.

Connect the batteries to prevent the position data from losing.

of the under cover.

(19) Disconnect the connectors except the battery connector.

Ground wire

Connectors X21, X22, X23, X30, XB22, XB23,

X221, X231, XU10, XU20

(20) Remove the ground wire.

62 RS Rev.5

(21) Cut off two wire ties bundling the cables

Pull out the cable unit 2.

Maintenance 4. Cable Unit

Wire tie

(22)

Remove the Connector plate.

For details, refer to Maintenance: 3.3 Connector plate.

(23)

Remove the Base cover.

For details, refer to Maintenance 3.4 Base cover.

(24)

Remove the D-sub connector from the plate securing the cables.

(25) Remove three air tubes.

Cut off two wire ties bundling the cables.

(26)

Pull out the cable unit 2 and air tubes.

(Be careful about the connector not to be caught.)

Wire tie

RS Rev.5 63

Maintenance 4. Cable Unit

e

X

Cable unit Installation

(1) Mark the position of the cable unit 1 using a permanent marker.

Arm #1 side

Marking

Base side

XU10

XU20

21, X22

23, XB22

B23, X30

X221

X231

Heat-shrinkable tube

Greasing point

15 120

15

120

(2) Cover both ends of the cables with plastic bags.

(The photo shows the one end covered with plastic bags.)

The plastic bags prevent grease adhesion to the ends of connectors/air tubes during the

cable drawing.

User wire (rough)

Signal c able (rough)

Power c able (rough)

Air tube ×3 (rough)

350

Ground wire 400mm (rough)

240

D-sub

X20 X30 X62 X63

Ground wir

X121 X131

(3) Insert the cables to the Joint #1 from the base side.

Be careful about the cable direction.

Refer to the connector label in Step (1).

Insert the connectors in order of size with the largest

one first, and then, the air tube and ground wire.

To prevent the cables and tube from falling off, pull

them out from the bottom side temporarily and apply

grease (GPL-224) to the marked point.

For the greasing point, refer to Step (1).

Joint #1

Cable

Inserting direction

64 RS Rev.5

Maintenance 4. Cable Unit

e

X

(4) Put two wire ties to the cable mounting jig in Arm

#1.

Wire tie

Secure cables, tube, and ground wire loosely.

Secrure the bottom of the tube and ground wire

where the grease (GPL-224) is applied.

Heat-shrinkable tube

(5) Connect the connectors to the battery baord of the base side.

Connectors X62, X63

(6) Draw out the connectors of Arm #1 side (X21, X22, XB22, X221) forward in the

arm.

(7) Connect the D-sub cable and air tubes connected to the J1 cable plate (inner side).

(8) Push the wires, tubes, and ground wire downward

and secure them to the cable mounting plate with

Wire tie

the wire tie.

When bundling the cables, untangle the cables and

put Arm #1 to the position of 90 degree (end of the

arm faces to the other side to the J1 motor.)

(9) Install the ground wire.

(10) Mark the position of the cable unit 2 using a permanent marker.

Arm #2 side

XU11 XU21

31, XB33

32 41, XB34

X331 X341

Heat-shrinkable tube

Air tube ×3 (rough)

User wire (rough)

Signal c able (rough)

Power c able (rough)

150

Marking

300

Greasing point

Marking

Arm #1 side

XU10 XU20

X23 XB23 X30

Ground wir

X231

Ground wire 600mm (rough)

(11) Insert the cables to the Arm #1.

150

50

Be careful about the cable direction.

Refer to the connector label in Step (1).

Cable

RS Rev.5 65

Maintenance 4. Cable Unit

(12) Secure the cables with the wire tie.

The wire tie should be a little away from the

greasing part of the cables.

Air tube

Untangle the cables and bundle them at the

D-sub cable

position of calibration point of Arm #2 (where

Arm #1 overlaps with Arm #2).

Brake release switch

(13) Connect the ground wire.

(14) Secure the air tubes and cables to both sides of

the motor.

(15) Connect the ground wire.

(16) Connect the connectors.

Connector

Connectors X21, X22, X23, X30, XB22,

XB23, X221, X231, XU10,

XU20.

(17) Remove the spare battery from XB12.

(18) Secure the cables with the wire tie.

(19) Install the ground wire to the connector plate.

(20) Connect the D-sub cable connectors (XU11,

Air tube

D-sub cable

XU21) and air tubes connected to the inner side

of connector plate.

(21) Put the cable unit 2 to the wire hole of Arm #2

Brake release switch

Wire tie

and bundle the cables with the wire tie.

(22) Connect the connectors.

Connectors X31, X32, X33, X41, XB33, XB34, X331, X341.

For details, refer to Maintenance 4.2 Wiring Diagrams.

(23) Remove the spare batteries from XB13 and XB14.

66 RS Rev.5

Maintenance 4. Cable Unit

(24) Mount the user plate to the Arm #2 cover.

For details, refer to Maintenance 3.5 User Plate.

(25) Set and secure the Arm #2 cover and Arm #2 maintenance cover without the cables

being stuck.

For details, refer to Maintenance 3.2 Arm #2.

(26) Mount the Arm #1 cover, Arm #1 side cover, and Arm #1 under cover.

For details, refer to Maintenance 3.1 Arm #1.

(27) Install the Base cover.

For details, refer to Maintenance 3.4 Base Cover.

(28) Connect the connector and install the connector plate.

For derails, refer to Maintenance 3.3 Connector Plate.

(29) Perform the calibration of all axis.

RS Rev.5 67

Maintenance 4. Cable Unit

4.2 Wiring Diagrams

4.2.1 Signal Cable

For the colors and symbols of the cables, refer to Maintenance 4.2.2 Power Cable.

Continues to the next page

68 RS Rev.5

Continued from the previous page

Maintenance 4. Cable Unit

RS Rev.5 69

Maintenance 4. Cable Unit

4.2.2 Power Cable

Continues to the next page

Code Cable color Code Cable color

B Black P Pink

BR Brown R Red

G Green V Violet

L Blue W White

O Orange Y Yellow

70 RS Rev.5

Continued from the previous page

Maintenance 4. Cable Unit

RS Rev.5 71

Maintenance 4. Cable Unit

4.2.3 User Cable

Code Cable color Code Cable color

BR Brown V Violet

B Black R Red

G Green W White

L Blue Y Yellow

The following table shows the types of the cable unit.

Environment Code Note

S R13B020028

C R13B020029 Waterproof connector : D-sub

72 RS Rev.5

5. Arm #1

■

WARNING

■

CAUTION

■

Maintenance 5. Arm #1

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

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

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

Be careful not to apply excessive shock to the motor shaft when replacing the motors. The shock may shorten the life cycle of the motors and encoder and/or damage them.

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

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

Joint #1 motor

Joint #1 reduction gear unit

(Figure : RS3-351S)

RS Rev.5 73

Maintenance 5. Arm #1

5.1 Replacing Joint #1 Motor

Maintenance parts and Tools

Name Quantity Note

Maintenance

parts

Tools

Joint #1 motor Removal

AC Servo Motor (400 W) 1 R13B000607

Grease (SK-1A) 13 g R13ZA00330100

Hexagonal wrench (width across flats: 2.5 mm) 1 For M5 set screw, M3 screw

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

Torque wrench M 4 1

Force gauge 1 Belt tension 150 N (15.3 kgf)

Suitable cord (Length about 800 mm) 1 For belt tension

Wiping cloth 1 For wiping grease

(1) Turn ON the Controller.

(2) Move the Manipulator Joint #1 to the origin.

(3) Turn OFF the Controller.

(4) Remove the connector plate.

For details, refer to Maintenance: 3.3 Connector Plate.

(5) Disconnect the following connectors.

Connectors X10, X20, X30, X111, X121, X131 (Hold the claw to remove.)

Connector X61

(6) Remove the base cover.

For details, refer to Maintenance: 3.4 Base Cover.

(7) Loosen the J1 belt.

Loosen four bolts on the Joint #1 motor unit.

Slide the Joint #1 motor unit toward the Joint #1

side.

Joint #1 motor unit

Pulley

4-M4×15 + Washer

J1 belt

74 RS Rev.5

(8) Remove the Joint #1 motor unit from the base.

Unscrew the bolts securing the Joint #1 motor

plate and pull it upward to remove.

(9) Remove the pulley from the Joint #1 motor.

Maintenance 5. Arm #1

Joint #1 motor unit

4-M4×15

Washer

M5

Pulley

Brass bushing

2-M5×8 set screw

(10) Remove the motor plate from the Joint #1 motor.

Motor plate

4-M4×15 +washer

RS Rev.5 75

Maintenance 5. Arm #1

Joint #1 motor

(1) Mount the motor plate on the Joint #1 motor.

Installation

4-M4×15 +washer

(2) Mount the pulley to the Joint #1 motor.

Fit the end face of the pulley with the end face of

the motor shaft.

Tighten one of the set screws on the flat face of

the motor shaft until the screw just touches the

surface.

Insert a bushing into the other set screw hole to

prevent damage to the motor shaft.

Then, tighten both set screws.

(3) Place the J1 belt around the pulley of the Joint #1

motor unit to secure the unit loosely.

NOTE

)

Make sure that the gear grooves of the belt are fit

into those of the pulleys completely.

Put the motor cable facing toward the other side

of Joint #1.

When securing the motor unit, make sure the unit

can be moved by hand, and it will not tilt when

pulled. If the unit is secured too loose or too

tight, the belt will not have the proper tension.

Motor plate

Pulley

Joint #1 motor unit

2-M5×8 set screw

M5 Brass bushing

J1 belt

4-M4×15 + Washer

(4)

Apply the proper tension to the J1 belt and secure

the Joint #1 motor unit.

J1 belt tension = 150N (15.3kgf)

To do so, pass a suitable cord or string around the

Joint #1 motor unit near its mounting plate.

Then, pull the cord using a force gauge or similar

tool to apply the specified tension shown in the

Force gauge

figure on the right.

76 RS Rev.5

(6) Mount the base cover.

(7) Connect the following connectors.

(8) Mount the connector plate.

(9) Perform the calibration of Joint #1.

Connect the connector to the battery board

(5)

Connector X61

For the details, refer to Maintenance: 3.4 Base Cover.

Connectors X10, X20, X30, X111, X121, X131

For details, refer to Maintenance: 3.3 Connector Plate.

For details refer to Maintenance: 13. Calibration.

Maintenance 5. Arm #1

RS Rev.5 77

Maintenance 5. Arm #1

M

5.2 Replacing Joint #1 Reduction Gear Unit

Maintenance Parts, Tools and Material

Name Quantity Note

Maintenance

Parts

Tools

Material

WARNING

Joint #1 reduction gear unit Removal

Reduction Gear Unit (HD25-50) 1 R13B010018

Grease (SK-1A) 40 g R13ZA00330100

Hexagonal wrench (width across flats: 1.5 mm) 1 For M2 screw

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

Hexagonal wrench (width across flats: 5 mm) 1 For M6 screw

Torque wrench M4 1

Torque wrench M6 1

Nippers 1

Spatula 1 For applying grease

Force gauge 1 Belt tension 150 N (15.3 kgf)

Suitable cord (Length about 800 mm) 1 For belt tension

1

Wiping cloth

Wire tie 4

■

When removing the Manipulator from the base table, the Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. RS3-351S : approx. 17 kg: 38 lb.

■

When removing the Manipulator from the base table, support the Manipulator, and then remove the anchor bolts. Removing the anchor bolts without supporting is extremely hazardous and may result in fall of the Manipulator.

(1) Remove the Manipulator from the base table.

To remove the Manipulator, please observe the WARNING above.

(2) Remove the Joint #1 motor unit.

For wiping grease (Flange)

1

For wiping grease (Bolt)

Execute the removal steps from (1) to (5) in

Motor.

78 RS Rev.5

(3) Remove the air tube, D-sub cable, ground wire on the J1 cable plate. Cut off the wire

tie.

(4) Remove the J1 cable plate.

aintenance: 5.1 Replacing Joint #1

2-M4×10

×

(

)

(5) Remove the Arm #1 under cover.

For details, refer to Maintenance: 3.1 Arm #1.

(6) Remove the ground wire and connectors in the

Joint #1 side of Arm #1.

(7) Cut off two wire tie bundling the cables.

Pull out the Cable unit 1 (except air tubes)

from the base side.

When pulling out the cables, first, pull out the

air tubes from the Arm #1 side (the other side

to the cables).

And pull out from smaller connectors in order

from the base side.

Maintenance 5. Arm #1

Ground wire

Wire tie

Do not try to pull out the cables forcibly.

Otherwise, connectors may be stuck,

disconnected, or connector pins may fall off.

(8) Remove the Arm #1.

12-M6×20

(9) Remove the reduction gear unit from the base.

16-M4×20

Be sure to keep the O ring (S90A).

O ring (S90A)

(10) Remove the J1 ring falling-off-prevention

J1 ring

screws and remove the J1 ring.

(11) Remove the J1 flange (with Metallic pipe).

Be sure to keep the O ring (S65A).

O ring

S65A

J1 flange

Reduction gear unit

12-M4

2-M2×6 J1 ring falling-offprevention screw

30

RS Rev.5 79

Maintenance 5. Arm #1

Joint #1 reduction gear unit Installation

(1) Unpack the new reduction gear unit.

(2) Set the O ring to the O ring (S90A) groove in the J1 flange.

(3) Set the hole on the reduction gear and the tap

hole on the J1 flange.

Loosely secure all bolts in a crisscross pattern

so that the bolts will be secured evenly.

Then, using a torque wrench, tighten each bolt

securely in a crisscross pattern at the torque

specified in the table below.

(4) Set the J1 ring and secure the J1 ring falling-off-prevention screws.

Joint #1 reduction gear unit

J1 ring

Oring (S65A)

J1 flange

Reduction gear unit

12-M4×30

2-M2×6 J1 ring falling- offprevention screw

Item Bolt type Number of bolts Tightening torque

600 N

2200 N

⋅cm (61.2 kgf)

⋅cm (22.4 kgf)

M4×30 12

×15 8

M6

(5) Set the O ring to the O ring (S65A) groove in

16-M4×20

the Base.

(6) Mount the reduction gear unit to the base.

Be sure to keep the O ring.

O ring (S90A)

(7) Mount the Arm #1.

12-M6×20

(8) Mount the Joint #1 cable plate.

2-M4×10

(9) Insert the cable unit to the Arm #1.

Follow the steps in Maintenance: 4.1 Cable Unit - Installation (1) - (9).

(10) Secure the Joint #1 motor and mount the cover.

Follow the steps in Maintenance: 5.1 Replacing Joint #1 Motor - Installation (4) - (8).

(11) Mount the Manipulator to the base table.

80 RS Rev.5

5.3 Replacing J1 Belt

Maintenance 5. Arm #1

J1 belt Removal

J1 belt Installation

(1) Remove the J1 motor unit.

Follow the steps in Maintenance: 5.1 Replacing Joint

J1 Motor unit

4-M4×15

Washer

#1 Motor - Removal (1) - (8).

(2) Remove the J1 belt.

(1) Mount the J1 belt to the pulley of the Joint #1 side.

(2) Mount the J1 motor unit.

Follow the steps in Maintenance: 5.1 Replacing Joint #1 Motor - Installation (3) -

(9).

J1 belt

RS Rev.5 81

Maintenance 6. Arm #2

6. Arm #2

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

■

is turned ON. Inserting or pulling out the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

■

To shut off power to the robot system, pull out the power plug from the power

WARNING

CAUTION

source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source.

■

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

Be careful not to apply excessive shock to the motor shaft when replacing the motors.

■

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

■

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

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

Joint #2 motor

Joint #2 reduction gear unit

(Figure: RS3-351S)

82 RS Rev.5

6.1 Replacing Joint #2 Motor

Maintenance Parts, Tools and Material

Maintenance 6. Arm #2

Maintenance

Parts

Tools

Material

Joint #2 motor Removal

Name Quantity Note

AC Servo Motor (200W) 1 R13B000614

Grease (SK-1A) 6 g R13ZA00330100

Hexagonal wrench (width across flats: 2.5 mm) 1 For M5 set screw

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

Hexagonal wrench (width across flats: 4 mm) 1 For M5 screw

Nippers 1 For cutting wire tie

Force gauge 1 Belt tension 100 N

Suitable cord (Length about 800 mm) 1 For belt tension

Wiping cloth 1 For wiping grease

Wire tie 4

(1) Remove the Arm #1 cover.

For details, refer to Maintenance: 3.1 Arm #1.

(2) Remove the Arm #1 under cover.

For details, refer to Maintenance: 3.1 Arm #1.

(3) Disconnect the following connectors.

Connectors X21, X221, XB22 (Hold the claw to

remove.)

Joint #2 motor unit

4-M4×5 + washer

(4) Loosen the J2 belt.

Loosen four bolts securing the Joint #2 motor unit.

Slide the Joint #2 motor unit toward the Joint #2

side.

Pulley

(5) Remove the Joint #2 motor unit from the Arm #1.

Unscrew the bolts securing the Joint #2 motor plate

and pull the plate upward to remove.

Joint #2 motor unit

J2 belt

4-M4×15

Washer

RS Rev.5 83

Maintenance 6. Arm #2

(6) Remove the pulley from the Joint #2 motor.

(7) Remove the motor plate from the Joint #2 motor.

Pulley

M5 brass bushing

Motor plate

2-M5×8 set screw

4-M5×12

84 RS Rev.5

Joint #2 motor

(1) Mount the motor plate to the Joint #2 motor.

Installation

(2) Mount the pulley to the Joint #2 motor.

Secure the pulley to the distance of 5 mm from

the end of the motor shaft.

Tighten one of the set screws on the flat face of

the motor shaft until the screw just touches the

surface.

Insert a bushing into the other set screw hole to

prevent damage to the motor shaft.

Then, tighten both set screws.

Maintenance 6. Arm #2

Motor plate

Pulley

M5 brass bushing

Motor shaft end face

Pulley end face

4-M5×12

2-M5×8 set screw

(3) Set the J2 belt around the pulley of the Joint #2

motor unit and secure the unit loosely.

NOTE

)

Make sure the gear grooves of the belt are fit into

those of the pulleys completely.

Set the motor cable facing toward the other side

to J2 axis.

Pulley

J2 belt

4-M4×15

When securing the unit, make sure that the motor

unit can move by hand, and it will not tilt when

pulled. If the unit is secured too loose or too

tight, the belt will not have the proper tension.

Washer

Joint #2 motor unit

RS Rev.5 85

Maintenance 6. Arm #2

(4) Apply the proper tension to J2 belt and

secure the Joint #2 motor unit.

To do so, pass a suitable cord or string

around the Joint #2 motor unit near its

mounting plate. Then, pull the cord using

a force gauge or similar tool to apply the

specified tension shown in the figure on

the right.

(5) Insert the cables to Arm #1.

(6) Connect the connectors.

Connectors X21, X221, XB22

(7) Mount the Arm #1 cover.

For details, refer to Maintenance: 3.1 Arm #1.

(8) Mount the Arm #1 under cover.

For details, refer to Maintenance: 3.1 Arm #1.

J2 belt tension=100N (10.2 kgf)

Force gauge

(9) Perform the calibration of Joint #2.

For details refer to Maintenance: 13. Calibration.

86 RS Rev.5

6.2 Replacing Joint #2 Reduction Gear Unit

Maintenance parts and Material

Maintenance 6. Arm #2

Maintenance

parts

Material

Joint #2 reduction gear unit Removal

Name Quantity Note

Reduction Gear Unit (SG20-50) 1 R13B010019

Grease (SK-1A) 12 g R13ZA00330100

Hexagonal wrench (width across flats: 2 mm) 1

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

Hexagonal wrench (width across flats: 3 mm) 1

Hexagonal wrench (width across flats: 4 mm) 1 For M5 screw

1

For wiping grease (Flange)

For wiping grease (Bolt)

Torque wrench M3 1

Torque wrench M5 1

Nipper 1

Spatula 1 For applying grease

Force gauge 1 Belt tension 100 N

Suitable cord (Length about 800 mm) 1 For belt tension

Wiping cloth

Wire tie 4

(1) Remove the Arm #1 cover.

For details, refer to Maintenance: 3.1 Arm #1.

(2) Remove the Arm #1 under cover.

For details, refer to Maintenance: 3.1 Arm #1.

(3) Disconnect the connectors:

Connectors X30, X23, XB23, X231, XU10, XU20 (Hold the claw to remove.)

(4) Put the cables over the J2.

(5) Cut off two wire ties bundling the cables.

(6) Disconnect the ground wire.

(7) Remove the user plate.

For details, refer to Maintenance: 3.5 User plate.

(8) Remove the air tubes from the user plate. Press the ring of fittings of the air tube to pull

it out (ø6×2, ø4×1）.

Be sure to remember the cable location to connect them to the original position.

(9) Pull out the air tubes from the upper side of Joint #2.

Wire tie

RS Rev.5 87

Maintenance 6. Arm #2

(10) Remove the J2 ring.

(11) Remove the J2 cover.

For details, refer to Maintenance: 3.1 Arm #1.

M4×20

2-M4×15

J2 ring

(12) Loosen the J2 belt.

Unscrew four bolts securing the Joint #2 motor unit.

Slide the Joint #2 motor unit toward the Joint #2 side.

(13)

Remove the screws secured with nuts.

Joint #2 motor unit

Pulley

4-M4×5 +Washer

J2 belt

Nut

(14) Use the holes and rotate the Arm #2 to remove the

screws.

16-M3×15

(15) Pull out the cables (except air tube) to downward from Joint #1.

Pull out cables in order of size (smaller cables first).

Do not try to pull out the cables forcibly. Otherwise, connectors may be stuck,

disconnected, or connector pins may fall off.

88 RS Rev.5

EPSON RS3-351C, RS3-351S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

WARRANTY

TRADEMARKS

NOTICE

INQUIRIES

SERVICE CENTER

MANUFACTURER & SUPPLIER

SUPPLIERS

For Customers in the European Union

Before Reading This Manual

Structure of Control System

Turning ON/OFF Controller

Shape of Motors

Setting by Using Software

Figures in this Manual

TABLE OF CONTENTS

Setup & Operation

Maintenance

Setup & Operation

1. Safety

1.1 Conventions

1.2 Design and Installation Safety

1.3 Operation Safety

1.4 Emergency Stop

1.5 Emergency Movement Without Drive Power

1.6 Manipulator Labels

2. Specifications

2.1 Features of RS series Manipulators

2.2 Model Number

2.3 Part Names and Outer Dimensions

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

3.4 Unpacking and Transportation

3.5 Installation

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 Relocation and Storage

3.8.2 Relocation procedure

4. Setting of End Effectors

4.1 Attaching an End Effector

4.2 Attaching Cameras and Air valves

4.3 Weight and Inertia Settings

4.3.1 Weight Setting

Load on the Shaft

Load on the Arm

Automatic speed setting by 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 the shaft

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

Eccentric Quantity and the Inertia Setting

Eccentric quantity of load on the shaft

Automatic acceleration/deceleration setting by Inertia (eccentric quantity)

Calculating the Moment of Inertia

Automatic acceleration/deceleration vs. Joint #3 position

5. Motion Range

5.1 Motion Range Setting by Pulse 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

5.2 Motion Range Setting by Joint #3 Mechanical Stops

5.4 Standard Motion Range

Maintenance

1. Safety Maintenance

2. General Maintenance

2.1 Schedule for Maintenance Inspection

2.2 Inspection Point