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Epson G3 Series Manual

Scara robot
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SCARA ROBOT
G3 series
MANIPULATOR MANUAL
Rev.14
EM183R3623F

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  • Page 1 SCARA ROBOT G3 series MANIPULATOR MANUAL Rev.14 EM183R3623F...
  • Page 3 SCARA ROBOT G3 series Manipulator Manual Rev.14 Copyright  2008-2018 SEIKO EPSON CORPORATION. All rights reserved. G3 Rev.14...
  • Page 4 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...
  • Page 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.
  • Page 6 Regarding battery disposal 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.
  • Page 7 This section describes what you should know before reading this manual. Structure of Control System The G3 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.
  • Page 8 G3 Rev.14...

  • Page 9: Table Of Contents

    1.6 ACCELS Setting for CP Motions ............13 1.7 Warning Labels ..................14 2. Specifications 2.1 Features of G3 series Manipulators ............. 16 2.2 Model Number and Model Differences ..........17 2.3 Part Names and Outer Dimensions ............. 19 2.3.1 Table Top Mounting ..............19 2.3.2 Multiple Mounting ..............
  • Page 10 TABLE OF CONTENTS 4. Setting of End Effectors 4.1 Attaching an End Effector ..............52 4.2 Attaching Cameras and Valves ............. 53 4.3 Weight and Inertia Settings ..............54 4.3.1 Weight Setting ................54 4.3.2 Inertia Setting ................56 4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 ....60 5.
  • Page 11 TABLE OF CONTENTS 4. Cable 4.1 Replacing Cable Unit ................92 4.2 Wiring Diagrams ................... 98 4.2.1 Signal Cable ................98 4.2.2 Power Cable ................99 4.2.3 User Cable ................101 4.3 Replacing M/C Cable ................. 102 5. Arm #1 5.1 Replacing Joint #1 Motor ..............
  • Page 12 TABLE OF CONTENTS 15. Maintenance Parts List 15.1 Common Parts .................. 185 15.2 Parts by Environment Model ............. 187 G3 Rev.14...

  • Page 13: Setup & Operation

    Setup & Operation This volume contains information for setup and operation of the G3 series Manipulators. Please read this volume thoroughly before setting up and operating the Manipulators.

  • Page 15: Safety

    Setup & Operation 1. Safety 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.

  • Page 16: Design And Installation Safety

    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.

  • Page 17: Strength Of The Ball Screw Spline

    Setup & Operation 1. Safety 1.2.1 Strength of the Ball Screw Spline If a load exceeding the allowable value is applied to the ball screw spline, it may not work properly due to deformation or breakage of the shaft. If the ball screw spline is applied the load exceeding the allowable value, it is necessary to replace the ball screw spline unit.

  • Page 18: Operation Safety

    Setup & Operation 1. Safety 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 Safety and Installation manual 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.
  • Page 19 Setup & Operation 1. Safety ■ 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.

  • Page 20: Emergency Stop

    Setup & Operation 1. Safety 1.4 Emergency Stop Emergency stop motions of the Manipulators vary due to difference of control methods of the Controllers. See the section for your Controller model. 1.4.1 RC180 If the Manipulator moves abnormally during operation, immediately press the Emergency Stop switch.
  • Page 21 Setup & Operation 1. Safety For details of the Safeguard system, refer to the following manuals. EPSON RC+ User’s Guide 2. Safety - Installation and Design Precautions - Safeguard System Safety and Installation 2.6 Connection to EMERGENCY Connector To check brake problems, refer to the following manuals.

  • Page 22: Rc700-A

    For the Safeguard system, do not use the circuit for E-STOP. For details of the Safeguard system, refer to the following manuals. EPSON RC+ User’s Guide 2. Safety - Installation and Design Precautions - Safeguard System Safety and Installation 2.6 Connection to EMERGENCY Connector...
  • Page 23 Setup & Operation 1. Safety To check brake problems, refer to the following manuals. Manipulator Manual Maintenance 2.1.2 Inspection Point - Inspection While the Power is ON (Manipulator is operating) Safety and Installation 5.1.1 Manipulator - Inspection While the Power is ON (Manipulator is operating) Free running distance in emergency The operating Manipulator cannot stop immediately after the Emergency Stop switch is pressed.

  • Page 24: Emergency Movement Without Drive Power

    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 .....

  • Page 25: Accels Setting For Cp Motions

    Setup & Operation 1. Safety 1.6 ACCELS Setting for CP Motions To make the Manipulator move in CP motion, see the following and set ACCELS properly according to the tip load and the Z-axis height. Improper setting may cause following problems. NOTE ...

  • Page 26: Warning Labels

    Setup & Operation 1. Safety 1.7 Warning Labels The Manipulator has the following warning labels. The warning labels are attached around the locations where specific dangers exist. Be sure to comply with descriptions and warnings on the labels to operate and maintain the Manipulator safely.
  • Page 27 Setup & Operation 1. Safety Location Label Common Table Top Mounting Multiple Mounting G3 Rev.14...

  • Page 28: Specifications

    Obtain the stroke under the body Succeeded E2C series advantages Compatibility with the E2C series Manipulators The installation procedure and mounting dimensions of end effector for the G3 series are compatible with those for E2C series * Secure the compatible mounting position with optional parts...

  • Page 29: Model Number And Model Differences

    Setup & Operation 2. Specifications 2.2 Model Number and Model Differences G3-25 1 S □-R-UL UL specification UL : UL compliant □ : Non UL compliant Type □ : Standard : Right-Curved : Left-Curved Mounting type □ : Table Top Mounting : Multiple Mounting Environment : Standard...
  • Page 30 Setup & Operation 2. Specifications Joint #3 Model Arm type Mounting type Environment length stroke Number Standard G3-251S 250 mm Standard Table Top Mounting Cleanroom G3-251C Standard G3-301S Table Top Mounting Cleanroom G3-301C Standard Standard G3-301SM Multiple Mounting Cleanroom G3-301CM 300 mm Standard G3-301S-R...

  • Page 31: Part Names And Outer Dimensions

    Setup & Operation 2. Specifications 2.3 Part Names and Outer Dimensions 2.3.1 Table Top Mounting Standard-model G3-**1S Joint #2 − (rotating) Joint #1 (rotating) Joint #3 Brake release switch − LED Lamp Arm #2 Base Arm #1 Joint #3 − Shaft (Up/Down) −...
  • Page 32 Setup & Operation 2. Specifications or more Space for cables G3-251S G3-301S G3-351S (*) indicates the stroke margin Max.545 Max.575 Max.595 by mechanical stop. 1 mm flat cut Conical hole Ø3,90° Max.ø11 through hole shaft diameter mechanical stop diameter Reference through hole Detail of “A”...
  • Page 33 Setup & Operation 2. Specifications Cleanroom-model: G3-***C The following figures show the additional parts and specifications for Cleanroom-model (Table Top mounting) when compared with the Standard-model in appearance. Plate cover Upper bellows (For Anti-static) Exhaust port Cover Lower bellows for Table Top mounting surface Plate cover (For Anti-static) G3 Rev.14...
  • Page 34 Setup & Operation 2. Specifications more Space for cables G3-251C G3-301C G3-351C (*) indicates the stroke margin by mechanical stop. Max.545 Max.575 Max.595 1 mm flat cut Conical hole Ø3,90° Max.ø11 through hole shaft diameter mechanical stop diameter Reference through hole (View from the bottom of the base) Detail of “A”...

  • Page 35: Multiple Mounting

    Setup & Operation 2. Specifications 2.3.2 Multiple Mounting Standard-model: G3-**1SM Joint #2 − (rotating) Joint #3 Brake release switch LED lamp Base − Arm #1 Arm #2 Joint #3 Joint #1 (Up/Down) (rotating) Shaft − − Face plate (Manipulator serial No.) User connector (15-pin D-sub connector) Power cable...
  • Page 36 Setup & Operation 2. Specifications G3-301SM G3-351SM Max.410 Max.450 (*) indicates the stroke margin by mechanical stop. 1 mm flat cut Conical hole Ø3,90° Max.ø11 through hole shaft diameter mechanical stop diameter Reference through hole Detail of “A” (View from the bottom of the base) (Calibration point position of Joints #3 and #4) G3 Rev.14...
  • Page 37 Setup & Operation 2. Specifications Cleanroom-model: G3-**1CM The following figures show the additional parts and specifications for Cleanroom-model (Multiple Mounting) when compared with the Standard-model in appearance. Upper bellows Exhaust port Plate cover (For Anti-static) Lower bellows G3 Rev.14...
  • Page 38 Setup & Operation 2. Specifications G3-301CM G3-351CM (*) indicates the stroke Max.410 Max.450 margin by mechanical stop. 1 mm flat cut Conical hole Ø3,90° Max.ø11 through hole Reference through hole shaft diameter (View from the bottom of the base) mechanical stop diameter Detail of “A”...

  • Page 39: Specifications

    Setup & Operation 2. Specifications 2.4 Specifications Item G3 series Manipulator Arm #1, #2 250 mm 300 mm 350 mm Arm length Arm #1 120 mm 170 mm 220 mm Arm #2 130 mm 130 mm 130 mm Joints #1, #2...
  • Page 40 Setup & Operation 2. Specifications Max. motion range (deg) (mm) / Max. pulse range (pulse) Standard-model, Table Top Mounting G3-251S G3-301S-* G3-351S-* Item ± 140 Joint #1 Straight ± 141 ± 142 Joint #2 − 125~150 − 110~165 Right hand Joint #1 Max.
  • Page 41 Setup & Operation 2. Specifications Cleanroom-model, Table Top Mounting G3-251C G3-301C-* G3-351C-* Item ± 140 Joint #1 Straight ± 137 ± 141 ± 142 Joint #2 − 125~150 − 110~165 Right hand Joint #1 Max. − 150~125 − 165~110 Left hand motion range Curved −...
  • Page 42 Setup & Operation 2. Specifications *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.

  • Page 43: How To Set The Model

    The custom specifications may require a different configuration procedure; check the custom specifications number (MT***) 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. G3 Rev.14...

  • Page 44: Environments And Installation

    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...

  • Page 45: Base Table

    Setup & Operation 3. Environments and Installation 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.
  • Page 46 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. WARNING G3 Rev.14...

  • Page 47: Mounting Dimensions

    Setup & Operation 3. Environments and Installation 3.3 Mounting Dimensions The maximum space described in figures shows that the radius of the end effector is 60 mm or less. If the radius of the end effector exceeds 60 mm, define the radius as the distance to the outer edge of maximum space.

  • Page 48: Table Top Mounting - Straight Arm

    Setup & Operation 3. Environments and Installation 3.3.1 Table Top Mounting – Straight Arm Center of Joint#3 Maximum space Motion range Area limited by mechanical stop Base mounting face G3-251S 141° 2.3° 84.0 79.3 250 221.9 224.5 143.3° G3-251C 137° 6.3° 92.0 10.7 G3-301S...

  • Page 49: Table Top Mounting - Left-Curved Arm

    Setup & Operation 3. Environments and Installation 3.3.2 Table Top Mounting – Left-Curved Arm Center of Joint#3 Motion range Maximum space Area limited by mechanical stop Base mounting face G3-301S-L 150° 3.3° 150° 3° 125° 6° 135° 79.5 86.8 113.2 120.7 277.2 G3-301C-L...

  • Page 50: Table Top Mounting - Right-Curved Arm

    Setup & Operation 3. Environments and Installation 3.3.3 Table Top Mounting – Right-Curved Arm Center of Joint#3 Maximum space Motion range Area limited by mechanical stop Base mounting face G3-301S-R 150° 125° 6° 150° 3° 135° 3.3° 79.5 86.8 113.2 120.7 G3-301C-R 145°...

  • Page 51: Multiple Mounting - Straight Arm

    Setup & Operation 3. Environments and Installation 3.3.4 Multiple Mounting – Straight Arm Center of Joint#3 Maximum space Motion range Area limited by mechanical stop Base mounting face G3-301SM/CM 115° 135° 112.0 120.7 201.8 212.4 138.8° 4° 3.8° G3-351SM/CM 120° 142°...

  • Page 52: Multiple Mounting - Left-Curved Arm

    Setup & Operation 3. Environments and Installation 3.3.5 Multiple Mounting – Left-Curved Arm Center of Joint#3 Maximum space Motion range Area limited by mechanical stop Base mounting face G3-351SM-L 3.3° 160° 2.8° 107.5 130° 105° 5° 120° 103.3 183.0 191.9 G3-351CM-L 2°...

  • Page 53: Multiple Mounting - Right-Curved Arm

    Setup & Operation 3. Environments and Installation 3.3.6 Multiple Mounting – Right-Curved Arm Center of Joint#3 Maximum space Motion range Area limited by mechanical stop Base mounting face G3-351SM-R 3.3° 160° 107.5 105° 5° 130° 120° 3.8° 103.3 183.0 191.9 G3-351CM-R 2°...

  • Page 54: Unpacking And Transportation

    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.

  • Page 55: Installation Procedure

    Setup & Operation 3. Environments and Installation 3.5 Installation Procedure ■ The robot system must be installed to avoid interference with buildings, structures, utilities, other machines and equipment that may create a trapping hazard or pinch points. ■ Oscillation (resonance) may occur during operation depending on rigidity of the CAUTION installation table.

  • Page 56: Multiple Mounting

    Setup & Operation 3. Environments and Installation (2) Using nippers, cut off the wire tie binding the shaft and arm retaining bracket on the base. (3) Remove the bolts securing the wire ties removed in step (2). (4) Remove the fixing jig for transport. Wire tie Bolt :M4×15...

  • Page 57: Cleanroom-Model

    Setup & Operation 3. Environments and Installation Standard-model (1) Unpack the manipulator with retaining the arm posture. (2) Secure the base to the wall with four bolts. Screw Hole (depth 20 mm or more) NOTE Use bolts with specifications conforming ...

  • Page 58: Connecting The Cables

    Setup & Operation 3. Environments and Installation 3.6 Connecting the Cables ■ To shut off power to the robot system, disconnect the power plug from the power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source.

  • Page 59: User Wires And Pneumatic Tubes

    Setup & Operation 3. Environments and Installation 3.7 User Wires and Pneumatic Tubes ■ Only authorized or certified personnel should be allowed to perform wiring. Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system. CAUTION User electrical wires and pneumatic tubes are contained in the cable unit.
  • Page 60 Setup & Operation 3. Environments and Installation Table Top Mounting Fitting (white) for User connector ø6 mm pneumatic tube (15-pin D-sub connector) Fitting (black or blue)* for Fitting (black or blue)* ø6 mm pneumatic tube for ø4 mm pneumatic tube Base back side Multiple Mounting User connector...

  • Page 61: Relocation And Storage

    Setup & Operation 3. Environments and Installation 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.
  • Page 62 Setup & Operation 3. Environments and Installation 3.8.2 Table Top Mounting ■ Install or relocate the Table Top Mounting 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. G3-251* : approx.

  • Page 63: Multiple Mounting

    Setup & Operation 3. Environments and Installation 3.8.3 Multiple Mounting ■ Install or relocate the Multiple Mounting 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. G3-301*M : approx.

  • Page 64: Setting Of End Effectors

    Setup & Operation 4. Setting of End Effectors 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.

  • Page 65: Attaching Cameras And Valves

    Setup & Operation 4. Setting of End Effectors 4.2 Attaching Cameras and Valves Arm #2 has threaded holes as shown in the figure below. Use these holes for attaching [Unit: mm] cameras, valves, and other equipment. Common Dimensions Table Top Mounting Multiple Mounting G3 Rev.14...

  • Page 66: Weight And Inertia Settings

    Manipulator, and/or shorten the life cycle of parts/mechanisms. The acceptable weight capacity (end effector and work piece) in G3 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.
  • Page 67 Setup & Operation 4. Setting of End Effectors <Example> A “1 kg” camera is attached to the end of the G3 series arm (180 mm away from the rotation center of Joint #2) with a load weight of “1 kg”.

  • Page 68: Inertia Setting

    CAUTION 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 G3 series Manipulator is 0.005 kgm at the default rating and 0.05 kgm at the maximum. When the moment of inertia of the load exceeds the rating, change the setting of the moment of inertia parameter of the Inertia command.
  • Page 69 Manipulator, and/or shorten the life cycle of parts/mechanisms. The acceptable eccentric quantity of load in G3 series is 0 mm at the default rating and 150 mm at the maximum. When the eccentric quantity of load exceeds the rating, change the setting of eccentric quantity parameter of Inertia command.
  • Page 70 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 Enter a value into the [Eccentricity:] text box on the [Inertia] panel ([Tools] - [Robot Manager]).
  • Page 71 Setup & Operation 4. Setting of End Effectors (a) Moment of inertia of a rectangular parallelepiped Rotation center Rectangular parallelepiped’s center of gravity Mass (m) + m × L (b) Moment of inertia of a cylinder Cylinder’s center of gravity Rotation center + m ×...

  • Page 72: Precautions For Auto Acceleration/Deceleration Of Joint #3

    Setup & Operation 4. Setting of End Effectors 4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 When you move the Manipulator in horizontal PTP motion with Joint #3 (Z) at a high position, the motion time will be faster. When Joint #3 gets below a certain point, then auto acceleration/deceleration is used to reduce acceleration/deceleration.

  • Page 73: Motion Range

    Manipulator does not move. EPSON 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].)

  • Page 74: Max. Pulse Range Of Joint #1

    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 (-).

  • Page 75: Max. Pulse Range Of Joint #2

    Setup & Operation 5. Motion Range 5.1.2 Max. Pulse Range of Joint #2 The 0 (zero) pulse position of Joint #2 is the position where Arm #2 is in-line with Arm #1. With the 0 pulse as a starting point, the counterclockwise pulse value is defined as the positive (+) and the clockwise pulse value is defined as the negative (-).

  • Page 76: Max. Pulse Range Of Joint #3

    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.

  • Page 77: Motion Range Setting By Mechanical Stops

    Setup & Operation 5. Motion Range 5.2 Motion Range Setting by Mechanical Stops Mechanical stops physically limit the absolute area that the Manipulator can move. Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for the mechanical stop settings.
  • Page 78 Setup & Operation 5. Motion Range Joint #1 Mechanical Stops Views from the bottom of Arm #1 Model ±140° -110° +110° ±140° G3-**1S/C -110° +110° ±140° -110° +110° -125° ~ +150° -105° +130° G3-**1S/C-R -110° ~ +165° -90° +145° -150° ~ +125° -130°...
  • Page 79 Setup & Operation 5. Motion Range Joint #2 Mechanical Stops Ｌ Ｒ Views from the top of Arm #1 Model +141° -141° +120° -120° G3-**1S/C +142° -142° +120° -120° +142° -142° +120° -120° +150° -135° +130° -115° G3-**1S/C-R +165° -120° +145°...
  • Page 80 The angle of Joint #1 is set from –110 degrees to +110 degrees. The angle of Joint #2 is set from -120 degrees to +120 degrees. EPSON Execute the following commands from the [Command Window]. ' the pulse range of Joint #1 >JRANGE 1,-582542,5825423...

  • Page 81: Setting The Mechanical Stop Of Joint #3

    Setup & Operation 5. Motion Range 5.2.2 Setting the Mechanical Stop of Joint #3 NOTE This method applies only to the Standard-model Manipulator (G3-**1S*) / Multiple  Mounting Manipulator (G3-**1SM). For the Cleanroom-model ( the motion range set with the Joint #3 mechanical G3-**1C*), stop cannot be changed.
  • Page 82 = lower limit Z coordinate value (mm) / Resolution ( mm/pulse ** For the Joint #3 resolution, refer to the section Setup & Operation 2.4 Specifications. EPSON Execute the following command from the [Command Window]. Enter the calculated value in X.

  • Page 83: Setting The Cartesian (Rectangular) Range In The Xy Coordinate System Of The Manipulator (For Joints #1 And #2)

    The maximum physical range is based on the position of the mechanical stops. Set the XYLim setting on the [XYZ Limits] panel shown by selecting [Tools]-[Robot EPSON Manager]. (You may also execute the XYLim command from the [Command Window].) 5.4 Standard Motion Range...
  • Page 84 Setup & Operation 5. Motion Range G3 Rev.14...

  • Page 85: Maintenance

    Maintenance This volume contains maintenance procedures with safety precautions for G3 series Manipulators.

  • Page 87: Safety Maintenance

    Maintenance 1. Safety Maintenance 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.

  • Page 88: General Maintenance

    Maintenance 2. General Maintenance ■ Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure.

  • Page 89: Inspection Point

    Maintenance 2. General Maintenance 2.1.2 Inspection Point Inspection While the Power is OFF (Manipulator is not operating) Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual √ √ √ √ √ End effector mounting bolts Check looseness or backlash of √...

  • Page 90: Overhaul (Pars Replacement)

    EPSON RC+ 7.0. For details, refer to the following manual. Robot Controller RC700 / RC700-A Maintenance 6. Alarm For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the NOTE  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 5.0.
  • Page 91 (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) For the parts subject to overhaul, refer to Maintenance 15. Maintenance Parts List.

  • Page 92: Greasing

    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 the Manipulator.
  • Page 93 For details, refer to the following manual. Robot Controller RC700 / RC700-A Maintenance 6. Alarm NOTE For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the  recommended replacement time for the grease can be checked in the [Maintenance] dialog box of the EPSON RC+ 5.0.

  • Page 94: Tightening Hexagon Socket Head Cap Bolts

    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 Execute the following command from the [Command Window]. >PULSE...

  • Page 95: Layout Of Maintenance Parts

    Maintenance 2. General Maintenance 2.6 Layout of Maintenance Parts 2.6.1 Table Top Mounting G3-**1S : Standard-model Brake release switch LED lamp Cable unit Ball screw spline unit Joint #3 Arm cover motor Lithium battery & Joint #4 motor Joint #2 motor Battery board Z belt Joint #2 reduction gear unit...

  • Page 96: Multiple Mounting

    Maintenance 2. General Maintenance 2.6.2 Multiple Mounting G3-**1SM : Standard-model Brake release switch Ball screw LED lamp spline unit Cable unit Joint #3 Power cable motor Arm cover Signal cable Joint #4 motor Lithium battery & Battery board Joint #3 Z belt motor U1 belt...

  • Page 97: Covers

    Maintenance 3. Covers 3. Covers All procedures for removing and installing covers in maintenance are described in this chapter. ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
  • Page 98 Maintenance 3. Covers Table Top Mounting Arm top cover bottom cover Arm cap Connector plate Connector Heatsink plate sub plate Base bottom cover Multiple Mounting Connector sub plate Connector plate Heatsink plate Arm top cover Arm bottom cover G3 Rev.14...

  • Page 99: Arm Top Cover

    Maintenance 3. Covers 3.1 Arm Top Cover ■ Do not remove the arm top cover forcibly. Removing the cover 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.

  • Page 100: Arm Bottom Cover

    Maintenance 3. Covers Arm Top Cover (1) Set the arm top cover to the arm and secure with Brake release switch Installation the arm top cover mounting bolts. Lower limit mechanical stop After mounting the arm top cover, make sure that the lower limit mechanical stop does not touch the cylindrical part of the arm top cover.

  • Page 101: Arm Cap

    Maintenance 3. Covers 3.3 Arm Cap Unscrew the arm cap mounting bolts and remove the cover. Arm cap is not installed to the Multiple Mounting Manipulators. G3-**1 Table Top Mounting M4×8 Flat washer Arm cap 3.4 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.

  • Page 102: Connector Sub Plate

    Maintenance 3. Covers 3.5 Connector Sub Plate ■ Do not remove the connector sub plate forcibly. Removing the connector sub plate forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

  • Page 103: Heatsink Plate

    Maintenance 3. Covers 3.7 Heatsink Plate Unscrew the heatsink plate mounting bolts to remove the plate. G3-**1* Table Top Mounting G3-**1*M Multiple Mounting Heatsink plate Truss: Heatsink plate 4-M4×8 Truss: Truss: 4-M4×8 2-M4×8 Heat release sheet Truss: 2-M4×8 Heat release sheet Be careful of the Heat release sheet at the side of the Motor, and be sure to keep it.

  • Page 104: Cable

    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.
  • Page 105 Maintenance 4. Cable Table Top mounting Cable Unit (Figure: G3-301S) Multiple Mounting Cable unit (Figure: G3-301SM) G3 Rev.14...
  • Page 106 Maintenance 4. Cable ■ 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.
  • Page 107 Maintenance 4. Cable (7) Disconnect the air tubes, ground wire, D-sub cable, and seven connectors (X10, X20, X30, X111, X121, X131, XB10) connected to the connector plate and connector sub plate (inner side). - Be sure to keep the connectors of the battery board connected at cables NOTE ...
  • Page 108 Maintenance 4. Cable (12) Disconnect 11 connectors on the Arm side. Connectors X21, X22, X31, X32, X33, X41, X42, X61, X221, X231, X241 X61 is connected to the battery board. NOTE  Be sure to keep the connectors of the battery board connected at cables replacement. Otherwise, the Joint #2, #3, and #4 motors will lose position data and the calibration must be executed again.
  • Page 109 Maintenance 4. Cable Cable unit (1) Mount the cable unit to the Manipulator. Installation (2) Connect the following to inner connector plate and connector sub plate. Air tube // Ground wire // D-sub cable Joint #1 Signal cable connector and Power cable connector 4 connectors (X20, X30, X121, X131) (3) Connect Joint #1 Signal cable connector and XB10.

  • Page 110: Wiring Diagrams

    Maintenance 4. Cable 4.2 Wiring Diagrams 4.2.1 Signal Cable G3 Rev.14...

  • Page 111: Power Cable

    Maintenance 4. Cable 4.2.2 Power Cable RC180 G3 Rev.14...
  • Page 112 Maintenance 4. Cable RC700-A, RC700DU-A G3 Rev.14...

  • Page 113: User Cable

    Maintenance 4. Cable 4.2.3 User Cable Code Cable color Code Cable color Black Brown Violet Green White Blue Yellow The following table shows the types of the use cable. Mounting type Arm length Code 250 mm R13B020023 S, C 300 mm R13B020024 (Table Top Mounting) 350 mm...

  • Page 114: Replacing M/C Cable

    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. NOTE ...
  • Page 115 Maintenance 4. Cable Table Top Mounting M/C Cable (Figure: G3-301S) Multiple Mounting M/C Cable (Figure: G3-301SM) G3 Rev.14...
  • Page 116 Maintenance 4. Cable M/C Cable (1) Turn OFF the Controller. Removal (2) Disconnect the power cable and signal cable connectors from the controller. (3) Remove the Connector Sub Plate. For details, refer to Maintenance: 3.5 Connector Sub Plate. NOTE  Do not pull the Sub plate forcibly.

  • Page 117: Arm #1

    Maintenance 5. Arm #1 5. Arm #1 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 118: Replacing Joint #1 Motor

    Maintenance 5. Arm #1 5.1 Replacing Joint #1 Motor Name Quantity Note Maintenance AC Servo Motor (200 W) R13B000614 parts Hexagonal wrench width across flats: 2 mm For M4 set screw width across flats: 3 mm For M4 screw width across flats: 4 mm For M5 screw Tools width across flats: 5 mm...
  • Page 119 Maintenance 5. Arm #1 (7) Unscrew the bolts from Joint #1 Motor flange and remove the motor unit There is an oil seal (soft metal) in the assembly position of the motor flange and Oil seal Joint #1 Joint #1 flange. Motor unit Be sure to keep the oil seal.
  • Page 120 Maintenance 5. Arm #1 Joint #1 motor (1) Mount the motor flange on the Joint #1 Installation motor. Motor flange Joint #1 motor (2) Apply grease (SK-1A) to the between the waveform generator and motor flange. 4-M5×12 Grease volume 4 g (3) Mount the waveform generator on the Joint #1 motor.

  • Page 121: Replacing Joint #1 Reduction Gear Unit

    Maintenance 5. Arm #1 5.2 Replacing Joint #1 Reduction Gear Unit A reduction gear unit consists of the following three parts. When replacing the reduction gear unit, be sure to always replace the waveform generator, flexspline, and circular spline all together as one set. Waveform generator / Flexspline / Circular spline For details of the reduction gear unit, refer to Maintenance: 14.
  • Page 122 Maintenance 5. Arm #1 Joint #1 (1) A new reduction gear unit contains the Flexspline and reduction gear Cross roller bearing unit parts shown in the picture on the right unit O-ring when it is unpacked. Installation The gear grooves of the flexspline, circular spline, and the bearings of the waveform generator have been greased.
  • Page 123 Maintenance 5. Arm #1 (5) Secure the reduction gear flange to the circular Flange spline. 16-M3×15 Loosely fasten all bolts in a crisscross pattern so that the bolts will be fastened evenly. Then, using a torque wrench, tighten each bolt securely in a crisscross pattern at the torque specified in Reduction gear unit the table below.

  • Page 124: Arm #2

    Maintenance 6. Arm #2 6. Arm #2 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 125: Replacing Joint #2 Motor

    Maintenance 6. Arm #2 6.1 Replacing Joint #2 Motor Name Quantity Note Maintenance AC Servo Motor (150W) R13B000615 Parts width across flats: 2 mm For M4 set screw Hexagonal wrench width across flats: 3 mm For M4 screw width across flats: 4 mm For M5 screw Tools Torque wrench...
  • Page 126 Maintenance 6. Arm #2 (11) Remove the waveform generator from the Joint Waveform generator #2 motor. M4 Brass bushing 2-M4×6 Set screw There is a brass bushing in one of the set screw Joint #2 motor holes. Be careful not to lose it. (12) Remove the motor flange from the Joint #2 Motor flange motor.
  • Page 127 Maintenance 6. Arm #2 Joint #2 motor (1) Mount the motor flange on the Joint #2 motor. Motor flange Installation Joint #2 motor 2-M4×10 (2) Mount the waveform generator on the Joint Joint #2 motor #2 motor. M4 Brass bushing Be sure to fit the end face of the waveform 2-M4×6 Set screw generator to the end face of the motor shaft.
  • Page 128 Maintenance 6. Arm #2 (10) Re-bundle the cables in their original positions with a wire tie removed in the Removal procedure step (7). Do not allow unnecessary strain on the cables. (11) Mount the arm top cover. For details, refer to Maintenance: 3.1 Arm Top Cover. (12) Perform the calibration of Joint #2.

  • Page 129: Replacing Joint #2 Reduction Gear Unit

    Maintenance 6. Arm #2 6.2 Replacing Joint #2 Reduction Gear Unit A reduction gear unit consists of the following three parts. When replacing the reduction gear unit, be sure to always replace the waveform generator, flexspline, and circular spline all together as one set. Waveform generator / Flexspline / Circular spline For details of the reduction gear unit, refer to Maintenance: 15.
  • Page 130 Maintenance 6. Arm #2 Joint #2 (1) A new reduction gear unit contains the Flexspline and reduction gear Cross roller bearing unit parts shown in the picture on the right unit when it is unpacked. O-ring Installation The gear grooves of the flexspline, circular spline, and the bearings of the waveform generator have been greased.
  • Page 131 Maintenance 6. Arm #2 (5) Mount the circular spline to Arm #2. 10-M3×20 Loosely secure all bolts in a crisscross Arm #2 pattern so that the bolts will be secured evenly. Then, using a torque wrench, Reduction gear unit tighten each bolt securely in a crisscross O-ring pattern at the torque specified in the table below.

  • Page 132: Arm #3

    Maintenance 7. Arm #3 7. Arm #3 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 133: Replacing Joint #3 Motor

    Maintenance 7. Arm #3 7.1 Replacing Joint #3 Motor Name Quantity Note Maintenance AC Servo Motor (150W) R13B000615 parts width across flats: 2.5 mm For M4 set screw Hexagonal wrench width across flats: 3 mm For M4 screw Torque wrench Nippers For cutting wire tie Tools...
  • Page 134 Maintenance 7. Arm #3 Joint #4 (10) Loosen bolts of the Joint #4 motor unit. Motor unit Pull the Joint #4 motor unit upward to remove. 3-M4×12 + Washer Joint #3 Motor unit Joint #4 Intermediate shaft 3-M4×12 + washer 3-M4×12 +washer (11) Unscrew the bolts securing the Joint #3 3-M4×12+ washer...
  • Page 135 Maintenance 7. Arm #3 Joint #3 motor (1) Mount the pulley and brake hub to the Joint #3 2-M4×10 Installation motor. Insert the brake hub until it touches the end face Joint #3 motor of motor shaft and secure the hub. Bush: M5 Pulley Be sure to fit the end face of the pulley to the...
  • Page 136 Maintenance 7. Arm #3 Joint #4 (7) Loosely secure the Joint #4 motor unit to motor unit Arm #2. U1 pulley Check that the motor unit can be moved by U2 pulley 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.

  • Page 137: Replacing The Timing Belt

    Maintenance 7. Arm #3 7.2 Replacing the Timing Belt Name Quantity Note Maintenance Z belt width 9 mm R13B030213 parts width across flats: 2.5 mm For M3 screw Hexagonal wrench width across flats: 3 mm For M4 screw Nippers For cutting wire tie Tools Belt tension 74N (7.5 ±...
  • Page 138 Maintenance 7. Arm #3 Z belt (1) Place a new Z belt around the brake unit, 3-M3×10 Installation and then mount it to the motor plate. Motor plate Z belt Brake unit (2) Mount the Joint #3 motor unit. 2-M4×10 Joint #3 motor Bush: M5...
  • Page 139 Maintenance 7. Arm #3 Joint #4 (6) Put the pulley to the U2 belt and place the motor unit Joint #4 motor unit on the Arm #2 surface. Make sure the motor cables face to the 3-M4×12 + washer end of the arm. Joint #3 motor unit Joint #4...
  • Page 140 Maintenance 7. Arm #3 (12) Connect the backup connectors for Joint #3 and #4 (X63, X64) to the battery board. Bundle the backup cable with wire tie to prevent the cable connector to fall off by mistake. (13) Re-bundle the cables in their original positions with a wire tie removed in step (5). Do not allow unnecessary strain on the cables.

  • Page 141: Replacing The Brake

    Maintenance 7. Arm #3 7.3 Replacing the Brake Name Quantity Note Maintenance Solenoid brake R13B030501 parts width across flats: 1.5 mm For M3 set screw width across flats: 2.5 mm For M3 screw Hexagonal wrench width across flats: 3 mm For M4 screw width across flats: 4 mm For M5 screw...
  • Page 142 Maintenance 7. Arm #3 Joint #3 brake (1) Mount the brake to the brake plate. 3-M3×10 Installation Z belt (2) Mount the brake hub to the Joint #3 motor. 3-M3×10 (3) Mount the motor unit to the Z plate. Brake Align the position of the disk on the brake and the hub.

  • Page 143: Arm #4

    Maintenance 8. Arm #4 8. Arm #4 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 144: Replacing Joint #4 Motor

    Maintenance 8. Arm #4 8.1 Replacing Joint #4 Motor Name Quantity Note Maintenance AC Servo Motor (150 W) R13B000615 parts width across flats: 2 mm For M4 set screw Hexagonal wrench width across flats: 3 mm For M4 screw Torque wrench Tools Nippers For cutting wire tie...
  • Page 145 Maintenance 8. Arm #4 Joint #4 (9) Remove the Joint #4 motor unit from Arm motor unit Unscrew the bolts securing the Joint #4 3-M4×12 + washer motor unit to the Motor plate. Pull the Joint #3 motor unit upward to remove. motor unit Joint #4 Intermediate shaft...
  • Page 146 Maintenance 8. Arm #4 (1) Mount the motor plate to the Joint #4 motor. Joint #4 motor Screw: 2-M4×8 Installation (2) Secure the pulley to the new Joint #4 motor. M4 bushing Be sure to fit the end face of the pulley to the end face 2-M4×8 set screw of the motor shaft.
  • Page 147 Maintenance 8. Arm #4 (7) Connect the backup cable of Joint #4: X64. Bundle the cables with the wire tie to prevent the backup connector from falling off by mistake. 2-M4×5 (8) Mount the battery board to Arm #2. Battery board NOTE The screws on the rear side secure both the ...

  • Page 148: Replacing The Timing Belt

    Maintenance 8. Arm #4 8.2 Replacing the Timing Belt Name Quantity Note U1 belt (width 10 mm) R13B030214 Maintenance U2 belt (width 16 mm) R13B030215 parts Hexagonal wrench (width across flats: 3 mm) For M4 screw Spanner (width across flats: 7 mm) Torque wrench Belt tension Tools...
  • Page 149 Maintenance 8. Arm #4 Joint #4 (9) Loosen the bolts securing the Joint #4 motor unit motor unit and pull the motor unit upwards. 3-M4×12 + washer (10) Remove the screws securing the ball screw Joint #3 motor unit spline on the surface of Arm #2. Joint #4 intermediate shaft (11) Remove the screws on the Joint #3 motor...
  • Page 150 Maintenance 8. Arm #4 U2 belt (1) Hold the spline upper rotator part and set the Installation U1 belt around the U1 pulley. U1 belt NOTE Make sure the gear grooves of the belt are fit  into those of the pulleys completely. (2) Pass the Z belt through the ball screw spline 3-M4×12 + washer of Joint #3 motor unit and set the belt around...
  • Page 151 Maintenance 8. Arm #4 (6) Loosely secure the Joint #4 intermediate Joint #4 motor unit unit with screws. Make sure the motor unit can be moved 3-M4×12 + washer by hand, and it will not tilt when pulled. Joint #3 If the unit is secured too loose or too motor unit tight, the belt will not have the proper...
  • Page 152 Maintenance 8. Arm #4 (12) Apply the proper tension to the Z belt, and Z belt tension = 74 N (7.5 ± 0.5 kgf) then secure the Joint #3 motor unit. Joint #3 motor unit Pass a suitable cord or string around the Joint #3 motor unit near its mounting plate.
  • Page 153 Maintenance 8. Arm #4 U1 belt (1) Remove the Joint #4 motor with referring Joint #4 motor unit Removal to the procedure of Joint #4 motor Removal (1) to (9). 3-M4×12 + washer Joint #3 motor unit Joint #4 Intermediate shaft 3-M4×12 + washer 3-M4×12 + washer...
  • Page 154 Maintenance 8. Arm #4 U1 belt (1) Place the U2 belt in Arm #2 around the 3-M4×12 Installation small pulley and put it on the Arm #2. + washer At this point, keep the U1 belt on the large pulley of Joint #4 intermediate unit. Make sure the gear grooves of the belt are NOTE ...
  • Page 155 Maintenance 8. Arm #4 (6) Apply the proper tension to the U1 belt, and U1 belt tension = 7.5 ± 0.5 kgf then secure the Joint #4 intermediate shaft unit. Joint #4 Pass a suitable cord or string around the Joint #4 motor unit motor unit near its mounting plate.

  • Page 156: Replacing Arm #1

    Maintenance 9. Replacing Arm #1 9. Replacing Arm #1 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
  • Page 157 Maintenance 9. Replacing Arm #1 Name Quantity Notes 250 mm Arm #1_25ST R12B031914 Standard arm 300 mm Arm #1_30ST R12B031915 Table Top 350 mm Arm #1_35ST R12B031916 Mounting 300 mm Arm #1_30B R12B031917 Maintenance Curved arm parts 350 mm Arm #1_35B R12B031918 300 mm Arm #1_M_30ST...
  • Page 158 Maintenance 9. Replacing Arm #1 Arm #1 (1) Remove the arm cap. Removal For details, refer to Maintenance: 3.3 Arm Cap. (2) Remove the harmonic mounting screws on the Joint #2 side and remove the Arm #2 unit. This procedure should be done with an assistant. The assistant supports the Arm #2 unit.
  • Page 159 Maintenance 9. Replacing Arm #1 (5) Remove the harmonic mounting screws on the Joint #1 side and remove the Arm #1 unit. In case of Multiple mounting type, Arm #1 falls without mounting screws. Support Arm #1 when removing the screws. Remove the O ring which is attached to the Joint #1 mounting part.
  • Page 160 Maintenance 9. Replacing Arm #1 Arm #1 (1) Prepare the spare Arm #1 and mount the mechanical stop. Installation Base side Table Top M8×10 1 unit (Bottom surface, Center, 1 point) Multiple M8×10 2 units (Top surface, Center, 2 points) Arm #2 side M8×10 2 units (Top surface, Center, 2 points) (2) Insert the base side of Arm #1 to the harmonic drive of the base.
  • Page 161 Maintenance 9. Replacing Arm #1 (6) Put washer on screws and mount the Arm #1 unit with specified torque. M3 tightening torque: 3.0 N⋅m (30.6 kgf⋅cm) Use 35 mm screws to all side and the middle one in each side is 20 mm. Do not use screws of different length.
  • Page 162 Maintenance 9. Replacing Arm #1 (9) Change the robot model. (9)-1 From the Setup Menu, select Controller. EPSON RC+ 5.0 (9)-2 Click on the Robot folder in the tree on the left side to open the Robot Model page. (9)-3 Select the model for your robot from the Model dropdown list. Only robot models that can be used with the amplifiers currently in the controller are listed.
  • Page 163 Maintenance 9. Replacing Arm #1 (9)-1 From the Setup Menu, select System Configuration. EPSON RC+ 6.0 (9)-2 Click on Robots in the tree on the left. (9)-3 Click Add and the next dialog will appear. (9)-4 Type in a name for the new robot and enter the serial number from the robot’s nameplate.
  • Page 164 Maintenance 9. Replacing Arm #1 (9)-1 From the Setup Menu, select System Configuration. EPSON RC+ 7.0 (9)-2 Click [Robots] in the tree on the left. (9)-3 Click <Add> and the following dialog box will appear. (9)-4 Type in a name for the new manipulator and enter the serial number on the manipulator’s nameplate.

  • Page 165: Bellows

    Maintenance 10. Bellows 10. Bellows NOTE  The bellows are provided in a unit of one piece. The upper and lower bellows have the same shape. A large amount of dust is emitted when replacing the bellows. Take the Manipulator to an outer room such as the room in front of the clean room’s entrance, or take the necessary countermeasures to prevent dust emission before removing the bellows.
  • Page 166 Maintenance 10. Bellows Bellows (1) To attach the upper bellows, move the shaft to its lower limit. Installation To attach the lower bellows, move the shaft to its upper limit. To move the shaft up/down, press and hold the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.

  • Page 167: Ball Screw Spline Unit

    Maintenance 11. Ball Screw Spline Unit 11. Ball Screw Spline Unit ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 168: Standard-Model

    Maintenance 11. Ball Screw Spline Unit 11.1.1 Standard-model (S type) Cover the surrounding area such as the end effector and peripheral equipment in case the grease drips. (1) Turn ON the Controller. Stop motor excitation. (MOTOR OFF) (2) Move the arm to a position where Joint #3 can be moved in full stroke. (3) Move the shaft to its upper limit manually while Brake release switch pressing the brake release switch.

  • Page 169: Cleanroom-Model / Protected-Model

    Maintenance 11. Ball Screw Spline Unit 11.1.2 Cleanroom-model (C with bellows) Cover the surrounding area such as the end effector and peripheral equipment in case the grease drips. Upper Part (1) Turn ON the Controller. Stop motor excitation. (MOTOR OFF) of the Shaft (2) Move the arm to a position where Joint #3 can be moved in full stroke.

  • Page 170: Replacing The Ball Screw Spline Unit

    Maintenance 11. Ball Screw Spline Unit 11.2 Replacing the Ball Screw Spline Unit A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to the weight of the end effector while the power to the Controller is OFF or while the motor is in OFF status (MOTOR OFF).
  • Page 171 Maintenance 11. Ball Screw Spline Unit 2-M4×5 (7) Remove the battery board from Arm #2. Battery board 2-M4×12 (8) Remove the user plate and grounding wire from Arm #2. (9) Disconnect the following connectors. Connectors X231, X31，X341，X41 (Hold the claw to remove.) Connector X32 Connector X63, X64 (Backup cable connector for Joint #3, #4) Joint #4...
  • Page 172 Maintenance 11. Ball Screw Spline Unit (15) Remove the screws securing the Joint #4 3-M4×12 intermediate unit. +plain washer Remove the unit by pulling it up. (16) Remove the U2 belt. (17) Hold the spline upper rotator part. U2 belt Remove the U2 belt.
  • Page 173 Maintenance 11. Ball Screw Spline Unit Ball screw (1) Pass the U2 belt through the ball screw spline spline unit unit and U3 pulley and insert the belt to Arm #2 U2 belt Installation from above. (2) Secure the ball screw spline shaft on lower side of Arm #2.

  • Page 174: Lithium Battery

    Maintenance 12. Lithium Battery 12. Lithium Battery ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 175: Replacing The Battery Unit (Lithium Battery)

    EPSON RC+ 7.0. For details, refer to the following manual. Robot Controller RC700 / RC700-A Maintenance 6. Alarm For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the NOTE  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 5.0.
  • Page 176 Maintenance 12. Lithium Battery 12.1 Replacing the Battery Unit (Lithium Battery) Battery unit (1) Turn OFF the Controller. (lithium battery) (2) Push down the shaft to its lower limit while pressing the brake release switch. Be Removal sure to keep enough space and prevent the end effector hitting any peripheral equipment.

  • Page 177: Replacing The Battery Board

    Maintenance 12. Lithium Battery 12.2 Replacing the Battery Board After battery board and 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.
  • Page 178 Maintenance 12. Lithium Battery 2-M4×15 Battery board (1) Mount the new battery board and secure it with Battery board Installation screws. 2-M4×12 (2) Connect the connectors. Connectors: X61, X62, X63, X64 Battery board (3) Fix the connector cable with wiring tie. Refer to Removal step (4).

  • Page 179: Led Lamp

    Maintenance 13. LED Lamp 13. LED Lamp ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 180: Calibration

    Manipulator. ■ To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to EPSON RC+ User’s Guide: 2.4 Installation and Design Precautions. ■ Before operating the robot system, make sure that no one is inside the safeguarded area.

  • Page 181: Calibration Procedure

    Maintenance 14. Calibration 14.2 Calibration Procedure EPSON RC+ has a wizard for calibration. This section indicates the calibration using the calibration wizard of EPSON RC+. You can also calibrate with option TP1 in TEACH mode. For details, refer to EPSON RC+ 5.0...
  • Page 182 Maintenance 14. Calibration i. Select EPSON RC+ menu-[Setup]-[System Configuration]. EPSON RC+ 7.0 ii. Select the [Robot]-[Robot**]-[Calibration]. NOTE  Only selected robot can be calibrated. iii. Select the joint and click the <Calibrate…> button. (2) Confirm the warning message and click the <Yes> button.
  • Page 183 Maintenance 14. Calibration 0 pulse position of Joint #1: position aligned with X-axis in Robot coordinate system 0 pulse 0 pulse 0 pulse position of Joint #2: position where Arms #1 and #2 are in a straight line (Regardless of the Joint #1 direction.) 0 pulse position of Joint #3: upper limit position in...
  • Page 184 Maintenance 14. Calibration (4) Click the <Yes> button to reset the encoder. * This window will disappear when the Controller starts up. (5) Reboot the Controller. * This window will disappear when the Controller starts up. (6) Select the reference point to use for calibration, and click the <Next> button. Select a point from the current points to use for checking the accuracy.
  • Page 185 Maintenance 14. Calibration (8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Before operating the robot, open the [Jog & Teach] tab and execute <Motor ON>. (9) Click the <Next>...
  • Page 186 Maintenance 14. Calibration (10) The manipulator moves to the reference point. Click the <Execute> button. Input JUMP P0:z(0). ↑ Point selected in step (6) (11) Confirm the message and click the <Yes> button. (12) After the manipulator moves to the reference point, click the <Next> button. JUMP P0:z(0) G3 Rev.14...
  • Page 187 Maintenance 14. Calibration (13) Jog to the accurate reference position. (14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Position Joint #2 only and move Joint #3 to around 0 pulse. G3 Rev.14...
  • Page 188 Maintenance 14. Calibration (15) Click the <Next> button. (16) Execute the procedure in “Calibration Using Right / Left Arm Orientations” to accurately calibrate Joint #2. Go on to the step (17) for the other joints calibration. i. Move to another point that has different pose (from righty to lefty) using Jump command.
  • Page 189 Maintenance 14. Calibration iii. Jog to the accurate reference position and adjust the position. Click the <OK> button. iv. Click the <Next> button. G3 Rev.14...
  • Page 190 Maintenance 14. Calibration (17) Calibration is complete. Click the <Finish> button. (18) Move the manipulator to other points and check if it can move without problems. Teach points where appropriate. G3 Rev.14...

  • Page 191: Accurate Calibration Of Joint #2

    Maintenance 14. Calibration 14.3 Accurate Calibration of Joint #2 When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately. If the accuracy of Joint #2 is not obtained through the steps in the section Maintenance: NOTE ...
  • Page 192 Maintenance 14. Calibration Calibration Using Right / Left Arm Orientations (1) Check the point data for calibration Use a pose (point) you can easily verify the accuracy within the work envelop of both right and left arm. Then, check the number of pose (point) you want to use. (2) Open the Tools menu | Robot Manager | Control Panel and click the MOTOR ON.

  • Page 193: Calibration Procedure Without Using Calibration Wizard

    Maintenance 14. Calibration 14.4 Calibration Procedure without using Calibration Wizard This section indicates the calibration without using the calibration wizard of EPSON RC+. NOTE  For details of calibration using the calibration wizard, refer to 14.2 Calibration Procedure. When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately.
  • Page 194 Arm #2 Groove Flat surface (3)-3 Connect EPSON RC+ to the Controller. Select the robot to be calibrated. Input as below in the [Command EPSON Window] and execute. RC+ 7.0 (This example uses “robot 1”.)
  • Page 195 Joint #3 >calib 3 Joint #4 >calib 3, 4 Calibration (Accurate Positioning) (5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools] -[Robot Manager]-[Control Panel]. (5)-2 Click the <Free All> button to free all joints from servo control. Now, you can move arms by hands.
  • Page 196 Maintenance 14. Calibration (5)-5 Move the joint to the specified point using a motion command. For example, when the specified point data is “P1”, execute “Jump P1:Z(0)” from [Jog & Teach]. * The joint NOT being calibrated moves to the original position. (5)-6 Accurately align the joint* being calibrated to the specified point using jog commands.

  • Page 197: Maintenance Parts List

    Maintenance 15. Maintenance Parts List 15. Maintenance Parts List 15.1 Common Parts Ref. Overhaul Mainte Part Name Code Note nance 250 mm R13B020023 300 mm R13B020024 Cable Unit 350 mm R13B020025 300 mm R13B020026 350 mm R13B020027 For RC180 R12B020431 For RC700-A, Straight R12NZ900KA For RC700-A, L-shaped...
  • Page 198 Maintenance 15. Maintenance Parts List Ref. Overhaul Mainte Part Name Code Note nance Lithium battery for 4.1, replacement Battery Unit R13ZA00600300 12.1 ER17330V (TOSHIBA) LED Lamp R13A030000200 For purchasing the For Ball Screw Spline : AFB Grease grease, please contact For Reduction Gear Unit : SK-1A the sales company in your region.

  • Page 199: Parts By Environment Model

    Maintenance 15. Maintenance Parts List 15.2 Parts by Environment Model 15.2.1 S: Standard-model Reference: Overhaul *1 Part Name Code Note Maintenance  Ball Screw Spline 150 mm R13B010220 11.1.1 Arm Cover White R13B030421 As a rough indication, perform the overhaul (parts replacement) before reaching 20,000 operation hours of the Manipulator.
  • Page 200 Maintenance 15. Maintenance Parts List G3 Rev.14...

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