G6 series SCARA ROBOT MANIPULATOR MANUAL Rev.11 EM111R2121F

SCARA ROBOT

G6 series

MANIPULATOR MANUAL

Rev.11 EM111R2121F

SCARA ROBOT

G6 series

Manipulator Manual

Rev.11

Copyright

© 2007-2011 SEIKO EPSON CORPORATION. All rights reserved.

G6 Rev.11 i

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 and 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

G6 Rev.11

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

G6 Rev.11 iii

MANUFACTURER & SUPPLIER

Japan & Others

SEIKO EPSON CORPORATION

Suwa Minami Plant

Factory Automation Systems Dept.

1010 Fujimi, Fujimi-machi,

Suwa-gun, Nagano, 399-0295

JAPAN

SUPPLIERS

North & South America EPSON AMERICA, INC.

18300 Central Avenue

Carson, CA 90746

USA

Europe

EPSON DEUTSCHLAND GmbH

Otto-Hahn-Str.4

D-40670 Meerbusch

Germany

China EPSON China Co., Ltd

7F, Jinbao Building No. 89 Jinbao Street

Dongcheng District, Beijing,

China, 100005

Taiwan EPSON Taiwan Technology & Trading Ltd.

14F, No.7, Song Ren Road, Taipei 110

Taiwan, ROC iv

G6 Rev.11

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)

G6 Rev.11 v

Before Reading This Manual

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

Structure of Control System

The G6 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

Software

RC180 Controller EPSON RC+ 5.0

RC620

Control Unit

Drive Unit

EPSON RC+ 6.0

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

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.

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

G6 Rev.11

TABLE OF CONTENTS

Table of Contents

Before Reading This Manual..............................................................................v

Setup & Operation

1. Safety···························································································· 3

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

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

1.3 Operation Safety .......................................................................................5

1.4 Emergency Stop ........................................................................................6

1.5 Emergency Movement Without Drive Power .............................................7

1.6 Manipulator Labels ....................................................................................8

2. Specifications ············································································ 10

2.1 Features of G6 series Manipulators.........................................................10

2.2 Model Number and Model Differences .................................................... 11

2.3 Part Names and Outer Dimensions .........................................................12

2.3.1 Table Top Mounting ............................................................................12

2.3.2 Wall Mounting .....................................................................................18

2.3.3 Ceiling Mounting.................................................................................24

2.4 Specifications ..........................................................................................30

2.5 How to Set the Model ..............................................................................33

3. Environments and Installation·················································· 34

3.1 Environmental Conditions........................................................................34

3.2 Base Table...............................................................................................36

3.3 Mounting Dimensions ..............................................................................37

3.4 Unpacking and Transportation.................................................................40

3.5 Installation ...............................................................................................41


3.5.2 Wall Mounting .....................................................................................42


3.5.4 Cleanroom-model ...............................................................................44

3.5.5 Protected-model .................................................................................44

3.6 Connecting the Cables ............................................................................45

3.7 User Wires and Pneumatic Tubes ...........................................................47

3.8 Relocation and Storage ...........................................................................49

3.8.1 Precautions for Relocation and Storage.............................................49


3.8.3 Wall Mounting .....................................................................................51


G6 Rev.11 vii

TABLE OF CONTENTS

4. Setting of End Effectors···························································· 53

4.1 Attaching an End Effector ....................................................................... 53

4.2 Attaching Cameras and Valves ............................................................... 54

4.3 Weight and Inertia Settings ..................................................................... 55

4.3.1 Weight Setting.................................................................................... 55

4.3.2 Inertia Setting..................................................................................... 60

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3..................... 60

5. Motion Range············································································· 61

5.1 Motion Range Setting by Pulse Range (for All Joints)............................. 62

5.1.1 Max. Pulse Range of Joint #1............................................................ 62




5.2 Motion Range Setting by Mechanical Stops............................................ 65

5.2.1 Setting the Mechanical Stops of Joints #1 and #2............................. 66

5.2.2 Setting the Mechanical Stop of Joint #3 ............................................ 69

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

System of the Manipulator (for Joints #1 and #2) ................................... 71

5.4 Standard Motion Range .......................................................................... 71

Maintenance

1. Safety Maintenance ··································································· 77

2. General Maintenance ································································ 78

2.1 Schedule for Maintenance Inspection ..................................................... 78

2.2 Inspection Point ...................................................................................... 79

2.2.1 Inspection While the Power is OFF

(Manipulator is not operating) ......................................................................... 79

2.2.2 Inspection While the Power is ON

(Manipulator is operating)................................................................................ 79

2.3 Greasing ................................................................................................. 80

2.4 Tightening Hexagon Socket Head Cap Bolts .......................................... 81

2.5 Matching Origins ..................................................................................... 81

2.6 Layout of Maintenance Parts .................................................................. 82

2.6.1 Table Top Mounting............................................................................ 82

2.6.2 Wall Mounting .................................................................................... 83

2.6.3 Ceiling Mounting ................................................................................ 84

3. Covers ························································································ 85

3.1 Arm Top Cover ........................................................................................ 87

3.2 Arm Bottom Cover .................................................................................. 89

3.3 Arm #1 Cover.......................................................................................... 90

3.3.1 G6-***S*, G6-***C*............................................................................. 90

3.3.2 G6-***D*, P* ....................................................................................... 91 viii

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G6 Rev.11

TABLE OF CONTENTS

3.4 Connector Plate.......................................................................................92

3.5 Connector Sub Plate ...............................................................................94

3.6 User Plate................................................................................................95

3.7 Maintenance Plate...................................................................................95

3.8 Base Bottom Cover .................................................................................96

4. Cable Unit ··················································································· 97

4.1 Replacing Cable Unit...............................................................................98

4.2 Wiring Diagrams ....................................................................................109

4.2.1 Signal Cable .....................................................................................109

4.2.2 Power Cable ..................................................................................... 110

4.2.3 User Cable........................................................................................ 111

5. Arm #1 ······················································································ 112

5.1 Replacing Joint #1 Motor....................................................................... 113

5.2 Replacing Joint #1 Reduction Gear Unit................................................ 115

6. Arm #2 ······················································································ 118

6.1 Replacing Joint #2 Motor....................................................................... 119

6.2 Replacing Joint #2 Reduction Gear Unit................................................122

7. Arm #3 ······················································································ 125

7.1 Replacing Joint #3 Motor.......................................................................126

7.2 Replacing the Timing Belt......................................................................130

7.3 Replacing the Brake ..............................................................................133

8. Arm #4 ······················································································ 136

8.1 Replacing Joint #4 Motor.......................................................................137

8.2 Replacing the Timing Belt......................................................................141

8.3 Replacing the Brake ..............................................................................149

9. Bellows ····················································································· 152

10. Ball Screw Spline Unit ··························································· 155

10.1 Greasing the Ball Screw Spline Unit ....................................................156

10.1.1 Standard-model ..............................................................................156

10.1.2 Cleanroom-model / Protected-model .............................................157

10.2 Replacing the Ball Screw Spline Unit ..................................................158

11. Lithium Battery······································································· 164

11.1 Replacing the Battery Unit (Lithium Battery) ........................................166

11.2 Replacing the Battery Board ................................................................167

12. LED Lamp ··············································································· 169

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TABLE OF CONTENTS

13. Calibration·············································································· 170

13.1 About Calibration ................................................................................ 170

13.2 Calibration Procedure ......................................................................... 171

13.3 Accurate Calibration of Joint #2 .......................................................... 181

13.4 Calibration Procedure without using Calibration Wizard ..................... 183

14. Maintenance Parts List ························································· 187

14.1 Common Parts .................................................................................... 187

14.2 Parts by Environment Model ............................................................... 189 x

G6 Rev.11

Setup & Operation

This volume contains information for setup and operation of the

G6 series Manipulators.

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

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.

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

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

WARNING

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

CAUTION

This symbol indicates that a danger of possible harm to people or physical damage to equipment and facilities exists if the associated instructions are not followed properly.

G6 Rev.11

3


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

G6 Rev.11


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.

WARNING

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

■ Before operating the robot system, make sure that no one is inside the safeguarded area. The robot system can be operated in the mode for teaching even when someone is inside the safeguarded area.

The motion of the Manipulator is always in restricted (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.

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

WARNING

■ 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.

CAUTION

■ 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.

G6 Rev.11

5

6


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

Speed Setting

Load [kg]

Weight Setting

100

100

6

6

Start point of operation

Point where the emergency stop signal is input

Joint #1

Target point

Stop point

Joint #2

Free running time

Free running angle

Free running distance

Controller

Manipulator

Joint #1 + Joint #2 [sec.]

Joint #3

Joint #1

Joint #2

[sec.]

[deg.]

[deg.]

Joint #1 + Joint #2 [deg.]

Joint #3 G6-**1** [mm]

G6-**3**

RC180 / RC620

G6-45*** G6-55*** G6-65***

0.6 0.7 0.8

0.4 0.4 0.4

35 45 55

60 60 65

100

40

80

110

40

80

120

40

80

G6 Rev.11


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 switch.

Joint #4........... For G6-**1**,

Rotate the shaft by hand.

For G6-**3**,

The shaft cannot be rotated by hand until the electromagnetic brake applied to the shaft has been released.

Move the shaft while pressing the brake release button switch.

Joint #3 and #4 brake release button

Joint #2

(rotating)

−

+

Joint #1

(rotating)

−

+

Arm #1

Arm #2

G6 Rev.11

NOTE

)

Base

+

Joint #3

(up and down)

−

−

Shaft

+

Joint #4

(rotating)

The brake release button affects both Joints #3 and #4. When the brake release button is pressed in emergency mode, the brakes for both Joints #3 and #4 are released simultaneously. (For G6-**1**, Joint #4 has no brake on it.)

Be careful of the shaft falling and rotating while the brake release button is pressed because the shaft may be lowered by the weight of an end effector.

7


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:

Location Labels NOTE

A

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

Manipulator.

B

C

D

E

F

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 cover when bringing your hand close to moving parts.

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

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

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

Be careful of the hand falling while the brake release button is being pressed.

G

8

G6 Rev.11

Location Labels

H

Table Top Mounting

G6-***S

C

F

D

B

E

A

Ceiling Mounting

G6-***SR

H

G

C

H

Wall Mounting

G6-***SW

D

F

C

B

A

C

E

G

F

C

D


NOTE

H

B

A

G

E

G6 Rev.11

9

Setup & Operation 2. Specifications

2. Specifications

2.1 Features of G6 series Manipulators

The G6 series Manipulators are high-performance manipulators intended to achieve high speed, high accuracy, space saving, and high cost-performance. The features of the G6 series Manipulators are as follows:

Compatibility with E2 series Manipulators

The installation procedure and mounting dimensions of the end effector for the G6 series are compatible with those for the E2 series.

Space Saving

Compactness achieved by using a ductless design.

Motion Range Extended

The motion range of the G6 series manipulator has been extended by 20% compared to

E2S.

Improved Productivity

The numbers of user wires and pneumatic tubes have been increased.

The speed of Joints #1, 2, 3, and 4 has been enhanced.

Cycle time has been improved.

Increased Load Capacity

The load capacity has been increased up to a maximum 6 kg to handle greater work load.

Various Types Available

10

G6 Rev.11


2.2 Model Number and Model Differences

G6-45 1 S □ -UL

UL specification

UL : UL compliant

□

: Non UL compliant

Type

□

: Table Top mounting

W : Wall mounting

R : Ceiling mounting

Environment

S : Standard

C : Clean room

D : Protected

P : Protected

Joint #3 stroke

1

: IP 54 (with bellows option)

: IP 65

: 180 mm (G6-***S* / D*)

150 mm (G6-***C* / P* / D* bellows option)

3

: 330 mm (G6-***S* / D*)

300 mm (G6-***C* / P* / D* bellows option)

Arm length

45 : 450 mm

55 : 550 mm

65 : 650 mm

Environment

Cleanroom-model

Cleanroom-model Manipulator includes additional features that reduce dust emitted by the Manipulator to enable use in clean room environments.

Protected-model (IP54 / IP65)

The Protected-model Manipulators operate under adverse conditions with dust and oily smoke.

G6-***D*

Normal G6-***D* Manipulators do not have bellows. The normal G6-***D*

Manipulator (without bellows option) operates under adverse conditions with oily mist.

If necessary, select the bellows option at shipment.

The Manipulators with bellows (option) comply with grade of protection IP54 (IEC

60529, JIS C0920).

G6-***P*

G6-***P* Manipulators comply with grade of protection IP65 (IEC 60529, JIS

C0920).

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

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2.3 Part Names and Outer Dimensions

2.3.1 Table Top Mounting

Standard-model G6-***S

Joint #2

(rotating)

−

+

Joint #1

(rotating)


−

+

Arm #1

LED lamp

Arm #2

Base

+

Joint #3

(up and down)

−

−

+

Joint #4

(rotating)

Shaft

Signature label

(Serial No. of Manipulator)

UR label

MT label

(only for custom specification)

CE label

NOTE

)

12

User connector

(9-pin D-sub connector)

Signal cable

User connector


Power cable

Fitting (white)

for ø 6 mm pneumatic tube

Fitting (black)


Fitting (white)


Fitting (black)


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

(For G6-**1**, Joint #4 has no brake on it.)

- While the LED lamp is on, the current is being applied to the manipulator. Performing any work with the power ON is extremely hazardous and it may result in electric shock and/or improper function of the robot system. Make sure to turn OFF the controller power before the maintenance work.

G6 Rev.11

Setup & Operation 2. Specifications d b c a

G6-45*S G6-55*S G6-65*S

200 300 400

G6-**1S G6-**3S

180 330

119 -31

684 834

(*) indicates the stroke margin by mechanical stop.

90 or more

Space for cables

1 mm flat cut

Conical hole

ø4,90°

Max.ø14 through hole

ø20 h7 shaft diameter

ø40 mechanical stop diameter

Detail of “A”

(Calibration point position of Joints #3 and #4)

Root both side chamfer C0.5

Reference through hole

(View from the bottom of the base)

G6 Rev.11

13


Cleanroom-model G6-***C

The following figure shows the additional parts and specifications for the Table Top mounting

Cleanroom-model when compared with the Standard-model in appearance.

Upper bellows

Plate cover

(For static electricity countermeasure)

Lower bellows

Plate cover


Cover for Table Top mounting surface

Exhaust port

14

G6 Rev.11

Setup & Operation 2. Specifications b c d a

G6-45*C G6-55*C G6-65*C

200 300 400

G6-**1C G6-**3C

150 300

116 -34

792 942


90 or more

Space for cables

1 mm flat cut

Conical hole

ø4,90°




Detail of “A”





G6 Rev.11

15


Protected-model G6-***D/P

The following figure shows the additional parts and specifications for the Table Top mounting

Protected-model when compared with the Standard-model in appearance.

Normal G6-***D* Manipulators do not have bellows. If necessary, select the bellows option at shipment.

The following figure is a Manipulator with bellows option.

For dimensions of the end part of G6-***D* without bellows option, refer to G6-***S.

Upper bellows

Lower bellows

Stainless steel plate

G6-***P only

Plate cover (For oil resistant)

User connector

(Protected-model)


(Protected-model)

Fittings with cover

(Protected-model)


G6-***P only


Stainless steel plate for Table Top mounting surface

Exhaust port

User connector

(Protected-model)

Fittings with cover

(Protected-model)

16

NOTE

)

For Protected-model, all the screws used for outer parts are stainless steel screws. (Excluding the screw used for mechanical stop.)

G6 Rev.11

Setup & Operation 2. Specifications d b c a

G6-45*D/P G6-55*D/P G6-65*D/P

200 300 400

G6-**1D/P G6-**3D/P

150 300

116 -34

795.5 945.5


90 or more

Space for cables

1 mm flat cut

Conical hole

ø4,90°




Detail of “A”





G6 Rev.11

17


2.3.2 Wall Mounting

Standard-model G6-***SW


Joint #2

(rotating)

−

+

LED lamp

MT label


Signature label


CE label

UR label

Base

18

Arm #1

−

+

Joint #1

(rotating)

Joint #3

(up and down)

+

−

−

Arm #2

Shaft

+

Joint #4

(rotating)

Power cable

Signal cable

User connector


User connector


Fitting (white)


Fitting (black)


Fitting (white)


Fitting (black)


NOTE

)




G6 Rev.11


(*) indicates the stroke margin by mechanical stop

Detail of “B”

Space for cables

90 or more

1 mm flat cut

Conical hole

ø4,90°




Detail of “A”


G6-45*SW G6-55*SW a 200 300

G6-**1SW G6-**3SW b 180 c -9 d 385

330

141

535

G6-65*SW

400



G6 Rev.11

19


Cleanroom-model G6-***CW

The following figure shows the additional parts and specifications for the Wall mounting Cleanroom-model when compared with the Standard-model in appearance.

Upper bellows

Plate cover


Lower bellows

Plate cover


Exhaust port

20

G6 Rev.11



G6-45*CW G6-55*CW a 200 300

G6-**1CW G6-**3CW b 150 c 99 d 526

300

249

676

G6-65*CW

400

Detail of “B”

Space for cables

90 or more

1 mm flat cut

Conical hole

ø4,90°




Detail of “A”


G6 Rev.11



21


Protected-model G6-***DW / PW

The following figure shows the additional parts and specifications for the Wall mounting Protected-model when compared with the Standard-model in appearance.

Normal G6-***DW Manipulators do not have bellows. If necessary, select the bellows option at shipment.


For dimensions of the end part of G6-***DW without bellows option, refer to G6-***SW.



Upper bellows

22

Lower bellows

G6-***PW only


User connector (Protected-model)


(Protected-model)

Fittings with cover

(Protected-model)

G6-***PW only



Exhaust port

Fittings with cover

(Protected-model)

NOTE

)


G6 Rev.11



G6-45*DW/PW G6-55*DW/PW G6-65*DW/PW a 200 300

G6-**1DW/PW G6-**3DW/PW b 150 300 c 102.5 252.5 d 529.5 679.5

400

Detail of “B”

Space for cables

90 or more

1 mm flat cut

Conical hole

ø4,90°




Detail of “A”


G6 Rev.11



23


2.3.3 Ceiling Mounting

Standard-model G6-***SR


Joint #2

(rotating)

−

+

LED lamp

Base

Arm #1

−

+

Joint #1

(rotating)

Joint #3

(up and down)

+

−

−

+

Joint #4

(rotating)

Arm #2

Shaft

NOTE

)

Fitting (black)


Fitting (black)


Power cable

Fitting (white)


Fitting (white)


Signal cable

User connector


User connector


MT label


CE label

Signature label


UR label




24

G6 Rev.11



Space for cables

90 or more

Detail of “B”

1 mm flat cut

Conical hole

ø4,90°




Detail of “A”

(Calibration point position of Joints #3 and #4) b c d a

G6-45*SR G6-55*SR G6-65*SR

200 300 400

G6-**1SR G6-**3SR

180 330

-9 141

385 535

G6 Rev.11

25


Cleanroom-model G6-***CR

The following figure shows the additional parts and specifications for the Ceiling mounting Cleanroom-model when compared with the Standard-model in appearance.

Cover for Ceiling mounting surface

Upper bellows

Plate cover


Lower bellows

Plate cover


Exhaust port

26

G6 Rev.11


Space for cables

90 or more


1 mm flat cut

Conical hole

ø4,90°




Detail of “A”


Detail of “B” b c d a

G6-45*CR G6-55*CR G6-65*CR

200 300 400

G6-**1CR G6-**3CR

150 300

99 249

526 676

G6 Rev.11

27


Protected-model G6-***DR / PR

The following figure shows the additional parts and specifications for the Ceiling mounting Protected-model when compared with the Standard-model in appearance.

Normal G6-***DR Manipulators do not have bellows. If necessary, select the bellows option at shipment.


For dimensions of the end part of G6-***DR without bellows option, refer to G6-***SR.


Stainless steel plate for Ceiling mounting surface

Upper bellows


Lower bellows

G6-***PR only


G6-***PR only




(Protected-model)

Fittings with cover

(Protected-model)

Fittings with cover

(Protected-model)


Exhaust port

NOTE

)


28

G6 Rev.11


Space for cables

90 or more


Detail of “B”

1 mm flat cut

Conical hole

ø4,90° a

G6-45*DR/PR G6-55* DR/PR G6-65* DR/PR

200 300 400 b c d




Detail of “A”


G6-**1 DR/PR G6-**3 DR/PR

150 300

102.5 252.5

529.5 679.5

G6 Rev.11

29


2.4 Specifications

Item

Mount method

Environment

G6-**** G6-****R G6-****W

Table Top Ceiling Wall

Cleanroom-model *1 / Protected-model *2

Arm

#1, #2

Arm length

Weight

(not include the weight of cables)

Driving method All joints

Max. operating speed *3

Arm #3

Joints

#1, #2

Joint #3

1

3

45/55

65

180 mm : G6-**1S* / D*

150 mm : G6-**1C* / P* / D* with bellows option

330 mm : G6-**3S* / D*


27 kg : 60 lb.

28 kg : 62 lb.

29 kg : 64 lb.

29.5 kg : 65 lb.

45

55

65

AC servo motor

6440 mm/s

7170 mm/s

7900 mm/s

Repeatability

Max. motion

Max.

range pulse range

(pulse)

Joint #4

Joints #1, #2

Joint #3

Joint #4

Joint #1

Joint #2

2400 deg/s

±0.015 mm

±0.010 mm

±0.005 deg

45

±120 deg

55

±152 deg

65

45

±142 to 147.5 deg *a ±130 deg

55/65

±147.5 deg

Joint #3

1

180 mm : G6-**1S* / D*


Joint #4

Joint #1

Joint #2

±105 deg

±135 deg

±148 deg

3

330 mm : G6-**3S* / D*


±360 deg

45

55

−1805881 to +7048761

−873814 to + 6116694 −436907 to +5679787

−1310720 to +6553600

65

45

±2585031 to 2685156 *a ±2366578

−1689373 to +6932253

Joint #3

Joint #4

*a : G6-45*** Joint #2

55/65 ±2685156

1

−1976708 : G6-**1S* / D*

−1647257 : G6-**1C* / P* / D with bellows option

3

−1811982 : G6-**3S* / D*

−1647257 : G6-**3C* / P* / D* with bellows option

±1961226

G6-45*S* / D*

G6-45*C*/ P* / D* with bellows option

Z 0～–270

Z –270～–330

Z 0～–240

Z –240～–300

Max. motion range

147.5 deg

145 deg

147.5 deg

142 deg

Max. pulse range

±2685156 pulse

±2639645 pulse

±2685156 pulse

±2585031 pulse

30

G6 Rev.11


Resolution

Item G6-*****

Joint #1

Joint #2

0.0000343 deg/pulse

0.0000549 deg/pulse

Joint #3

Motor power consumption

Joint #4

Joint #1

Joint #2

Joint #3

Joint #4

0.0001836 deg/pulse

400 W

400 W

200 W

100 W

Payload

Joint #4 allowable moment of inertia *4 kg rated 0.01 kg

·m

2

Hand

Joint #3 down force

Installed wire for customer use

Installed pneumatic tube for customer use

Environmental requirements

Ambient

Temperature

Ambient relative humidity

Equivalent continuous A-weighted sound pressure level *5

150 N

24 (15 pin + 9 pin : D-sub)

2 pneumatic tubes (ø6 mm) : 0.59 Mpa (6 kgf/cm

2

: 86 psi)

2 pneumatic tubes (ø4 mm) : 0.59 Mpa (6 kgf/cm

2

: 86 psi)

5 to 40

°C (with minimum temperature variation)

10 to 80% (no condensation)

L

Aeq

= 70 dB(A)

Assignable Value

( ) Default values

SPEED

ACCEL *7

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

0,250 to (3,250) 6,250

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: The exhaust system in the Cleanroom-model Manipulator (G6-***C*) draws air from the base interior and arm cover interior.

A crack or other opening in the base unit can cause loss of negative air pressure in the outer part of the arm, which can cause increased dust emission.

Do not remove the 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.)

G6 Rev.11

31


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)

*2: IP (International Protection) for the Protected-model Manipulator indicates International Standard of the protection level against dust and water.

Normal G6-***D* Manipulators do not have bellows. The normal G6-***D* Manipulator (without bellows option) operates under adverse conditions with oily mist.

If necessary, select the bellows option at shipment.

The Manipulators with bellows (option) comply with grade of protection IP54 (IEC 60529, JIS C0920).

Model

G6-***D* with bellows option

IP54

Dust : 5

Water : 4

Degree of protection

Dust shall not ingress in a quantity to interfere with satisfactory operation of the equipment.

Water splashing against the enclosure from any direction shall have no harmful effect.

Dust : 6 No ingress of dust.

G6-***P* IP65

Water : 5

Water projected by a nozzle against enclosure from any direction shall have no harmful effects.

*3: In the case of PTP command. Maximum operating speed for CP command is 2000 mm/s on horizontal plane.

*4: 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.

*5: 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.

*6: For delivery in April, 2008 or earlier, there are systems in combination of G series and RC170.

*7: 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.

32

G6 Rev.11


2.5 How to Set the Model

CAUTION

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

NOTE

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.

G6 Rev.11

33

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

Ambient temperature

*1

Conditions

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

NOTE

)

· Keep away from direct sunlight.

· Keep away from dust, oily smoke, salinity, metal powder or other contaminants.

· Keep away from flammable or corrosive solvents and gases.

· Keep away from water.

· Keep away from shocks or vibrations.

· Keep away from sources of electric noise.

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.

34

G6 Rev.11


For the Protected-model Manipulator, be sure to install the robot system in an environment that also meets the following conditions:

Item Conditions

WARNING

· Keep away from direct sunlight.

· Keep away from salinity or other contaminants.

· Keep away from flammable or corrosive solvents (including water)*² and gases.

· Keep away from shock or vibration.

· Keep away from sources of electric noise.

· It can be used under conditions with dust, oily smoke, metal powder or other contaminants.*³

*2 The Manipulator body is mainly made of iron and aluminum. It is not rust-proofed.

Do not use the Manipulator under conditions where the Manipulator can expose to water or any other corrosive liquid.

*3 Any contaminants that can deteriorate sealing performance of nitrile rubber oil sealing,

O-rings, packing seals and liquid gasket should be avoided.

Special Environmental Conditions

The protective seals are attached on the Protected-model Manipulator to prevent dust, water, etc. from the outside. Follow the precautions in use environment described below:

The surface of the Manipulator has general oil resistance. However, if your requirements specify that the Manipulator must withstand certain kinds of oil, please consult your distributor.

Rapid change in temperature and humidity can cause condensation inside the Manipulator.

If your requirements specify that the Manipulator handles food, please consult your distributor to check whether the Manipulator gives damage to the food or not.

The Manipulator cannot be used in corrosive environments where acid or alkaline is used.

In a salty environment where the rust is likely to gather, the Manipulator is susceptible to rust.

The controller used with the Protected-model Manipulator does not have protection features for dusty, wet, or oily environment. The controller must be placed in an environment that meets the specified conditions.

■ Use an earth leakage breaker on the AC power cable of the Controller to avoid the electric shock and circuit breakdown caused by an unexpected water leak.

Prepare the earth leakage brake that pertains the controller you are using. For details, refer to the controller manual.

G6 Rev.11

35


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

Max. Vertical reaction force

: 2500 N

: 1500 N

The threaded holes required for mounting the Manipulator base are M8. 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.

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.

[unit : mm]

47

53

95 26

18

Power Cable

Connector

Signal Cable

Connector

M/C Cables

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

NOTE

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

36

G6 Rev.11


3.3 Mounting Dimensions

The maximum space described in figures shows that the radius of the end effector is 60 mm or less. If the radius of the end effector exceeds 60 mm, define the radius as the distance to the outer edge of maximum space.

If a camera or 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 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.

Ensure distance to the safeguard from the maximum motion range is more than 100 mm.

G6 Rev.11

37


Table Top Mounting

G6-45**

Center of Joint#3

G6-55**

G6-65**

Maximum space a Length of Arm #1 (mm) b Length of Arm #2 (mm) d Motion range of Joint #1 (degree) e Motion range of Joint #2 (degree) f (Mechanical stop area) g Joint #1 angle to hit mechanical stop (degree) h Joint #1 angle to hit mechanical stop (degree)

NOTE

)

S / D

Z : 0 to –270

Z : –270 to –330

Z : 0 to –270

Z : –270 to –330

Z : 0 to –270

Z : –270 to –330

G6-45*

C / P / D bellows

200

250

134.8

Z : 0 to –240

134.8

143.5

Z : –240 to –300

153.9

152

147.5

Z : 0 to –240

147.5

145

Z : –240 to –300

142

124.4

3.5

3

Z : 0 to –270

3

5.5

Z : –270 to –330

8.5

G6-55** G6-65**

300

250

161.2 232

152 152

147.5 147.5

133.8

3.5

400

250

207.5

3.5

6.3 6.3

The bellows for G6-***D are options at shipment.

In the range Z: 0 to –270 mm, the area is limited by interference of the Manipulator body and the arm.

38

G6 Rev.11

Wall Mounting

G6-45**W


G6-65**W

G6-55**W a b g h

Length of Arm #1 (mm)

Length of Arm #2 (mm) d Motion range of Joint #1 (degree) e Motion range of Joint #2 (degree) f (Mechanical stop area)

Joint #1 angle to hit mechanical stop (degree)

Joint #2 angle to hit mechanical stop (degree)

Ceiling Mounting

G6-45**R

G6-55**R

G6-45**W

200

250

195.5

105

130

182.4

3.5

3.8

G6-55*

SW / DW

CW / PW

/ DW bellows

300

250

161.2

135

147.5

146.8

3.5

3.3

172.1

145

5.8

G6-65**W

400

250

232

148

147.5

207.5

7.5

6.3

The bellows for G6-***DW are options at shipment.

G6-65**R a Length of Arm #1 (mm) b Length of Arm #2 (mm) d Motion range of Joint #1 (degree) e Motion range of Joint #2 (degree) f (Mechanical stop area) g Joint #1 angle to hit mechanical stop (degree) h Joint #2 angle to hit mechanical stop (degree)

G6-45**R

SR / DR

G6-55*

CR / PR

/ DR bellows

200

250

300

250

195.5 161.2

120 152

130

182.4

5.5

147.5

146.8

3.5

3.8 3.3

172.1

145

5.8

G6-65**R

400

250

232

152

147.5

207.5

3.5

6.3

The bellows for G6-***DR are options at shipment.

G6 Rev.11

39


3.4 Unpacking and Transportation

THE INSTALLATION SHALL BE PREFORMED BY QUALIFIED INSTALLATION

PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL

CODES.

WARNING

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

■ 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.

■ 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.

Table Top Mounting

G6-45**/G6-55**

Approx. 27 kg : 60 lb.

G6-65**


CAUTION

Wall Mounting

G6-45**W /G6-55**W


G6-65**W

Approx. 29.5 kg : 65 lb.

Ceiling Mounting

G6-45**R/G6-55**R


G6-65**R


■ 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.

40

G6 Rev.11


3.5 Installation

CAUTION

■ 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.

The following sections describe the installation of the Standard Manipulator.


3.5.2 Wall Mounting


When the Manipulator is a Cleanroom-model or Protected-model, refer to each section.

3.5.4 Cleanroom-model

3.5.5 Protected-model


CAUTION

■ Install 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.

G6-45** : Approximately 27 kg: 60 lb.



Standard-model

(1) Secure the base to the base table with four bolts.

NOTE

)

Use bolts with specifications conforming to

ISO898-1 Property Class: 10.9 or 12.9.

4-M8

×40

Spring

Washer

Plane

Washer

20 mm

Screw Hole

(depth 20 mm or more)

(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).

Sheet

Wire tie

Bolt

:M4

×15

Bolt

:M5

×15

G6 Rev.11

41


WARNING

3.5.2 Wall Mounting

■ Install the Wall Mounting Manipulator with two or more people.


G6-45**W : Approximately 29 kg: 64 lb.


G6-65**W : Approximately 29.5 kg: 65 lb.

■ When installing the Manipulator to the wall, 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.

Standard-model

(1) Unpack the manipulator with retaining the arm posture.

NOTE

)

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



Screw Hole


Plane Washer

Spring Washer

42

G6 Rev.11


WARNING


■ Install the Ceiling Mounting Manipulator with two or more people.


G6-45**R : Approximately 27 kg: 60 lb.



■ 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.

Standard-model

(1) Unpack the manipulator with retaining the arm posture.

(2) Secure the base to the ceiling with four bolts.

NOTE

)



Screw Hole


Plane

Washer

Spring

Washer

4-M8

×40

G6 Rev.11

43


3.5.4 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.

3.5.5 Protected-model

Refer to the installation procedure of each Manipulator model and install the Manipulator.

When the Manipulator is a Protected-model, be aware of the followings.

WARNING

■ Connect the power cable connection and the signal cable connector to the

Manipulator immediately after the Manipulator installation. The Manipulator without connecting them may result in electric shock and/or malfunction of the robot system as it cannot ensure IP54 / IP65.

CAUTION

■ When operating the Manipulator under special environmental conditions (adverse conditions with dust and oily smoke), do not place the controller in the same condition since the controller does not comply with IP54 / IP65. Doing so may cause equipment damage to and/or malfunction of the controller.

44

G6 Rev.11


3.6 Connecting the Cables

WARNING





■ 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.

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

CAUTION

■ When connecting the Manipulator to the Controller, make 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 G series Manipulator or E2 series Manipulator is connected to the

Controller for the PS series (ProSix), it may result in malfunction of the

Manipulator.

When the Manipulator is a Cleanroom-model, be aware of the followings.

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


WARNING

■ Connect the power cable connection and the signal cable connector to the

Manipulator immediately after the Manipulator installation. The Manipulator without connecting them may result in electric shock and/or malfunction of the robot system as it cannot ensure IP54 / IP65.

CAUTION

■ When operating the Manipulator under special environmental conditions (adverse conditions with dust and oily smoke), do not place the controller in the same condition since the controller does not comply with IP54 / IP65. Doing so may cause equipment damage to and/or malfunction of the controller.

G6 Rev.11

45


Cable Connections

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

Power Connector

Signal Connector

46

G6 Rev.11


3.7 User Wires and Pneumatic Tubes

CAUTION

■ 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.

Electrical Wires

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

Rated Voltage Allowable Current

AC/DC30 V 1 A

Wires Nominal Sectional Area

24 0.211 mm

2

15 pin

9 pin

Maker Standard

Suitable Connector JAE DA-15PF-N (Solder

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

Suitable Connector JAE DE9PF-N (Solder

Clamp Hood JAE DE-C8-J9-F2-1R

(Connector setscrew: #4-40 NC)

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

Pneumatic Tubes

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

0.59 MPa (6 kgf/cm

2

: 86 psi)

2

2

ø6 mm

× ø4 mm

ø4 mm

× ø2.5 mm

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


■ Be sure to use IP54 or IP65 compliant wires and tubes when using the

Manipulator under special environmental conditions (adverse condition with dust and oily smoke). Using unprotected wires and tubes may cause equipment damage to and/or malfunction of the Manipulator as proper operation of the

Manipulator under the conditions is no more guaranteed.

CAUTION

■ Be sure to attach the cap on the user cable connector when not using the connector. Using the Manipulator without the cap may cause equipment damage to and/or malfunction of the Manipulator as dust or oily smoke gets into the connector.

Common Parts

9-pin D-sub connector

Fitting (black) for

ø6 mm pneumatic tube

Fitting (white) for


15-pin D-sub connector

Fitting (black) for


Fitting (white) for


Brake release button switch

G6 Rev.11

47


Table Top Mounting

48

User connector


Fitting (white) for


User connector


Wall Mounting

Ceiling Mounting

Fitting (white) for ø4 mm pneumatic tube

Fitting (black) for ø6 mm pneumatic tube



User connector





User connector






User connector


User connector


G6 Rev.11


3.8 Relocation and Storage

3.8.1 Precautions for Relocation and Storage

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

WARNING

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

CAUTION

■ 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.

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

Manipulator to the delivery equipment or hold the bottom of Arm #1, the bottom of the main cable fitting, and the bottom of the base by hand. When holding the bottom of the base by hand, be very careful not to get hands or fingers caught.

■ Stabilize the Manipulator with your hands when hoisting 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.

G6 Rev.11

49



CAUTION

■ Install or relocate the Table Top Mounting Manipulator with two or more people.





NOTE

)

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

Remove the mechanical stops if using them to limit the motion range of Joints #1 and

#2. For details on the motion range, refer to Setup & Operation: 5.2 Motion Range

Setting by Mechanical Stops.

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

Tie the lower end of the shaft and arm, and the base and arm together with a wire tie.

Be careful not to tie them too tight. Otherwise, the shaft may bend.

Example of Arm Retaining Posture

Sheet

Wire tie

Bolt

: M5

×15

Washer

: M6

Bolt

: M4

×15

Ｗａｓｈｅｒ

: M5

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

Then, remove the Manipulator from the base table.

50

G6 Rev.11


WARNING

3.8.3 Wall Mounting

■ Install or relocate the Wall Mounting Manipulator with two or more people.




G6-65**W : Approximately 29.5 kg: 65 lb.

■ When removing the Manipulator from the wall, 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.

NOTE

)






Refer to the figure below and bind the shaft and arm retaining bracket on the base.


Bolt

: M4

×15

Washer

: M5

Wire tie

Sheet

Arm mounting bolt

Bolt for Arm #1 mechanical stop

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

Manipulator from the wall.

G6 Rev.11

51



■ Install or relocate the Ceiling Mounting Manipulator with two or more people.





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.

NOTE

)






Refer to the figure below and bind the shaft and arm retaining bracket on the base.


Bolt

: M4

×15

Washer

: M5

Wire tie

Sheet

Arm mounting bolt

Bolt for Arm #1 mechanical stop

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

Manipulator from the ceiling.

52

G6 Rev.11

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.

CAUTION

■ 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 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.

- 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

- Joints #3 and #4 (G6-**3**) cannot be moved

Brake release button up/down by hand because the electromagnetic brake is applied to the joints while power to the robot system is turned OFF. This prevents the shaft from hitting peripheral equipment and rotating 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.

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

To move Joint #3 up/down or rotate Joint #4

(G6-**3**) while attaching an end effector, turn ON the Controller and move the joint up/down or rotate the joint while pressing the brake release button.

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

The respective brakes for Joints #3 and #4 (G6-**3**) are released simultaneously.

- 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.

- For G6-**1**, Joint #4 has no brake on it.

G6 Rev.11

53


Layouts

- When you operate the manipulator with an end effector, the end effector may interfere with the Manipulator because of the outer diameter of the end effector, the size of the work piece, or the position of the arms. When designing your system layout, pay attention to the interference area of the end effector.

4.2 Attaching Cameras and Valves

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

Common Dimensions

4-M4 depth 8

6.7

2-M4 depth 8

41 35 20

4-M4 depth 8

Table Top Mounting

20 80

A

A

B

110

2-M5 depth 10

28

2-M5 depth 10

Wall Mounting

Ceiling Mounting

54

B

A

G6 Rev.11


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.

4.3.1 Weight Setting

CAUTION

■ The total weight of the end effector and the work piece must not exceed 6 kg.

The G6 series Manipulators are not designed to work with loads exceeding 6 kg.

Always set the Weight parameters according to the load. Setting a value that is smaller than the actual load may cause errors, excessive shock, insufficient function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.

The acceptable weight capacity (end effector and work piece) in G6 series is 3 kg at the default rating and 6 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+

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

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

Load on the Arm

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

Equivalent Weight Formula

When you attach the equipment near Arm #2:

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

W

M

M

: equivalent weight

: weight of camera etc.

L

1

L

2

L

M

: length of Arm #1

: length of Arm #2

W

M

= M (L

1

)

2

/(L

W

M

= M (L

M

)

2

/(L

1

2

+L

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

)

2

2

)

2 of camera etc.

G6 Rev.11

55


<Example> A “1 kg” camera is attached to the end of the G6 series arm (450 mm away from the rotation center of Joint #2) with a load weight of “2 kg”.

56

L

2

= 350

L

M

= 450

W

M

= 1

× 450

2

/350

2

= 1.65

→ 1.7 (round up)

W + W

M

= 2 + 1.7 = 3.7

Enter “3.7” for the Weight Parameter.

Automatic speed setting by Weight

(%) 140

120

100

100 100 100

100

100

* The percentage in the graph is based on the speed at rated weight (3 kg) as 100%.

80

60

40

20

70

70

0 1 2 3 4 5 6 (kg)

Weight setting

(%) 140

Automatic acceleration/deceleration setting by Weight

* The percentage in the graph is

120

120

120 120 120 based on the acceleration

100

115

100

/ deceleration at rated weight

(3 kg) as 100%.

80

80

60

70

70

40

G6-45*S*

G6-55*S*

20

(%)

140

120

100

80

60

40

20

0 1 2 3 4 5 6 (kg)

120 120 120

115

100

80

70

Weight setting

* The percentage in the graph is based on the acceleration

/ deceleration at rated weight

(3 kg) as 100%.

G6-65*S*

0 1 2 3 4 5 6 (kg)

Weight setting

G6 Rev.11


CAUTION

4.3.2 Inertia Setting

Moment of Inertia and the Inertia Setting

The moment of inertia is defined as “the ratio of the torque applied to a rigid body and its resistance to motion”. This value is typically referred to as “the moment of inertia”,

“inertia”, or “GD

2

”. 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 0.12 kgwm

2

or less. The G6 series Manipulators are not designed to work with a moment of inertia exceeding 0.12 kgwm

2

.

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.

EPSON

RC+

The acceptable moment of inertia of load for a G6 series Manipulator is 0.01 kgwm

2

at the default rating and 0.12 kgwm

2

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.

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


Automatic acceleration/deceleration setting of Joint #4 by Inertia

(moment of inertia)

(%) 120

100

100

80

60

40

40

20

20

15

0 0.02 0.04 0.06 0.08 0.10 0.12 (kg･m

2

)

Moment of inertia setting

G6 Rev.11

57


Eccentric Quantity and the Inertia Setting

CAUTION

■ The eccentric quantity of load (weight of the end effector and work piece) must be

150 mm or less. The G6 series Manipulators are not designed to work with eccentric quantity exceeding 150 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 G6 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. 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 (150 mm or less)

EPSON

RC+

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.

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


Automatic acceleration/deceleration setting by Inertia (eccentric quantity)

(%) 120

100

100

* The percentage in the graph is based on the acceleration /

80

60

60 deceleration at rated eccentricity

(0 mm) as 100%.

40

40

20

20

0 50 100 150 (mm)

Eccentricity setting

58

G6 Rev.11


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

Work piece (b)

End effector (a)

Work piece (c)

G6 Rev.11

Whole moment of inertia

=

Moment of inertia of end effector (a)

+

Moment of inertia of work piece (b)

+

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 b

2

+ h

2

12

Mass (m) h

L b

(b) Moment of inertia of a cylinder

Cylinder’s center of gravity

Rotation center r

Mass (m)

L r

2

2

59


(c) Moment of inertia of a sphere

Rotation center

Sphere’s center of gravity r

Mass (m) m

2

5 r

2

+ m

× L

2

L

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. (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 after considering the relation between the current position and the destination position.

The upper limit of Joint #3 during horizontal motion using Jump command can be set by the LimZ command.

Automatic acceleration/deceleration vs. Joint #3 position

(%)

120

* The percentage in the graph is

100

100 100 based on the acceleration /

80

60 deceleration at the upper-limited position of Joint #3

40

20

20

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

Height of the shaft

NOTE

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

) over-shoot at the time of final positioning.

60

G6 Rev.11

Setup & Operation 5. Motion Range

5. Motion Range

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

CAUTION

The motion range is preset at the factory as explained in Setup & Operation: 5.4 Standard

Motion Range. That is the maximum motion range of the Manipulator.

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

1. Setting by pulse range (for all joints)

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

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

Manipulator (for Joints #1 and #2)

Rectangular range setting

Mechanical stop

Motion range

Mechanical stop

Pulse range

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.

G6 Rev.11

61


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

Pulses are the basic unit of Manipulator motion. The motion range of the Manipulator is controlled by the pulse range between the pulse lower limit and upper limit of each joint.

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

For the maximum pulse range, refer to the following sections.

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

5.1.1 Max. Pulse Range of Joint #1



5.1.4 Max. Pulse Range of Joint #4.

NOTE

)

EPSON

RC+

Once the Manipulator receives an operating command, it checks whether the target position specified by the command is within the pulse range before operating. If the target position is out of the set pulse range, an error occurs and the Manipulator does not move.

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].)

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 (-).

+Y

A

A

+X 0 pulse

B B

A

Max. Motion

Range

Arm length Table Top Mounting

45

55

65

45

±152 degrees

B

Max. Pulse

Range

55

65

-1805881 to +7048761

Ceiling Mounting

±120 degrees

-873814 to +6116694

Wall mounting

±105 degrees

±135 degrees

±148 degrees

-436907 to +5679787

-1310720 to +6553600

-1689373 to +6932253

62

G6 Rev.11



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 (-).

0 pulse

A A

B B

A

Max. Motion

Range

B

Max. Pulse

Range

G6-45*S* / D*

Model

Z : 0 to –270 mm

Table Top Mounting Ceiling / Wall Mountings

±147.5 degrees

Z : –270 to –330 mm

±145 degrees

Z : 0 to –240 mm

±147.5 degrees

±130 degrees

G6-45*C* / P*

/ D* bellows

Z : –240 to –300 mm

±142 degrees

G6-55*** / G6-65***

±147.5 degrees

G6-45*S* / D*

G6-45*C* / P*

/ D* bellows

Z : 0 to –270 mm

±2685156

Z : –270 to –330 mm

±2369645

Z : 0 to –240 mm

±2685156

Z : –240 to –300 mm

±2585031

G6-55*** / G6-65***

±2685156

±2366578 °

NOTE

)

The bellows for G6-***D are options at shipment.


G6 Rev.11

63



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

Model

G6-**1S* / D*

G6-**3S* / D*

G6-**1C* / P* / D* bellows

G6-**3C* / P* / D* bellows

Joint #3 Stroke

180 mm

330 mm

150 mm

300 mm

Minimum Limit Pulse

-1976708

-1811982

-1647257

-1647257

The bellows for G6-***D* are options at shipment.

NOTE

)

For the Cleanroom-model (G6-***C*) and Protected-model (G6-*** P*/D* with bellows option)

, the motion range set with the Joint #3 mechanical stop cannot be changed.


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 (-).

Counterclockwise (+value)

+Y

+X 0 pulse

±1961226 pulse

Clockwise (-value)

64

G6 Rev.11


5.2 Motion Range Setting by Mechanical Stops

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

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

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

Table Top Mounting

Mechanical stop of Joint #3

(Lower limit mechanical stop)

(Do not move the upper limit mechanical stop.)


(Fixed)

Mechanical stop of

Joint #1 (Adjustable)


(Adjustable)

Mechanical stop of

Joint #1 (Fixed)

Wall Mounting

Mechanical stop of Joint #1 (Fixed)

Ceiling Mounting

Mechanical stop of Joint #1 (Adjustable)

G6 Rev.11

Mechanical stop of Joint #1 (Fixed)

Mechanical stop of Joint #1 (Adjustable)

* The different mechanical stop positions from Table Top mounting are indicated for Wall mounting and Ceiling mounting.

65


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

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

Joint #1 Mechanical Stops e f g h d i c j b k a l

Joint #1

Mounting

Arm

Length a b c d e f g h i j k l

Table Top 45/55/65

+152

° +135°

Ceiling

55/65

Wall

Ceiling

65

°

+105

°

55

°

45

°

+60

° +20°

+5

°

-5° -20° -60°

-105°

-135° -152°

-148°

-135°

+75

° +30°

-30° -75°

-120°

Wall 45

Setting Angle +152

°

+148

° +135° +120° +105°

+75

°

+60

°

Pulse Value 7048761 6932253 6553600 6116694 5679787 4805974 4369067

Setting Angle +30

° +20°

+5

°

-5° -20° -30°

Pulse Value

3495254 3203983 2767076 2475805 2038898 1747627

-60°

873814

Setting Angle

Pulse Value

-75°

436907

-105°

-436907

-120°

-873814

-135°

-1310720

-148°

-1689373

-152°

-1805881

(°: degree)

66

G6 Rev.11


Joint #2 Mechanical Stops m n o p q

Joint #2 m p

Table Top / Ceiling / Wall

Table Top

G6-45*S / D

G6-45*C / P

/ D bellows

Ceiling / Wall

55/65

45 (Z : 0 to –270)

45 (Z :–270 to –330)

45 (Z : 0 to –240)

45 (Z :–240 to –300)

45

+147.5

°

+100

° +125°

+145

°

+147.5

°

+142

°

+130

°

-125° -100°


Setting Angle

+147.5° +145° +142° +130° +125° +100°

Pulse Value

2685156 2639645 2585031 2366578 2275556 1820445

Setting Angle

-100° -125° -130° -142° -145° -147.5°

Pulse Value

-1820445 -2275556 -2366578 -2585031 -2639644 -2685156

(°: degree)

G6 Rev.11

67


(1) Turn OFF the Controller.

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

Joint

1

2

Hexagon socket head cap bolt (fully threaded)

M10 × 20

M8 × 10

The number of bolts

Recommended tightening torque

1 bolt /

12740 N

⋅cm (1300 kgf⋅cm) one side

3720 N

⋅cm (380 kgf⋅cm)

(3) Turn ON the Controller.

NOTE

)

(4) Set the pulse range corresponding to the new positions of the mechanical stops.

Be sure to set the pulse range inside the positions of the mechanical stop range.

The angle of Joint #1 is set from –135 degrees to +135 degrees.

The angle of Joint #2 is set from -125 degrees to +125 degrees.

EPSON

RC+

Execute the following commands from the [Command Window].

>JRANGE 1,-1310720,6553600 ' Sets the pulse range of Joint #1

>JRANGE 2,-2275556,+2275556 ' Sets the pulse range of Joint #2

>RANGE

' Checks the setting using Range

-1310720,6553600,-2275556,2275556,-1976708

,0,-1961226, 1961226

(5) Move the arm by hand until it touches the mechanical stops, and make sure that the arm does not hit any peripheral equipment during operation.

(6) Operate the joint changed at low speeds until it reaches the positions of the minimum and maximum pulse range. Make sure that the arm does not hit the mechanical stops. (Check the position of the mechanical stop and the motion range you set.)

68

EPSON

RC+




>MOTOR ON

' Turns ON the motor

>CP ON

' Enters low-power mode

>SPEED 5

' Sets at low speeds

>PULSE -1310720,0,0,0

' Moves to the min. pulse position of Joint #1

>PULSE 6553600,0,0,0

' Moves to the max. pulse position of Joint #1

>PULSE 2621440,-2275556,0,0 ' Moves to the min. pulse position of Joint #2

>PULSE 2621440,2275556,0,0 ' Moves to the max. pulse position of Joint #2

The Pulse command (Go Pulse command) moves all joints to the specified positions at the same time. Specify safe positions after considering motion of not only the joints whose pulse range have been changed, but also other joints.

In this example, Joint #1 is moved to the center of its motion range (pulse value:

2621440) when checking Joint #2.

If the arm is hitting the mechanical stops or if an error occurs after the arm hits the mechanical stops, either reset the pulse range to a narrower setting or extend the positions of the mechanical stops within the limit.

G6 Rev.11


5.2.2 Setting the Mechanical Stop of Joint #3

NOTE This method applies only to the Standard-model Manipulator (G6-***S*)/Protected-model

)

Manipulator (G6-***D* without bellows option).

For the Cleanroom-model (G6-***C*) and Protected-model (G6-***D* with bellows option), the motion range set with the Joint #3 mechanical stop cannot be changed.

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

(2) Push up the shaft while pressing the brake release button.

Brake release button

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

Lower limit mechanical stop

2-M5×6

NOTE When you press the brake release button, the shaft may lower and rotate due to the

) weight of the end effector. Be sure to hold the shaft by hand while pressing the button.


(4) Loosen the lower limit mechanical stop screw (M4

×15).

NOTE

A mechanical stop is mounted on both the top and bottom of Joint #3. However, only

) the position of the lower limit mechanical stop on the top can be changed. Do not remove the upper limit mechanical stop on the bottom because the calibration point of

Joint #3 is specified using the stop.

(5) The upper end of the shaft defines the maximum stroke. Move the lower limit mechanical stop down by the length you want to limit the stroke.

For example, when the lower limit mechanical stop is set at “150 mm” stroke, the lower limit Z coordinate value is

“-150”. To change the value to “-100”, move the lower limit mechanical stop down “50 mm”. Use calipers to measure the distance when adjusting the mechanical stop.

Measure this distance.

(6) Firmly tighten two lower limit mechanical stop screws (M4

× 15) so that they do not enter the shaft groove.

Recommended tightening torque: 490 N

⋅cm (500 kgf⋅cm)


G6 Rev.11

69


(8) 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.

(9) 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.

G6-**1S (Z: 150mm)

Lower limit of pulse = lower limit Z coordinate value / 20

× 131072 × (62 / 37)

G6-**4S (Z: 300mm)

Lower limit of pulse = lower limit Z coordinate value / 40

× 131072 × (62 / 37)

Example: When lowering the mechanical stop by 50 mm and changing the lower limit Z coordinate value to “-100” in 150 mm stroke

(-100) / 20 × 131072 × (62 / 37 ) = - 1098171

EPSON

RC+

Execute the following command from the [Command Window].

>JRANGE 3,-1098171,0

' Sets the pulse range of Joint #3

(10) Using the Pulse command (Go Pulse command), move Joint #3 to the lower limit position of the pulse range at low speed. If the mechanical stop range is less than the pulse range, Joint #3 will hit the mechanical stop and an error will occur. When the error occurs, either change the pulse range to a lower setting or extend the position of the mechanical stop within the limit.

The clearance between the lower-limit pulse position and the mechanical stop should be approximately 5 mm.

NOTE

If it is difficult to check whether Joint #3 hits a mechanical stop, turn OFF the

)

Controller and lift the arm top cover to check the condition causing the problem from the side.

For details on removing the top cover, refer to Maintenance: 3.1 Arm Top Cover.

Example: When lowering the mechanical stop by 50 mm and changing the lower limit Z coordinate value to “-100” in 150 mm stroke

EPSON

RC+


>MOTOR ON

' Turns ON the motor

>SPEED 5

' Sets low speed

>PULSE 0,0,-1098171,0 ' 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.)

70

G6 Rev.11


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.

EPSON

RC+

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.

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

Manager].

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

5.4 Standard Motion Range

The following “motion range” diagrams show the standard (maximum) specification.

When each Joint motor is under servo control, the center of Joint #3’s (shaft’s) lowest point moves in the areas shown in the figure.

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

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

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

G6 Rev.11

71


Table Top Mounting

G6-45**

G6-55**

Center of Joint#3

Motion range

G6-65**

Maximum space

Area limited by mechanical stop

Base mounting face

(°: degree) a b c d e f g h j k

G6-45*S / D

Z 0 to –270

Z –270 to –330

147.5° 3° 134.8

145° 5.5° 143.5

G6-45*C / P

/ D bellows

Z 0 to –240

Z –240 to –300

152° 3.5°

142° 8.5°

134.8

153.9

G6-65**

200 450 426.6 432

147.5° 6.3°

207.5

161.2

300

232 400 650 603.2 614

G6-45*S / D

G6-45*C / P

Z 0 to –270

147.5°

Z –270 to –330

Z 0 to –240

145°

150.5° 64.4

/ D bellows

Z –240 to –300

142°

G6-65**

147.5° 153.8°

147.5

G6-**1S / D

G6-**3S / D

G6-**1C / P / D bellows

G6-**3C / P / D bellows

180

330

150

300

4.2 12.2

119

−31

1.2 4.2

116

−34


NOTE

)


72

G6 Rev.11

Wall Mounting

G6-45**W


G6-55**W

Center of Joint#3

Motion range

G6-65**W

Maximum space

A rea limited by mechanical stop

Center of base reference hole

(°: degree) a b c d e f g h

G6-55*CW/PW/DW bellows

G6-65**W

135°

3.5°

148° 7.5°

145° 5.8°

146.8

172.1

300 550

6.3° 207.5 232 400 650 j k q r s

G6-45**W 301.8

133.8° 122.4

G6-55*CW/PW/DW bellows 145°

150.8° 86.8

G6-65**W 589.2

614 m n p t

G6-**3SW/DW bellows 330

G6-**3CW/PW/DW bellows 300

The bellows for G6-***DW are options at shipment.

G6 Rev.11

73


Ceiling Mounting

G6-45**R

G6-55**R

Center of Joint#3

Motion range

G6-65**R

Maximum space

Area limited by mechanical

Base mounting face

(°: degree) a b c d e f g h j k

G6-45**R 120° 182.4 195.5

200 450

G6-55*SR/DR 147.5° 3.3°

G6-55*CR/PR/DR bellows 152° 3.5° 145° 5.8°

G6-65**R

146.8

161.2

172.1

300 550 514.9 523

147.5° 6.3° 207.5

232 400 650 603.2 614 q r s

G6-55*CR/PR/DR bellows 145° m n p t

G6-**1SR/DR 180

−9

G6-**3SR/DR bellows 330 141

G6-**1PR/DR 150 102.5

G6-**3PR/DR bellows 300 252.5

The bellows for G6-***DR are options at shipment.

74

G6 Rev.11

Maintenance

This volume contains maintenance procedures with safety precautions for G6 series Manipulators.

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.

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 maintenance- training classes held by the manufacturer, dealer, or locally-incorporated company are allowed to maintain the robot system.

WARNING

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.





G6 Rev.11

77

Maintenance 1. Safety Maintenance

CAUTION


2. General Maintenance

This chapter describes maintenance inspections and procedures. Performing maintenance inspections and procedures properly is essential for preventing trouble and ensuring safety.

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

2.1 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.

Daily inspection

Monthly inspection

Inspection Point

Quarterly inspection

Biannual inspection

Annual inspection

1 month (250 h)

2 months (500 h)

3 months (750 h)

4 months (1000 h)

5 months (1250 h)

6 months (1500 h)

7 months (1750 h)

8 months (2000 h)

9 months (2250 h)

10 months (2500 h)

11 months (2750 h)

12 months (3000 h)

13 months (3250 h)

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√ h = hour

78

G6 Rev.11

Maintenance 2. General Maintenance

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

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.

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

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Check for bends or improper location. Repair or place it properly Safeguard etc. if necessary.

Check tension of timing belts.

Tighten it if necessary.

Inside of Arm #2

Grease conditions

√

Refer to Maintenance: 2.3 Greasing.

√ √ √

√

√

√

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

Inspection Point Inspection Place

√ √ √ √

Daily Monthly Quarterly Biannual Annual

√

√

√

√

Check motion range

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.

Each joint

External cables

(including cable unit of the

Manipulator)

Each arm

Whole √ √ √

Measure the accuracy repeatedly by a gauge.

Whole

√

√

√

√

√

√

√

G6 Rev.11

79


2.3 Greasing

CAUTION

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

Greasing part Greasing Interval

Joint #3 Ball screw spline shaft

First time: after 50 km operation

2nd or more: after 100 km operation

Joint #1

Joint #2

Reduction gear units In the replacement of motor*

Grease Refer to:

AFB

Maintenance: 10.1 Greasing the Ball

Screw Spline Unit

Maintenance:

SK-1A

5.2 Replacing the Joint #1 Reduction

Gear Unit

6.2 Replacing the Joint #2 Reduction

Gear Unit

* 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.

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

CAUTION

If grease gets into your eyes

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

If grease gets into your mouth

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

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

If grease gets on your skin

: Wash the area thoroughly with soap and water.

80

G6 Rev.11


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.

Bolt Tightening Torque

Refer below for the set screw.

Set Screw Tightening Torque

N N

⋅cm (25 kgf⋅cm)

N N

⋅cm (40 kgf⋅cm)

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

1

Bolt hole

3

5

7

8

6

4

Do not fasten all bolts securely at one time.

Divide the number of times that the bolts are fastened into two or three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench so that the bolts are fastened with tightening torques shown in the table above.

2

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+

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

G6 Rev.11

81

82


2.6 Layout of Maintenance Parts

2.6.1 Table Top Mounting type

G6-***S : Standard-model

LED lamp


Arm cover

Ball screw spline unit

Joint #2 motor

Joint #3 motor

Joint #2 reduction gear unit

Cable unit

Z belt

U2 belt

Joint #3 brake

Joint #4 brake

U1 belt

Lithium battery and Battery board

Joint #4 motor


Joint #1 motor

Power cable

Signal cable

(Figure: G6-551S)

G6-***C : Cleanroom-model

G6-***D/P : Protected-model (D: With bellows option)

Brake release button switch (for D/P)

Gasket (D/P)

Bellows (C/D/P)

Gasket (P)

Gasket (P)

Gasket (C/D/P)

Bellows (C/D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

(Figure: G6-551P)

G6 Rev.11


2.6.2 Wall Mounting type

G6-***SW : Standard-model

LED lamp


Arm cover


Power cable

Signal cable

Joint #3 motor

Joint #1 motor

Z belt


U2 belt

Joint #3 brake

Joint #4 brake

U1 belt


Joint #2 motor Cable unit


Joint #4 motor

(Figure: G6-551SW)

G6-***CW : Cleanroom-model

G6-***DW/PW : Protected-model (D: With bellows option)


Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Bellows (C/D/P)

Gasket (D/P)

Gasket (P)

Gasket (C/D/P)

Bellows (C/D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (P)

Gasket (D/P)

Gasket (D/P)

(Figure: G6-551PW)

G6 Rev.11

83


2.6.3 Ceiling Mounting type

G6-***SR : Standard-model

LED lamp


Arm cover


Power cable

Signal cable

Joint #3 motor

Joint #1 motor

Z belt


U2 belt

Joint #3 brake

Joint #4 brake

Joint #2 motor

Cable unit

U1 belt



Joint #4 motor

(Figure: G6-551SR)

G6-***CR : Cleanroom-model

G6-***DR/PR : Protected-model (D: With bellows option)


Gasket (D/P)

Gasket (D/P)

Bellows (C/D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (P)

Gasket (C/D/P)

Bellows (C/D/P)

Gasket (D/P)

Gasket (D/P)

Gasket (P)

Gasket (D/P)

Gasket (D/P)

(Figure: G6-551PR)

84

G6 Rev.11

Maintenance 3. Covers

3. Covers

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

WARNING


■ 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.



■ 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.

Maintenance Parts and Tools

Name Quantity Note

Maintenance parts

Gasket unit

Arm #2 Gasket

Silicon adhesive

(for the gasket on the

Connector Plate)

Hexagonal wrench

(width across flats: 2.5 mm)

1

1

1

1

R13B031226

R13B031227

For M3 screw

Only for Cleanroom-model and

Protected-model


Protected-model

Only for Table top mounting and

Ceiling mounting

/ Protected-model

Only for Wall mounting

/ Cleanroom-model and

Protected-model

Tools

Hexagonal wrench

(width across flats: 3 mm)

1 For M4 screw

Cross-point screwdriver

Wiping cloth

1

1

For bellows removal

For wiping adhesive


Protected-model

G6 Rev.11

85


Table Top mounting

Arm cap

Side cover

Arm top cover

Side cover

Arm cap

Arm bottom cover

Connector plate

Wall mounting

Connector sub plate

Connector plate

Connector sub plate

Maintenance plate

Base bottom cover (Except G6-***S)

Ceiling mounting

Base bottom cover

(Except G6-***SR)

Maintenance plate

Arm top cover

Maintenance plate

Arm top cover

Arm cap

Side cover

Base bottom cover

Side cover

Arm cap

Arm cap

Side cover

Arm bottom cover

Connector sub plate

Connector plate

Side cover

Arm top cover

86

G6 Rev.11


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.

CAUTION

Arm Top Cover

Removal

■ 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.


(2) Press and hold the brake release button switch to let the shaft down. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.

NOTE

)

The brake release button switch affects both Joints #3 and #4. When the brake release button switch is pressed, the brakes for both Joints #3 and #4 are released simultaneously. (Joint #4 brake is installed to G6-**3** only.)

Be careful of the shaft falling or rotation while the brake release button switch is being pushed because it may be lowered by the weight of an end effector.


NOTE

)

(4) Unscrew the arm top cover mounting bolts, and then lift the cover.

When bellows are installed to the manipulator, remove the upper bellows and then remove the arm top cover. For bellows removal, refer to Maintenance 9. Bellows.

The cover cannot be removed completely because user wires and tubes are connected.

However, you can continue regular maintenance.

LED lamp and the cable of the brake release button switch are located between the main part and the cover. Do not pull the cable strong or the connector may be damaged.

G6 Rev.11

87


G6-***S* (Standard-model)

4-M4

×12

G6-***C* (Cleanroom-model),

G6-***D*/P* (Protected-model)

G6-***C*

: 4-M4

×12

G6-***D*/P*

: 4-M4

×15 (SUS)

Gasket

(G6-***P* only)

Gasket

(G6-***P* only)

Arm Top Cover

Installation

Gaskets are installed only to G6-***P*.

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

Lower limit mechanical stop

Cylinder part of the arm top cover


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.

Shaft

When bellows are installed to the manipulator, install the arm top cover and then install the upper bellows. For bellows installation, refer to Maintenance 9. Bellows.

88

G6 Rev.11


3.2 Arm Bottom Cover

Unscrew the arm bottom cover mounting bolts, and then pull the cover downward and remove it.

NOTE

)

The arm bottom 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.

If it is not necessary to remove the cover completely, move the shaft to the lower limit, and lower the arm bottom cover. Then, perform maintenance or inspection.

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

Bellows.


G6-***C* (Cleanroom-model)


Gasket

4-M4

×10

4-M4

×10

A gasket is installed to G6-***C* (Cleanroom-model) and G6-***D*/P* (Protected-model).

G6 Rev.11

89


3.3 Arm #1 Cover

There are two sets of Arm #1 covers.

- Arm caps

- Side covers

Unscrew the bolts mounting the covers and the caps to remove them.

3.3.1 G6-***S* (Standard-model), G6-***C* (Cleanroom-model)

Arm side (Common part) Base side

Table Top mounting

For the arm cap

: 4-M4

×5

For the side cover

: 4-M4

×15

For the arm cap

: 4-M4

×5

Wall mounting

For the side cover

: 4-M4

×15

For the side cover

: 4-M4

×15

Ceiling mounting

For the arm cap

: 4-M4

×5

For the side cover

: 4-M4

×15

For the arm cap

: 4-M4

×5

90

G6 Rev.11


3.3.2 G6-***D*/P* (Protected-model)

Arm side (Common part) Base side

Table Top mounting

For the arm cap

: 4-M4

×5

Gasket

Gasket

For the side cover

: 4-M4

×15

Gasket

For the arm cap

: 4-M4

×5

Wall mounting

For the side cover

: 4-M4

×15

For the side cover

: 4-M4

×15

Gasket

Ceiling mounting

For the arm cap

: 4-M4

×5

For the side cover

: 4-M4

×15

Gaskets are installed to G6-***D*/P* (Protected-model).

Gasket

For the arm cap

: 4-M4

×5

G6 Rev.11

91


3.4 Connector Plate

CAUTION

■ 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 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.

Table

Top mounting


4-M4

×10


Gasket

6-M4

×10

Wall mounting

4-M4

×10

4-M4

×10

Part to apply silicon adhesive

Gasket

92

Ceiling mounting

4-M4

×10

6-M4

×10

Gasket

Part to apply silicon adhesive

G6 Rev.11


NOTE

)

A gasket is installed to G6-***D*/P* (Protected-model).

When installing the gasket to Table Top mounting (G6-***D/P) or ceiling mounting

(G6-***DR/PR), apply silicon adhesive to the gasket installing part on the base side

(shaded part in the photo).

G6 Rev.11

93


3.5 Connector Sub Plate

CAUTION

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

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

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

When routing the cables, observe the cable locations after removing the connector sub plate. Be sure to place the cables back to their original locations.

Table Top mounting

Unscrew the connector sub plate mounting bolts and remove the plate.

G6-***C* (Cleanroom-model) G6-***D*/P* (Protected-model)

4-M4

×10

4-M4

×15

Gasket

Spacer

Wall mounting

4-M4

×10

Sealing washer

4-M4

×15

Sealing washer

Spacer

Gasket

94

Ceiling mounting

4-M4

×10

Gasket

4-M4

×15

Spacer

Sealing washer

A gasket, spacers, and sealing washers are installed to G6-***D*/P* (Protected-model).

G6 Rev.11


3.6 User Plate

Unscrew the user plate mounting bolts and remove the plate.

NOTE

)

Do not remove the nut by force. The nut for the user plate is combined with the user plate. And if you try to remove the nut, it will damage the user plate.


G6-***C* (Cleanroom-model) G6-***D*/P* (Protected-model)

User plate

User plate

Gasket

4-M4

×8

Sealing washer

4-M4

×10

A gasket and sealing washers are installed to G6-***D*/P* (Protected-model).

3.7 Maintenance Plate

Unscrew the maintenance plate mounting bolts and remove the plate.




Table Top mounting

Maintenance plate

4-M4

×5

Maintenance plate

4-M4

×10

Gasket

Wall mounting

4-M4

×5

Spacer

Maintenance plate

Gasket

Ceiling mounting

4-M4

×5

Spacer

4-M4

×10

Maintenance plate

Gasket

Spacer

4-M4

×10

A gasket and spacers are installed to G6-***D*/P* (Protected-model).

G6 Rev.11

95


3.8 Base Bottom Cover

The base bottom cover is removed only when replacing the gasket unit.

Unscrew the base bottom cover mounting bolts and remove the cover.

Table Top mounting

Gasket

Ceiling mounting 6-M3

×8

6-M3

×8

6-M3

×8

6-M3

×8

Gasket

NOTE

)

A gasket is installed to G6-***D*/P* (Protected-model).

A base bottom cover is not installed to G6-***S* (Standard-model).

96

G6 Rev.11

Maintenance 4. Cable Unit

4. Cable Unit

WARNING






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

CAUTION


G6 Rev.11

97


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.

For details, refer to Maintenance: 13. Calibration.

Maintenance parts, Tools and Materials

Maintenance parts

Cable unit

Tools

Material

Grease for cable (GPL-224)

Battery Unit (Lithium battery)

Hexagonal wrench (width across flats: 3 mm)



Spanner (width across flats: 5 mm)

Nut screwdriver (width across flats: 5 mm)

Nippers

Alcohol

Wiping cloth

Wire tie

Note

1

1

1

1

1

Each manipulator model

(Refer to Maintenance:

14. Maintenance parts)

10 g R13B030304

1 R13ZA00600300

For M4 screw

For M5 screw

For M6 screw

For D-sub connector removal

1

1

Proper quantity

1

9

For D-sub connector removal

For cutting wire tie

For wiping grease

For wiping grease

98

G6 Rev.11

Table Top mounting


Cable Unit

Wall mounting

Cable Unit

Ceiling mounting

G6 Rev.11

Cable Unit

99


■ 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.

CAUTION

■ 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.


Cable unit

Removal

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

(2) Press and hold the brake release button switch to let the shaft down. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.

The brake release button switch affects both Joints #3 and #4. When the brake release button switch is pressed, the brakes for both Joints #3 and #4 are released simultaneously. (Joint #4 brake is installed to G6-**3** only.)

Be careful of the shaft falling or rotation while the brake release button switch is being pushed because it may be lowered by the weight of an end effector.

(3) Turn OFF the Controller and disconnect the power cable and signal cable connectors from thee controller.

(4) Remove the connector plate.

For details, refer to Maintenance: 3.4 Connector Plate.

(5) Connect the spare battery to connector XB11.

- The position data of Joint #1 motor is stored with the battery on Arm #2.

Connect the spare battery otherwise the Joint #1 position data will be lost.

NOTE

)

(6) Disconnect the connectors, air tubes, ground wire, D-sub cable, and seven connectors

(X10, X20, X30, X111, X121, X131, XB10) connected to the connector plate (inner side).

- Remember the cable layout so that the cables can be reconnected correctly after replacement.

(7) The procedure of step (7) differs by mounting types.

Follow the corresponding procedure.

100

G6 Rev.11


When using Table Top mounting type or Ceiling mounting type

(7)-1 Remove the saddle part mounting cables inside the base.

(8) 2-M4

×10

Wire tie

(7)-2 Remove the spring plate.

(7)-3 Cut off the two wire ties binding cables.

Saddle part

(7) 2-M4

×10

Spring plate

When using Wall mounting type

(7)-1 Remove the ground plate.

2-M4

×10

Ground plate

(7)-2 Remove the spring plate.

(7)-3 Cut the wire tie banding the cables.

Wire tie

Spring plate

2-M4

×10

(7)-4 Pull out the spring plate.

Spring plate

G6 Rev.11

(7)-5 Remove the saddle part mounting the cables.

2-M4

×10

Saddle part

101


(8) Remove the arm caps and side covers on Arm #1.

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

(9) Remove the arm top cover.

For details, refer to Maintenance: 3.1 Arm Top Cover.

(10) Remove the user plate.

For details of user plate removal, refer to Maintenance 3.6 User Plate.

D-sub cable connector of the brake release button switch from the user plate.

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

Air tube

NOTE

)

Press the ring on the fitting and pull out the air tube. (ø6

×2, ø4×2)

Brake release button cable

Be sure to observe the connection for connecting the disconnected parts after replacement.

(12) Cut off the wire tie binding cables on the Arm

#2 side.

Wire tie

NOTE

)

(13) Remove the 11 connectors on the Arm side.

X21, X22, X31, X32, X33, X41, X42, X61,

X221, X231, X241

Be sure to keep the connectors excluding X61 of the battery board connected at cables replacement. Otherwise, the motor will lose position data and the calibration must be executed again.

NOTE

)

(14) Remove the ground terminals mounted to Arm

#2.

Record the connection terminal and the connection point before disconnect the ground terminal.

G6-***S*/C*: 2 terminals

G6-***D*/P*: 3 terminals

Ground terminal

(15) Remove the saddle part mounting cables inside

Arm #2.

(16) Remove the spring plate.

(18) 2-M4

×10

Saddle part

(17) Cut off the wire ties binding cable and fixing spring.

Spring plate

Wire tie

(17) 2-M5

×10

102

G6 Rev.11


NOTE

)

(18) Pull out the Base side cables from Arm #1.

Table Top mounting

: Pull out from the upper part of Arm #1

Wall mounting / Ceiling mounting

: Pull out from the lower part of Arm #1

When pulling out the cables, first, pull out the air tubes. Then, pull out from the smaller connectors in order.

Do not try to pull out the cables forcibly.

Otherwise, connectors may be stuck, disconnected, or connector pins may fall off.

(19) Pull out the cables that were pulled out from

Arm #1 in step (18) to the side of Arm #1.

Table Top mounting

Cable

Wall / Ceiling mounting

Table Top mounting

Cable

Cable


Cable

NOTE

)

(20) Pull out the Arm #2 side cables from the lower part of Arm #1.

When pulling out the cables, first, pull out the air tubes. Then, pull out from the smaller connectors in order.

Do not try to pull out the cables forcibly.

Otherwise, connectors may be stuck, disconnected, or connector pins may fall off.

(21) Pull out the cables that were pulled out to the lower part of Arm #1 in step (20) to the side of

Arm #1.

Cable

Cable

(22) Remove the Arm #1 four mounting bolts on the spring plate side.

4-M6

×15

G6 Rev.11

(23) Pull out the cables to the base side.

103


Cable unit

Installation

(1) Apply grease (GPL-224) to the cables.

Grease volume: 5 g each (10 g in total)

200 mm

Greasing

Spring

200 mm

Greasing

Spring

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

(The photo shows one end covered with plastic bags)

The plastic bags prevent grease adhesion to the ends of connectors and air tubes during the cable drawing.

Applying positions

Each cable inside the spring

Air tube

Periphery of spring (shaded part)

104

(3) Insert the cables to Arm #1 in the proper direction.

Arm side Base side

Cable

(4) Set the mounting holes of the spring plate to the base side and mount the spring plate to Arm #1.

(5) When using Table Top mounting, pull out the base side cables to the upper part of Arm #1 and pull the cables into the base.

When using Wall mounting or Ceiling mounting, pull out the base side cables to the lower part of Arm #1 and pull the cables into the base.

4-M6

×15

Table Top mounting

Cable


(6) The procedure of step (6) differs by mounting types.

Follow the corresponding procedure.

Cable

G6 Rev.11

G6 Rev.11


When using Table Top mounting type or Ceiling mounting type

Spring plate to the spring plate with a wire tie.

(6)-2 Mount the spring plate to the base.

Spring

Wire tie

2-M4

×10

Spring plate

NOTE

)

(6)-3 Move Arm #1 to the right or left until the arm touches the mechanical stop to make allowance (push the cables toward the spring by approx. 20 mm).

Then, band the cables and air tubes with a wire tie.

If you band the cables and tubes without allowance, the cables are pulled and may be disconnected during the robot operation. Make sure to make allowance.

Wire tie

(6)-4 Remove the plastic bags on the base side applied in step (2). plate.

Push the cables by approx. 20 mm.

Spring plate

Saddle part

2-M4

×10

105


When using Wall mounting type

(6)-1 Pull out the spring and mount it to the spring plate with a wire tie.

(6)-2 Mount the saddle part to mount the cables.

2-M4

×10

Saddle part

Spring plate

(6)-3 Loosely band the cables with a wire tie.

Be sure to keep the wire tie loose enough so that the cables move.

NOTE

)

(6)-4 Move Arm #1 to the right or left until the arm touches the mechanical stop to make allowance (push the cables toward the spring by approx. 20 mm).


If you band the cables and tubes without allowance, the cables are pulled and may be disconnected during the robot operation. Make sure to make allowance.

Push the cables by approx. 20 mm

Wire tie

(6)-5 Remove the plastic bags on the base side applied in step (2).

(6)-6 Mount the spring plate.

106

(6)-7 Mount the ground plate.

Spring plate

2-M4

×10

2-M4

×10

Ground plate

G6 Rev.11


(inner side).

D-sub cable

Spring washer

Nut

Air tube

Plain washer

Ground terminal

D-sub

(8) Loosely mount the connector plate with two screws (M4).


(9) Pull out the Arm #2 side cables to the lower part of Arm #1 and pull the cables into Arm

#2.

Cable

(10) Mount the spring for cable protection to the spring plate with a wire tie.

Secure the spring plate to Arm 2.

Connector plate

Wire tie

Spring

Spring plate

(11) Move Arm #2 until the arm touches the mechanical stop to make allowance (push the cables toward the spring by approx. 20 mm).


NOTE

)

If you band the cables and tubes without allowance, the cables are pulled and may be disconnected during the robot operation.

Make sure to make allowance.

Wire tie

(12) Remove the plastic bags on the Arm side applied in step (2).

Press the cables by approx. 20 mm

G6 Rev.11

107


(13) Mount the saddle part to the spring plate.

Saddle part

(14) Connect the connectors and the ground wire.

For details, refer to Maintenance: 4.2 Wiring Diagrams.

(15) Bind the excess cables with a wire tie.

(16) Connect the D-sub cable, air tubes, and connector of the brake release button switch cable to the user plate.

D-sub cable

2-M5

×10

Air tube

Brake release button cable

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

For details of user plate installation, refer to Maintenance 3.6 User Plate.

(18) Set and secure the Arm #2 cover without the cables being stuck.


(19) Mount the arm caps and side covers for Arm #1.


NOTE

)

(20) Remove the conector plate mounted loosely in the step (8) and remove the spare battery in theXB11. Then, mount the connector plate.

In this replacement method, calibration is not needed.

However, perform the calibration if it is required.

108

G6 Rev.11

4.2 Wiring Diagrams

4.2.1 Signal Cable


G6 Rev.11

109


4.2.2 Power Cable

110

G6 Rev.11

4.2.3 User Cable


Code Cable color

B Black

BR Brown

G Green

L Blue

Code Cable color

R Red

V Violet

W White

Y Yellow

The following table shows the types of the use cable.

Environment Arm Code

S/C

P/D

450 mm

550 mm

650 mm

450 mm

550 mm

650 mm

R13B020042

R13B020043

R13B020044

R13B020045

R13B020046

R13B020047

Note

Waterproof connector

G6 Rev.11

111

Maintenance 5. Arm #1

5. Arm #1


WARNING





CAUTION

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

■ Never disassemble the motor and encoder. A disassembled motor and encoder will cause a 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.

112


Joint #1 motor

G6 Rev.11


5.1 Replacing Joint #1 Motor

Maintenance parts and Tools

Note

R13B000607

Maintenance parts

AC Servo Motor (400 W)

Grease (SK-1A)

Hexagonal wrench (width across flats: 2.5 mm)

1

13 g

1

R13B000616

(For S/N:1**** or later)

R13ZA00330100

For M5 set screw, M3 screw

Tools

Joint #1 motor

Removal



Wiping cloth

(1) Remove the connector plate.

1

1

1

For M4 screw

For M5 screw

For wiping grease


(2) Disconnect the following connectors.

Connectors X111, X10 (Hold the claw to remove.)

Connector XB10

For details, refer to Maintenance: 3.7 Maintenance Plate.


For the details, refer to Maintenance: 4.1 Replacing Cable Unit - Cable unit Removal

Step (7)-2 for Table mounting, Ceiling mounting.

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

Motor unit

To do so, unscrew the bolts from the Joint #1 motor flange. Then, pull out the motor straight and downward.

To unscrew the two bolts on the maintenance hole side, insert a hexagonal wrench through the maintenance hole.

4-M4

×10

If the motor cannot be pulled out easily, pull it out while moving Arm #1 slowly by hand.

(6) Remove the wave generator from the Joint #1 motor.

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

Be careful not to lose it.

Wave generator

M5 brass bushing

2-M5

×8 set screw

Remove the motor flange from the Joint #1 motor.

Motor flange

4-M5

×15

G6 Rev.11 113


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

Installation

Motor flange

4-M5

×15

(2) Mount the waveform generator on the Joint #1 motor.

Apply grease without touching the motor axis.

Be sure to fit the end face of the waveform generator to 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.

Wave generator

M5 brass bushing

2-M5

×8 set screw

SK-1A grease

(13g)

O-ring

CAUTION

■ See the figures above for the orientation of the waveform generator. Be sure to install the waveform generator properly. Improper installation of the waveform generator will result in improper function of the Manipulator.

(3) Insert the oil seal and mount the Joint #1 motor unit on the base.

Motor Unit

Be sure to fit the O-ring properly.

The motor cable must face the connector plate side.

If it is difficult to mount the motor, push it while moving Arm #1 slowly by hand.

4-M4

×10

(4) Connect the connectors X111, X10, and XB10.

114

For the details, refer to Maintenance: 4.1 Replacing Cable Unit - Cable unit

Installation Step (6)-2 for Table mounting, Ceiling mounting.

(6) Mount the connector plate.


(7) Mount the maintenance plate.

For details, refer to Maintenance: 3.7 Maintenance Plate.

(8) Perform the calibration of Joint #1.

For details refer to Maintenance: 13. Calibration.

G6 Rev.11


5.2 Replacing Joint #1 Reduction Gear Unit

A reduction gear unit consists of the following three parts and two attached parts. At replacing the reduction gear unit, be sure to always replace them all together as one set.

Reduction gear unit : Waveform generator / Flexspline / Circular spline

For details of the reduction gear unit, refer to Maintenance: 14. Maintenance parts list.

Maintenance Parts and Tools

Maintenance

Parts

Tools

Note

Reduction Gear Unit (HD25-80)

Grease (SK-1A)

Hexagonal wrench

Hexagonal wrench

Hexagonal wrench

Screw (M4)

(width across flats: 2.5 mm)



1

1

1

1

2

R13B010011

For M4 screw

Hexagonal wrench

Torque wrench

Torque wrench


M4

M6

1

1

1

For M6 screw

Tightening torque 600 N

⋅cm

(61.2 kgf

⋅cm)


⋅cm

(224.3 kgf

⋅cm)

Nippers 1

Spatula 1

1

For apply grease

Wiping cloth

1

For wiping grease (Flange)

For wiping grease (Bolt)

About 20mm in length

For flexspline removal

G6 Rev.11 115


Joint #1 (1) Execute the removal steps from (1) to (5) in Maintenance: 5.1 Replacing Joint #1 reduction gear unit

Motor and remove the waveform generator.

(2) Remove the arm cap on the base side.

Removal


(3) Turn the Manipulator laterally.

CAUTION

■ When turning the Manipulator laterally, there must be two or more people to work on it so that at least one of them can support the arm while others are removing the bolts. Removing the bolts without supporting the arm may result in the arm falling, bodily injury, and/or malfunction of the robot system.

(4) Use the extracting M4 screws and remove the flexspline and the grip ring.

Be sure to keep the spacer.

8-M6

×15

Spacer

Flexspline

Grip ring

(5) Remove the circular spline from the base.

16-M4

×20

Circular spline

116 G6 Rev.11



Installation

(1) A new reduction gear unit contains the parts shown in the picture on the right when it is unpacked.

Apply grease (SK-1A) to the waveform generator and flexspline so that the gear surface is filled with grease.

(2) Set the hole on the circular spline and the tap hole on the base.

16-M4

×20

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.

Item


Circular spline

Bolt type Number of bolts Tightening torque

M4

×20 16 600

M6

×15 8

N

⋅cm (224.3 kgf⋅cm)

(3) Set the grip ring by aligning it with the tap hole.

Set the flexspline by aligning it with the tap hole.

Align the position of the air vent of the spacer.

8-M6

×15

Spacer

Flexspline

Grip ring

(4) Apply grease (SK-1A) inside the flexspline.

Grease volume 27 g

G6 Rev.11

(5) Apply grease (SK-1A) to the bearing part of the waveform generator.

(6) Execute steps from (2) to (3) in Maintenance: 5.1 Replacing Joint #1 Motor.

(7) Turn and secure the Manipulator to the mounting position.

(8) Execute steps from (4) to (7) in Maintenance: 5.1 Replacing Joint #1 Motor.

117


6. Arm #2


WARNING





CAUTION




Controller.




Joint #2 motor


118 G6 Rev.11



Maintenance Parts, Tools and Material

Name Quantity Note

R13B000607

Maintenance

Parts

AC Servo Motor (400W) 1

R13B000616

(For S/N：1**** or later)

R13ZA00330100

Tools

Grease (SK-1A)




Nippers

6 g

1

1

1

1

For M4 set screw

For M4 screw

For M5 screw


Wiping cloth 1 For wiping grease

Material

Joint #2 motor

Wire tie


Removal

4

(2) Push down the shaft to its lower limit while pressing the brake release button switch.

Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.

The brake release button switch is applied to both Joints #3 and #4. When the brake release button switch is pressed, the respective brakes of the Joints #3 and #4 are released simultaneously. (Joint #4 brake is installed to G6-**3** only.)

Be careful of the shaft falling and rotating while the brake release button switch is being pressed because the shaft may be lowered by the weight of an end effector.




(5) Disconnect the connectors X22, X33 connected to the arm top cover.

(6) Cut off the wire tie used for binding the motor cables to the Joint #2 motor.



Connector X62


2-M4

×10

G6 Rev.11

Spring plate

119


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

To do so, unscrew the bolts from the Joint #2 motor flange. Pull the Joint #2 motor unit upward to remove.

If the motor cannot be removed easily, pull it out while moving Arm #2 slowly by hand.

4-M4

×15

(10) Remove the wave generator from the Joint #2 motor.

There is a brass bushing in one of the set screw holes. Be careful not to lose it.

M4 bushing

2-M4

×8 set screw

(11) Remove the motor flange from the Joint #2 motor.

4-M5

×15

120 G6 Rev.11


Joint #2 motor

Installation

(1) Mount the motor flange on the Joint #2 motor.

4-M5

×15

+

M5 small washer

CAUTION

(2) Mount the waveform generator on the Joint #2 motor.

Apply grease without touching the motor axis.

Be sure to fit the end face of the waveform generator to 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.

M4 bushing

2-M4

×8 set screw

SK-1A grease (6g)

Waveform generator

■ See the figures above for the orientation of the waveform generator. Be sure to install the waveform generator properly. Improper installation of the waveform generator will result in improper function of the Manipulator.

(3) Mount the Joint #2 motor unit on Arm #2.

If it is difficult to mount the motor, push it while moving Arm #2 slowly by hand.

4-M4

×15

G6 Rev.11

(4) Mount the spring plate.

(5) Connect the connectors X221, X21, and X62.

(6) Re-bundle the cables in their original positions with a wire tie removed in the removal procedure step (6).

Do not allow unnecessary strain on the cables.

2-M4

×10

Spring plate

(7) Make sure that the connectors X22 and X33 are connected.

(8) Mount the arm top cover.



For details refer to Maintenance: 13. Calibration.

121


6.2 Replacing Joint #2 Reduction Gear Unit

A reduction gear unit consists of the following three parts and two attached parts. At replacing the reduction gear unit, be sure to always replace them all together as one set.

Reduction gear unit : Waveform generator / Flexspline / Circular spline

For details of the reduction gear unit, refer to Maintenance: 14. Maintenance parts list.

Maintenance parts and Material

Reduction Gear Unit (HD20-50)

Grease (SK-1A)



Maintenance parts

Material

Torque wrench M3

Torque wrench M5

Spatula

Wiping cloth

Screw (M3) Length about 20 mm

Wire tie

1

21 g

1

1

1

1

1

1

1

2

4

R13B010012

R13ZA00330100

For M3 screw

For M5 screw


⋅cm

(30.5 k gf

⋅cm

)


⋅cm

(122.3 k gf

⋅cm )

For apply grease

For wiping grease (Flange)

For wiping grease (Bolt)

For flexspline removal

122 G6 Rev.11



Removal




The brake release button switch is applied to both Joints #3 and #4. When the brake release button switch is pressed, the respective brakes of the Joints #3 and #4 are released simultaneously. (Joint #4 brake is installed to G6-**3** only.)



(4) Execute steps from (1) to (10) in Maintenance: 6.1 Replacing Joint #2 Motor and remove the waveform generator from the Joint #2 motor.

(5) Use the extracting M3 screws and remove the flexspline and grip ring from Arm #2.

Spacer

Flexspline

8-M5

×15

Grip ring

(6) Remove the circular spline from Arm #2.

16-M3

×15

Circular spline

G6 Rev.11 123


Joint #2 (1) A new reduction gear unit contains the parts reduction gear shown in the picture on the right when it is unit

Installation unpacked.

Apply grease (SK-1A) to the waveform generator and flexspline so that the gear surface is filled with grease.

(2) Set the hole on the circular spline and the tap hole on the base.

16-M3

×15

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.

Circular spline

Item Bolt type Number of bolts Tightening torque

M3

×15 16 300 N⋅cm (30.5 kgf⋅cm)


M5

×15 8

N

⋅cm (122.3 kgf⋅cm)

(3) Set the grip ring by aligning it with the tap hole.

Spacer

8-M5

×15

Set the flexspline by aligning it with the tap hole.

Flexspline

Grip ring

Align the tap hole and mount the flexspline.

Align the position of the air vent of the spacer.

If it is difficult to align the position, move Arm

#2 from side to side.

Grease volume 15 g

(5) Apply grease (SK-1A) to the bearing part of the waveform generator.

(6) Execute steps from (2) to (9) in Maintenance: 6.1 Replacing Joint #2 Motor.

124 G6 Rev.11


7. Arm #3

WARNING






CAUTION




Controller.




Joint #3 motor

Z belt

Joint #3 brake

G6 Rev.11 125



Maintenance parts, Tools and Material

Name Quantity

Maintenance parts

AC Servo Motor (200W)

Tools

Material




Torque wrench M5

Nippers

Force gauge

Suitable cord (Length about 800 mm)

Wire tie

1

1

1

1

1

1

1

1

2

Note

R13B000608

R13B000614


For M5 set screw

For M4 screw

For M5 screw


⋅cm

(71.3 kgf

⋅cm)


Belt tension 80 N (8.2 kgf)

For belt tension

A brake is mounted on the motor of Joints #3 and #4 to prevent the shaft from moving down due to the weight of the end effector while the power to the Controller is OFF or while the motor is in OFF status (MOTOR OFF). (The brake for Joint #4 is only installed to G6-**3**.)

Note that the brake will not work during the replacement procedure.

Move the shaft down to its lower limit before starting the replacement procedure by following the removal steps from (1) to (3).

126 G6 Rev.11


Joint #3 motor

Removal




The brake release button switch is applied to both Joints #3 and #4. When the brake release button switch is pressed, the respective brakes of the Joints #3 and #4 are released simultaneously. (The brake for Joint #4 is only installed to G6-**3**.)



(4) Remove the arm top cover and the arm bottom cover.

For details, refer to Maintenance: 3. Covers.




Connector X63

(7) Loosen the Z belt.

Loosen four bolts on the Joint #3 motor unit.

Slide the Joint #3 motor unit to the end of the arm.

4-M4×12

+ Washer

Joint #3 motor unit


Unscrew the bolts securing the Joint #3 motor unit. Remove the Z1 pulley from the Z belt.

Pull the Joint #3 motor unit upward to remove.

Z belt

Pulley

(9) Remove the Joint #3 motor from the Joint #3 motor unit.

(10) Remove the pulley from the Joint #3 motor.


(10) M5 bushing

(10) 2-M5

×6 set screw

(9) 4-M5

×10

Joint #3 motor

Pulley

G6 Rev.11 127


Joint #3 motor

Installation

(1) Secure the pulley to the new motor shaft.

Be sure to fit the end face of the pulley to 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.

Brake hub

90

°

M5 bushing

2-M5

×6

Set screw

Z1 Pulley

Push

Joint #3 motor

2-M3

×4

Set screw

0.5 ㎜

Insert a bushing into the other set screw hole to prevent damage to the motor shaft. Then, tighten both set screws.

(2) Mount the Z plate to the Joint #3 motor.

Screw : 4-M5

×12

Tightening torque : 700N

⋅cm (71.3 kgf⋅cm)

Z plate

(3) Loosen the screw securing the pulley.

Push up the pulley to the brake and tighten the screw.

Joint #3 motor

4-M5ｘ12

[Torque:700Nxcm

(71.3 kgf

⋅cm)]

PUSH

Z1 pulley

2-M5

×

6

(4) Loosen the screw securing the hub.

Push down the hub to the pulley side.

Tighten the screw with the space 0.1 - 0.3mm between.

2-M3

×

4 Set screw

0.1 - 0.3mm

Brake hub

PUSH

Joint #3 motor unit

(5) Place the Joint #3 motor unit in the arm so that the motor cable faces toward the front of the arm.

Make sure that the rotor hub on the end face of the pulley is completely set in the fitting on the brake friction plate.

4-M4 ×12

+ Washer

128 G6 Rev.11


(6) Place the Z belt around the Z1 pulley and the Z2 pulley so that the gear grooves of the belt are fit into those of the pulleys completely.

Z belt

Joint #3 motor unit

Z2 pulley Z1 pulley

NOTE

)

(7) Loosely secure the Joint #3 motor unit to Arm #2.

Loosely secure the Joint #3 motor unit to Arm #2 so that the motor unit can be moved by hand, and it will not tilt when pulled. If the unit is secured too loose or too tight, the belt will not have the proper tension.

(8) Apply the proper tension to the Z belt, and then secure the Joint #3 motor unit.

At this point, be careful of the battery board.

To remove the battery board, take out the set screws with cables connected.

Hexagonal wrench (Stubby type) makes it easier to tighten / remove screws.

Z belt tension = 80 N (8.2 kgf)

Joint #3 motor unit

Force gauge

4-M4

×12 + Washer

To do so, pass a suitable cord or string around the Joint #3 motor unit near its mounting plate. Then, pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right.

Make sure that the brake cables do not touch the pulley.

(9) Connect the connectors X231, X31, and X63.

(10) Re-bundle the cables in their original positions with a wire tie removed in step (5).


(11) Install the arm top cover and the arm bottom cover.



For details on the calibration method, refer to Maintenance: 13. Calibration.

G6 Rev.11 129


7.2 Replacing the Timing Belt


Maintenance parts

Z belt (288-3GT-10 width 10 mm)

Tools

Material


Nippers

Force gauge


Wire tie

1

1

1

1

1

2

R13B030206

For M4 screw



For belt tension



Move the shaft down to its lower limit before the replacement procedure following the removal steps from (1) to (3).

130 G6 Rev.11

Z belt

Removal





The brake release button switch is applied to both Joints #3 and #4. When the brake release button switch is pressed, the respective brakes for Joints #3 and #4 are released simultaneously. (The brake for Joint #4 is only installed to G6-**3**.)








Connector X32, X63


4-M4×12

+ Washer

Joint #3 motor unit

(8) Remove the Z belt.

Remove the bolts securing the spline plate and pull out the spline plate upward to remove it.

3-M4

×12

Z belt

Spline plate

G6 Rev.11 131


Z belt (1) Pass a new Z belt through the shaft from above,

Installation and then place it under the spline plate.

(2) Loosely secure the spline plate to Arm #2.

After moving the shaft up and down several times, secure the spline plate to Arm #2.

3-M4

×12

Z belt

(3) Set the Joint #3 motor unit in the arm so that motor cable faces toward the back of the arm.

4-M4×12

+ Washer

Spline plate

Joint #3 motor unit

132

(4) Place the Z belt around the Z1 pulley and the

Z2 pulley so that the gear grooves of the belt are fit into those of the pulleys completely.

Z belt

Joint #3 motor unit

Z2 pulley

Z1 pulley

NOTE

)

(5) Loosely secure the Joint #3 motor unit to Arm #2.



To do so, pass a suitable cord or string around the Joint #3 motor unit near its mounting plate.

Then, pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right.


Joint #3 motor unit

Force gauge

4-M4

×12 + Washer


(7) Connect the connectors X231, X31, X32, and X63.






For details, refer to Maintenance: 13. Calibration.

G6 Rev.11


7.3 Replacing the Brake


Note

Maintenance parts

Solenoid brake




Hexagonal wrench (width across flats: 4 mm) Tools

Nippers

Force gauge


Material Wire tie

1

1

1

1

1

1

1

1

3

R13B030501

For M3 set screw

For M3 screw

For M4 screw

For M5 screw



For belt tension




G6 Rev.11 133


Joint #3 brake (1) Turn ON the Controller.

Removal











Connector X32, X63


4-M4×12

+ Washer

Joint #3 motor unit

(8) Remove the Joint #3 motor from the Z plate.

(9) Remove the brake hub from the Z1 pulley.

(10) Remove the brake from the brake plate.

(8) 4-M5

×12

Joint #3 motor

Z1 pulley

Brake hub

(9) 2-M3

×4 set screw

Z plate

2-M3

×10

Brake

Brake plate

Z plate

134 G6 Rev.11


Joint #3 brake

Installation

(1) Mount the brake to the brake plate.

2-M3

×10

Brake

Brake plate

Z plate

(2) Mount the brake hub to the Z1 pulley.

(3) 4-M5

×12

Joint #3 motor

For the brake hub mounting procedure, refer to the section 7.1 Replacing Joint #3 Motor - Joint

#3 motor installation - Step (1) - (4).

(3) Mount the motor unit to the Z plate.

Align the position of the disk on the brake and the hub.

When the brake disk is not aligned, turn ON the

Controller and connect the connector X32.

Press the brake release button switch and release the brake to manually adjust the position.

(4) Mount the Joint #3 brake unit to Arm #2 so that the open side faces toward the end of the arm.

4-M4×12

+ Washer

Z1 pulley

Brake hub

(2) 2-M3

×4

Z plate set screw

Disk

Hub

Joint #3 motor unit








G6 Rev.11 135


8. Arm #4


WARNING





CAUTION




Controller.




U2 belt

Joint #4 brake

U1 belt

Joint #4 motor

136 G6 Rev.11




Maintenance parts

Tools

Name Quantity

AC Servo Motor (100 W)



Nippers

Force gauge


1

1

1

1

1

1

Note

R13B000609

R13B000617


For M4 set screw

For M4 screw



For belt tension




G6 Rev.11 137


Joint #4 motor (1) Turn ON the Controller.

Removal









(6) Disconnect the following connectors. (X42: G6-**3** only)


Connector X42, X64


Be careful not to break the battery board.

2-M4

×12

+ Washer

Joint #4 motor

Unscrew the bolts securing the Joint #4 motor unit to the Motor plate. Remove the U1 belt from the pulley. Pull the Joint #4 motor unit upward to remove.

(8) Remove the pulley from the Joint #4 motor.


M4 bushing

2-M4

×8 set screw

(9) Remove the motor plate from the Joint #4 motor.

Motor plate

2-M4

×8

138 G6 Rev.11

Joint #4 motor

Installation

(1) Mount the motor plate to the Joint #4 motor.


Motor plate

(2) Secure the pulley to the new Joint #4 motor.

Be sure to fit the end face of the pulley to 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 Joint #4 motor unit in the arm so that the motor cable faces toward the left of the arm.

(4) Place the U1 belt around the U1 pulley and the

U2 large pulley (upper side) so that the gear grooves of the belt are fit into those of the pulleys completely.

(5) Loosely secure the Joint #4 motor unit to Arm

#2.

U1 belt

2-M4

×8

M4 bushing

2-M4

×8 set screw

2-M4

×12

+ Washer

Joint #4 motor

G6 Rev.11

NOTE

)

U2 large pulley

U1 pulley


(6) Apply the proper tension to the U1 belt, and then secure the Joint #4 motor unit.



U1 belt tension = 70 N (7.1 kgf)

Joint #4 motor unit

Force gauge

4-M4

×12 + Washer

(7) Connect the connectors X241, X41, X42, and X64. (X42:G6-**3** only)

139








140 G6 Rev.11


8.2 Replacing the Timing Belt


Maintenance parts

Tools

Force gauge

Name Quantity

U1 belt (236-2GT width 9 mm)

U2 belt (380-2GT width 20 mm)


1

1

1

1

Nippers


1

1

Note

R13B030207

R13B030208

For M4 screw

Belt tension : 70N / 80N / 130N

(7.1 kgf / 8.2 kgf / 13.2 kgf)


For belt tension




G6 Rev.11 141


U1 belt (1) Turn ON the Controller.

Removal








(5) Loosen the bolts securing the Joint #4 motor unit.

(6) Loosen the blots securing the Joint #4 intermediate shaft unit.

Joint #4 motor unit

Joint #4 intermediate shaft unit

(7) Remove the U2 belt from the U2 small pulley and remove the U1 belt from the U1 pulley and

U2 large pulley.

Put the Joint #4 motor unit and the Joint #4 intermediate shaft unit to the shaft side and remove the belt from the pulley.

4-M4

×12 + Washer

Joint #4

Intermediate shaft unit

U1 belt

U2 belt

Joint #4

Motor unit

U2 small pulley

U2 large pulley

U1 pulley

142 G6 Rev.11

U1 belt

Installation


(1) Set the U1 belt around the U1 pulley and U2 large pulley (upper side) so that the gear grooves of the belt are fit into those of the pulleys completely.

(2) Set the U2 belt around the U3 pulley and U2 small pulley so that the gear grooves of the belt are fit into those of the pulleys completely.

U1 belt

U2 large pulley

U1 pulley

U2 belt

G6 Rev.11

(3) Loosely secure the Joint #4 intermediate shaft unit, Joint #4 motor unit to Arm #2 in this order.

Make sure that the gear grooves of the belt are fit into those of the pulleys completely.

U3 pulley

U2 small pulley

Joint #4 motor unit

Joint #4


6-M4

×12 + Washer

NOTE

)

Loosely secure the units to Arm #2 so that the motor unit can be moved by hand, and it will not tilt when pulled. If the units are secured too loose or too tight, the belt will not have the proper tension.

(4) Apply the proper tension to the U2 belt, and then secure the Joint #4 intermediate shaft unit.

To do so, pass a suitable cord or string around the Joint #4 intermediate shaft unit near its mounting plate. Then, pull the cord using a force gauge or similar tool to apply the specified tension shown in the figure on the right.


Joint #4


Force gauge

2-M4

×12 + Washer





Joint #4 motor unit

Force gauge

4-M4

×12 + Washer

143






144 G6 Rev.11

U2 belt

Removal













Connector X63, X32


Remove the bolts securing the Joint #3 motor plate. Remove the Z belt from the pulley.

Pull the Joint #3 motor unit upward to remove.

Z belt

4-M4×12

+ Washer

Pulley

Joint #3 motor unit

G6 Rev.11


(9) Loosen the bolts securing the Joint #4 intermediate shaft unit.

Joint #4 motor unit


6-M4

×12 + Washer

145



U2 large pulley.


U1 belt

U2 belt

Joint #4 motor unit

Put the Joint #4 motor unit and the Joint #4 intermediate shaft unit to the shaft side and remove the belt from the pulley.

(11) Remove the U2 belt.

Remove the bolts securing the spline plate.

Hold the spline plate up and remove the U2 belt from the shaft by pulling them up.

U2 small pulley

U2 large pulley

U1 pulley

U2 belt

3-M4

×12

Spline plate

146 G6 Rev.11

U2 belt

Installation

(1) Pass the U2 belt through the shaft and mount the ball screw spline unit to Arm #2.




U2 belt

3-M4

×12

(3) Place the Joint #3 motor unit back to Arm #2.

(4) Set the Z belt around the Z1 pulley and Z2 pulley so that the gear grooves of the belt are fit into those of the pulleys completely.

Spline plate

Z belt

Joint #3 motor unit


Z2 pulley

Z1 pulley

U1 belt


U2 large pulley

U1 pulley

U2 belt

G6 Rev.11

(7) Loosely secure the Joint #3 motor unit, Joint #4 intermediate shaft unit, Joint #4 motor unit to

Arm #2 in this order.


U3 pulley

U2 small pulley

Joint #4 motor unit

Joint #4


NOTE

)

6-M4

×12 + Washer

Loosely secure the unitｓ to Arm #2 so that the motor unit can be moved by hand, and it will not tilt when pulled. If the units are secured too loose or too tight, the belt will not have the proper tension.

147





Joint #4


Force gauge

2-M4

×12 + Washer





Joint #4 motor unit

Force gauge

4-M4

×12 + Washer





Joint #3 motor unit

Force gauge

4-M4

×12 + Washer





(13) Install the arm top cover and arm bottom cover.


(14) Perform the calibration of Joints #3 and #4.


148 G6 Rev.11


8.3 Replacing the Brake


Maintenance parts

Solenoid brake

Name Quantity

1

Tools

Material



Nippers

Wire tie

1

1

1

1

Note

R13B030502

For M2.5 set screw

For M2.5 screw


The brake for U axis is installed to G6-**3**.




G6 Rev.11 149


Joint #4 brake (1) Turn ON the Controller.

Removal








(5) Disconnect the connector X42.

(6) Cut off the wire tie banding brake cables.

(7) Remove the rubber cap.

Rubber cap

(8) Remove the brake hub.

(9) Remove the brake.

Brake hub

2-M2.5

×25

Brake

150 G6 Rev.11

Joint #4 brake

Installation

(1) Mount the brake to the Joint #4 intermediate shaft unit.

(2) Mount the brake hub to the Joint #4 intermediate shaft unit.


Brake hub

2-M2.5

×25

Brake

Rubber cap

(3) Mount the rubber cap.

Insert 9 mm to the brake.

If the cap is inserted 10 mm or more, the rotation part touches the rubber cap and may result in malfunctions.

Rubber cap

Rotator part

(Brake hub)

(4) Connect the connector X42.



(6) Install the arm top cover.


G6 Rev.11 151

Maintenance 9. Bellows

9. Bellows

NOTE

)

Two bellows make a set as maintenance parts. There is no difference between the upper bellows and lower bellows.

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.


Note

Maintenance parts

Tools

Bellows

Cross-point screwdriver

150 mm

300 mm

1

1

R13B030701

R13B030702

For clamp band removal

Bellows

Removal

(1) Remove the end effector.

(2) Remove the wires and tubes from the end effector.

(3) Turn ON the controller. Stop motor excitation. (MOTOR OFF)

(4) Loosen the two clamp bands on each bellows.

(5) Pull the bellows, rubber sheet, and clamp bands out of the shaft.

(The rubber sheet is not used for the upper bellows.)

Clamp band (small)

Bellows

Clamp band (medium) without rubber sheet

Clamp band (large)

Clamp band (small)

152

G6 Rev.11

Bellows

Installation

G6 Rev.11


(1) To attach the upper bellows, move the shaft to its lower limit.

To attach the lower bellows, move the shaft to its upper limit.

To move the shaft up/down, press and hold the brake release button switch.




(2) Pass the shaft through the bellows from the larger joint.

(3) Secure the cover side of the bellows.

The bellows has two joints:

The larger joint must be attached to the cover side.

The smaller joint must be attached to the end face side of the shaft.

Be careful not to misplace the clamp bands.

The clamp band has three sizes; small, medium, and large.

Attach the mounting part of the bellows until the end touches the cylindrical part of the cover.

Attach the rubber sheet. Be sure to attach the rubber sheet so that no space is made between the bias cut. (No rubber sheet for the upper bellows cover side)

Bias cut

Then, secure them with clamp bands.

Upper bellow cover side

Lower bellow cover side

Rubber sheet

Clamp band

Bellows

(4) Secure the end face side of the bellows to the shaft.

Cover the bearing case (black) on the end face of the shaft with the bellows mounting part.

Attach the rubber sheet. Be sure to attach the rubber sheet so that no space is made between the bias cut.

Bias cut


Upper bellow end face

Lower bellow end face

153


(5) After completing the attachment of the bellows, move the shaft up/down by hand several times and rotate Joint #4. Make sure that the bellows can expand and contract smoothly without any excessive force.

(6) Turn OFF the Controller and peripheral equipment.

(7) Attach the end effector.

(8) Connect the wires and tubes to the end effector.

154

G6 Rev.11

Maintenance 10. Ball Screw Spline Unit

10. Ball Screw Spline Unit


WARNING



NOTE

)




Controller.




G6 Rev.11

155


10.1 Greasing the Ball Screw Spline Unit


Maintenance parts

Name Quantity

For Ball Screw Spline Unit (AFB grease)

Note

Proper quantity R13ZA00330200

Wiping cloth 1 For wiping grease (Spline shaft)

Tools

Cross-point screwdriver 1

For clamp band removal


Protected-model

NOTE

The brake release button switch is applied to both Joints #3 and #4. When the brake

) release button switch is pressed, the respective brakes of the Joints #3 and #4 are released simultaneously. (Joint #4 brake is installed to G6-**3** only.)

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

10.1.1 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 pressing the brake release button switch.



(5) Wipe off the old grease from the upper part of the shaft, and then apply new grease to it.

When applying the new grease to the upper part of the shaft, directly fill the grooves on it by hand. Wipe off excess grease from the shaft.


(7) Move the shaft to its lower limit manually while pressing the brake release button switch.

(8) Wipe off the old grease from the lower part of the shaft, and then apply new grease to it.

When applying the new grease to the lower part of the shaft, directly fill the grooves on it by hand. Wipe off excess grease from the shaft.

(9) Move the shaft up and down several times while pressing the brake release button switch to smooth out the grease on the shaft. Wipe off excess grease from the shaft.

When wiping off the excess grease from the upper part of shaft, turn OFF the

Controller and remove the arm top cover.


156

G6 Rev.11

Upper Part of the Shaft

Lower Part of the Shaft

G6 Rev.11


10.1.2 Cleanroom-model / Protected-model

(C / D with bellows / P 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.



(4) Loosen the clamp band under the bellows, and then lift the bellows.

(5) Move the shaft to its upper limit manually while pressing the brake release button switch.

(4) Clamp band

(6) Wipe off the old grease from the upper part of the shaft, and then apply new grease to it.

Directly fill the grooves on the shaft inside the bellows with grease by hand.

Wipe off excess grease from the shaft.

(6) Shaft

(7) Loosen the clamp band on the bellows, and then move the bellows downward.


(9) Wipe off the old grease from the lower part of the shaft, and then apply new grease to it.

Directly fill the grooves on the shaft inside the bellows with grease by hand.

Wipe off excess grease from the shaft.

(10) Move the shaft up and down several times while pressing the brake release button switch to smooth out the grease on the shaft. Wipe off excess grease from the shaft.

(7) Clamp band

(9) Shaft

(11) Secure the bellows.

To attach the upper bellows, move the shaft to its lower limit.

To attach the lower bellows, move the shaft to its upper limit.

To move the shaft up/down, press and hold the brake release button switch.

Attach the mounting part of the bellows until it touches the cylindrical part of eth cover.

Bias cut

Attach the rubber sheet. Be sure to attach the rubber sheet so that no space is made between the bias cut. (No rubber sheet for the upper bellows cover side)


157


10.2 Replacing the Ball Screw Spline Unit


Maintenance parts

Ball Screw Spline Unit 1

Each manipulator model

(Refer to Maintenance:

14. Maintenance parts)

Tools

Material

For Ball Screw Spline Unit (AFB grease)


Nippers

Force gauge


Wiping cloth

Wire tie

Proper quantity

1

1

1

1

1

2

R13ZA00330200

For M4 screw


Belt tension 70N / 80N / 130N

(7.1 kgf / 8.1 kgf / 13.2 kgf)

For belt tension

For wiping grease

NOTE

)




158

G6 Rev.11


Removal








(4) Detach the wires/tubes from the end effector, and remove the end effector.

(5) This step is only for Cleanroom-model and Protected-model (C / D with bellows option / P).

Remove the bellows. For details, refer to Maintenance: 9. Bellows.

(6) Remove the arm top cover and arm bottom cover.


(7) Cut off the wire tie banding motor cables to the Joint #3 motor.



Connector X32

(9) Remove the Joint #3 motor from Arm #2.

Remove the bolts securing the Joint #3 motor plate. Remove the Z belt from the pulley.

Remove the motor by pulling it up.

Z belt

4-M4×12

+ Washer

Pulley

Joint #3 motor unit

G6 Rev.11


Joint #4 motor unit

Joint #4 intermediate shaft unit intermediate shaft unit.

4-M4

×12 + Washer

159



U2 large pulley.

Joint #4


U1 belt

U2 belt

Joint #4

Motor unit

(13) Put the Joint #4 motor unit and the Joint #4 intermediate shaft unit to the shaft side and remove the belt from the pulley.

U2 small pulley

U2 large pulley

U1 pulley

(14) Remove the U2 belt and Z belt.

Remove the bolts securing the spline plate.

Hold the spline plate up and remove the U2 belt and Z belt from the shaft by pulling them up.

Z belt

U2 belt

3-M4

×12

(15) Remove the nut mounting screws of the ball screw spline shaft on the lower part of Arm #2.

Spline plate

(16) Pull out the ball screw spline unit from Arm #2.

4-M4

×12

160

G6 Rev.11


Installation


(1) Pass the U2 belt and Z belt through the shaft and mount the ball screw spline unit to Arm #2.

U2 belt

Z belt

(2) Secure the nut mounting screws of the ball screw spline shaft on lower side of Arm #2.

Be sure to keep the timing belt from being stuck between the nut and Arm #2.



4-M4

×12

Z belt

U2 belt

3-M4

×12

G6 Rev.11

Spline plate

(4) Place the Joint #3 motor unit back to Arm #2.

(5) Set the Z belt around the Z1 pulley and Z2 pulley so that the gear grooves of the belt are fit into those of the pulleys completely.

Z belt

Joint #3 motor unit

Z2 pulley Z1 pulley


U1 belt

U2 large pulley

U1 pulley

161



U2 belt

U3 pulley

U2 small pulle y

(8) Loosely secure the Joint #3 motor unit, Joint #4 intermediate shaft unit, Joint #4 motor unit to

Arm #2 in this order.


Joint #4 motor unit

Joint #4


10-M4

×12

+ Washe r

Joint #3 motor unit

NOTE

)





Joint #4


Force gauge

Battery board

2-M4

×12 + Washer

If the string is touching the battery board, remove mounting screw for the battery board to put it aside.





Joint #4 motor unit

Force gauge

4-M4

×12 + Washer

Battery board

162

G6 Rev.11






Joint #3 motor unit

Force gauge

Battery board

4-M4

×12 + Washer


(12) Connect the X231, X31, and X32 connectors.



(14) If the position of the lower limit mechanical stop was changed for area limit, secure it to the proper position.

(15) Grease the shaft.

For details, refer to Maintenance: 10.1. Greasing the Ball Screw Spline Unit.

(16) Install the arm top cover and arm bottom cover.


(17) Turn OFF the Controller and peripheral equipment.

(18) Install the end effector, and connect wires and tubes to the end effector.

(19) This step is only for Cleanroom-model and Protected-model (C / D with bellows option / P).

Install the bellows.

For details, refer to Maintenance: 9. Bellows.

(20) Perform the calibration of Joints #3 and #4.


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163

Maintenance 11. Lithium Battery

11. Lithium Battery

WARNING

CAUTION






■ Use meticulous care when handling the lithium battery. Improper handling of the lithium battery as mentioned below is extremely hazardous, may result in heat generation, leakage, explosion, or inflammation, and may cause serious safety problems.

<Improper Handling>

・Battery Charge

・ Disassembly

・ Incorrect Installation

・ Exposing to Fire

・ Forced Discharge

・ Deformation by Pressure

・ Short-circuit (Polarity; Positive/Negative)

・ Heating (85

°C or more)

・ Soldering the terminal of the lithium battery directly

■ When disposing of the battery, consult with the professional disposal services or comply with the local regulation.

Spent battery or not, make sure the battery terminal is insulated. If the terminal contacts with the other metals, it may short and result in heat generation, leakage, explosion, or inflammation.

When the lithium battery power is low, an error will occur to warn the user about the low battery status when the Controller is turned ON (when software is started up).

When the error occurs, the position data in motors will be lost and all joints need to be completely calibrated again.

The life span of the lithium battery is 3 years. Even if the Manipulator is constantly connected to power, the lithium battery needs to be replaced every 3 years.

If the error of the Power-low warning is not occurred, the calibration of the all joints is not necessary. However, when the position is out of place after the battery replacement, perform the calibration.

Be sure to use the specified lithium battery and the battery board.

(Refer to Maintenance: 14. Maintenance Parts List.)

Be sure to set the correct polar when installing the battery.

164

G6 Rev.11

Material

Wire tie 2



Name Quantity

Maintenance parts

Tools

Battery unit (Lithium battery)

Battery board

Nippers


1

1

1

1

Note

R13ZA00600300

R13B041202


For M4 screw

For fixing battery unit (battery)

For fixing cable

G6 Rev.11

165


11.1 Replacing the Battery Unit (Lithium Battery)

Battery unit (1) Turn OFF the Controller.

(lithium battery)


Removal






(4) Connect the connector of the new lithium battery to the battery board.

User the unused connector of the two connectors

X60A, X60B on the upper part of the battery board.

Be sure to connect the connector of the new battery before disconnecting the old battery. If the current battery is disconnected before connecting the new battery, the robot will lose the home position data and the calibration must be executed again.

NOTE

)

Except when the Power-Low warning is appearing.

(5) Cut off the wire tie banding the lithium battery and remove the lithium battery.

X60B

Battery board

Wire tie

X60A

(6) Cut off the wire tie banding the lithium battery,

Remove the battery.

Lithium battery

Battery board

Battery unit

(lithium battery)

Installation

(1) Mount the new lithium battery to the battery board.

(2 ) Fix the cable of lithium battery and connector cable connecting to battery board with wire tie. Refer to the procedure (4).




(5) Check if the Manipulator moves to points (poses) correctly.

To do so, select 2 points (poses) or more from the registered points (poses) and move the Manipulator to the points (poses).

(6) If the Manipulator does not move to the points (poses) correctly, perform the calibration of all joints and axes.


166

G6 Rev.11


11.2 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.




Battery board

Removal







For details, refer to

Maintenance: 3.1 Arm Top Cover.

(4) Disconnect the wiring tie connecting the connector cable.

G6 Rev.11

(5) Disconnect the connectors X61, X62, X63, and

X64 connected to the battery board.

(6) Loosen the screws securing the battery board and remove the battery board.

X63

X64

X61

X62

Battery board

Battery board

2-M4

×10

167


Battery board

Installation

(1) Mount the new battery board and secure it with screws.

Battery board


(3) Fix the connector cable with wiring tie. Refer to procedure (4).

2-M4

×10

X63

X64

X61

X62

Battery board




(6) Perform the calibration of all joints.


168

G6 Rev.11

Maintenance 12. LED Lamp

12. LED Lamp

WARNING







Maintenance parts

LED Lamp

Tools

1 R13A030000200

Cross-point screwdriver 1 For wire removal

Nippers 1

Wire tie 1

Material

LED Lamp

Removal



(2) Disconnect the X1 and X2 terminals from the

LED.

(3) Turn the lens counterclockwise to remove it.

Then, turn the lens holder counterclockwise to remove it.

Lens

Lens holder

Ring

LED

X1 terminal

X2 terminal

LED Lamp

Installation

(4) Remove the LED from the arm top cover.

(1) Connect the X1 and X2 terminals to the LED.

Each terminal must be connected to its terminal number on the LED.

(2) Put the arm top cover between the ring and lens holder, and then mount the LED on the arm top cover.

(3) Install the lens to the lens holder.

(4) Install the arm top cover.


G6 Rev.11

169

Maintenance 13. Calibration

13. Calibration

13.1 About Calibration

After parts have been replaced (motors, reduction gear units, timing belts, etc.), the

Manipulator cannot execute the positioning properly because a mismatch exists between the origin stored in each motor and its corresponding origin stored in the Controller.


WARNING

The process of aligning the two origins is called “Calibration”. Note that calibration is not the same as teaching*.

*: “Teaching” means to teach the Controller coordinate points (including poses) anywhere in the operating area of the 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. 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.

Command Input

Calibration procedures include the process to input commands. Select EPSON RC+ menu-[Tools]-[Command Window] to use the command window.

The information above is omitted in the calibration procedure.

Jog Motion

The process to set the jog motion is included in the [Jog & Teach] page of the Robot

Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog &

Teach] tab to use the [Jog & Teach] page.

The page above is indicated as [Jog & Teach] in the calibration procedure.

In the following calibration procedure, it uses EPSON RC+ 5.0. When the procedure is different for each type of software, see your software type.

EPSON

RC+ 5.0

EPSON

RC+ 6.0

170

G6 Rev.11


13.2 Calibration Procedure

EPSON

RC+ 5.0

EPSON RC+ has a wizard for calibration.

This section indicates the calibration using the calibration wizard of EPSON RC+.

You can also calibrate with TP1 in TEACH mode. For details, refer to RC170/RC180 option Teach pendant TP1 manual Operation: 2.7 Calibrating Origin : E2 Series / G

Series / RS series.

The same calibration procedure is used for each joint.

The follow the steps below are calibration using Joint #1. Follow the steps below to calibrate other joints.

When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately. Execute the procedure in “Calibration Using

Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to

Maintenance: 13.3 Accurate Calibration of Joint #2.

When calibrating Joint #4, you must calibrate Joint #3 and #4 at the same time. You cannot calibrate Joint #4 alone because of the structure of the Manipulator.

NOTE If Err9716 or 5016 (Power supply failure of the absolute encoder. Replace the battery.

)

Check the robot internal wiring) occurs, apply the procedure of 13.4 Calibration

Procedure without using Calibration Wizard - 3. Encoder Initialization and then, start the calibration wizard.

The reference point (a point to check the accuracy) needs to be specified for calibration.

(1) Start the calibration wizard.

EPSON

RC+ 5.0 i. Select EPSON RC+ menu-[Setup]-[Controller] to display the [Controller] dialog. ii. Select [Robot]-[Calibration] to display [Robot Calibration]. iii. Select the joint and click the <Calibrate…> button.

G6 Rev.11

171


EPSON

RC+ 6.0 i. Select EPSON RC+ 6.0 menu-[Setup]-[System Configuration]. ii. Select the [Robot]-[Robot**]-[Calibration].

NOTE

)

Only selected robot can be calibrated. iii. Select the joint and click the <Calibrate…> button.

172

(2) Confirm the warning message and click the <Yes> button.

(3) Move the joint to calibrate manually to approximate zero position, as shown in the dialog. After moving the joint click the <Next> button.

G6 Rev.11

0 pulse position of Joint #1: position aligned with X-axis in

Robot coordinate system

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

0 pulse

0 pulse position of Joint #3: upper limit position in motion range

The height of Joint #3 depends on manipulator model.

0 pulse position of Joint #4: position where the flat surface

(or groove in the up/down mechanical stop) on the shaft faces toward the tip of Arm #2

Standard model

Cleanroom model /

Protected model with bellows option

0 pulse

Groove

Flat surface

G6 Rev.11

173


(4) Click the <Yes> button to reset the encoder.

(5) Reboot the Controller.

* This window will disappear when the Controller starts up.

(6) Select the reference point to use for calibration, and click the <Next> button.

Select a point from the current points to use for checking the accuracy.

(7) Click the <Jog…> button to display the [Jog & Teach] dialog.

174

G6 Rev.11


(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 click on the <Motor

ON> button.

G6 Rev.11

(9) Click the <Next> button.

175


(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 )

176

G6 Rev.11


(13) Jog to the accurate reference position. Click the <Jog> button.

(14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button.

G6 Rev.11

* Position Joint #2 only and move Joint #3 to around 0 pulse.

177


(15) Click the <Next> button.

(16) Execute the procedure in “Calibration Using Right / Left Arm Orientations” to accurately calibrate Joint #2 only.

Go on to the step (19) for the other joints calibration. i. Move to another point that has different pose (from righty to lefty) using Jump command. Click the <Yes> button. ii. Jog to the accurate reference position. Click the <Jog> button.

178

G6 Rev.11

Maintenance 13. Calibration iii. Jog to the accurate reference position and adjust the position. Click the <OK> button.

G6 Rev.11 iv. Click the <Next> button.

179


(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.

180

G6 Rev.11


13.3 Accurate Calibration of Joint #2

When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately.

NOTE

If the accuracy of Joint #2 is not obtained through the steps in the section 13.2 Calibration

)

Procedure, follow the steps below “Calibration Using Right / Left Arm Orientations” to accurately calibrate Joint #2.

The reference point is the center of the ball screw spline shaft during this calibration.

The center of the shaft

When there is a misalignment between the center of the end effector and the center of the ball screw spline shaft, remove the end effector and perform the calibration of the shaft.

There is a misalignment between the center of the end effector and the center of the shaft.

Make a calibration jig as shown in the right figure and attach it on the end of the shaft to make the center of the shaft clear.

Decide a target point and mark a cross (

×) on it so that you can easily verify the center of the shaft after switching the arm pose between right and left.

The center of the shaft

Calibration jig at the end of the shaft

(Example)

G6 Rev.11

Target point

After removing the end effector and performing the calibration, install the end effector and move the Manipulator to the teaching point to verify whether there is a positional gap. If there is a positional gap, fine-tune the installation position of the end effector and teach the point again.

Coordinates for the working point requires calculation in the following cases:

· Teaching the working point by entering the coordinate values (MDI teaching)

· Switching the arm orientation between right and left at a given point

· Using the Pallet command

· Executing CP control (such as liner or circular interpolation)

· Using the Local command

· Pose data specified with relative coordinates <Example: P1+X(100) >

· Vision Guide camera calibrations

181


Calibration Using Right / Left Arm Orientations

182

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.

(3) Click the Free All to free all joints from servo control. Now, you can move arms by hands.

(4) Move the arms to the position of point data for calibration in rightly arm orientation.

(5) From the current position, teach any point data number unused.

This pose (point) is now called P1.

Specify the point number “1” and click the <Teach> button in the [Jog & Teach].

(6) Click the Lock All in the [Control Panel] to lock all joints under servo control.

(7) Switch to the lefty arm orientation. Then, move the arm to the same point.

>Jump P1/L:Z(0) ' Change the arm orientation from righty to lefty

Z is the maximum position

* If there is interference on the way from right to lefty, click the Free All in the

[Control Panel] and change the arm orientation to lefty by hands. Then, go to the step (6), (7).

(8) The joints are slightly out of position.

Adjust the gap with the

−Z in the Jogging group in the [Jog & Teach]. Then, teach another point data number unused. This pose (point) is now called P2.

Specify point number “P2” and click the <Teach> button in [Jog & Teach].

(9) Input the new Hofs value.

> Hofs Hofs (1), Hofs (2) + (Ppls(P1,2) + Ppls(P2,2)) /

2, Hofs(3), Hofs(4)

(10) From the current lefty arm orientation (the position in the step (8)), teach the point data number used in the step (8). This pose (point) is called P2.

Specify point number “P2” and click the <Teach> button in [Jog & Teach].

(11) Switch to the righty arm orientation. Then, make sure the manipulator move to the correct position.

>Jump P2/R ' Change the arm orientation from lefty to righty

* If there is any interference on the way from lefty to righty, click the Free All in the

[Control Panel] and change the arm orientation to righty by hands. Then, go to the step (6), (11).

(12) Move the manipulator to other point data and make sure it moves to the correct position. Teach some more points if required.

* Delete the two points taught for the Joint #2 calibration.

G6 Rev.11


13.4 Calibration Procedure without using Calibration Wizard

NOTE

)

NOTE

)

This section indicates the calibration without using the calibration wizard of EPSON RC+.

For details of calibration using the calibration wizard, refer to 13.2 Calibration Procedure.

When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately. Execute the procedure in “Calibration Using

Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to

Maintenance: 13.3 Accurate Calibration of Joint #2.

You cannot calibrate Joint #4 alone because of the structure of the Manipulator. When calibrating Joint #4, you must calibrate Joint #3 and #4 at the same time.

The reference point (a point to identify the position of the manipulator) needs to be specified for calibration.

Follow steps 1 to 6 described below in order to calibrate the origin.

1. Basic Pose Confirmation

(1)-1 After the part replacement, perform the calibration using the point data currently registered.

Confirm the point data number (P*) to reconstruct the correct manipulator position.

* Point data before the parts replacement (motor, reduction gear, belt, etc.) is necessary for the calibration.

(2)-1 Replace parts as dictated by this manual.

* Be careful not to injure yourself or damage parts during part replacement.

(3)-1 Turn ON the Controller when all joints are in the motion range.

(3)-2 Manually move the joint that needs origin alignment to its approximate 0 pulse position.

G6 Rev.11

183


0 pulse position of Joint #1: position aligned with X-axis in

Robot coordinate system

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 motion range

0 pulse

0 pulse

The height of Joint #3 depends on manipulator model.

0 pulse position of Joint #4: position where the flat surface

(or groove in the up/down mechanical stop) on the shaft faces toward the tip of Arm #2

Standard model

Cleanroom model /

Protected model with bellows option

0 pulse

Groove

Flat surface

184

G6 Rev.11


(3)-3 Connect EPSON RC+ to the Controller.

EPSON

RC+ 6.0

Select a robot to be calibrated. Input as below in the [Command

Window] and execute it.

(This example uses “robot 1”.)

> robot 1

(3)-4 Execute the absolute encoder initialization command.

Input one of the following commands to [Command Window] according to the joint being calibrated.

Joint #1: >EncReset 1



Joint #4: >EncReset 3, 4

Controller.

Select EPSON RC+ menu-[Tools]-[Controller] and click the <Reset

Controller> button.

* This window will be disappeared when the Controller starts up.

(4)-1 Turn ON the motor from EPSON RC+ menu-[Tools]-[Robot Manager]-

[Controller Panel].

(4)-2 Click the <Free All> button in the [Control Panel] page to free all joints and move the arms manually.

(4)-3 Move the Manipulator to the approximate position and orientation.

(4)-4 To perform temporary calibration, input the pulse value of the specified point data.

When the specified point data is “P1,” input and perform the following command to [Command Window] according to the joint being calibrated.

> Calpls Ppls(P1,1), Ppls(P1,2), Ppls(P1,3), Ppls(P1,4)

G6 Rev.11

185


Input and perform one of the following commands to [Command Window] according to the joint being calibrated.

Joint #1: >Calib 1

Joint #2: >Calib 2

Joint #3: >Calib 3

Joint #4: >Calib 3, 4

5. Calibration (Accurate Positioning)

(5)-1 Click the <Lock All> button in [Control Panel] to put all joints back under servo control.

(5)-2 Move the joint to the specified point using a motion command.

For example, when the specified point data is “P1”, click <MOTOR ON> button in [Control Panel] and execute “Jump P1:Z(0)” from [Jog & Teach].

* The joint NOT being calibrated moves to the original position.

(5)-3 Accurately align the joint* being calibrated to the specified point using jog commands.

* You must move Joint #3 and #4 to the position when calibrating Joint #4.

Select the jog mode [Joint] from [Jog & Teach] to execute the jog motion.

(5)-4 Perform the calibration.

Input and perform one of the following commands to [Command Window] according to the joint being calibrated.

Joint #1: >Calib 1

Joint #2: >Calib 2

Joint #3: >Calib 3

Joint #4: >Calib 3, 4

(6)-1 Move the Manipulator to another point to confirm that it moves to the same position.

If it does not move to the same position, re-calibrate using another point.

You must set the point again if reproducibility cannot be assured through calibration.

186

G6 Rev.11

Maintenance 14. Maintenance Parts List

14. Maintenance Parts List

14.1 Common Parts

Part Name Code Note

Reference page

AC Servo Motor

Timing Belt

Battery Board

Battery Unit

Joint #1, 2

Joint #3

Joint #4

Joint #1, 2

Joint #3

Joint #4

Reduction Gear Unit

Joint #1

** Joint #2

Z axis

Solenoid Brake

U axis

Joint #3

Joint #4

R13B000607

R13B000608

R13B000609

R13B000616

R13B000614

R13B000617

R13B010011

R13B010012

R13B030501

R13B030502

R13B030206

R13B030207

R13B030208

R13B041202

R13ZA00600300

400 W

200 W

100 W

108, 115

122

400 W (For S/N: 1**** or later)

U2 : width 20 mm 380-2GT

108, 115



HD25-80

U1 : width 9 mm 236-2GT

122

133

111

HD20-50

Z : width 10 mm 288-3GT

118

129

For G6-**3** (Z: 300/330 mm) *1 145

126

137

137

With lithium battery

Installed in Arm #2

ER17330V (TOSHIBA)

Lithium battery for replacement *3

ER17330V (TOSHIBA)

133

161

160

R13B031223

R13A030000200

For Motor flange of Joint #1 110

*2 163

O-ring

LED Lamp

Grease

Ball Screw Spline

Reduction Gear Unit

R13ZA00330200 AFB grease (400 g)

R13ZA00330100 SK-1A (500 g)

Cable R13B030304 Tube of GPL-224 (227 g)

*1 G6-**1** (Z: 150/180 mm) do not have U axis Solenoid Brake.

*2 Common with E2 series

*3 Common with E2C

*2 78

*2 78

93

G6 Rev.11

187


**

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

This waveform generator consists of an ellipsoidal cam with ball bearings on its outer circumference.

The inner ring of bearings is secured to the cam, while the outer ring is capable of flexible deformation through the ball bearings.

Flexspline

A thin, elastic, cup-shaped metal body with gear teeth around the outer circumference of the opening.

Circular spline

Waveform generator

A rigid, ring-shaped body with gear teeth on the inner circumference.

The circular spline has two more teeth than the flexspline does.

Circular spline Flexspline

The splines are greased. Be sure to keep the grease from being attaching to the clothes.

188

G6 Rev.11


14.2 Parts by Environment Model

Part Name

(S: Standard-model C: Cleanroom-model D/P: Protected-model)

Code Note

Ref. page

Ball Screw Spline

Cable Unit

M/C Cable

S/D

(without bellows)

C

180 mm

330 mm

150 mm

300 mm

P/D with

bellows option

S/C

P/D

S/C

D/P

150 mm

450 mm

550 mm

650 mm

Cable Length 3 m

Cable Length 5 m

Cable Length 10 m

Cable Length 3 m

Cable Length 5 m

Cable Length 10 m

300 mm

450 mm

550 mm

650 mm

450 mm

550 mm

650 mm

450 mm

550 mm

650 mm

R13B010202

R13B010203

R13B010204

R13B010205

R13B010206

R13B010207

R13B020012

R13B020013

R13B020014

R13B020042

R13B020043

R13B020044

R13B020015

R13B020016

R13B020017

R13B020045

R13B020046

R13B020047

R12B020425

R12B020426

R12B020427

R12B020428

R12B020429

R12B020430

Inner wiring cable

(For S/N: 1**** or later)

Inner wiring cable

(For S/N: 1**** or later)

*4

*4

150

152

152

93

93

93

93

45

45

Arm Cover

Bellows

Gasket Unit

Arm #2 Gasket

Brake Release

Switch

C/P

150 mm

/D with bellows option

300 mm

D/P

P

R13B030701

R13B030702

R13B031226

R13B031227

White

85

Plating

*4

148

*1 G6-**1** (Z: 150/180 mm) do not have U axis Solenoid Brake.

*2 Common with E2 series *3 Common with E2C *4 Common with G10/G20 series

G6 Rev.11

189


190

G6 Rev.11

G6 series SCARA ROBOT MANIPULATOR MANUAL Rev.11 EM111R2121F

SCARA ROBOT

G6 series

MANIPULATOR MANUAL

SCARA ROBOT

G6 series

Manipulator 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 G6 series Manipulators

2.2 Model Number and Model Differences

2.3 Part Names and Outer Dimensions

2.3.1 Table Top Mounting

2.3.2 Wall Mounting

2.3.3 Ceiling Mounting

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 Table Top Mounting

3.5.2 Wall Mounting

3.5.3 Ceiling Mounting

3.5.4 Cleanroom-model

3.5.5 Protected-model

3.6 Connecting the Cables

Cable Connections

3.7 User Wires and Pneumatic Tubes

Electrical Wires

Pneumatic Tubes

3.8 Relocation and Storage

3.8.1 Precautions for Relocation and Storage

3.8.2 Table Top Mounting

3.8.3 Wall Mounting

3.8.4 Ceiling Mounting

4. Setting of End Effectors

4.1 Attaching an End Effector

4.2 Attaching Cameras and Valves

4.3 Weight and Inertia Settings

4.3.1 Weight Setting

4.3.2 Inertia Setting

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3

5. Motion Range

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

5.1.1 Max. Pulse Range of Joint #1

5.1.2 Max. Pulse Range of Joint #2

5.1.3 Max. Pulse Range of Joint #3

5.1.4 Max. Pulse Range of Joint #4

5.2 Motion Range Setting by Mechanical Stops

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

5.2.2 Setting the Mechanical Stop of Joint #3

5.3 Setting the Cartesian (Rectangular) Range in the XY

3.3.2 G6-***D/P (Protected-model)