S5 series EPSON ProSix MANIPULATOR MANUAL Rev.4 EM119R2226F

S5 series EPSON ProSix MANIPULATOR MANUAL Rev.4 EM119R2226F
EPSON ProSix
S5 series
MANIPULATOR MANUAL
Rev.4
EM119R2226F
EPSON ProSix S5 series
MANIPULATOR MANUAL Rev. 4
EPSON ProSix
S5 series
Manipulator Manual
Rev. 4
Copyright © 2010-2011 SEIKO EPSON CORPORATION. All rights reserved.
S5
Rev.4
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 robot and its optional parts are shipped to our customers only after being subjected to
the strictest quality controls, tests, and inspections to certify its compliance with our high
performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1. Damage or malfunction caused by improper use which is not described in the manual,
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 robot 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
S5
Rev.4
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
INQUIRIES
Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier office for
your region.
Please prepare the following items before you contact us.
-
Your controller model and its serial number
Your manipulator model and its serial number
Software and its version in your robot system
A description of the problem
SERVICE CENTER
S5
Rev.4
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
TEL
: +81-(0)266-61-1802
FAX
: +81-(0)266-61-1846
SUPPLIERS
iv
North & South
America
EPSON AMERICA, INC.
Factory Automation/Robotics
18300 Central Avenue
Carson, CA 90746
USA
TEL
: +1-562-290-5900
FAX
: +1-562-290-5999
E-MAIL : [email protected]
Europe
EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto-Hahn-Str.4
D-40670 Meerbusch
Germany
TEL
: +49-(0)-2159-538-1391
FAX
: +49-(0)-2159-538-3170
E-MAIL : [email protected]
China
EPSON China Co., Ltd
Factory Automation Division
7F, Jinbao Building No. 89 Jinbao Street
Dongcheng District, Beijing,
China, 100005
TEL
: +86-(0)-10-8522-1199
FAX
: +86-(0)-10-8522-1120
Taiwan
EPSON Taiwan Technology & Trading Ltd.
Factory Automation Division
14F, No.7, Song Ren Road, Taipei 110
Taiwan, ROC
TEL
: +886-(0)-2-8786-6688
FAX
: +886-(0)-2-8786-6677
S5
Rev.4
For Customers in the European Union
The crossed out wheeled bin label that can be found on your product indicates that this
product and incorporated batteries should not be disposed of via the normal household
waste stream. To prevent possible harm to the environment or human health please
separate this product and its batteries from other waste streams to ensure that it can be
recycled in an environmentally sound manner. For more details on available collection
facilities please contact your local government office or the retailer where you purchased
this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used
in the battery.
This information only applies to customers in the European Union, according to
DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and
accumulators and repealing Directive 91/157/EEC and legislation transposing and
implementing it into the various national legal systems.
For other countries, please contact your local government to investigate the possibility of
recycling your product.
The battery removal/replacement procedure is described in the following manuals:
Controller manual / Manipulator manual (Maintenance section)
S5
Rev.4
v
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
S5 series Manipulators can be used with the following combinations of Controllers and
software.
Controller
Software
Type
Composition (Hardware)
RC180
Controller
EPSON RC+ 5.0
RC620
Control Unit
Drive Unit
EPSON RC+ 6.0
For details on commands, refer to “EPSON RC+ User’s Guide” or “Online 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 hardware components, see the table
above.
Photos and Illustrations Used in This Manual
The appearance of some parts may differ from those on an actual product depending on
when it was shipped or the specifications. The procedures themselves, however, are
accurate.
vi
S5
Rev.4
Table of Contents
Before Reading This Manual..............................................................................v
Setup & Operation
1.
Safety ···························································································· 3
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2.
Specifications ············································································ 17
2.1
2.2
2.3
2.4
2.5
3.
3.3
3.4
3.5
3.6
3.7
Rev.4
Features of Manipulators .......................................................................17
Model Number .......................................................................................18
Appearance ...........................................................................................19
Specifications .........................................................................................24
2.4.1 Table ..................................................................................................24
2.4.2 Option Table ......................................................................................25
How to Set the Model ............................................................................26
Environment and Installation ···················································· 27
3.1
3.2
S5
Conventions .............................................................................................3
Design and Installation Safety .................................................................4
Operation Safety ......................................................................................5
Emergency Stop ......................................................................................6
How to Move Arms the Electromagnetic Brake is Applied to ...................7
1.5.1 Moving the Arm Using the Brake Release Unit ...................................8
1.5.2 Moving the Arm Using the Software ..................................................13
Precaution for Operation in Low Power Status ......................................14
Manipulator Labels ................................................................................15
Environmental Conditions ......................................................................27
Unpacking, Transportation, and Relocation ...........................................29
3.2.1 Using a Crane ...................................................................................30
3.2.2 Using a Forklift ..................................................................................31
3.2.3 Removing / Attaching the Shipping Bolts and Jigs ............................31
3.2.4 Relocating .........................................................................................32
Mounting Dimensions ............................................................................33
Installation .............................................................................................34
3.4.1 Base Table Mounting .........................................................................35
3.4.2 Floor Mounting ..................................................................................36
3.4.3 Cleanroom-model .............................................................................37
3.4.4 Protection-model ................................................................................37
Connecting the Cables ..........................................................................38
3.5.1 Cable Connections ............................................................................39
3.5.2 Grounding ..........................................................................................40
Setting the Basic Pose for Calibration ...................................................41
User Wires and Pneumatic Tubes .........................................................43
vii
4.
End Effectors ············································································· 45
4.1
4.2
4.3
4.4
5.
Attaching an End Effector ...................................................................... 45
Attaching Valves .................................................................................... 46
WEIGHT and INERTIA Settings ............................................................ 46
4.3.1 WEIGHT Setting ............................................................................... 49
4.3.2 INERTIA Setting ................................................................................ 53
Precautions for Auto Acceleration / Deceleration .................................. 57
Motion Range ············································································· 58
5.1
Motion Range Setting by Pulse Range (for All Arms) ............................ 59
5.1.1 Max. Pulse Range of Arm #1 ............................................................ 60
5.1.2 Max. Pulse Range of Arm #2 ............................................................ 61
5.1.3 Max. Pulse Range of Arm #3 ............................................................ 62
5.1.4 Max. Pulse Range of Arm #4 ............................................................ 63
5.1.5 Max. Pulse Range of Arm #5 ............................................................ 64
5.1.6 Max. Pulse Range of Arm #6 ............................................................ 65
5.2 Restriction of Manipulator Operation by Joint Angle Combination ........ 66
5.3 Coordinate System ................................................................................ 68
5.4 Setting the Cartesian (Rectangular) Range in
the XY Coordinate System of the Manipulator ........................................ 68
Maintenance
1.
Safety Maintenance ··································································· 71
2.
Periodic Inspection ··································································· 73
2.1
2.2
2.3
2.4
2.5
3.
Covers ························································································ 87
3.1
3.2
3.3
3.4
viii
Schedule for Maintenance Inspections ................................................. 73
Inspection Tasks .................................................................................... 74
Grease Replenishment ......................................................................... 76
2.3.1 Joint #1 Reduction Gear Unit ........................................................... 78
2.3.2 Joint #1 Gear .................................................................................... 79
2.3.3 Joint #2 Reduction Gear Unit ........................................................... 80
2.3.4 Joint #3 Reduction Gear Unit ........................................................... 81
2.3.4 Joint #4 Reduction Gear Unit ........................................................... 82
2.3.6 Joint #5 Reduction Gear Unit ........................................................... 83
2.3.7 Joint #6 Reduction Gear Unit ........................................................... 84
Tightening Hexagon Socket Head Cap Bolts ........................................ 85
Removing Condensation (Only protection-model) .................................. 86
Arm #1 Cover.......................................................................................... 88
Arm #2 Cover ........................................................................................ 89
Arm #3 Cover ........................................................................................ 90
Arm #4 Cover ........................................................................................ 91
S5
Rev.4
4.
Joint #1 ······················································································· 92
4.1
4.2
5.
Replacing the Joint #1 Motor .................................................................92
Replacing the Joint #1 Reduction Gear Unit ..........................................98
4.2.1 Greasing the Reduction Gear Unit ....................................................99
4.2.2 Replacing the Reduction Gear Unit ................................................100
Joint #2 ····················································································· 106
5.1
5.2
5.3
6.
Replacing the Joint #2 Motor ...............................................................106
Replacing the Joint #2 Reduction Gear Unit ........................................ 110
5.2.1 Greasing the Reduction Gear Unit .................................................. 112
5.2.2 Replacing the Reduction Gear Unit ................................................ 113
Replacing the Joint #2 Timing Belt .......................................................120
Joint #3 ····················································································· 122
6.1
6.2
6.3
7.
Replacing the Joint #3 Motor ...............................................................122
Replacing the Joint #3 Reduction Gear Unit ........................................126
6.2.1 Greasing the Reduction Gear Unit ..................................................127
6.2.2 Replacing the Reduction Gear Unit ................................................129
Replacing the Joint #3 Timing Belt .......................................................136
Joint #4 ····················································································· 138
7.1
7.2
7.3
8.
Replacing the Joint #4 Motor ...............................................................138
Replacing the Joint #4 Reduction Gear Unit ........................................141
7.2.1 Greasing the Reduction Gear Unit ..................................................142
7.2.2 Replacing the Reduction Gear Unit ................................................143
Replacing the Joint #4 Timing Belt .......................................................149
Joint #5 & Joint #6 ··································································· 151
8.1
8.2
9.
Replacing the Joint #5 & Joint #6 Motor ..............................................151
Replacing the Joint #5 & Joint #6 Timing Belt ......................................156
Cable Unit ················································································· 158
9.1
9.2
10.
Replacing the Cable Unit .....................................................................158
Wiring Diagrams ................................................................................170
9.2.1 Signal Cable ....................................................................................170
9.2.2 Power Cable ....................................................................................171
9.2.3 User Cable ......................................................................................172
Battery Unit (Lithium Battery) ··············································· 173
10.1 Precautions of the Data .....................................................................173
10.2 Replacing the Battery Unit ...............................................................174
10.3 Data Recovery .................................................................................176
11.
S5
Rev.4
Replacing the LED Lamp ······················································· 178
ix
12.
Calibration ·············································································· 180
12.1 Overview ......................................................................................... 180
12.2 Calibration Procedure ...................................................................... 182
12.3 Calibration Jig ................................................................................... 185
13.
Maintenance Parts List ························································· 187
13.1
13.2
x
Standard ............................................................................................ 187
Option ............................................................................................... 189
S5
Rev.4
Setup & Operation
This volume contains information for setup and operation of the
Manipulators.
Please read this volume thoroughly before setting up and operating
the Manipulators.
Setup & Operation
1.
1. Safety
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.
S5
Rev.4
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 harm to people
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.
3
Setup & Operation
1.2
1. Safety
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 or the Safety 1.3 Design Precautions in
the SPEL CT 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 or the Safety part in the
SPEL CT 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, and 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. Environment and Installation. Please read this chapter carefully to understand
safe installation procedures before installing the robots and robotic equipment.
4
S5
Rev.4
Setup & Operation
1.3
1. Safety
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 or the Safety 1.1 Safety-related Requirements in
the SPEL CT User’s Guide before operating the robot system. Operating the
robot system without understanding the safety requirements is extremely
hazardous and may result in serious bodily injury and/or severe equipment
damage to the robot system.
■ Do not enter the operating area of the Manipulator while the power to the robot
system is turned ON. Entering the operating area with the power ON is
extremely hazardous and may cause serious safety problems as the Manipulator
may move even if it seems to be stopped.
WARNING
■ Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
The motion of the Manipulator is always in restricted status (low speeds and low
power) to secure the safety of an operator. However, operating the robot
system while someone is inside the safeguarded area is extremely hazardous
and may result in serious safety problems in case that the Manipulator moves
unexpectedly.
■ Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally while the robot system is operated. Continuing the operating the
robot system while the Manipulator moves abnormally is extremely hazardous
and may result in serious bodily injury and/or severe equipment change to the
robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT
connect it directly to a factory power source. To shut off power to the robot
system, pull out the power plug from the power source. Performing any work
while connecting the AC power cable to a factory power source is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
WARNING
■ 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
S5
Rev.4
■ 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.
5
Setup & Operation
1.4
1. Safety
Emergency Stop
If the Manipulator moves abnormally during operation, immediately press the Emergency
Stop switch. It 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 robot system in emergency mode during normal operation, press the
Emergency Stop switch when the Manipulator is not moving.
Refer to the Controller manual for instructions on how to wire the Emergency Stop switch
circuit.
Free running distance in emergency
The operating Manipulator cannot stop immediately after the Emergency Stop switch is
pressed.
However, remember that the values vary depending on conditions such as the weight of
the end effector and work piece, WEIGHT/SPEED/ACCEL settings, operating pose, etc.
The free running time/angle/distance of the Manipulator are shown below.
Conditions of Measurement
ACCEL Setting
100
SPEED Setting
100
Load [kg]
5
WEIGHT Setting
5
RC180 / RC620
S5-A701**
Free running time
[second]
Free running angle
[degree]
6
Arm #1
Arm #2
Arm #3
Arm #4
Arm #5
Arm #6
Arm #1
Arm #2
Arm #3
Arm #4
Arm #5
Arm #6
S5-A901**
0.4
0.4
0.4
0.4
0.4
0.1
55
35
30
60
40
35
40
50
10
S5
Rev.4
Setup & Operation
1.5
1. Safety
How to Move Arms the Electromagnetic Brake is Applied to
When the electromagnetic brake is applied to all arms (such as emergency mode), you
cannot move any arm by pushing it manually.
There are two methods to release the electromagnetic brake. Follow either method to
release the electromagnetic brake and move the arms manually.
1.5.1 Moving the Arm Using the Brake Release Unit
Follow the method when you just unpack the delivered boxes or when the
Controller does not start up yet.
1.5.2 Moving the Arm Using the Software
Follow the method when you can use the software.
Arm Motion
J3−
J4+
Joint #5
J5+
Arm #5
J6+
Joint #6
Arm #3
Arm #6
J3+
J4−
Joint #3
J5−
J6−
Arm #4
Joint #4
Arm #2 (Lower Arm)
J2−
J2+
Joint #2
J1+
Arm #1
Joint #1
J1−
Base
S5
Rev.4
7
Setup & Operation
1.5.1
1. Safety
Moving the Arm Using the Brake Release Unit
With the electromagnetic brake is ON (such as in Emergency Stop status), you cannot
move all arms by hand.
You can move Arms by hand using the brake release unit while the controller power is
OFF or right after unpacking.
■ Before connecting/disconnecting the connector of Brake release unit, be sure to
check the powers of the controller and break release unit are OFF.
WARNING
Otherwise, it leads to the electrical shock or breakdown.
■ Release a brake for each joint one by one. If you need to release some brakes
at a time, take a great care. Because when some joints are released at a time,
the arms may fall to unintended directions. This is extremely dangerous and
may break the manipulator or catch your hand, fingers.
CAUTION
■ Take care of the arm downward motion when the brake is released.
While you are pressing the brake release switch, the arm moves downward by its
own weight. This is extremely dangerous and may break the manipulator or
catch your hand, fingers.
Width
Depth
Height
Weight (Cables are not included.)
Cable to the Manipulator
Power cable length
Power cable (US, Japan)
Power cable (EU)
A
Power switch Power cable
8
180 mm
150 mm
87 mm
1.7 kg
2m
2m
100 V specification
200 V specification
View from A
Power lamp
Arm switches
S5
Rev.4
Setup & Operation
1. Safety
Precautions for use
CAUTION
NOTE
)
■ After the brake release unit is disconnected, be sure to connect the external short
connector. Otherwise, you cannot release the brakes.
■ Keep the external short connector.
Otherwise you cannot release the brakes.
■ If you turn ON the brake release unit while the brake release switch is being
pressed, an unintended arm may move downward.
Before turning ON the brake release unit, make sure that the brake release
switch is not pressed.
■ If you turn ON the brake release unit without the connector, it may lead to the
short for the male pin used in the connector.
Before turning ON the brake release unit, make sure that the connector is
connected.
■ When you purchased several S5 series Manipulators and use the brake release
unit in the manipulator without the connection cable, you need to change the
connection cable inside the manipulator.
To skip this switching work, purchase the cable set for the brake release unit.
If you purchased the manipulator and connection cable together, the cable has
been installed to the manipulator before shipment.
For additional external short connector or connection cable, please contact us.
S5
Rev.4
9
Setup & Operation
1. Safety
How to connect the connection cable
If you purchased the manipulator and connection cable together, the cable has been
installed to the manipulator before shipment. This procedure is not necessary.
(1) Turn OFF the controller.
(2) Remove the hiding plate.
2-M4×10
(3) Open the connector plate.
4-M4×10
(2) 2-M4×8
Hiding plate
Connector plate
(3) 4-M4×8
(4) Pass the cable through the hole below
the hiding plate from the outside.
Connection cable
Connect the connection cable to the
connector plate.
Connector plate
2-M4×10
(5) Take out the connector of internal cable
SW1.
(6) Disconnect the internal short connector.
Keep the short connector to the inside
of base or somewhere not to lose.
Internal short connector
(7) Connect the connection cable and
internal cable SW1.
Connection
cable
Connector
SW1
(8) Mount the connector plate. Be careful not to catch the cables.
4-M4×10
(9) If the brake release unit is not used,
mount the external short connector.
To prevent the external short connector
from falling off, secure the two screws
included with the connector.
10
External short connector
S5
Rev.4
Setup & Operation
1. Safety
Mount the brake release unit
(1) Turn OFF the controller.
(2) Remove the external short connector.
External short connector
(3) Connect the brake release unit to the
connector of the connection cable.
Connector of the
connection cable
Remove the brake release unit
(1) Turn OFF the brake release unit.
(2) Remove the power cable of the brake release unit.
(3) Disconnect the brake release unit from the connector of connection cable.
(4) Connect the external short connector to the connector of connection cable.
S5
Rev.4
11
Setup & Operation
1. Safety
How to use the brake release unit
CAUTION
■ Be careful of the arm downward motion while you release the brakes.
The arm will move downward by its own weight while you are pressing a brake
release switch. This is extremely dangerous and may break the manipulator or
catch your hand, fingers.
■ If the arm you released the brake moves strange or slower than normal, stop the
motion promptly and contact us. The brake release unit is possibly broken and
if you keep operating the manipulator, it may lead to the brake of the
manipulator or you will be caught by the hand or fingers.
Power switch
Power cable
Power lamp
Arm switches
(1) Mount the brake release unit on the manipulator.
For the mounting procedure, refer to Mount the brake release unit described in the
previous page.
(2) Plug the power cable into the brake release unit.
(3) Plug the power cable into the power supply plug.
(4) Turn ON the brake release unit.
When the brake release unit is enabled, the power lamp lights up.
(5) Press the arm switch J1 ~ J6 you want to move and then move the arm.
Press the switch again, then the brake will be released.
The brake will be enabled by pressing the switch once again.
NOTE
)
Move the arm the brake is released by two persons or more (one presses the switch
and one moves the arm). The arm can be very heavy and needs the significant force
to move.
When the Manipulator is a Protection-model, be aware of the followings.
CAUTION
12
■ Do not leave the brake release unit in special environmental conditions (adverse
conditions with dust and oily smoke). The brake release unit does not comply
with IP65. Leaving the brake release unit in the special environmental
conditions may cause damage to and/or malfunction of the brake release unit.
S5
Rev.4
Setup & Operation
1. Safety
1.5.2 Moving the Arm Using the Software
■ Normally, release the brake of a single joint at a time. Take extra care to release
the brakes of two or more joints simultaneously from necessity. Releasing the
brakes of two or more joints simultaneously may cause hands and fingers to be
caught and/or equipment damage to or malfunction of the Manipulator as the
arms of the Manipulator may move in unexpected directions.
CAUTION
■ Be careful of the arm falling when releasing the brake.
While the brake is being released, the Manipulator’s arm falls by its own weight.
The arm falling may cause hands and fingers to be caught and/or may cause
equipment damage to or malfunction of the Manipulator.
■ Before releasing the brake, be sure to keep the Emergency Stop switch handy so
that you can immediately press the Emergency Stop switch. If you cannot
immediately press the Emergency Stop switch, you have no means to stop the
arms urgently when a wrong operation causes the arm to fall. The arm falling
may cause equipment damage to and/or malfunction of the Manipulator.
After releasing the Emergency Stop switch, Execute the following commands.
[Command Window]
>Reset
>Brake Off,[the number (from 1 to 6) corresponding to the arm whose brake will be
turned off]
Execute the following command to turn on the brake again.
>Brake On,[The number (from 1 to 6) corresponding to the arm whose brake will be
turned on]
S5
Rev.4
13
Setup & Operation
1.6
1. Safety
Precaution for Operation in Low Power Status
When the power mode is low, the Manipulator will operate at low speed and low torque.
However, comparatively high torque is generated under some circumstances so that the
Manipulator can support its own weight. The maximum torque of each joint in the low
power status is shown in the following table “Max. Joint Torque in Low Power Status”.
Even though the Manipulator is in the low power status, carefully operate the Manipulator
since a comparatively high joint torque may be generated. Be careful not to get hands or
fingers caught during operations. The Manipulator may also collide with peripheral
equipment and it may cause equipment damage to or malfunction of the Manipulator.
Max. Joint Torque in Low Power Status
CAUTION
14
[Unit: N·m]
Joint
#1
#2
#3
#4
#5
#6
S5-A701**
121.80
135.82
56.59
12.72
19.21
8.01
S5-A901**
167.06
169.78
70.74
12.72
19.21
8.01
■ Carefully operate the Manipulator even though it is in the low power status. A
comparatively high joint torque may be generated. The comparatively high joint
torque may cause hands and fingers to be caught and/or may cause equipment
damage to or malfunction of the Manipulator as it may collide with peripheral
equipment.
S5
Rev.4
Setup & Operation
1.7
1. Safety
Manipulator Labels
The following labels are attached around the locations of the Manipulator where specific
dangers exist.
Be sure to comply with descriptions and warnings on the labels to operate and maintain
the Manipulator safely.
Do not tear, damage, or remove the labels. Use meticulous care when handling those
parts or units to which the following labels are attached as well as the nearby areas:
Location
of Labels
Labels
(1)
Location
of Labels
Labels
(5)
NOTE:
Hazardous voltage exists while
the Manipulator is ON. To avoid
electric shock, do not touch any
internal electric parts.
(2)
(6)
(3)
(4)
(7)
(8)
S5
Rev.4
15
Setup & Operation
1. Safety
Location of Labels
(1)
(3)
(4)
(6)
(7)
Lateral View (Left side)
Lateral View (Right side)
(1)
(5)
(2)
(1)
Back View
16
Front View
S5
Rev.4
Setup & Operation
2.
Specifications
2.1
Features of Manipulators
2. Specifications
(1) High-speed and high-accuracy control
S5 Manipulator is controlled at high speed and high accuracy by techniques we have
acquired while improving our SCARA robots.
- S5 Manipulator moves at high speed and stops at target points as you desire.
- High-speed and high-accuracy positioning shortens cycle time.
- Maximum operating speed has been improved at the highest level for the small
industrial robot industry.
- Residual vibration has been decreased.
- Improved rigidity of the arms reduces vibration and deflection of the Manipulator.
- S5 Manipulator holds position with great stability.
(2) High-accuracy trajectory control
The accuracy of CP trajectory control has been improved so that you can operate the
Manipulator with more flexibility while taking advantage of six degrees of freedom.
(3) Available for large payloads
Large allowable moment of inertia has made it possible to support relatively large
payloads.
Optimal control for payload by using the WEIGHT and INERTIA commands make
handling large payloads more stable.
UL specification (UL1740 Conformance Type)
UL1740 is the Standard for Industrial Robots and Robotic Equipment established by
Underwriters Laboratories Inc. (UL). The UL1740 conformance product has a safety
mark which shows that Underwriters Laboratories Inc. (UL) has recognized it.
In the United States, the robot system is recommended to be used with the Manipulators
and Controller that conform to UL1740 in accordance with ANSI/RIA R15.06.
S5
Rev.4
17
Setup & Operation
2.2
2. Specifications
Model Number
S5 - A 701 S R - UL
UL specification
UL : UL compliant
□ : Non UL compliant
Type
□ : Table Top mounting
W
: Wall mounting
R
: Ceiling mounting
Environment
S
C
P
: Standard model
: Clean-room model
: Protection-model
Arm length
7
: 706 mm
9
: 895 mm
Environment
Cleanroom-model
Cleanroom-model Manipulator includes additional features that reduce dust emitted by
the Manipulator to enable use in clean room environments.
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 cm3 (1cft) sample-air around the
center of the motion rang: 10 particles or less.)
Exhaust System
: Exhaust port diameter:
Inner diameter: ø12 mm / Outer diameter: ø16 mm
Exhaust tube : Polyurethane tube
Outer diameter: ø12 mm (Inner diameter:ø8 mm)
or Inner diameter ø16mm.
Recommended exhaust flow rate : Approx. 1000 cm3/s (Normal)
Protection-model (IP65)
The Protection-model Manipulators operate under adverse conditions with dust and oily
smoke.
IP (International Protection) for the Protection-model Manipulator indicates
International Standard of the protection level against dust and water.(IEC 60529, JIS
C0920)
Degree of protection
Dust : 6
IP65
Water : 5
No ingress of dust.
Water projected by a nozzle against enclosure from any direction
shall have no harmful effects.
For details on the specifications, refer to Setup & Operation: 2.4 Specifications.
18
S5
Rev.4
Setup & Operation
2.3
2. Specifications
Appearance
Part Names and Motion Range of Each Arm
Upper Arm (Arms #3 to #6)
LED Lamp
(This lamp lights up
while the motors are ON.)
J3−
J4+
Arm #5
Joint #5
J5+
J6+
Joint #6
Arm #3
Arm #6
J3+
J5−
J4−
Arm #4
Joint #4
Joint #3
J6−
Arm #2 (Lower Arm)
J2+
J2−
Arm #1
Joint #2
J1+
Joint #1
Arm Motion
Arm #1 : The whole Manipulator revolves.
Arm #2 : The lower arm swings.
J1−
Arm #3 : The upper arm swings.
A
Arm #4 : The wrist revolves.
Base
Arm #5 : The wrist swings.
Arm #6 : The wrist rotates.
Details of Connector Plate (View A)
A : Grease Supply Opening
B : User Cable Connector
(15 pin D-sub connector)
A
B
C D
E
F
Standard model
Protection-model
S5
Rev.4
A
B
C D
E
F
G
Cleanroom-model
C : Air Supply Opening
D : Air Supply Opening
E : Signal Connector
F : Power Connector
G : Exhaust Port
(Only Cleanroom-mode)
19
Setup & Operation
2. Specifications
Outer Dimensions
S5-A701**
[Unit: mm]
Air Supply Opening
M5 Tap
with cover plug
423
298
25
40
110
87
Space
for cables
90 or more
114
55
59
70
2-M4 Tap P0.7 Depth: 8mm
2×2 M4 Tap P0.7Depth 8 mm
(Front & Back)
4-M8 Tap P1.25 Depth: 16mm
100
88
305
80
109
199
330
752
310
40
66
1 09
473
150.2
623.2
20
S5
Rev.4
Setup & Operation
2. Specifications
S5-A901**
[Unit: mm]
Air Supply Opening
M5 Tap
with cover plug
523
398
87
Space
for cables 90 or more
114
55
25
40
110
70
2-M4 Tap P0.7 Depth: 8mm
2×2 M4 Tap P0.7Depth 8 mm
(Front & Back)
4-M8 Tap P1.25 Depth: 16mm
100
88
405
80
109
199
330
842
400
40
66
109
150.2
573
723.2
S5
Rev.4
21
Setup & Operation
2. Specifications
Standard Motion Range
S5-A701**
[Unit: mm] (° = degree)
Top View
+170° (Arm #1)
Motion range of P point*
P point*
R235
Joint #1
0 pulse position
R706
−170° (Arm #1)
Joint #2
0 pulse position
Lateral View
Front View
706
501
88
305
80
Joints #4, #6
0 pulse position
15
−190°
+190°
−360°
+360°
40
+135°
+65°
310
179
246
156
239
330
Joints #3, #5
0 pulse position
136°
233
277
51
Motion range of P point*
114
203
246
22
P point*
−150°
752
948
−135°
225°
* P point: Intersection of the rotation
centers for Joints #4, #5, and #6
S5
Rev.4
Setup & Operation
S5-A901**
2. Specifications
[Unit: mm] (° = degree)
Top View
+170° (Arm #1)
Motion range of P point*
P point*
R267
Joint #1
0 pulse position
R895
−170° (Arm #1)
Joint #2
0 pulse position
Lateral View
681
88
405
Front View
895
80
Joints #4, #6
0 pulse position
9
+190°
−190°
−360°
+360°
40
+135°
P point*
−135°
842
400
1137
+65°
255°
97
317
423
138°
341
400
14
132
209
251
S5
Rev.4
Joints #3, #5
0 pulse position
198
330
−150°
Motion range of P point*
* P point: Intersection of the rotation
centers for Joints #4, #5, and #6
23
Setup & Operation
2.4
2. Specifications
Specifications
2.4.1
Specifications Table
Item
Model Number
Degree of protection
Cleanliness level (ISO class)
Weight (not including cables, shipping jigs)
Driving method
All arms
Arm #1
Arm #2
Max. operating
Arm #3
speed *1
Arm #4
Arm #5
Arm #6
Repeatability
Arm #1 to #6
Arm #1
Arm #2
Arm #3
Max. motion range
Arm #4
Arm #5
Arm #6
Arm #1
Arm #2
Max. pulse range
Arm #3
Arm #4
Arm #5
Arm #6
Arm #1
Arm #2
Resolution
Motor power
consumption
Payload *2
Allowable moment
Allowable moment
of inertia (GD2/4) *3
24
Arm #3
Arm #4
Arm #5
Arm #6
Arm #1
Arm #2
Arm #3
Arm #4
Arm #5
Arm #6
Rated
Max.
Arm #4
Arm #5
Arm #6
Arm #4
Arm #5
Arm #6
Specification
S5-A701S S5-A701C S5-A701P S5-A901S S5-A901C S5-9701P
IP65
IP65
Class 3
Class 3
36 kg : 80 lb.
38 kg : 84 lb.
AC servo motor
6.56 rad/s, 376 deg/s
4.71 rad/s, 270 deg/s
6.11 rad/s, 350 deg/s
4.88 rad/s, 280 deg/s
6.98 rad/s, 400 deg/s
5.23 rad/s, 300 deg/s
7.85 rad/s, 450 deg/s
7.85 rad/s, 450 deg/s
12.57 rad/s, 720 deg/s
±0.02 mm
±0.03 mm
±170 deg (Wall mounting: ±30 deg)
−150 deg, +65 deg
−70 deg, +190 deg
−72 deg, +190 deg
±190 deg
±135 deg
±360 deg
±5920402 pulse
±8120639 pulse
(Wall mounting: ±1044777 pulse) (Wall mounting: ±1433054 pulse)
+2524350 pulse
+3155438 pulse
−5825423 pulse
−7281778 pulse
+6149057 pulse
+7686321 pulse
−2265442 pulse
−2912712 pulse
±5534152 pulse
±3932160 pulse
±6553600 pulse
0.00002871 deg/pulse
0.00002093deg/pulse
0.00002574 deg/pulse
0.00002059 deg/pulse
0.00003089 deg/pulse
0.00002471 deg/pulse
0.00003433 deg/pulse
0.00003433 deg/pulse
0.00005493 deg/pulse
400 W
400 W
200 W
50 W
50 W
50 W
2 kg
(with conditions)
5 (7) kg
12 N·m (1.22kgf·m)
12 N·m (1.22kgf·m)
7 N·m (0.71kgf·m)
0.3 kg·m2
0.3 kg·m2
0.1 kg·m2
S5
Rev.4
Setup & Operation
Item
Installed wire for customer use
Specification
15 wires : D-sub 15 pin connector
2 pneumatic tubes (ø6 mm),
Allowable pressure: 0.49MPa
(5kgf/cm2) (71 psi)
0 deg.C to 45 deg.C
(with minimum temperature variation)
Installed pneumatic tube for customer use
Ambient Temperature
Environmental
requirements *4
Ambient relative
humidity
Equivalent continuous A-weighted sound
pressure level *5
Applicable Controller
SPEED
ACCEL
SPEEDS
Default values
ACCELS
(Max. setting values)
FINE
WEIGHT
Safety standard
2. Specifications
20% to 80% (no condensation)
LAeq = 80 dB (A) or under
RC180, RC620
5 (100)
5, 5 (100, 100)
50 (2000)
200 (25000)
10000, 10000, 10000, 10000, 10000, 10000
(65535, 65535, 65535, 65535, 65535, 65535)
2, 0
ANSI/RIA R15.06 compliance
CE compliance
EN775, EN60204-1, EN55011,
EN61000-6-2, EN60950
*1 In the case of PTP control
*2 When the setting payload is more than 5 kg and less than or equal to 7 kg, refer to the section “Restrictions
on payload exceeding 5 kg (more than 5 kg and less than or equal to 7 kg)” in the Setup & Operation 4.3.1
WEIGHT Setting.
*3 In the case where the center of gravity is at the center of each arm. If the center of gravity is not at the
center of each arm, set the eccentric quantity using INERTIA command.
*4 For details of the environmental requirements, refer to the Setup & Operation 3.1 Environmental
Conditions.
*5 Conditions of Manipulator at measurement are as follows:
Operating conditions: Under rated load, 6 arms simultaneous motion, maximum speed,
maximum acceleration, and duty 50%.
Measurement point: 1000 mm apart from the rear of Manipulator
2.4.2
Option Table
S5 series has the following options:
Item
Brake release unit
Camera plate
PS compatible plate
PS installation compatible plate
Mechanical stops for Arm #1, #2, #3 *
Specification
Refer to Setup & Operation
1.5.1 Moving the Arm Using the Brake Release Unit.
Call your EPSON Regional Sales Manager for the detail
information.
* If manipulator is equipped with the mechanical stop, it conforms to the safety standard “ANSI/RIA
R15.06”and “CE”, but not to “UL1740”.
S5
Rev.4
25
Setup & Operation
2.5
2. Specifications
How to Set the Model
The Manipulator model for your system has been set before the shipment from the factory.
It is normally not required to change the model when you receive your system.
CAUTION
NOTE
)
■ 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.
If an MT label is attached to the rear of a Manipulator, the Manipulator has custom
specifications. If the Manipulator has custom specifications, the methods for setting the
model may differ from those described below. Please contact us with the number on the
MT label.
The method for setting the Manipulator model depends on the software used.
Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide.
26
S5
Rev.4
Setup & Operation
3.
3. Environment and Installation
Environment and Installation
Installation and transportation of robots and robotic equipment shall be performed
by qualified personnel and should conform to all national and local codes.
3.1
Environmental Conditions
A suitable environment is necessary for the robot system to function properly and safely.
Be sure to install the robot system in an environment that meets the following conditions:
Item
Ambient temperature*1
Conditions
0 deg C to 45 deg C (with minimum temperature variation)
Ambient relative humidity 20% to 80% (no condensation)
First transient burst noise
2 kV or less (Power wire)
1 kV or less (Signal wire)
Electrostatic noise
4 kV or less
Environment
· Install indoors.
· Keep away from direct sunlight.
· Keep away from dust, oily smoke, salinity, metal
powder or other contaminants.
· Keep away from flammable or corrosive solvents
and gases.
· Keep away from water.
· Keep away from shock or vibration.
· Keep away from sources of electric noise.
*1 The ambient temperature conditions are for the Manipulators only. For the Controller
the Manipulators are connected to, refer to the Controller manual.
NOTE
)
S5
Rev.4
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.
27
Setup & Operation
3. Environment and Installation
For the Protection-model Manipulator, be sure to install the robot system in an
environment that also meets the following conditions:
Item
Environment
Conditions
· Install indoors.
· 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 Protection-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 Protection-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.
WARNING
28
■ 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.
S5
Rev.4
Setup & Operation
3.2
3. Environment and Installation
Unpacking, Transportation, and Relocation
Using a cart or similar equipment, transport the Manipulator in the same conditions as it
was delivered. Observe the following when unpacking the Manipulator.
THE INSTALLATION SHALL BE MADE BY QUALIFIED INSTALLATION
PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL
CODES.
■ Only authorized personnel should perform sling work and operate a crane or
forklift. When these operations are performed by unauthorized personnel, it is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.
WARNING
■ Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is
extremely hazardous and may results in serious bodily injury and/or severe
equipment damage to the robot system as the fall of the Manipulator.
■ When removing the anchor bolts, support the Manipulator to prevent falling.
Removing the anchor bolts without supporting the Manipulator may get hands,
fingers, or feet caught as the Manipulator will fall.
■ Do not remove the wire tie securing the arm until you finish the installation.
You may get your hands caught in the Manipulator when the wire tie is removed
before completing the installation.
■ To carry the Manipulator, have at least 3 people to work on it and secure the
Manipulator to the delivery equipment or hold it by hand. Do not hold the bottom
of the base (the screened parts in the figure). Holding these parts by hand is
extremely hazardous and may cause your hands and fingers to be caught or cut
by the grounding electrode.
CAUTION
S5-A701**
Approx. 38 kg (Manipulator weight: 36 kg (80 lb.))
S5-A901**
Approx. 40 kg (Manipulator weight: 38 kg (84 lb.))
Shipping bolts
and jigs
DO NOT hold
the bottom of the
base by hand.
■ Avoid excessive vibration or shock during Manipulator transporting. Excessive
vibration or shock may cause equipment damage to and/or malfunction of the
Manipulator.
S5
Rev.4
29
Setup & Operation
3. Environment and Installation
Use a crane for transporting the Manipulator during unpacking and relocation.
When using a lifting device other than a crane or forklift for transportation, avoid
applying external force to the arms and motors of the Manipulator.
Check that the eyebolts are securely fastened.
The weight of the Manipulator S5-A701** (S5-A901**) is approx. 38 (40) kg
including the shipping bolts and jigs (the Manipulator weight: 36 (38) kg (80 (84)
lb.)). Use a cable strong enough to withstand the weight.
The attached eyebolts are designed to support the Manipulator weight. Do not
use them for anything other than transporting the Manipulator.
Mount the shipping bolts and jigs for transporting the Manipulator.
After transporting the Manipulator, remove the eyebolts and keep them for future
use.
When transporting the Manipulator for a long distance, secure it to the delivery
equipment so that the Manipulator cannot fall. If necessary, pack the Manipulator
in the same way as it was delivered.
When condensation occurs on the Manipulator during transport or storage, turn ON
the power only after the condensation dries.
When using the Manipulator for the robot system again after long-term storage,
perform a test run to verify that the Manipulator works properly. Then, operate the
Manipulator thoroughly.
3.2.1
Using a Crane
To hoist the Manipulator with a crane, secure the Manipulator with shipping bolts and jigs
and posture the Manipulator as shown in the figures below (the same posture as shipping).
Using a cable threaded through the eyebolts attached to the Manipulator as shown.
Transporting Posture
° = degree
( ) is for S5-A901**.
29°
(22°)
59°
(52°)
60°
(60°)
30
S5
Rev.4
Setup & Operation
3.2.2
3. Environment and Installation
Using a Forklift
Position the Manipulator as shown in the figures below (the same posture as shipping) and
secure it onto a pallet with shipping bolts and jigs. Insert the forklift claws under the
pallet and transport the Manipulator together with the pallet. The pallet must have
enough strength to bear the weight of the Manipulator. Transporting of the Manipulator
must be performed slowly in order to avoid overturning or slippage.
Transporting Posture
Bolt
(4-M10)
Controller
Pallet
Inset here the forklift claws.
3.2.3
Removing / Attaching the Shipping Bolts and Jigs
The shipping bolts and jigs are attached to the Manipulator as shown the figure below
(points A, B) for protecting the Manipulator from various external forces during
transportation. The jigs are painted yellow.
Point A : 6-M5×14 hexagon socket head cap bolts with plain washers
and disc spring washers
Point B : 2-M6×10 hexagon socket head cap bolts with plain washers
and disc spring washers
Point A
Point B
S5
Rev.4
31
Setup & Operation
3. Environment and Installation
Removal
(1) Remove the bolts combining the shipping jigs at the point A.
6-M5×14 hexagon socket head cap bolts with plain washers and disc spring washers
(2) Remove the bolts securing the shipping jigs at the point B.
part of the shipping jigs.
Then, remove the upper
2-M6×10 hexagon socket head cap bolts with plain washers and disc spring washers
NOTE
)
Before turning on the power, be sure that the shipping bolts and jigs have been removed.
The shipping bolts and jigs must then be stored for future use, in the event that the
Manipulator must be moved again.
Installation
(1) Position the Manipulator as show in the figure above.
(2) Attach the upper part of the shipping jigs to the Manipulator at the point B.
it with the bolts.
Secure
2-M6×10 hexagon socket head cap bolts with plain washers and disc spring washers
(3) Secure the shipping jigs at the point A with the bolts.
6-M5×14 hexagon socket head cap bolts with plain washers and disc spring washers
3.2.4
Relocating
Follow the procedures described below when relocating the Manipulator.
(1) Turn OFF the power for all devices and unplug the cables.
Remove the mechanical stops if using them to limit the motion range.
NOTE
)
For details on the motion range, refer to the Setup & Operation 5.2 Motion Range
Setting of Arm #1 by Mechanical Stops.
(2) Unscrew the anchor bolts.
Then, remove the Manipulator from the base table.
(3) Position the Manipulator as shown in the figure. Then, secure the Manipulator to
the delivery equipment or have three or more people to carry the Manipulator.
Do not hold the bottom of the base (the screened parts in the figure). Holding these
parts by hand is extremely hazardous and may cause your hands and fingers to be
caught or cut by the grounding electrode.
S5-A701**
Approx. 38 kg (Manipulator weight: 36 kg (80 lb.))
S5-A901**
Approx. 40 kg (Manipulator weight: 38 kg (84 lb.))
Shipping bolts
and jigs
DO NOT hold
the bottom of the
base by hand.
32
S5
Rev.4
Setup & Operation
3.3
3. Environment and Installation
Mounting Dimensions
Mounting Area
Be sure to have the following space available in addition to the space for mounting the
Manipulator, Controller, and peripheral equipment.
Space for teaching points
Space for maintenance and inspections
Space for cables
NOTE
)
The minimum bend radius of the power cable is 90 mm. When installing the cable, be
sure to maintain sufficient distance from obstacles. In addition, leave enough space for
other cables so that they are not bent forcibly.
[Unit: mm]
160
194
105
S5
Rev.4
12
9
A
100±0.05
138
90
Power Cable
160
194
Mounting Dimensions
4-ø12(Mounting hole)
100±0.05
View A
33
Setup & Operation
3.4
3. Environment and Installation
Installation
THE INSTALLATION SHALL BE MADE BY QUALIFIED INSTALLATION
PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL
CODES.
■ To ensure safety, a safeguard must be installed for the robot system. For details
on the safeguard, refer to the Installation and Design Precautions in the Safety
chapter of the EPSON RC+ User’s Guide or the Safety 1.3 Design Precautions in
the SPEL CT User’s Guide.
■ Install the Manipulator at a location with sufficient space so that a tool or a work
piece on the end effector does not reach a wall or a safeguard when the
Manipulator extends its arm fully while holding a work piece. Installing the
Manipulator at a location with insufficient space is extremely hazardous and may
result in serious bodily injury and/or severe equipment damage to the robot
system as a tool or a work piece may collide with a wall and a safeguard.
WARNING
■ Anchor the Manipulator before turning ON the power to or operating the
Manipulator. Turning ON the power to or operating the Manipulator that is not
anchored is extremely hazardous and may result in serious bodily injury and/or
severe equipment damage to the robot system as the Manipulator may fall down.
■ Before installing and operating the Manipulator, make sure that all parts of the
Manipulator are in place and have no external defects. Missing or defective
parts may cause improper operation of the Manipulator. Improper operation of
the Manipulator is extremely hazardous and may result in serious bodily injury
and/or severe equipment damage to the robot system.
■ Before first turning ON the power, be sure to remove the shipping bolts and jigs
from the Manipulator. Turning ON the power while the shipping bolts and jigs
are attached may result in equipment damage to the Manipulator.
CAUTION
■ Do not remove the wire tie securing the arm until you finish the installation.
You may get your hands caught in the Manipulator when the wire tie is removed
before completing the installation.
■ 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.
3.4.1 Table Top Mounting
3.4.2 Floor Mounting
For Cleanroom-model / Protection-model Manipulator, refer to each section.
3.4.3 Cleanroom-model
3.4.4 Protection-model
34
S5
Rev.4
Setup & Operation
3. Environment and Installation
3.4.1 Base Table Mounting
A base table for anchoring the Manipulator is not supplied. Please make or obtain the
base table for your Manipulator. The shape and size of the base table will differ
depending on the use of the robot system. For your reference, we list some basic
Manipulator table requirements here.
The base table must not only be able to bear the weight of the Manipulator but also be able
to withstand the dynamic movement of the Manipulator when it operates at maximum
acceleration. Ensure that there is enough strength on the base table by attaching
reinforcing materials such as crossbeams.
The torque and reaction force produced by the movement of the Manipulator are as
follows:
S5-A701**
S5-A901**
Max. Horizontal rotating torque
600 N·m
900 N·m
Max. Horizontal reaction force
1000 N
1400 N
Max. Vertical rotating torque
800 N·m
900 N·m
Max. Vertical reaction force
3000 N
3500 N
There are 4 threaded holes for the Manipulator base.
conforming to the strength, ISO898-1 property class: 12.9.
the Setup & Operation 3.3 Mounting Dimensions.
Use M10 mounting bolts
For the dimensions, refer to
The plate for the Manipulator mounting face should be 30 mm thick or more and made of
steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or
less.
The base table must be secured on the floor to prevent it from moving.
The Manipulator must be installed horizontally.
When using a leveler to adjust the height of the base table, use a screw with M16 diameter
or more.
If you are making holes for the cables and passing the cables through the holes on the base
table, see photos below.
[Unit: mm]
47
53
26
95
Power Cable
Connector
18
Signal Cable
Connector
M/C Cable
NOTE
)
S5
Rev.4
Do not remove the M/C cables from the Manipulator.
For environmental conditions regarding space when placing the Controller on the base
table, refer to the Controller manual.
35
Setup & Operation
3. Environment and Installation
Bolt (4-M10)
Spring Washer
10
30 mm or more
Manipulator Base
Manipulator Base
Base Table
Anchor Bolt (M10 or larger)
Base Table
3.4.2
Floor Mounting
The floor should have enough strength to bear the weight of the Manipulator. Construct a
solid foundation with the appropriate thickness to withstand maximum torque and reaction
force of the Manipulator (refer to the table in Setup & Operation 3.4.1 Base Table
Mounting). As a rough standard, when there is a concrete floor with thickness of 150
mm or more, the base of the Manipulator can be secured directly to the floor with M10
anchor bolts. However, before mounting the Manipulator, check that the floor is level
and that all cracks, etc. are repaired. Any thickness less than 150 mm is insufficient for
mounting, even if the floor is concrete.
Anchor bolt (4-M10)
150 mm
or more
36
Concrete
S5
Rev.4
Setup & Operation
3.4.3
3. Environment and Installation
Cleanroom-model
For Cleanroom-model Manipulator, the following procedure is necessary before
installation.
(1) Unpack it outside of the clean room.
(2) Secure the Manipulator to delivery equipment such as a pallet with bolts so that the
Manipulator does not fall.
(3) Wipe off the dust on the Manipulator with a little alcohol or distilled water on a
lint-free cloth.
(4) Carry the Manipulator in the clean room.
(5) Refer to the installation procedure of each Manipulator model and install the
Manipulator.
(6) Connect an exhaust tube (ø 8 mm) to the exhaust port.
3.4.4
Protection-model
Refer to the installation procedure of each Manipulator model and install the Manipulator.
When the Manipulator is a Protection-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 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 IP65. Doing so may cause
equipment damage to and/or malfunction of the controller.
S5
Rev.4
37
Setup & Operation
3.5
3. Environment and Installation
Connecting the Cables
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
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.
■ Before wiring, turn OFF the Controller and related equipment, and then pull up a
warning sign (e.g. DO NOT TURN ON THE POWER.). Wiring with the power
ON is extremely hazardous and may result in electric shock and/or malfunction of
the robot system.
■ When connecting the Manipulator and the Controller, make sure that the serial
numbers on each equipment match.
Improper connection between the
Manipulator and Controller may not only cause improper function of the robot
system but also safety problems. The connection method varies with the
Controller used. For details on the connection, refer to the Controller manual.
CAUTION
38
■ 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.
S5
Rev.4
Setup & Operation
3.5.1
3. Environment and Installation
Cable Connections
Cable Connections
Connect the power connector and signal connector of the M/C cables to the Controller.
<Example> Connection of S5 series Manipulator and Robot Controller RC180
M/C power cable
M/C signal cable
Cleanroom-model
When the Manipulator is Cleanroom-model, be aware that it needs an exhaust system.
Protection-model
When the Manipulator is a Protection-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 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 IP65. Doing so may cause
equipment damage to and/or malfunction of the controller.
S5
Rev.4
39
Setup & Operation
3.5.2
3. Environment and Installation
Grounding
■ Ground resistance must be 100 Ω or less. Improper ground resistance may
result in fire and/or electric shock.
WARNING
■ Do not use the ground line for the Manipulator in common with other ground lines
or grounding electrodes for other electric power, motor power, welding devices,
etc. Using the ground line for the Manipulator in common with other ground
lines or grounding electrodes may result in electric shock and/or malfunction of
the robot system.
■ When using metal ducts, metallic conduits, or distributing racks for cable, ground
in accordance with national and local electric equipment technical standards.
Grounding that dose not meet the standards may result in electric shock and/or
malfunction of the robot system.
Follow local regulations for grounding. It is recommended that the core size of the
grounding wire be 5.5 mm2 or more.
Directly connect the ground line to the Manipulator as shown in the figure below.
Grounding Method
A
A
2
5.5 mm or more
M8 bolt for grounding
(Attached at factory)
View A
40
S5
Rev.4
Setup & Operation
3.6
3. Environment and Installation
Setting the Basic Pose for Calibration
After certain parts have been replaced (motors, reduction gear unit, belts, etc.), a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller. It is necessary to match these origins after replacing the parts. The process
of aligning the two origins is called “Calibration”.
Before performing the calibration, a specific point must be set as “reference point”, and
also the pose data (point data) on the reference point (hereinafter referred to as the “basic
pose”) must be recorded. This must be carried out as soon as the robot system is installed.
Follow the procedure below to record pulses of the basic pose.
For EPSON RC+, a coordinate point including the arm pose is defined as “point”.
data is called “point data”.
The
How to set the reference points for calibration
(1) Decide the reference points.
The reference points should be two or more around the points (poses) where your
Manipulator moves frequently. Also, Arms #2, #3, and #5 should not form a straight
line at these reference points (the Manipulator should not stretch completely). Be
sure that the Manipulator moves to the reference points without problems.
(2) Attach the calibration jigs to the reference points.
Attach your end effector or the calibration jigs described in the section Maintenance
12.3 Calibration Jig to the Manipulator.
(3) Move the Manipulator to the reference points and set the basic pose as the point data.
Refer to the following manual for how to move the Manipulator.
EPSON RC+ 5.0 / EPSON RC+ 6.0
: EPSON RC+ User’s Guide 5.11.1 Robot Manager Command Tools: Robot Manager:
Jog and Teach Page
(4) Place tram marks on the Manipulator so that you can reproduce each joint position to
create the set basic pose.
You should place tram marks on the Manipulator if the Manipulator cannot move to
the 0 pulse positions.
S5
Rev.4
41
Setup & Operation
3. Environment and Installation
(5) Display the origin data that are currently stored in the Controller and record them.
(The origin data are not used in this calibration procedure. However, record the
origin data in case of calibration failure.)
EPSON RC+ 5.0 (RC180)
Select menu-[Setup]-[Controller] to display the [Setup Controller] dialog.
Select [Robot]-[Calibration] and “Hofs” values are indicated.
EPSON RC+ 6.0 (RC620)
Select menu-[Setup]-[System Configuration]-[Robot]-[Robot**]-[Calibration].
To save the “Hofs” value to a file, click the <Save> button.
(6) Remove the calibration jigs.
When using the jigs explained in the Maintenance 12.3 Calibration Jig, remove the
jig attached to the end effector after setting the reference points and basic pose. You
can leave the other jigs attached. If you remove the jigs, attach them to the same
positions for next calibration.
42
S5
Rev.4
Setup & Operation
3.7
3. Environment and Installation
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.
User electrical wires and pneumatic tubes are contained in the cable unit.
Electrical Wires
Rated Voltage
Allowable Current
AC/DC30 V
3.1 A
Wires
JST
2
15
Manufacture
Suitable
Connector
Nominal Sectional Area
0.2 mm
Note
Shielded
Standard
Wrist
JAZ-15S-3 (D-sub) *JST*
JAZ-15P-3 (D-sub) *JST*
Base
JAZ-15P-3 (D-sub) *JST*
JAZ-15S-3 (D-sub) *JST*
(On the Manipulator side)
(On the other side)
(On the Manipulator side)
(On the other side)
Pins with the same number, indicated on the connectors on both ends of the cables, are
connected.
Pneumatic Tubes
Max. Usable Pneumatic Pressure
2
0.49 MPa (5 kgf/cm ) (71 psi)
Pneumatic Tubes
Outer Diameter × Inner Diameter
2
ø 6 mm × ø 4 mm
Fittings for ø 6 mm (outer diameter) pneumatic tubes are supplied on the both ends of the
pneumatic tubes.
When the Manipulator is a Protection-model, be aware of the followings.
■ Be sure to use 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
S5
Rev.4
■ 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.
43
Setup & Operation
3. Environment and Installation
User Wires and Pneumatic Tubes
B
User Cable Connector:
JAZ-15S-3 (D sub) *JST*
Prepare the connector
JAZ-15P-3 (D sub) *JST*.
Air Supply Opening
M5 Tap
with cover plug
View B
User Cable Connector:
JAZ-15P-3 (D sub) *JST*
Prepare the connector
JAZ-15S-3 (D sub) *JST*.
Air Supply Opening
Applicable tube outside diameter: φ 6 mm
A
View A
Numbers of Pins in Use
B side
A side
JAZ-15S-3
(Female pin)
JAZ-15P-3
(Male pin)
Pin
The same pin number (1-15) of two connectors is connected in the lead line of single 0.2
mm2.
When the Manipulator is a Protection-model, be aware of the followings.
CAUTION
44
■ 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.
S5
Rev.4
Setup & Operation
4.
End Effectors
4.1
Attaching an End Effector
4. End Effectors
Create an end effector for your Manipulator that will attach to Arm #6. Before attaching
the end effector to the end of Arm #6, observe these guidelines.
The wrist flange dimensions are shown in the following figure. In order to see the tram
marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth
of inside and outside fittings must be 5 mm or less.
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.
Wrist Flange
4-M5 Tap P0.8 Depth: 9 mm
(° = degree)
45°
Ø12H7
P.C.D 31.5
5 (Fitting depth)
NOTE
)
ø5H7 hole Depth: 7mm
Wash off anti-corrosive paint (solid yellow paint) on the wrist flange surface with thinner
or light oil before mounting the end effector.
Arm #6
Attach an end effector to the end of the Arm #6 using an M5 bolt.
Layouts
When you operate the Manipulator with an end effector, the end effector may interfere
with the Manipulator because of the outer diameter of the end effector, the size of the work
piece, or the position of the arms. When designing your system layout, pay close
attention to the interference area of the end effector.
S5
Rev.4
45
Setup & Operation
4.2
4. End Effectors
Attaching Valves
There are two decks on the upper arm called “upper arm rear deck” and “upper arm center
deck” as shown in the figures below to mount peripheral equipment such as valves.
When the weight on the fore-end of Arm #6 is 5 kg or less, the available weight on the
deck is 6 kg or less including the weight on Arm #6. For example, when the weight on
Arm #6 is 5 kg, the remaining 1 kg is available weight on the deck.
For details of the payload exceeding 5 kg, refer to the section Setup & Operation 4.3.1
WEIGHT Setting - “Restriction on payload exceeding 5 kg (more than 5 kg and less than
or equal to 7 kg)”.
Deck on the Upper Arm
[Unit: mm]
A
View A
423
298
2×2-M4×P0.7 Depth 8 mm
(Front & Back)
4.3
57
55
55
57
12.5
4-M8×P1.25 Depth 16 mm
12.5
20
20
55
87
70
Rotation Center
of the Upper Arm
2-M4×P0.7 Depth 8 mm
WEIGHT and INERTIA Settings
The WEIGHT and INERTIA commands are for setting the load parameters of the
Manipulator. These settings optimize the Manipulator motion.
WEIGHT Setting
The WEIGHT command is for setting the load weight. The more the load weight
increases, the more the speed and acceleration/deceleration for the Manipulator movement
are reduced.
INERTIA Setting
The INERTIA command is for setting the moment of inertia and the eccentricity of the
load. The more the moment of inertia increases, the more the acceleration and
deceleration of the Arm #6 are reduced. The more the eccentricity increases, the more
the acceleration and deceleration for the Manipulator movement are reduced.
To ensure optimum Manipulator performance, it is important to make sure that the load
(weight of the end effector and work piece) and moment of inertia of the load are within
the maximum rating for the Manipulator, and that Arm #6 does not become eccentric.
46
S5
Rev.4
Setup & Operation
4. End Effectors
If the load or moment of inertia exceed the ratings or if the load becomes eccentric, follow
the steps in the Setup & Operation 4.3.1 WEIGHT Setting and 4.3.2 INERTIA Setting, to
set parameters.
Setting parameters makes the operation of the Manipulator optimal, reduces vibration to
shorten the operating time, and improves the capacity for larger loads. In addition, it
reduces persistent vibration produced when the moment of inertia of the end effector and
work piece is bigger.
The allowable weight for S5 series Manipulators is up to 5 kg (7 kg*). However, the
moment and the moment of inertia should also be considered due to limitations for these
factors.
If force is applied to the Manipulator instead of the weight, force on the Arms #4, #5, and
#6 should be within the values shown in the table “Allowable Moment and Moment of
Inertia for S5 series Manipulators”.
* When the load of the Manipulator is more than 5 kg and less than or equal to 7 kg,
refer to the section Setup & Operation 4.3.1 WEIGHT Setting - “Restriction on
payload exceeding 5 kg (more than 5 kg and less than or equal to 7 kg)”.
Allowable Moment and Moment of Inertia for S5 series Manipulators
Arm
Allowable Moment N·m (kgf·m)*1
GD2/4 Allowable Moment of Inertia (kg·m2)
#4
12 (1.22)
0.3
#5
12 (1.22)
#6
7 (0.71)
*2
0.3 *2
0.1
*1 Gravitational unit
*2 The allowable moment and allowable moment of inertia of Arm #5 are calculated by
the distance from the Arm #5 rotation center (a + 80 mm). (Refer to the figure in the
“Critical Location of the Load on S5 series Manipulators”).
The following figure shows the critical location of the load on the S5 series Manipulators.
Critical Location of the Load on S5 series Manipulators
80
a
Position of
Load’s Center
of Gravity
(mm)
300
W=1.5 kg
b
258
Flange
Arm #5
Rotation Center
Arm #6
Rotation
Center
200
182
b
141
100
0
W=3 kg
W=5 kg
W=7 kg
100
200
300
170
244
316
400
a
500
(mm)
a: Distance from the Flange
b: Distance from the Arm #6 Rotation Center
S5
Rev.4
47
Setup & Operation
4. End Effectors
When calculating the critical location of the load on the Arm #5 using the allowable
moment and allowable moment of inertia, the calculated value represents a distance from
the Arm #5 rotation center, not the distance from the flange. Therefore, to get a value of
the critical location of the load on Arm #5, subtract 80 (mm) from the calculated distance
from the Arm #5 rotation center as shown the example below.
Example: Calculate the critical location of the load on the Arm #5 (c) when a 5 kg load is
on the Arm #6 rotation center line (b = 0).
Allowable Moment of the Arm #5 (N·m) / Load (kg)
= Distance from the Arm #5 rotation center (m)
12 (N·m) / 9.8 / 5 (kg) = 0.2448 → 0.295 (round down) (m) = 244 (mm)
c (mm) = Distance from the Arm #5 rotation center (mm) − 80 (mm)
c = 244 (mm) − 80 (mm) = 164 (mm)
Moment
A moment is a necessary torque (holding torque) to counteract the gravity affecting the
load.
Design an end effector so that the eccentric quantity at the position where the load is
attached is within the allowable moment.
A maximum torque (T) is calculated by the following formula.
L
T = m (kg) × L (m) × g (m/s2)
m: Weight of load (kg)
L: Eccentric quantity of load (m)
g: Gravitational acceleration (m/s2)
Joint Rotation Center
T
Maximum eccentric quantities of load for S5 series Manipulators are shown in the
following table.
Max. Eccentric Quantity of Load for S5 series Manipulators
Max. Eccentric Quantity of Load (mm)
(Distance between the joint rotation center and the load’s center of gravity)
Axis
WEIGHT 1.5 kg
WEIGHT 3 kg
WEIGHT 5 kg
WEIGHT 7 kg
#5
#6
48
447 mm
258 mm
316 mm
183 mm
244 mm
141 mm
174 mm
101 mm
S5
Rev.4
Setup & Operation
4.3.1
4. End Effectors
WEIGHT Setting
CAUTION
■ Set the total weight of the end effector and the work piece to 5 kg or less.
The S5 series Manipulators can operate without limitations on the condition that
the load of the Manipulator should be 5 kg or less. When the payload of the
Manipulator is more than 5 kg and less than or equal to 7 kg, refer to the section
“Restrictions on payload exceeding 5 kg (more than 5 kg and less than or equal
to 7 kg)” in the later part of this section for details.
Always set the Weight parameters of the WEIGHT command according to the
load. Setting a value that is smaller than the actual load may cause errors,
excessive shock, insufficient function of the Manipulator, and/or shorten the life
cycle of parts/mechanisms.
The acceptable weight capacity (end effector and work piece) for S5 series Manipulators is
2 kg nominal rating and 5 (7*) kg maximum. When the load (weight of the end effector
and work piece) exceeds the rating, change the setting of the Weight parameter.
After the setting of the Weight parameter is changed, the maximum acceleration /
deceleration and speed of the robot system corresponding to the Weight parameter is set
automatically.
* When the payload of the Manipulator is more than 5 kg and less than or equal to 7 kg,
refer to the section “Restrictions on payload exceeding 5 kg (more than 5 kg and less
than or equal to 7 kg)” in the later part of this section for details.
Setting method of Weight parameters
From EPSON RC+-[Tools]-[Robot Manager], enter into the [Weight:] text box on the
[Weight] panel.
You may also execute the Weight command from [Command Window].
S5
Rev.4
49
Setup & Operation
4. End Effectors
Load on the Manipulators
The Manipulator can load valves or any other devices onto the following two points.
A point on the fore-end of the Arm #6
Upper arm deck
A
Upper Arm Deck
Load on the
Fore-end of Arm #6
View A
When you attach the equipment to the deck on the upper arm, convert its weight into
equivalent weight assuming that the equipment is attached to the end of the Arm #6.
Then, this equivalent weight added to the load will be a Weight parameter.
Calculate the Weight parameter by following the formula below and enter the value.
Weight Parameter Formula
Weight parameter = Mw + Wa
Mw
Wa
: Load on the fore-end of Arm #6 (kg)
: Equivalent weight of the upper arm deck (kg)
Wa = ma (La)²/ (L)²
ma
L
La
: Weight of the equipment on the upper arm deck
: Length of the upper arm (mm)
: Distance between the Joint #3 and the center of gravity of
the equipment on the upper arm deck (mm)
L
ma
La
Mw
50
S5
Rev.4
Setup & Operation
4. End Effectors
<Example> The fore-end of Arm #6 is 385 mm (L) away from the Joint #3.
Load on the fore-end of Arm #6 is 1 kg (Mw).
Load on the upper arm deck is 1.5 kg (ma).
The deck is 60 mm (L a) away from Joint #3.
Wa = 1.5 × 602 / 3852 = 0.036 → 0.04 (round up)
Mw + Wa = 1 + 0.04 = 1.04
Enter “1.04” for the Weight parameter.
Automatic speed setting by Weight parameter
Speed
Acceleration /
Deceleration
Weight Parameter
* The percentage in the graph is based on the speed at rated weight (2 kg) as 100%.
* When the payload of the Manipulator is more than 5 kg and less than or equal to 7 kg,
refer to the section “Restrictions on payload exceeding 5 kg (more than 5 kg and less
than or equal to 7 kg)” in the later part of this section for details.
S5
Rev.4
51
Setup & Operation
4. End Effectors
Restrictions on payload exceeding 5 kg (more than 5 kg and less than or equal to 7 kg)
Although the maximum payload of the S5 series Manipulator is 5 kg, you can increase the
payload up to 7 kg when you restrict the arm pose range of Arm #5 as shown below.
When the payload exceeds 5 kg, the arm pose of Arm #5 should be within the restricted
angle range shown in the following graph.
The graph shows the relation between the load and the Arm #5 restricted angel (A1)
measured vertically (in the direction of gravitational effect). The more the load on the
fore-end of Arm #6 increases, the more the restricted angle range narrows.
When the Manipulator operating direction is vertical to the working plane, the arm pose
restriction of the Arm #5 is equivalent to the tilt restriction of working plane (A2).
In the case of eccentric load, the restricted angle is an angle (B) forming with a vertical
line and a straight line passing through the center of gravity of load and the rotation center
of Arm #5.
The eccentric quantity of load should be within the allowable moment and the allowable
moment of inertia of Arms #4, #5, and #6.
Arm #5 Restricted Angel (A1 )
(deg.)
Relation between load and Arm #5 restricted angle
(No load on the deck)
Load on the Fore-end of Arm #6 (kg)
Arm #4
Rotation Center of Arm #5
Rotation Center
of Arm #5
Arm #5
Center of
Gravity
Arm #6
90 deg.
Load on the
Fore-end of
Arm #6
Vertical Line
A2: Working Plane
Angle from the
Horizontal Plane
Working
Plane
Load on the
Fore-end of
Arm #6
Horizontal Plane
1
2
(A = A )
Vertical Line
B
A1: Arm #5 Angle from
the Vertical Line
Relation between Arm #5 Angle and Working Plane Angle
52
Restricted Angle for Eccentric Angle
S5
Rev.4
Setup & Operation
4. End Effectors
4.3.2 INERTIA Setting
Moment of Inertia and the INERTIA Setting
The moment of inertia is defined as “the ratio of the torque applied to a rigid body and its
resistance to motion”. This value is typically referred to as “the moment of inertia”,
“inertia”, or “GD2”. When the Manipulator operates with objects such as an end effector
attached to the Arm #6, the moment of inertia of load must be considered.
CAUTION
■ The moment of inertia of load (weight of the end effector and work piece) must be
0.1 kg·m2 or less. The S5 series Manipulators are not designed to work with
moment of inertia exceeding 0.1 kg·m2.
Always set the moment of inertia (INERTIA) parameter according to the moment
of inertia. Setting a value that is smaller than the actual moment of inertia may
cause errors, excessive shock, insufficient function of the Manipulator, and/or
shorten the life cycle of parts/mechanisms.
The acceptable moment of inertia of load in S5 series Manipulator is 0.1 kgxm2 nominal
rating and 0.1 kgxm2 maximum. When the moment of inertia of load exceeds the rating,
change the setting of the moment of inertia using the INERTIA command. After the
setting has been changed, the maximum acceleration/deceleration speed of Arm #6
responding to “moment of inertia” is set automatically.
Moment of inertia of load on Arm #6
The moment of inertia of load (weight of the end effector and work piece) on Arm #6 can
be set by the “moment of inertia (INERTIA)” parameter of the INERTIA command.
From EPSON RC+-[Tools]-[Robot Manager], enter into the [Load inertia:] text box on the
[Inertia] panel.
You may also execute the Inertia command from [Command Window].
S5
Rev.4
53
Setup & Operation
4. End Effectors
Eccentric Quantity and the INERTIA Setting
The acceptable eccentric quantity of load in S5 series Manipulators is 50 mm nominal
rating. When the eccentric quantity of load exceeds the rating, change the setting of
eccentric quantity parameter using the INERTIA command. After the setting has been
changed, the maximum acceleration/deceleration speed of Manipulator corresponding to
“eccentric quantity” is set automatically.
Rotation Center
a
a, b = Eccentric Quantity
b
Flange
To set the parameter, enter
the larger value of “a” or “b”.
Position of Load’s Center of
G i
Eccentric Quantity
Eccentric quantity of load on Arm #6
The eccentric quantity of load (weight of the end effector and work piece) on Arm #6 can
be set by the “eccentric quantity” parameter of the INERTIA command.
Enter the larger value of “a” or “b” in the figure above to the [Eccentricity] text box.
The method for setting the parameter varies with the software used.
From EPSON RC+-[Tools]-[Robot Manager], enter into the [Eccentricity:] text box on the
[Inertia] panel.
You may also execute the Inertia command from [Command Window].
Automatic acceleration/deceleration setting by INERTIA (eccentric quantity)
Eccentric Quantity (mm)
* The percentage in the graph is based on the acceleration/ deceleration at rated eccentricity
(50 mm) as 100%.
54
S5
Rev.4
Setup & Operation
4. End Effectors
Calculating the Moment of Inertia
Refer to the following examples of formulas to calculate the moment of inertia of load
(end effector with work piece).
The moment of inertia of the entire load is calculated by the sum of each part (a), (b), and
(c).
Rotation Center
End Effector (a)
Work Piece (b)
Whole Moment
of Inertia
=
Moment of Inertia
of End Effector (a)
Work Piece (c)
+
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 on this
page or the next page. Find the whole moment of inertia using the basic formulas on the
next page.
S5
Rev.4
55
Setup & Operation
4. End Effectors
(a) Moment of inertia of a rectangular parallelepiped
Rotation Center
Rectangular Parallelepiped’s Center of Gravity
2
Weight = m
L
2
m
b +h
2
+m×L
12
m
r
2
+m×L
2
b
h
(b) Moment of inertia of a cylinder
Cylinder’s Center of Gravity
Rotation Center
r
2
Weight = m
L
(c) Moment of inertia of a sphere
Sphere’s Center of Gravity
Rotation Center
r
m
2 2
2
r +m×L
5
Weight = m
L
56
S5
Rev.4
Setup & Operation
4.4
4. End Effectors
Precautions for Auto Acceleration/Deceleration
The speed and acceleration / deceleration of the Manipulator motion are automatically
optimized according to the values of WEIGHT and INERTIA and the Manipulator’s
postures.
WEIGHT Setting
The speed and acceleration / deceleration of the Manipulator are controlled according to
the load weight set by the WEIGHT command.
The more the load weight increases, the more the speed and acceleration/deceleration are
reduced to prevent residual vibration.
INERTIA Setting
The acceleration / deceleration of Arm #6 are controlled according to the moment of
inertia set by the INERTIA command. The acceleration / deceleration of the whole
Manipulator are controlled according to the eccentricity set by the INERTIA command.
The more the moment of inertia and eccentricity of the load increase, the more the
acceleration / deceleration are reduced.
Auto Acceleration/Deceleration According to Manipulator’s Posture
The acceleration / deceleration are controlled according to the Manipulator’s posture.
When the Manipulator extends its arms or when the movement of the Manipulator
produces vibration frequently, the acceleration / deceleration are reduced.
Set appropriate values for WEIGHT and INERTIA so that the Manipulator operation is
optimized.
S5
Rev.4
57
Setup & Operation
5.
5. Motion Range
Motion Range
WARNING
■ When setting up the motion range for safety, both the pulse range and
mechanical stops must always be set at the same time. Failure to set both of
them together may cause serious safety problems.
The motion range is preset at the factory as explained in the section “Standard Motion
Range” in the Setup & Operation 2.3 Appearance. This is the maximum motion range of
the Manipulator.
There are three methods for setting the motion range described as follows:
1. Setting by pulse range (for all arms)
2. Setting by mechanical stops
3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the
Manipulator
Rectangular Range Setting
Mechanical
Stop
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 5.4 to set the range.
58
S5
Rev.4
Setup & Operation
5.1
5. Motion Range
Motion Range Setting by Pulse Range (for All Arms)
Pulses are the basic unit of Manipulator motion. The motion range of the Manipulator is
controlled by the pulse range between the pulse lower limit and upper limit of each axis.
Pulse values are read from the encoder output of the servo motor.
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
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
CAUTION
NOTE
)
Max. Pulse Range of Arm #1
Max. Pulse Range of Arm #2
Max. Pulse Range of Arm #3
Max. Pulse Range of Arm #4
Max. Pulse Range of Arm #5
Max. Pulse Range of Arm #6
■ Do not set and/or use the Arm #4 with pulse range beyond the maximum value.
The Arm #4 does not have a mechanical stop. The used of Arm #4 in motion
exceeding the maximum pulse range may cause inner wiring damage to and/or
malfunction of the Manipulator.
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 from EPSON RC+-[Tools]-[Robot manager]-[Range] panel.
You may also execute the Range command from the [Command Window].
S5
Rev.4
59
Setup & Operation
5. Motion Range
5.1.1 Max. Pulse Range of Arm #1
The 0 pulse position for Arm #1 is shown in the figure below. Counterclockwise pulse
values are positive (+) and clockwise pulse values are negative (-).
S5-A701** Top View
+170°
+1044777 pulse
+5920402 pulse
+30°
Arm #1
0 pulse position
−30°
−5920402 pulse
Arm #1
−1044777 pulse
−170°
S5-A901** Top View
+170°
+1433054 pulse
+30°
+8120639 pulse
Arm #1
0 pulse position
−8120639 pulse
Arm #1
−30°
−1433054 pulse
−170°
60
S5
Rev.4
Setup & Operation
5. Motion Range
5.1.2 Max. Pulse Range of Arm #2
The 0 pulse position for Arm #2 is shown in the figure below. Counterclockwise pulse
values are positive (+) and clockwise pulse values are negative (-).
S5-A701** Lateral View
Arm #2
0 pulse position
+65 deg.
+2524350 pulse
−150 deg.
Arm #2
−5825423 pulse
S5-A901** Lateral View
Arm #2
0 pulse position
+65 deg.
+3155438 pulse
−150 deg
Arm #2
−7281778 pulse
S5
Rev.4
61
Setup & Operation
5. Motion Range
5.1.3 Max. Pulse Range of Arm #3
The 0 pulse position for Arm #3 is shown in the figure below. Counterclockwise pulse
values are positive (+) and clockwise pulse values are negative (-).
S5-A701** Lateral View
+190 deg.
Arm #3
Arm #3
0 pulse position
+6149057 pulse
−70 deg.
−2265442 pulse
S5-A901** Lateral View
+190 deg.
Arm #3
Arm #3
0 pulse position
+7686321 pulse
−72 deg.
−2912712 pulse
62
S5
Rev.4
Setup & Operation
5. Motion Range
5.1.4 Max. Pulse Range of Arm #4
The 0 pulse position for Arm #4 is shown in the figure below. Clockwise pulse values
are positive (+) and counterclockwise pulse values are negative (-).
S5-A701** Front View
Arm #4
0 pulse position
−190 deg.
+190 deg.
−5534152 pulse
+5534152 pulse
Arm #4
S5-A901** Front View
Arm #4
0 pulse position
−190 deg.
+190 deg.
−5534152 pulse
+5534152 pulse
Arm #4
CAUTION
S5
Rev.4
■ Do not set and/or use the Arm #4 with pulse range beyond the maximum value.
The Arm #4 does not have a mechanical stop. The used of Arm #4 in motion
exceeding the maximum pulse range may cause inner wiring damage to and/or
malfunction of the Manipulator.
63
Setup & Operation
5. Motion Range
5.1.5 Max. Pulse Range of Arm #5
The 0 pulse position for Arm #5 is shown in the figure below. Counterclockwise pulse
values are positive (+) and clockwise pulse values are negative (-).
S5-A701** Lateral View
+3932160 pulse
+135 deg.
Arm #5
0 pulse position
Arm #5
−3932160 pulse
−135 deg.
S5-A901** Lateral View
+3932160 pulse
+135 deg.
Arm #5
0 pulse position
Arm #5
−3932160 pulse
64
−135 deg.
S5
Rev.4
Setup & Operation
5. Motion Range
5.1.6 Max. Pulse Range of Arm #6
The 0 pulse position for Arm #6 is shown in the figure below. Clockwise pulse values
are positive (+) and counterclockwise pulse values are negative (-).
S5-A701** Front View
Arm #6
0 pulse position
−360 deg.
+360 deg.
−6553600 pulse
+6553600 pulse
Arm #6
S5-A901** Front View
Arm #6
0 pulse position
−360 deg.
+360 deg.
−6553600 pulse
+6553600 pulse
Arm #6
S5
Rev.4
65
Setup & Operation
5.2
5. Motion Range
Restriction of Manipulator Operation by Joint Angle Combination
To prevent the arms of the Manipulator from interfering each other, the Manipulator
operation is restricted in the specified motion range according to the joint angle
combination of the Arm #2, #3, and #4.
The Manipulator operation is restricted and the Manipulator stops when the joint angles of
the Arm are within the gray areas in the following figure.
Combination of Joint #2 and #3
Joint #3 Angle (degree)
S5-A701**
Joint #2 Angle (degree)
Joint #3 Angle (degree)
S5-A901**
Joint #2 Angle (degree)
66
S5
Rev.4
Setup & Operation
5. Motion Range
Combination of Joint #3 and #4
Joint # 4 Angle (degree)
S5-A701**
Joint #3 Angle (degree)
Joint #4 Angle (degree)
S5-A901**
Joint #3 Angle (degree)
The restriction to Manipulator operation is enabled:
During CP motion command execution
You attempt to execute the motion command for moving the Manipulator to a target point
(or pose) in the specified motion range.
The restriction to the Manipulator operation is disabled:
The Arms of the Manipulator momentarily go through the specified motion range
during the PTP motion command execution even though the joint angles of the Arms
are in the gray areas of the figures above.
S5
Rev.4
67
Setup & Operation
5.3
5. Motion Range
Coordinate System
The origin point is located where the Manipulator base intersects with the rotation axis of
Joint #1.
For details on the coordinate system, refer to the software manual.
Table Top mounting
Ceiling mounting
+X
+Y
Wall mounting
+Z
+Z
+X
+Y
+X
+Z
+Y
5.4
Setting the Cartesian (Rectangular) Range in the XY Coordinate
System of the Manipulator
The Cartesian (rectangular) range in the XY coordinate system of the Manipulator is
specified by the limited Manipulator operation area and the XYLim setting.
The limited Manipulator operation area is defined so that the end effector does not
interfere with the rear side of the Manipulator. The XYLim setting is that you can set the
upper and lower limits of the X and Y coordinates.
The limited Manipulator operation area and XYLim setting apply only to the software.
Therefore, these settings do not change the physical range. The maximum physical range
is based on the position of the mechanical stops.
These settings are disabled during a joint jogging operation. Therefore, be careful not to
allow the end effector to collide with the Manipulator or peripheral equipment.
The method for changing the XYLim setting varies with the software used.
Set the XYLim setting from EPSON RC+-[Tools]-[Robot manager]-[XYZ Limits] panel.
You may also execute the XYLim command from the [Command Window].
68
S5
Rev.4
Maintenance
This volume contains maintenance procedures with safety
precautions for Manipulators.
69
70
Maintenance
1.
1. Safety Maintenance
Safety Maintenance
Please read this manual and other relevant manuals carefully to understand safe
maintenance procedures before performing any maintenance.
Only authorized personnel who have taken the safety training should be allowed
to maintain the robot system. The safety training is the program for the
industrial robot operator that follows the laws and regulations of each nation.
The personnel who have taken the safety training acquire knowledge of industrial
robots (operations, teaching, etc.), knowledge of inspections, and knowledge of
related rules/regulations. Only personnel who have completed the robot
system-training and maintenance-training classes held by the manufacturer,
dealer, or locally-incorporated company should be allowed to maintain the robot
system.
WARNING
WARNING
S5
Rev.4
■ 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 though 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 switches 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.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the
cables. (Do not put heavy objects on the cables. Do not bend or pull the
cables forcibly.) The unnecessary strain on the cables may result in damage to
the 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.
71
Maintenance
1. Safety Maintenance
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
CAUTION
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
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
72
: Wash the area thoroughly with soap and
water.
S5
Rev.4
Maintenance
2.
2. Periodic Inspection
Periodic Inspection
Performing the inspection steps properly is essential to preventing trouble and maintaining
safety. This section describes the schedule for maintenance inspections and the
procedures.
Be sure to perform the maintenance inspections in accordance with the schedule.
2.1
Schedule for Maintenance Inspections
Inspection tasks are divided into five stages: daily, 4 months, 24 months, 48 months, and
96 months. Move up the regular checks when the Manipulator has been used for the
following amount of time.
Inspection
Interval between Inspections
Daily
S5
Rev.4
Accumulated Operating Time
Inspect every day.
4-month
4 months
1000 hours
24-month
24 months
6000 hours
48-month
48 months
12000 hours
96-month
96 months
24000 hours
73
Maintenance
2.2
2. Periodic Inspection
Inspection Tasks
Inspection Tasks
Inspection
Method
Tram mark
Daily
Visual
Motion range
and Manipulator
Daily
Visual
Base plate mounting
bolts
Cover mounting
screws
Base connectors
Joint #5, Joint #6
timing belts
4-month
4-month
4-month
Check for tram mark misalignment or damage
at the home position.
Clean the area of motion range for each joint if
dust or spatter is present.
Check for damage and outside cracks.
Spanner,
Tighten loose bolts. Replace if necessary.
Wrench
Screw-driver,
Tighten loose screws. Replace if necessary.
Wrench
Manual
Check for loose connectors.
48-month
Manual
Cable unit *1
48-month
Visual,
Multimeter
Battery unit
-
-
24-month
Grease gun
24-month
Grease gun
24-month
Grease gun
24-month
Grease gun
24-month
Grease gun
24-month
Grease gun
Joint #1
reduction gear unit
Joint #2
reduction gear unit
Joint #3
reduction gear unit
Joint #4
reduction gear unit
Joint #5
reduction gear unit
Joint #6
reduction gear unit
Related
Details
Inspection and Maintenance
-
Check for proper belt tension and wear.
8.2
Check for conduction between the main
connector of base and intermediate connector. *2
Check for wear of protective spring. *2
Replace the battery unit when an error warning
that low battery status is occurring at startup of
the software or every three years.
Check for malfunction (Replace if necessary).
Perform grease replenishment*3
Check for malfunction (Replace if necessary).
Perform grease replenishment *3
Check for malfunction (Replace if necessary).
Perform grease replenishment *3
Check for malfunction (Replace if necessary).
Perform grease replenishment *3
Check for malfunction (Replace if necessary).
Perform grease replenishment *3
Check for malfunction (Replace if necessary).
Perform grease replenishment *3
9
10
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
*1 Replace the cable unit every 24000 hours. Refer to the Maintenance: 9. Cable Unit for details.
*2 When checking for conduction with a multimeter, connect the battery (for backing up motor encoder) to
the BAT and OBT connectors, which are encoder connectors for maintenance, on the motor side. Then,
disconnect the encoder connector on the cable unit side from the motor. If you disconnect the encoder
connector on the cable unit side from the motor before connecting the battery to the BAT and OBT
connectors, the arm position data will be lost and the arm will need to be calibrated again.
*3 Replenish grease every 6000 hours. Refer to the Maintenance 2.3 Grease Replenishment for details.
74
S5
Rev.4
Maintenance
2. Periodic Inspection
When the Manipulator is a Protection-model, be check of the followings.
Inspection Tasks
Arm #1 - #4
Oil Seals
Drain plug
Drain cover
Inspection
Method
Daily
Visual
4-month
Screw-driver,
Wrench
Related Details
Inspection and Maintenance
Keep the oil seals clean removing any
dust such as metal powders.
Remove the condensation if it
2.5
presents in manipulator. *4
*4 When the manipulator is used in the environment where rapid changes in temperature and humidity occur,
perform the inspection more often than specified above.
S5
Rev.4
75
Maintenance
2.3
2. Periodic Inspection
Grease Replenishment
The reduction gear units need greasing at intervals of 6000 hours of operation time.
only the grease specified.
WARNING
WARNING
Use
■ Move out of the safeguarded area before operating the Manipulator for run-in
during grease replenishment. Operating the Manipulator while someone is
inside of the safeguarded area is extremely hazardous and may cause serious
safety problems.
■ After the run-in, be sure to turn OFF the controller and related equipment, and
then pull out the power plug from the power source. Then, continue the grease
replenishment. Performing any grease procedure with the power ON is
extremely hazardous and may result in electric shock and/or malfunction of the
robot system.
■ Ensure that there is sufficient 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.
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
CAUTION
: 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
76
: Wash the area thoroughly with soap and
water.
S5
Rev.4
Maintenance
2. Periodic Inspection
Grease Gun Lubrication Nozzle Shape
øD
øD
øD
Use a commercially available grease gun.
We recommend the use of a grease gun with a nozzle shaped like that shown in the figure
below and an outer diameter (øD) 13 mm or less.
S5
Rev.4
Straight
Chuck
Hose
77
Maintenance
2.3.1
2. Periodic Inspection
Joint #1 Reduction Gear Unit
Reduction
Gear Unit
Air Vent
(Hexagon Socket Head
Cap Plug PT1/8)
Grease Inlet
(Hexagon Socket
Head Cap Bolt : M6)
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
25 g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the bolt from the grease inlet.
Hexagon socket head cap bolt: M6
(2) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: A-MT6×1
(3) Remove the plug from the air vent.
Hexagon socket head cap plug: PT1/8
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while the
plug is in the air vent, the internal pressure increases. Increasing internal pressure
may cause malfunction of the robot system.
(4) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
: 25 g
(5) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(6) Wipe off excess grease exhausted from the air vent with wiping cloth.
(7) Attach the plug to the air vent.
Hexagon socket head cap plug: PT1/8 (Apply liquid gasket.)
(8) Remove the grease nipple from the grease inlet.
Grease nipple: A-MT6×1
(9) Attach the bolt to the grease inlet.
Hexagon socket head cap bolt: M6 (Apply liquid gasket.)
78
S5
Rev.4
Maintenance
2.3.2
2. Periodic Inspection
Joint #1 Gear
Air Vent
(Hexagon Socket
Head Cap Plug
: PT1/8)
Gear of
Joint #1 Motor
Grease Inlet
(Hexagon Socket
Head Cap Plug
: PT1/8)
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
25 g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the plug from the grease inlet.
Hexagon socket head cap plug: PT1/8
(2) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: A-MT6×1
(3) Remove the plug from the air vent.
Hexagon socket head cap plug: PT1/8
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while the
plug is in the air vent, the internal pressure increases. Increasing internal pressure
may cause malfunction of the robot system.
(4) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
: 25 g
(5) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(6) Wipe off excess grease exhausted from the air vent with wiping cloth.
(7) Attach the plug to the air vent.
Hexagon socket head cap plug: PT1/8 (Apply liquid gasket.)
(8) Remove the grease nipple from the grease inlet.
Grease nipple: A-MT6×1
(9) Attach the bolt to the grease inlet.
Hexagon socket head cap bolt: M6 (Apply liquid gasket.)
S5
Rev.4
79
Maintenance
2.3.3
2. Periodic Inspection
Joint #2 Reduction Gear Unit
Joint #2 Motor
Air Vent
(Plug M5)
Joint #2
Reduction
Gear Unit
Grease Inlet
(Hexagon Socket
Head Cap Bolt: M6)
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
30 g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the bolt from the grease inlet.
Hexagon socket head cap bolt: M6
(2) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: A-MT6×1
(3) Remove the plug from the air vent.
Plug: LP-M5
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while the
plug is in the air vent, grease will go inside the motor and may cause malfunction of
the robot system.
(4) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
: 30 g
(5) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(6) Wipe off excess grease exhausted from the air vent with wiping cloth.
(7) Attach the plug to the air vent.
Plug: LP-M5 (Apply liquid gasket.)
(8) Remove the grease nipple from the grease inlet.
Grease nipple: A-MT6×1
(9) Attach the bolt to the grease inlet.
Hexagon socket head cap bolt: M6 (Apply liquid gasket.)
80
S5
Rev.4
Maintenance
2.3.4
2. Periodic Inspection
Joint #3 Reduction Gear Unit
Air Vent (Plug M5)
Cover
Joint #3
Reduction Gear Unit
Grease Inlet
(Hexagon Socket
Head Cap Bolt : M6)
Joint #3 Motor
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
20 g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the bolt from the grease inlet.
Hexagon socket head cap bolt: M6
(2) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: A-MT6×1
(3) Remove the plug from the air vent.
Plug: LP-M5
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while the
plug is in the air vent, grease will go inside the motor and may cause malfunction of
the robot system.
(4) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
: 20 g
(5) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(6) Wipe off excess grease exhausted from the air vent with wiping cloth.
(7) Attach the plug to the air vent.
Plug: LP-M5 (Apply liquid gasket.)
(8) Remove the grease nipple from the grease inlet.
Grease nipple: A-MT6×1
(9) Attach the bolt to the grease inlet.
Hexagon socket head cap bolt: M6 (Apply liquid gasket.)
S5
Rev.4
81
Maintenance
2.3.5
2. Periodic Inspection
Joint #4 Reduction Gear Unit
A
A
B
Grease Inlet (Plug M5)
B
Air Vent (Plug M5)
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
7g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the bolts and then remove the Arm #4 Cover.
For details, refer to Maintenance: 3.4 Arm #4 Cover.
(2) Remove the plug from the air vent.
Plug: LP-M5
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while
the plug is in the air vent, the internal pressure increases. Increasing internal
pressure may cause malfunction of the robot system.
(3) Remove the plug from the grease inlet.
Plug: LP-M5
(4) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: M5
(5) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
:7g
(6) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(7) Wipe off excess grease exhausted from the air vent with wiping cloth.
(8) Attach the plug to the air vent.
Plug: LP-M5 (Apply liquid gasket.)
(9) Mount the Arm #4 Cover.
NOTE
)
82
For details, refer to Maintenance: 3.4 Arm #4 Cover.
When mounting the cover, apply liquid grease on the contact surface with the arm.
Liquid gasket: 1206C
S5
Rev.4
Maintenance
2.3.6
2. Periodic Inspection
Joint #5 Reduction Gear Unit
A
A
Air Vent (Plug M5)
B
Grease Inlet (Plug M5)
B
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
5g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the plug from the air vent.
Plug: LP-M5
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while
the plug is in the air vent, the internal pressure increases. Increasing internal
pressure may cause malfunction of the robot system.
(2) Remove the plug from the grease inlet.
Plug: LP-M5
(3) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: M5
(4) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
:5g
(5) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(6) Wipe off excess grease exhausted from the air vent with wiping cloth.
(7) Attach the plug to the air vent.
Plug: LP-M5 (Apply liquid gasket.)
(8) Remove the grease nipple from the grease inlet.
Grease nipple: M5
(9) Attach the bolt to the grease inlet.
Plug: LP-M5 (Apply liquid gasket.)
S5
Rev.4
83
Maintenance
2.3.7
2. Periodic Inspection
Joint #6 Reduction Gear Unit
A
A
Air Vent: Gear part (Plug M5)
B
Air Vent: Reduction Gear Unit (Plug M5)
B
Grease Inlet: Gear part (Plug M5)
Grease Inlet: Reduction Gear Unit (Plug M5)
Name
Maintenance
Parts
Quantity
Grease for reduction gear
Liquid gasket
Note
5g
SK-1A
R13ZA00330100
Proper quantity
1206C
R13B031201
(1) Remove the plug from the grease inlet.
Plug: LP-M5
(2) Attach a grease nipple to the grease inlet.
(The grease nipple is supplied with the Manipulator.)
Grease nipple: M5
(3) Remove the plug from the air vent.
Plug: LP-M5
NOTE
)
Be sure to remove the plug from the air vent. When grease is being added while
the plug is in the air vent, the internal pressure increases. Increasing internal
pressure may cause malfunction of the robot system.
(4) Pump grease into the reduction gear unit from the grease inlet using a grease gun.
Grease
: Grease for reduction gear (SK-1A)
Quantity
:5g
(5) Operate the Manipulator at low power mode speed for one hour to run-in the grease.
(6) Wipe off excess grease exhausted from the air vent with wiping cloth.
(7) Attach the plug to the air vent.
Plug: LP-M5 (Apply liquid gasket.)
(8) Remove the grease nipple from the grease inlet.
Grease nipple: M5
(9) Attach the bolt to the grease inlet.
Plug: LP-M5 (Apply liquid gasket.)
84
S5
Rev.4
Maintenance
2.4
2. Periodic Inspection
Tightening Hexagon Socket Head Cap Bolts
Hexagon socket head cap bolts are used where mechanical strength is required. These
bolts are fastened with the tightening torques shown in the following table.
When it is necessary to refasten these bolts during 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
M3
245 N⋅cm
(25 kgf⋅cm)
M4
490 N⋅cm
(50 kgf⋅cm)
M5
980 N⋅cm
(100 kgf⋅cm)
M6
1,760 N⋅cm
(180 kgf⋅cm)
M8
3,720 N⋅cm
(380 kgf⋅cm)
M10
7,350 N⋅cm
(750 kgf⋅cm)
M12
12,740 N⋅cm (1,300 kgf⋅cm)
We recommend that the bolts aligned on circumference should be fastened in a crisscross
pattern as shown in the figure below.
1
5
8
Bolt hole
3
4
6
7
2
Do not fasten all bolts securely at one time. Divide the number of times that the bolts are
fastened into two or three times and fasten the bolts securely with a hexagonal wrench.
Then, use a torque wrench so that the bolts are fastened with the tightening torques shown
the table above.
S5
Rev.4
85
Maintenance
2.5
2. Periodic Inspection
Removing Condensation (Only protection-model)
For protection-model manipulators, condensation water should be drained.
Name
Maintenance
Parts
Liquid gasket (1206C)
Quantity
Proper quantity
Gasket
1
Note
R13B031201
R13B031275
For replacement
(1) Remove the bolt. Detach the drain cover and the
gasket of the No.1 drain vent.
NOTE
)
Replace the gasket with a new one if it is
damaged.
(2) Remove the drain plug of the No.2 drain vent.
Drain plug: PT1/8
(3) Incline the Arm #3 slightly toward the No.2 drain
vent side.
(4) Drain the condensation water.
(5) Put the gasket between the drain cover and arm, and then secure the cover of the No.1
drain vent with the bolt.
Bolt: Apply liquid gasket.
(6) Attach the plug to the No.2 drain vent.
Drain plug: PT1/8 (Apply liquid gasket.)
86
S5
Rev.4
Maintenance
3.
3. Covers
Covers
The common procedure for removing the covers for maintenance are described in this
chapter.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
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.
■ 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.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
S5
Rev.4
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
87
Maintenance
3.1
3. Covers
Arm #1 Cover
Remove the bolts and then remove the Arm #1 Cover.
Tool : Hexagonal wrench (width across flats: 3 mm)
Button bolt
: 6-M4×10
Tightening torque : 1.4 N·m (0.14 kg·m)
For cleanroom-model:
A gasket (R13B031270) is attached.
Removal
Remove the gasket with the cover.
Installation
Attach the gasket between the cover and
manipulator.
NOTE
)
You can’t reuse the gasket. Be sure to use a new gasket.
For protection-model:
Liquid gasket (R13B031201) is applied.
Removal
Remove caked-on liquid gasket residue with a
scraper or similar tool.
Installation
Apply liquid gasket on the contact surfaces of the cover and manipulator.
NOTE
)
88
Wipe off any excess liquid gasket with a wiping cloth treated with alcohol.
S5
Rev.4
Maintenance
3.2
3. Covers
Arm #2 Cover
Remove the bolts and then remove the Arm #2 Cover.
Tool : Hexagonal wrench (width across flats: 4 mm)
Button bolt
: 20-M5×10 (with washer)
Tightening torque : 2.8 N·m (0.29 kg·m)
NOTE
)
There is one cover on each side. Remove the
cover(s) as required in maintenance work.
For cleanroom-model:
A gasket is attached.
S5-A701C* : R13B031271
S5-A901C* : R13B031272
Removal
Remove the gasket with the cover.
Installation
Attach the gasket between the cover and manipulator.
NOTE
)
You can’t reuse the gasket. Be sure to use a new gasket.
For protection-model:
Liquid gasket (R13B031201) is applied.
Removal
Remove caked-on liquid gasket residue with a
scraper or similar tool.
Installation
Apply liquid gasket on the contact surfaces of the cover and manipulator.
NOTE
)
S5
Rev.4
Wipe off any excess liquid gasket with a wiping cloth treated with alcohol.
89
Maintenance
3.3
3. Covers
Arm #3 Cover
Remove the bolts and then remove the Arm #3 Cover.
Tool : Hexagonal wrench (width across flats: 3 mm)
Button bolt
: 4-M4×10 (with washer)
Tightening torque : 1.4 N·m (0.14 kg·m)
For cleanroom-model:
A gasket (R13B031273) is attached.
Removal
Remove the gasket with the cover.
Installation
Attach the gasket between the cover and manipulator.
NOTE
)
You can’t reuse the gasket. Be sure to use a new gasket.
For protection-model:
Liquid gasket (R13B031201) is applied.
Removal
Remove caked-on liquid gasket residue with a
scraper or similar tool.
Installation
Apply liquid gasket on the contact surfaces of the cover and manipulator.
NOTE
)
90
Wipe off any excess liquid gasket with a wiping cloth treated with alcohol.
S5
Rev.4
Maintenance
3.4
3. Covers
Arm #4 Cover
Remove the bolts and then remove the Arm #4 Cover.
Tool : Hexagonal wrench (width across flats: 3 mm)
Button bolt
: 18-M4×10 (with washer)
Tightening torque : 1.4 N·m (0.14 kg·m)
NOTE
)
There is one cover on each side. Remove the
cover(s) as required in maintenance work.
For cleanroom-model:
A gasket (R13B031274) is attached.
Removal
Remove the gasket with the cover.
Installation
Attach the gasket between the cover and manipulator.
NOTE
)
You can’t reuse the gasket. Be sure to use a new gasket.
For protection-model:
Liquid gasket (R13B031201) is applied.
Removal
Remove caked-on liquid gasket residue with a
scraper or similar tool.
Installation
Apply liquid gasket on the contact surfaces of the cover and manipulator.
NOTE
)
S5
Rev.4
Wipe off any excess liquid gasket with a wiping cloth treated with alcohol.
91
Maintenance
4. Joint #1 (Replacing the Motor)
4.
Joint #1
4.1
Replacing the Joint #1 Motor
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Never disassemble the motor and encoder. Disassembled motor and encoder
will cause a positional gap and cannot be used again.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
92
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
S5
Rev.4
Maintenance
4. Joint #1 (Replacing the Motor)
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
CAUTION
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
NOTE
)
: Flush them thoroughly with clean water, and
then see a doctor immediately.
: Wash the area thoroughly with soap and
water.
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software you
are using to perform the calibration.
Joint #1 Motor
Name
Maintenance
Parts
Material
S5
Rev.4
AC servo motor
Grease for reduction gear
Liquid gasket
Adhesive
Wire tie
Quantity
1
Proper quantity
Proper quantity
Proper quantity
-
Note
400 W
SK-1A
1206C
Loctite 242
R13B000626
R13ZA00330100
R13B031201
R13B031701
93
Maintenance
4. Joint #1 (Replacing the Motor)
Joint #1 Motor
Removal
(1) Remove the manipulator installation bolts and put the manipulator on its side.
NOTE
)
Before removing the installation bolts, position the manipulator to make sure you can
put the manipulator back in the installation position. If the manipulator installation
position changes after the motor replacement, you need to adjust the points already
taught.
(2) Remove the bolts and remove the bottom cover.
Button bolt: 6-M4×10
(3) Connect the backup battery to the Joint #1 motor cables.
(4) Remove the Joint #1 motor cables from the cables inside the manipulator.
(5) Remove the hexagon socket head cap bolts.
a: 2-M4×25 (with disc spring)
b: 2-M4×14 (with disc spring)
(6) Remove the Joint #1 motor with the motor
plate.
Use the hexagon socket head cap bolts as a
removal tap.
(7) Remove the Joint #1 input gear from the Joint #1
motor.
Hexagon socket head cap bolt
: 1-M5×16 (with disc spring)
NOTE
)
- Hold the Joint #1 input gear as shown in the
picture while removing the bolt to prevent the
gear from turning.
- There is a gasket between the Joint #1 input
gear and the motor shaft. Be sure to keep the
gasket.
94
S5
Rev.4
Maintenance
4. Joint #1 (Replacing the Motor)
(8) Remove the Joint #1 motor plate from the Joint #1
motor.
(9) Remove caked-on liquid gasket residue with a
scraper or similar tool.
S5
Rev.4
95
Maintenance
4. Joint #1 (Replacing the Motor)
NOTE
)
Joint # Motor
Installation
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the Joint #1 motor plate on the Joint #1
motor.
Hexagon socket head cap bolt
: 2-M4×14 (with disc spring, M4 washer)
Tightening torque: 2.8 N·m (0.29 kgf·m)
NOTE
)
- Be careful of direction of the Joint #1 motor plate.
- Be careful not to damage the oil seal in the Joint
#1 motor plate.
(2) Mount the gasket on the Joint #1 motor.
(3) Mount the Joint #1 input gear.
Hexagon socket head cap bolt
: 1-M5×16 (with disc spring 2H-5)
Apply the liquid gasket.
Tightening torque: 10 N·m (1.02 kgf·m)
NOTE
)
- Hold the Joint #1 input gear as shown in the
picture while removing the bolt to prevent the gear
from turning.
- Wipe excess adhesive from other parts of the
motor with a wiping cloth treated with alcohol.
(4) Apply the liquid gasket on surfaces of the Joint #1
motor plate and the Base.
Apply the grease for the reduction gear on the Joint
#1 input gear.
Grease: SK-1A
(5) Mount the Joint #1 motor on the Base.
Hexagon socket head cap bolt
: 2-M4×25 (with disc spring 2H-4, M4 washer)
Apply the liquid gasket.
Tightening torque: 2.8 N·m (0.29 kgf·m)
(6) Connect the Joint #1 motor cables with the cables inside the manipulator.
96
S5
Rev.4
Maintenance
4. Joint #1 (Replacing the Motor)
(7) Remove the backup battery.
(8) Mount the Bottom Cover.
Button bolt
: 6-M4×10
Tightening torque : 1.4 N·m (0.14 kgf·m)
(9) Put the manipulator in the installation position.
S5
Rev.4
97
Maintenance
4.2
4. Joint #1 (Replacing the Reduction Gear Unit)
Replacing the Joint #1 Reduction Gear Unit
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
then see a doctor immediately.
If grease gets into your mouth : If swallowed, do not induce vomiting.
doctor immediately.
See a
If grease just gets into your mouth, wash out
your mouth with water thoroughly.
If grease gets on your skin
98
: Wash the area thoroughly with soap and
water.
S5
Rev.4
Maintenance
NOTE
)
4. Joint #1 (Replacing the Reduction Gear Unit)
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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: 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
- A reduction gear unit consists of the three parts described below. When replacing the
reduction gear unit, be sure to always replace the waveform generator, flexspline, and
circular spline all together as one set.
For the structure details of the reduction gear, refer to Maintenance: 13. Maintenance
Parts List.
Joint #1
Reduction Gear Unit
4.2.1 Greasing the Reduction Gear Unit
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes : Flush them thoroughly with clean water, and
then see a doctor immediately.
CAUTION
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.
When greasing the reduction gear unit, use only the grease specified for the reduction
gear unit. While greasing the reduction gear unit, be careful not to allow any foreign
substances in the grease.
Location for applying grease on the waveform generator
Waveform Generator
Circular Spline
S5
Rev.4
Flexspline
99
Maintenance
4.2.2
4. Joint #1 (Replacing the Reduction Gear Unit)
Replacing the Reduction Gear Unit
■ Use at least three people when removing the upper structure (Arms #1 to #6).
One should support the upper arm and the others should hold Arm #1 up. The
upper structure is so heavy that attempting this task requires a large force.
CAUTION
NOTE
)
When replacing the reduction gear unit, the bearings should be replaced together.
Name
Maintenance
Parts
Material
Joint #1
Reduction Gear
Unit
Removal
Quantity
Reduction gear unit
1
Bearing
1
Grease for reduction gear
Grease for oil seal
Liquid gasket
Wire tie
Proper quantity
Proper quantity
Proper quantity
-
Note
S5-A701**
S5-A901**
6810VV*NS7*
6811LLU
SK-1A
MP-1
1206C
R13B010030
R13B010031
R13B030803
R13B030804
R13ZA00330100
R13B030306
R13B031201
(1) Turn OFF the Controller.
(2) Remove the cables from inside the manipulator.
For details, refer to Maintenance: 9.1 Replacing the Cable Unit.
(3) Remove the Joint #1 motor.
For details, refer to Maintenance: 4.1 Replacing the Joint #1 Motor.
CAUTION
■ Use at least three people when removing the upper structure (Arms #1 to #6).
One should support the upper arm and the others should hold Arm #1 up. The
upper structure is so heavy that attempting this task requires a large force.
(4) Remove the shaft from the Base.
GT-SA bolt
: 4-M4×12
Removal tap
: M3
(5) Remove the flange from the Base.
100
GT-SA bolt
: 7-M4×16
Removal tap
: M4
S5
Rev.4
Maintenance
4. Joint #1 (Replacing the Reduction Gear Unit)
(6) Remove the GT-SA bolts and then remove the
bearing holder.
GT-SA bolt: 4-M4×10
(7) Remove the Joint #1 output gear.
Hexagon socket head cap bolt
: 6-M3×30 (with disc spring)
(8) Detach the Base and Arm #1.
Hexagon socket head cap bolt
: 16-M5×30 (with disc spring)
If the Base and Arm #1 are not easily detached,
tap the corner of the Base using a plastic
hammer or similar tool.
(9) Remove the waveform generator and bearing
from the Arm #1.
S5
Rev.4
101
Maintenance
4. Joint #1 (Replacing the Reduction Gear Unit)
(10) Remove the circular spline and flexspline from
the Arm #1.
Hexagon socket head cap bolt
: 12-M5×40 (with disc spring)
(11) Remove the bearing from the waveform
generator using a hand press or similar tool.
(12) Remove the bearing from the Joint #1 output gear.
(13) Remove the oil seal from the Arm #1.
(14) Remove caked-on liquid gasket residue with a scraper or similar tool.
(15) Repair scratches incurred during tap use with a sharpening stone or similar tool.
102
S5
Rev.4
Maintenance
NOTE
)
Joint #1
Reduction Gear
Unit
Installation
4. Joint #1 (Replacing the Reduction Gear Unit)
Double-check the bolts to make sure that you have not forgotten to tighten any of them.
(1) Apply liquid gasket to contact surfaces of the
circular spline, flexspline, and Arm #1.
(2) Mount the circular spline, flexspline on the Arm
#1.
Hexagon socket head cap bolt
: 12-M5×40 (with disc spring 2H-5)
Tightening torque
: 8.4 N·m (0.86 kgf·m)
(3) Press the bearing into the waveform generator
using a hand press or similar tool.
(4) Apply grease on the bearing of the waveform
generator.
Grease for reduction gear: SK-1A
S5
Rev.4
103
Maintenance
4. Joint #1 (Replacing the Reduction Gear Unit)
(5) Insert the waveform generator into the circular spline and flexspline.
(6) Apply liquid gasket to contact surfaces of the
circular spline and flexspine of the Base.
(7) Mount the circular spline and flexspline to the Base.
Press the bearing into the Joint #1 output gear.
NOTE
)
Put a seal side of the bearing to the gear side (Base side), and the other side to the
Arm # side.
(8) Mount the spacer to the Joint #1 output gear.
(9) Mount the Joint #1 output gear to the Base.
Hexagon socket head cap bolt : 6-M3×30 (with disc spring 2H-3)
Tightening torque
104
: 2.25 N·m (0.23 kgf·m)
S5
Rev.4
Maintenance
4. Joint #1 (Replacing the Reduction Gear Unit)
(10) Mount the bearing holder.
GT-SA bolt
: 4-M4×10
Tightening torque : 2.8 N·m (0.29 kgf·m)
(11) Apply grease for reduction gear around the Joint
#1 output gear.
Grease for reduction gear: SK-1A
(12) Apply liquid gasket on the flange surface where it
joins with the Base.
(13) Mount the flange on the Base.
GT-SA bolt
: 7-M4×16
Tightening torque : 2.8 N·m (0.29 kgf·m)
(14) Mount the shaft to on the flange.
GT-SA bolt
: 4-M4×12
Apply liquid gasket.
Tightening torque : 2.8 N·m (0.29 kgf·m)
NOTE
)
- Apply grease for the oil seal on the contact
surfaces of the O-ring and oil seal.
Grease: MP-1
- Treat the O-ring and oil seal with extra care and
prevent from curing up.
(15) Mount the Joint #1 motor.
For details, refer to Maintenance: 4.1 Replacing the Joint #1 Motor.
(16) Mount the cables inside the manipulator.
For details, refer to Maintenance: 9.1 Replacing the Cable Unit.
S5
Rev.4
105
Maintenance
5. Joint #2 (Replacing the Motor)
5.
Joint #2
5.1
Replacing the Joint #2 Motor
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Never disassemble the motor and encoder. Disassembled motor and encoder
will cause a positional gap and cannot be used again.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
106
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
S5
Rev.4
Maintenance
5. Joint #2 (Replacing the Motor)
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
then see a doctor immediately.
If grease gets into your mouth : If swallowed, do not induce vomiting. See a
doctor immediately.
CAUTION
If grease just gets into your mouth, wash out
your mouth with water thoroughly.
If grease gets on your skin
NOTE
)
: Wash the area thoroughly with soap and
water.
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
Joint #2 Motor
WARNING
S5
Rev.4
■ Always use at least two people when removing the motor unit. Remove the
motor unit while one person is supporting the upper structure (Arms #2 to #6).
The upper structure folds inward at Joint #2 as soon as the motor unit is removed
and the brake is released. Failure to properly support the upper structure may
result in serious bodily injury and/or severe equipment damage.
107
Maintenance
5. Joint #2 (Replacing the Motor)
Name
Maintenance
Parts
Material
NOTE
)
Joint #2 Motor
Removal
AC servo motor
Grease for reduction gear
Liquid gasket
Adhesive
Wire tie
Quantity
1
Proper quantity
Proper quantity
Proper quantity
-
Note
400W
SK-1A
1206C
Loctite 242
R13B000626
R13ZA00330100
R13B031201
R13B031701
We recommend folding the upper structure (Arms #2 to #6) toward the stop side before
starting the replacement.
(1) Remove the Arm #2 Cover.
For details, refer to the Maintenance 3.2 Arm #2 Cover.
(2) Connect the backup battery to the Joint #2 motor cable.
(3) Remove the Joint #2 motor cable from inside the manipulator.
(4) Remove the Joint #2 motor and the motor plate from the Arm #2.
GT-SA bolt: 2-M4×16 (with M4 washer)
(5) Remove the Joint #2 motor plate from the Joint #2 motor.
Hexagon socket head cap bolt: 3-M4×16 (with disc spring 2H-4, M4 washer)
(6) Remove the Joint #2 input pulley from the Joint #2 motor.
Hexagon socket head cap bolt: 1-M4×18 (with disc spring 2H-4)
108
S5
Rev.4
Maintenance
NOTE
)
Joint #2 Motor
Installation
5. Joint #2 (Replacing the Motor)
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the Joint #2 input pulley to the Joint #2 motor.
Hexagon socket head cap bolt : 1-M5×16 (with disc spring 2H-5)
Apply adhesive.
Tightening torque
NOTE
)
: 6.0 N·m (0.62 kgf·m)
Hold the Joint #2 input pulley by using its grooves while tightening the bolt to
prevent the motor from turning.
(2) Mount the motor plate to the Joint #2 motor.
Hexagon socket head cap bolt : 3-M4×16 (with disc spring 2H-4, M4 washer)
Tightening torque
: 2.8 N·m (0.29 kgf·m)
(3) Place the timing belt around the Joint #2 input pulley and mount the Joint #2 motor to
the Arm #2.
GT-SA bolt
: 2-M4×16 (with M4 washer)
Tightening torque : 2.8 N·m (0.29 kgf·m)
NOTE
)
- Make sure the Arm #2 touches the radiation sheet on the motor side surface.
necessary for the heat radiation of the motor.
- Adjust the belt tension.
For details, refer to Maintenance: 5.3 Replacing the Joint #2 Timing Belt.
It is
(4) Attach two cables of the Joint #2 motor (power system, signal system) to the cables
inside the manipulator.
(5) Remove the backup battery from the Joint #2 motor.
(6) Mount the Arm #2 Cover.
For details, refer to Maintenance 3.2 Arm #2 Cover.
S5
Rev.4
109
Maintenance
5.2
5. Joint #2 (Replacing the Reduction Gear Unit)
Replacing the Joint #2 Reduction Gear Unit
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
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
110
: Wash the area thoroughly with soap and
water.
S5
Rev.4
Maintenance
NOTE
)
5. Joint #2 (Replacing the Reduction Gear Unit)
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
- A reduction gear unit consists of the three parts described below. When replacing the
reduction gear unit, be sure to always replace the waveform generator, flexspline, and
circular spline all together as one set.
For the structure details of the reduction gear, refer to Maintenance: 13. Maintenance
Parts List.
Joint #2
Reduction Gear Unit
S5
Rev.4
111
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
5.2.1 Greasing the Reduction Gear Unit
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
CAUTION
: 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.
When greasing the reduction gear unit, use only the grease specified for the reduction gear
unit. While greasing the reduction gear unit, be careful not to allow any foreign
substances in the grease.
Location for applying grease on the teeth of flexspline and circular spline and the
waveform generator
Waveform Generator
Circular Spline
112
Flexspline
S5
Rev.4
Maintenance
5.2.2
5. Joint #2 (Replacing the Reduction Gear Unit)
Replacing the Reduction Gear Unit
■ Always use at least two people when removing the motor unit. Remove the
motor unit while one person is supporting the upper structure (Arms #2 to #6).
The upper structure folds inward at Joint #2 as soon as the motor unit is removed
and the brake is released. Failure to properly support the upper structure may
result in serious bodily injury and/or severe equipment damage.
WARNING
NOTE
)
When replacing the reduction gear unit, the bearings should be replaced together.
Name
Reduction gear unit
Grease for reduction gear
Maintenance
Liquid gasket
Parts
Bearing
Material
Wire tie
NOTE
)
Quantity
1
Proper quantity
Proper quantity
1
1
1
-
Note
S5-A701**
R13B010032
S5-A901**
SK-1A
1206C
6000ZZ
6916DDU
6913ZZ
R13B010033
R13ZA00330100
R13B031201
R13B030805
R13B030806
R13B030807
- We recommend folding the upper structure (Arms #2 to #6) to the stop side before
the replacement.
- Structure of the reduction gear unit for the Joint #2 and Joint #3 are almost same.
The replacement procedure below uses pictures of Joint #3.
Joint #2
Reduction Gear
Unit
Removal
(1) Connect the backup battery to the motors of Joint #2, #3, #4, #5, and #6.
(2) Remove the cables from inside the manipulator.
For details, refer to Maintenance: 9.1 Replacing the Cable Unit.
(3) Remove the Joint #2 motor unit from the manipulator.
For details, refer to Maintenance: 5.1 Replacing the Joint #2 Motor.
(4) Remove the following:
Joint #2 output pulley
Waveform generator
Housing
Bearing
GT-SA bolt: 4-M4×10
NOTE
)
S5
Rev.4
As shown in the picture, use a removal tap to
remove.
113
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
(5) From the waveform generator, remove the Joint #2 output pulley.
Hexagon socket head cap bolt: 1-M5×20 (with disc spring 2H-5)
(6) From the waveform generator, remove the housing.
(7) From the housing, remove the bearing.
(8) From the waveform generator, remove the bearing.
(9) Remove the circular spline from the Arm #2.
Hexagon socket head cap bolt
: 29-M4×12 (with disc spring 2H-4)
114
S5
Rev.4
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
(10) Remove the housing from the Arm #2.
GT-SA bolt: 6-M4×10
NOTE
)
When the housing is removed, the Arm #1 and Arm #2 are detached.
hold the Arm #2 while removing the housing.
Therefore,
(11) Remove the bearing and oil seal from the Arm #1.
(12) Remove the flexspline from the Arm #1.
Hexagon socket head cap bolt: 30-M4×16 (with disc spring 2H-4)
(13) Remove caked-on liquid gasket residue with a scraper or similar tool.
(14) Repair scratches incurred during tap use with a sharpening stone or similar tool.
S5
Rev.4
115
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
NOTE
)
Joint #2
Reduction Gear
Unit
Installation
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the flexspline to the Arm #1.
Hexagon socket head cap bolt
: 30-M4×16 (with disc spring 2H-4)
Apply liquid gasket.
Tightening torque
: 2.8 N·m (0.29 kgf·m)
(2) Press the bearing into the Arm #1.
Apply adhesive to the contact surface with the Arm #2.
Apply liquid gasket to the outer periphery of the bearing.
NOTE
)
- Spread flat the adhesive and liquid gasket using a spatula.
- Be careful to keep the liquid gasket out of the bearing.
(3) Apply grease to the inside and lip of the oil seal.
Grease: MP-1
116
S5
Rev.4
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
(4) Press the oil seal into the Arm #1.
NOTE
)
- Before mounting the oil seal, wipe off any liquid gasket on the Arm #1.
- The height of the oil seal surface and Arm #1 surface should be the same.
(5) Apply grease for the reduction gear unit on the
teeth of the flexspline.
Grease for reduction gear unit : SK-1A
(6) Press bearing into the waveform generator.
(7) Apply liquid gasket to the inside of the bearing.
(8) Press the bearing into the waveform generator.
S5
Rev.4
117
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
(9) Apply liquid gasket to the inside of the housing.
(10) Press the waveform generator into the housing.
(11) Mount the Joint #2 output pulley to the waveform generator.
Hexagon socket head cap bolt
: 1-M5×20 (with disc spring 2H-5)
Tightening torque
: 10 N·m (1.02 kgf·m)
(12) Apply grease for the reduction gear unit to the
teeth of circular spline.
Grease for reduction gear unit : SK-1A
(13) Insert the bearing into the opposite side of the Arm #1’s reduction gear unit mounting
surface.
(14) Pass the circular spline through the Arm #1 and Arm #2 and joint the arms.
Hexagon socket head cap bolt : 29-M4×12 (with disc spring 2H-4)
Tightening torque
118
: 2.8 N·m (0.29 kgf·m)
S5
Rev.4
Maintenance
5. Joint #2 (Replacing the Reduction Gear Unit)
(15) Insert the housing into the Arm #2 and bearing.
GT-SA bolt
: 6-M4×10
Tightening torque : 2.8 N·m (0.29 kgf·m)
NOTE
)
If the housing is not easily inserted, tap the housing using a plastic hammer or similar
tool.
(16) Apply 5 mm-thick grease to the inner periphery of
the flexspline.
Grease for reduction gear unit: SK-1A
(17) Apply grease to the bearing of waveform generator.
Grease for the reduction gear unit: SK-1A
(18) Apply liquid gasket to the surfaces of the housing
(with the waveform generator mounted) and circular
spline.
(19) Mount the housing and circular spline.
(20) Mount the Joint #2 motor unit to the manipulator.
For details, refer to Maintenance: 5.1 Replacing the Joint #2 Motor.
(21) Mount the cables to inside of the manipulator.
For details, refer to Maintenance: 9.1 Replacing the Cable Unit.
S5
Rev.4
119
Maintenance
5.3
5. Joint #2 (Replacing the Timing Belt)
Replacing the Joint #2 Timing Belt
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
NOTE
)
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positionig properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
- Replacement procedure of the timing belt for the Joint #2 and Joint #3 are almost same.
The following replacement procedure uses pictures of Joint #3.
Name
Maintenance Part
120
Timing belt
Quantity
Note
1
R13B030228
S5
Rev.4
Maintenance
Joint #2
Timing belt
Removal
5. Joint #2 (Replacing the Reduction Gear Unit)
(1) Remove the Arm #2 Cover.
For details, refer to Maintenance: 3.2 Arm #2 Cover.
(2) Remove the bolts of the motor plate and then remove the
timing belt from the pulley.
GT-SA bolt
NOTE
)
Joint #2
Timing belt
Installation
: 2-M4×16 (with M4 washer)
When the timing belt is removed, the manipulator will
lose its posture. Therefore, hold the Arm #2 to prevent
it from turning while replacing the belt.
(1) Set the timing belt on the pulley and loosely secure the motor plate with the bolts.
GT-SA bolt
: 2-M4×16 (with M4 washer)
(2) Apply the specified tension to the timing belt and
secure the motor plate firmly.
Tightening torque : 2.8 N·m (0.29 kgf·m)
Belt tension
: 57.9 ~ 77.5 N (5.9 ~7.9 kgf)
(3) Check the belt tension.
(4) Mount the Arm #2 Cover.
For details, refer to Maintenance: 3.2 Arm #2 Cover.
S5
Rev.4
121
Maintenance
6. Joint #3 (Replacing the Motor)
6.
Joint #3
6.1
Replacing the Joint #3 Motor
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Never disassemble the motor and encoder. Disassembled motor and encoder
will cause a positional gap and cannot be used again.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
122
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
S5
Rev.4
Maintenance
6. Joint #3 (Replacing the Motor)
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
CAUTION
: 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
NOTE
)
: Wash the area thoroughly with soap and
water.
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software you
are using to perform the calibration.
Joint #3 Motor
WARNING
S5
Rev.4
■ Always use at least two people when removing the motor unit. Remove the
motor unit while one person is supporting the upper structure (Arms #3 to #6).
The upper structure folds inward at Joint #3 as soon as the motor unit is removed
and the brake is released. Failure to properly support the upper structure may
result in serious bodily injury and/or severe equipment damage.
123
Maintenance
6. Joint #3 (Replacing the Motor)
Maintenance
Parts
Material
Name
AC servo motor
Grease for reduction gear
Liquid gasket
Adhesive
Wire tie
NOTE
)
Joint #3 Motor
Removal
Quantity
1
Proper quantity
Proper quantity
Proper quantity
-
200W
SK-1A
1206C
Loctite 242
Note
R13B000627
R13ZA00330100
R13B031201
R13B031701
We recommend folding the upper structure (Arms #3 to #6) to the stop side before the
replacement.
(1) Remove the Arm #2 Cover.
For details, refer to the Maintenance 3.2 Arm #2 Cover.
(2) Connect the backup battery to the Joint #3 motor cable.
(3) Remove the Joint #3 motor cable from inside of the manipulator.
(4) Remove the Joint #3 motor and the Joint #3 motor plate from the Arm #2.
GT-SA bolt: 2-M4×16 (with M4 washer)
(5) Remove the Joint #3 motor plate from the Joint #3 motor.
Hexagon socket head cap bolt: 3-M4×16 (with disc spring 2H-4, M4 washer)
(6) Remove the Joint #3 input pulley from the Joint #3 motor.
Hexagon socket head cap bolt: 1-M4×18 (with disc spring 2H-4)
WARNING
124
■ Always use at least two people when removing the motor unit. Remove the
motor unit while one person is supporting the upper structure (Arms #3 to #6).
The upper structure folds inward at Joint #3 as soon as the motor unit is removed
and the brake is released. Failure to properly support the upper structure may
result in serious bodily injury and/or severe equipment damage.
S5
Rev.4
Maintenance
NOTE
)
Joint #3 Motor
Installation
6. Joint #3 (Replacing the Motor)
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the Joint #3 input pulley to the Joint #3 motor.
Hexagon socket head cap bolt : 1-M4×18 (with disc spring 2H-4, M4 washer)
Apply adhesive.
Tightening torque
NOTE
)
: 2.8 N·m (0.29 kgf·m)
When tightening the bolts using the hexagonal wrench, use the grooves of the Joint
#3 input pulley to prevent the motor from turning.
(2) Mount the motor plate to the Joint #3 motor.
Hexagon socket head cap bolt : 3-M4×16 (with disc spring 2H-4, M4 washer)
Tightening torque
: 2.8 N·m (0.29 kgf·m)
(3) Place the Joint #3 timing belt around the Joint #3 input pulley and mount the Joint #3
motor to the Arm #2.
GT-SA bolt
: 2-M4×16 (with M4 washer)
Tightening torque : 2.8 N·m (0.29 kgf·m)
NOTE
)
- Make sure the Arm #2 touches the radiation sheet on the motor side surface.
necessary for the heat radiation of the motor.
- Adjust the belt tension.
For details, refer to Maintenance: 6.3 Replacing the Joint #3 Timing Belt.
It is
(4) Attach two cables of the Joint #3 motor (power system, signal system) to the cables
inside the manipulator.
(5) Remove the backup battery from the Joint #3 motor.
(6) Mount the Arm #3 Cover.
For details, refer to the Maintenance 3.3 Arm #3 Cover.
S5
Rev.4
125
Maintenance
6.2
6. Joint #3 (Replacing the Reduction Gear Unit)
Replacing the Joint #3 Reduction Gear Unit
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
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
126
: Wash the area thoroughly with soap and
water.
S5
Rev.4
Maintenance
NOTE
)
6. Joint #3 (Replacing the Reduction Gear Unit)
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
- A reduction gear unit consists of the three parts described below. When replacing the
reduction gear unit, be sure to always replace the waveform generator, flexspline, and
circular spline all together as one set.
For the structure details of the reduction gear, refer to Maintenance: 13. Maintenance
Parts List.
Joint #3
Reduction Gear Unit
6.2.1 Greasing the Reduction Gear Unit
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
CAUTION
: 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
S5
Rev.4
: Wash the area thoroughly with soap and
water.
127
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
When greasing the reduction gear unit, use only the grease specified for the reduction
gear unit.
While greasing the reduction gear unit, be careful not to allow any foreign substances in
the grease.
Location for applying grease on the teeth of flexspline and circular spline and the
waveform generator
Waveform Generator
Circular Spline
128
Flexspline
S5
Rev.4
Maintenance
6.2.2
6. Joint #3 (Replacing the Reduction Gear Unit)
Replacing the Reduction Gear Unit
■ Always use at least two people when removing the motor unit. Remove the
motor unit while one person is supporting the upper structure (Arms #3 to #6).
The upper structure folds inward at Joint #3 as soon as the motor unit is removed
and the brake is released. Failure to properly support the upper structure may
result in serious bodily injury and/or severe equipment damage.
WARNING
NOTE
)
When replacing the reduction gear unit, the bearings should be replaced together.
Name
Reduction gear unit
Grease for reduction gear
Maintenance Liquid gasket
Adhesive
Parts
Bearing
Quantity
S5-A701**
S5-A901**
Proper quantity SK-1A
Proper quantity 1206C
Proper quantity Loctite 242
1
6913ZZ
1
6000ZZ
1
1
Material
Wire tie
NOTE
)
Joint #3
Reduction Gear
Unit
Removal
Note
6913DDU
R13B010034
R13B010035
R13ZA00330100
R13B031201
R13B031701
R13B030807
R13B030805
R13B030808
-
We recommend folding the upper structure (Arms #3 to #6) to the stop side before the
replacement.
(1) Remove the Joint #3 motor unit from the Manipulator.
For details, refer to Maintenance 6.1 Replacing the Joint #3 Motor.
(2) Remove the following:
Joint #3 output pulley / Waveform generator / Housing / Bearing
GT-SA bolt: 4-M4×10
NOTE
)
As shown in the picture, use a removal tap to remove.
(3) From the waveform generator, remove the Joint #3 output pulley.
S5
Rev.4
129
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
(4) From the waveform generator, remove the housing
(5) From the housing, remove the bearing.
(6) From the waveform generator, remove the bearing.
(7) Remove the circular spline from the Arm #2.
Hexagon socket head cap bolt: 6-M4×12
(8) Remove the housing from the Arm #2.
GT-SA bolt: 6-M4×10
NOTE
)
130
When the housing is removed, the Arm #1 and Arm #2 are detached.
hold the Arm #2 while removing the housing.
Make sure to
S5
Rev.4
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
(9) Remove the bearing and oil seal from the Arm #3.
(10) Remove the flexspline from the Arm #3.
Hexagon socket head cap bolt: 32-M3×10 (with disc spring 2H-3)
(11) Remove caked-on liquid gasket residue with a scraper or similar tool.
(12) Repair scratches incurred during tap use with a sharpening stone or similar tool.
S5
Rev.4
131
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
NOTE
)
Joint #3
Reduction Gear
Unit
Installation
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the flexspline to the Arm #3.
Hexagon socket head cap bolt:
32-M3×10 (with disc spring 2H-3)
Apply liquid gasket.
Tightening torque : 1.4 N·m (0.15 kgf·m)
(2) Press the bearing into the Arm #3.
Apply adhesive to the contact surface with the Arm #3.
Apply liquid gasket to the outer periphery of the bearing.
NOTE
)
- Spread flat the adhesive and liquid gasket using a spatula.
- Be careful to keep the liquid gasket out of the bearing.
(3) Apply grease to the inside and lip of the oil seal.
Grease: MP-1
(4) Press the oil seal into the Arm #3.
NOTE
)
- Before mounting the oil seal, wipe off
any liquid gasket on the Arm #3.
- The height of the oil seal surface and
Arm #1 surface should be the same.
(5) Apply grease for the reduction gear unit on the
teeth of the flexspline.
Grease for reduction gear unit: SK-1A
132
S5
Rev.4
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
(6) Press the bearing into the waveform generator.
(7) Apply liquid gasket to inside of the bearing.
(8) Press the
generator.
bearing
into
the
waveform
(9) Apply liquid gasket to inside of the housing.
(10) Press the waveform generator into the housing.
(11) Mount the Joint #3 output pulley to the waveform generator.
Hexagon socket head cap bolt : 1-M4×18 (with disc spring 2H-4)
Tightening torque
S5
Rev.4
: 4.8 N·m (0.49 kgf·m)
133
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
(12) Apply grease on teeth of the circular spline.
Grease for reduction gear unit: SK-1A
(13) Insert the bearing into the opposite side of the Arm #3’s reduction gear unit mounting
surface.
(14) Pass the circular spline through the Arm #2 and Arm #3 and joint the arms.
Hexagon socket head cap bolt: 16-M4×12
Tightening torque : 2.8 N·m (0.29 kgf·m)
(15) Insert the housing into the Arm #2 and bearing.
GT-SA bolt
: 6-M4×10
Tightening torque : 2.8 N·m (0.29 kgf·m)
NOTE
)
If the housing is not easily inserted, tap the housing using a plastic hammer or similar
tool.
(16) Apply 5 mm-thick grease for the reduction gear unit to
the inner periphery of the flexspline.
Grease for reduction gear unit: SK-1A
(17) Apply grease to the bearing of waveform generator.
Grease for reduction gear unit: SK-1A
(18) Apply liquid gasket to the surfaces of the housing (with
the waveform generator mounted) and circular spline.
134
S5
Rev.4
Maintenance
6. Joint #3 (Replacing the Reduction Gear Unit)
(19) Mount the housing and circular spline.
(20) Mount the Joint #3 motor unit to the manipulator.
For details, refer to Maintenance: 6.1 Replacing the Joint #3 Motor.
(21) Mount the cables to inside of the manipulator.
For details, refer to Maintenance: 9.1 Replacing the Cable Unit.
S5
Rev.4
135
Maintenance
6.3
6. Joint #3 (Replacing the Timing Belt)
Replacing the Joint #3 Timing Belt
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
NOTE
)
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positionig properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
Name
Maintenance Part
136
Timing belt
Quantity
1
Note
S5-A701**
S5-A901**
R13B030229
R13B030230
S5
Rev.4
Maintenance
Joint #3
Timing belt
Removal
6. Joint #3 (Replacing the Timing Belt)
(1) Remove the Arm #2 Cover.
For details, refer to Maintenance: 3.2 Arm #2 Cover.
(2) Remove the bolts of the motor plate and then remove
the timing belt from the pulley.
GT-SA bolt
NOTE
)
Joint #3
Timing belt
Installation
: 2-M4×16 (with M4 washer)
When the timing belt is removed, the manipulator will
lose its posture. Therefore, hold the Arm #3 to prevent
it from turning while replacing the belt.
(1) Set the timing belt on the pulley and loosely secure the motor plate with the bolts.
GT-SA bolt
: 2-M4×16 (with M4 washer)
(2) Apply the specified tension to the timing belt and
secure the motor plate firmly.
Tightening torque : 2.8 N·m (0.29 kgf·m)
Belt tension
: 57.9 ~ 77.5 N (5.9 ~7.9 kgf)
(3) Check the belt tension.
(4) Mount the Arm #2 Cover.
For details, refer to Maintenance: 3.2 Arm #2 Cover.
S5
Rev.4
137
Maintenance
7. Joint #4 (Replacing the Motor)
7.
Joint #4
7.1
Replacing the Joint #4 Motor
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. 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.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
Never put alcohol, liquid gasket, or adhesive close to fire.
Use alcohol, liquid gasket, or adhesive while ventilating the room.
Wear protective gear including a mask, protective goggles, and oil-resistant gloves.
If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
-
CAUTION
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
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
138
: Wash the area thoroughly with soap and water.
S5
Rev.4
Maintenance
NOTE
)
7. Joint #4 (Replacing the Motor)
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software you
are using to perform the calibration.
Joint #4 Motor
Name
Maintenance
Parts
Material
Quantity
AC servo motor
Grease for reduction gear
Liquid gasket
Adhesive
Wire tie
1
Proper quantity
Proper quantity
Proper quantity
-
Note
50W
SK-1A
1206C
Loctite 242
R13B000628
R13ZA00330100
R13B031201
R13B031701
Joint #4 Motor (1) Remove the Arm #3 Cover.
Removal
For details, refer to Maintenance 3.3 Arm #3 Cover.
(2) Remove the LED lamp.
(3) Remove the bolts that secure the supporting plate
and then pull out the lead line from the manipulator.
GT-SA bolt: 2-M4×10
(4) Connect the backup battery to the Joint #4 motor cable.
(5) Remove the Joint #4 motor cables from the cables inside the manipulator.
(6) Remove the bolts and then remove the Joint #4 motor.
GT-SA bolt
: 2-M3×12 (with M3 washer
(7) Remove the bolts and then remove the pulley.
Hexagon socket head cap bolt : M3×12 (with disc spring 2H-3)
S5
Rev.4
139
Maintenance
7. Joint #4 (Replacing the Motor)
NOTE
)
Joint #4 Motor
Installation
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the pulley to the Joint #4 motor.
Hexagon socket head cap bolt: M3×12 (with disc spring 2H-3)
Apply adhesive.
Tightening torque: 2.25 N·m (0.25 kg·m)
NOTE
)
When tightening the bolts using the hexagonal wrench, use the grooves of the pulley
to prevent the motor from turning.
(2) Set the belt around the pulley and mount the Joint
#3 motor to the Arm #3.
GT-SA bolt
: 2-M3×12 (with M3 washer)
Tightening torque : 1.4 N·m (0.14 kg·m)
NOTE
)
From the Arm #3 side surface, confirm that the
timing belt is properly set on the pulley.
(3) Mount the Joint #4 motor cable to the lead line.
(4) Remove the backup battery.
(5) Mount the supporting plate on the Arm #3.
GT-SA bolt
: 2-M4×10
Tightening torque : 2.8 N·m (0.28 kg·m)
(6) Mount the LED lamp.
(7) Mount the Arm #3 Cover.
For details, refer to Maintenance 3.3 Arm #3 Cover.
140
S5
Rev.4
Maintenance
7.2
7. Joint #4 (Replacing the Reduction Gear Unit)
Replacing the Joint #4 Reduction Gear Unit
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
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
S5
Rev.4
: Wash the area thoroughly with soap and
water.
141
Maintenance
NOTE
7. Joint #4 (Replacing the Reduction Gear Unit)
)
- After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software
you are using to perform the calibration.
- A reduction gear unit consists of the three parts described below. When replacing the
reduction gear unit, be sure to always replace the waveform generator, flexspline, and
circular spline all together as one set.
For the structure details of the reduction gear, refer to Maintenance: 13. Maintenance
Parts List.
Joint #4 Reduction Gear Unit
7.2.1 Greasing the Reduction Gear Unit
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
CAUTION
: 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.
When greasing the reduction gear unit, use only the grease specified for the reduction
gear unit.
While greasing the reduction gear units, be careful not to allow any foreign substances in
the grease.
Location for applying grease
- Teeth of the Joint #4 flexspline and the circular spline
- Waveform generator
- Between the waveform generator and the motor plate of the Joint #4 reduction gear
142
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Rev.4
Maintenance
7.2.2
7. Joint #4 (Replacing the Reduction Gear Unit)
Replacing the Reduction Gear Unit
NOTE
)
When replacing the reduction gear unit, the bearings should be replaced together.
Name
Maintenance
Parts
Reduction gear unit
Grease for reduction gear
Liquid gasket
Adhesive
Bearing
Material
Wire tie
Quantity
1
Proper quantity
Proper quantity
Proper quantity
1
1
-
Note
SK-1A
1206C
Loctite 242
6806ZZ
6808ZZ*NS7
R13B010036
R13ZA00330100
R13B031201
R13B031701
R13B030810
R13B030809
(1) Pull out the lead line toward the Arm #2 side.
Joint #4
Reduction Gear
For details, refer to Maintenance 9.1 Replacing the Cable
Unit
Unit.
Removal
(2) Remove the bolts and then remove the
pipe.
GT-SA bolt : 2-M3×12
(3) Remove he bolts and then remove the Joint #4 motor.
GT-SA bolt: : 2-M3×12 (with M3 washer)
(4) Remove the belt from the pulley.
S5
Rev.4
143
Maintenance
7. Joint #4 (Replacing the Reduction Gear Unit)
(5) Remove the bolts and then remove the wrist from the Arm #3.
Hexagon socket head cap bolt : 4-M6×16 (with disc spring 2H-6)
(6) Remove the bolts and then remove the pulley and washer from waveform generator.
GT-SA bolt
: 3-M3×10
(7) Remove the bolts and then remove the Joint #4 reduction gear unit using the removal
tap.
Hexagon socket head cap bolt : 16-M3×20 (with disc spring 2H-3)
(8) Remove the bearing from the housing.
(9) Remove the bearing from the waveform generator.
(10) Remove caked-on liquid gasket residue with a
scraper or similar tool.
(11) Repair scratches incurred during tap use with a
sharpening stone or similar tool.
(12) Remove he flexspline cap from the flexspline.
144
S5
Rev.4
Maintenance
NOTE
)
Joint #4
Reduction Gear
Unit
Installation
7. Joint #4 (Replacing the Reduction Gear Unit)
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Apply liquid gasket to contact surfaces of the circular spline, flexspline, and spacer.
Liquid gasket (1206C)
(2) Mount the circular spline and flexspline to the spacer.
Hexagon socket head cap bolt
: 12-M3×30 (with disc spring 2H-3)
Apply liquid gasket (1206C).
Tightening torque : 1.4 N·m (0.14 kgf·m)
(3) Apply liquid gasket to inner periphery of the bearing.
Press the bearing into the waveform generator.
Bearing
: 6806ZZ
Liquid gasket : 1206C
(4) Apply liquid gasket to the inner periphery of the bearing.
Press the bearing into the waveform generator.
Bearing
: 6808ZZ*NS7*
Liquid gasket : 1206C
(5) Apply the grease for the reduction gear to the bearing of the
waveform generator.
Grease for reduction gear: SK-1A (Approx. 2 g)
S5
Rev.4
145
Maintenance
7. Joint #4 (Replacing the Reduction Gear Unit)
(6) Apply liquid gasket to outer periphery of the bearing.
Bearing
: 6806ZZ
Liquid gasket : 1206C
(7) Insert the circular spline and flexspline into the waveform
generator.
(8) Apply liquid gasket to outer periphery of the bearing.
Bearing
: 6808ZZ*NS7*
Liquid gasket : 1206C
(9) Apply liquid gasket to contact surfaces of the housing,
circular spline, and flexspline.
Liquid gasket: 1206C
(10) Mount the housing to the circular spline and flexspline.
Hexagon socket head cap bolt: 16-M3×20 (with disc spring 2H-3)
Tightening torque: 1.4 N·m (0.14 kgf·m)
(11) Mount the pulley and washer to the waveform generator.
GT-SA bolt
: 3-M3×10
Tightening torque : 1.4 N·m (0.14 kgf·m)
(12) Mount the pipe to the spacer.
146
S5
Rev.4
Maintenance
7. Joint #4 (Replacing the Reduction Gear Unit)
(13) Apply liquid gasket to contact surfaces of the spacer and
Wrist Unit.
Liquid gasket: 1206C
(14) Mount the spacer to the Wrist Unit.
Hexagon socket head cap bolt
: 4-M6×16 (with disc spring 2H-6)
Tightening torque: 10 N·m (1.02 kgf·m)
(15) Apply liquid gasket to the contact surfaces of the spacer
and Arm #3.
Liquid gasket: 1206C
(16) Mount the spacer to the Arm #3.
Hexagon socket head cap bolt
: 4-M6×16 (with disc spring 2H-6)
Tightening torque: 10 N·m (1.02 kgf·m)
(17) Set the belt around the belt and mount the Joint #4 motor to the Arm #3.
GT-SA bolt
: 2-M3×12 (with M3 washer)
Tightening torque : 1.4 N·m (0.14 kg·m)
From the Arm #3 side surface, confirm that the timing belt is properly set on the
pulley.
S5
Rev.4
147
Maintenance
7. Joint #4 (Replacing the Reduction Gear Unit)
(18) Confirm that the specified tension is applied to the belt.
Belt tension: 19.6 ~ 26.5 N (2.0 ~ 2.7 kgf)
(19) Mount the pipe to the Arm #3.
GT-SA bolt
: 2-M3×12
Tightening torque : 1.4 N·m (0.14 kgf·m)
NOTE
)
Be careful of the pipe direction. (See the photo.)
(20) Mount the lead line.
For details, refer to Maintenance 9.1 Replacing the Cable Unit.
148
S5
Rev.4
Maintenance
7.3
7. Joint #4 (Replacing the Timing Belt)
Replacing the Joint #4 Timing Belt
■ 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.
WARNING
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Never disassemble the motor and encoder. Disassembled motor and encoder
will cause a positional gap and cannot be used again.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
NOTE
)
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software you
are using to perform the calibration.
Name
Maintenance Part
S5
Rev.4
Timing belt
Quantity
Note
1
R13B030231
149
Maintenance
Joint #4
Timing belt
Removal
7. Joint #4 (Replacing the Timing Belt)
(1) Remove the Arm #3 Cover.
For details, refer to Maintenance: 3.3 Arm #3 Cover.
(2) Remove the timing belt.
Follow the removal steps (1) to (4) in
Maintenance: 7.2.2 Replacing the Joint #4
Reduction Gear Unit.
Joint #4
Timing belt
Installation
Timing belt
(1) Mount the timing belt.
Follow the installation steps (17) to (21) in Maintenance: 7.2.2 Replacing the Joint
#4 Reduction Gear Unit.
(2) Mount the Arm #3 Cover.
For details, refer to Maintenance: 3.3 Arm #3 Cover.
150
S5
Rev.4
Maintenance
8. Joint #5 & Joint #6 (Replacing the Motor)
8.
Joint #5 & Joint #6
8.1
Replacing the Joint #5 & Joint #6 Motor
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. 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.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
NOTE
)
S5
Rev.4
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software you
are using to perform the calibration.
151
Maintenance
8. Joint #5 & Joint #6 (Replacing the Motor)
Joint #5 Motor
Name
Maintenance
Parts
Material
WARNING
Joint #5 & #6
Motor
Removal
AC servo motor
Joint #6 Motor
Quantity
1
Adhesive
Proper quantity
Wire tie
-
Note
50W
Common for Joint #5, Joint #6
R13B000629
Loctite 242
R13B031701
■ Lower the Arm #5 and Arm #6 before replacing the Joint #5 motor. Removing
the motor will disengage the brake, which may cause the Manipulator to fall and
may result in serious bodily injury and/or severe equipment damage.
(1) Remove the Arm #4 Cover.
For details, refer to Maintenance 3.4 Arm #4 Cover.
(2) Connect the backup battery to the motor cable.
(3) Remove the motor cable from the lead line.
(4) Remove the bolts and then remove the motor plate
and motor from the Arm #4.
GT-SA bolt
: 2-M4×16 (with M4 washer)
(5) Remove the bolts and then remove the pulley and shaft.
Hexagon socket head cap bolt : M3×30 (with disc spring 2H-3)
152
S5
Rev.4
Maintenance
8. Joint #5 & Joint #6 (Replacing the Motor)
(6) Remove the two types of bolts and then remove the
bracket.
Hexagon socket head cap bolt : 2-M2.6×5
GT-SA bolt
: 2-M3×12
(7) Remove the electromagnetic brake.
(8) Remove the bolts and then remove the motor plate.
GT-SA bolt: 2-M3×12 (with M3 washer)
(9) Remove the set screws and then remove the rotor
hub.
Hexagon socket head cap set screw: 2-M2
S5
Rev.4
153
Maintenance
8. Joint #5 & Joint #6 (Replacing the Motor)
NOTE
)
Joint #5 & #6
Motor
Installation
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Mount the rotor hub to the motor shaft.
Hexagon socket head cap set screw : 2-M2
Apply adhesive.
Tightening torque
NOTE
)
: 0.3 N·m (0.03 kgf·m)
Use a spacer or similar tool to secure the rotor hub at 2 mm from the motor edge
surface.
2 mm
(2) Mount the motor plate to the motor.
GT-SA bolt
: 2-M3×12 (with M3 washer)
Tightening torque : 1.4 N·m (0.14 kgf·m)
(3) Insert the electromagnetic brake into the rotor hub.
(4) Mount the bracket using the brake centering jig.
Hexagon socket head cap bolt
: 2-M2.6×5
Tightening torque
: 0.3 N·m (0.03 kgf·m)
GT-SA bolt
: 2-M3×12
Tightening torque
: 1.4 N·m (0.14 kgf·m)
154
S5
Rev.4
Maintenance
8. Joint #5 & Joint #6 (Replacing the Motor)
(5) Insert the shaft to center of the electromagnetic
brake.
(6) Mount the pulley and then secure the brake cable with a wire tie.
Hexagon socket head cap bolt: M3×30 (with disc spring 2H-3)
Apply adhesive.
Tightening torque: 2.25 N·m (0.23 kgf·m)
(7) Mount the motor plate and motor to the Arm #4.
GT-SA bolt: 2-M4×16 (with M4 washer)
(8) Set the timing belt on the pulley and adjust the belt tension.
For details, refer to Maintenance: 8.2 Replacing the Joint #5 & Joint #6 Timing Belt.
(9) Connect the motor cable to the lead line.
(10) Remove the backup battery.
(11) Mount the Arm #4 Cover.
For details, refer to Maintenance: 3.4 Arm #4 Cover.
S5
Rev.4
155
Maintenance
8.2
8. Joint #5 & Joint #6 (Replacing the Timing Belt)
Replacing the Joint #5 & Joint #6 Timing Belt
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life cycle of the motors and encoder
and/or damage them.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
NOTE
)
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder 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 12. Calibration and follow the steps that pertain to the software you
are using to perform the calibration.
156
S5
Rev.4
Maintenance
8. Joint #5 & Joint #6 (Replacing the Timing Belt)
Name
Maintenance Part
Joint #5 & #6
Timing Belt
Removal
Quantity
Timing belt
1
Note
R13B030232
(1) Remove the Arm #4 Cover.
For details, refer to the Maintenance 3.4 Arm #4 Cover.
(2) Remove the bolts of the motor plate.
Pull the motor unit so that it is leaning towards
you and remove the timing belt from the pulley.
GT-SA bolt: 2-M4×16 (with M4 washer)
Joint #5 & #6
Timing Belt
Installation
(1) Insert the motor unit to its original position in the Manipulator.
(2) Set the timing belt on the pulley and loosely fasten the motor plate with the bolts.
GT-SA bolt: 2-M4×16 (with M4 washer)
(3) Apply the specified tension to the timing belt and firmly fasten the motor plate.
Tightening torque : 2.8 N·m (0.29 kgf·m)
Belt tension
: 19.6 ~ 26.5 N (2.0 ~2.7 kgf)
(4) Check the belt tension.
(5) Mount the Arm #4 Cover.
For details, refer to the Maintenance 3.4 Arm #4 Cover.
S5
Rev.4
157
Maintenance
9.
Cable Unit
WARNING
9.1
9. Cable Unit
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
foreign substances exist in them is extremely hazardous and may result in
electric shock and/or malfunction of the robot system.
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the
cables. (Do not put heavy objects on the cables. Do not bend or pull the cables
forcibly.) The unnecessary strain on the cables may result in damage to the
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
or contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
Replacing the Cable Unit
If the power and signal connectors are unplugged without connecting the backup battery
for the motor encoder, the motor position data will be lost and the calibration must be
executed again. Connect a battery to the battery port on each motor when replacing
cables.
WARNING
158
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the
cover. Unnecessary strain on cables may result in damage to the cables,
disconnection, and/or contact failure. Damaged cables, disconnection, or
contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
When routing the cables, observe the cable locations after removing the cover.
Be sure to place the cables back to their original locations.
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the
cables. (Do not put heavy objects on the cables. Do not bend or pull the cables
forcibly.) The unnecessary strain on the cables may result in damage to the
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
or contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
S5
Rev.4
Maintenance
9. Cable Unit
■ When disconnecting the connectors during the replacement of the cable unit, be
sure to reconnect the connectors to their proper positions.
Improper connection of the connectors may result in improper function of the
robot system.
For details on the connections, refer to the Maintenance 9.2 Connector Pin
Assignments.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and
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
S5
Rev.4
: Wash the area thoroughly with soap and
water.
159
Maintenance
9. Cable Unit
Name
Maintenance
Parts
Material
Quantity
Cable unit
1
Backup battery
for motor encoder *
Wire tie
6
Note
S5-A701** :
R13B020056
S5-A901** :
R13B020057
For Joint #1, #2, #3, #4, #5, #6
R13B060006
-
* The backup battery for the motor encoder is only used for retaining the motor position data during
maintenance (cable replacement, etc.). It is not used for the Manipulator itself.
Cable Unit
Removal
(1) Return the Manipulator to the origin position (0 pulse
position).
(2) Remove the covers listed below.
Arm #1 Cover
Arm #4 Cover
Arm #2 Cover
Arm #3 Cover
Base Connector Plate
Refer to the Maintenance 3. Covers for details on removing
covers.
(3) Cut the wire ties that bind six connector packs (power system, signal system) of the
motors of the Joints #1, #2, #3, #4, #5, and #6.
(4) Connect the motor encoder backup battery for the Joint #1, #2, #3, #4, #5, and #6
motor to the each motor.
NOTE
)
If you unplug the power cable and signal cable without connecting the backup
batteries for the motor encoders, the position data in motors will be lost and the arms
will need to be calibrated again.
(5) Remove the connectors of the power cable and signal cable.
Connector: For Joint #5 (B), For Joint #6 (T)
(6) Remove the air hose and equipped cable connector.
Connector: 3BC, 4BC
(7) Remove the connectors of the power cable and signal cable.
Connector: For Joint #4 (R)
(8) Cut off all wire ties that secure the lead line inside the Arm #3.
160
S5
Rev.4
Maintenance
9. Cable Unit
(9) Remove the LED.
(10) Remove the supporting plate.
Hexagon socket head cap bolt : 2-M4×10
(11) Remove the saddle.
Hexagon socket head cap bolt
: M5×8 (with disc spring 2H-5, M5 washer)
(12) Cut off the wire ties and pull out the lead line toward the Arm #3.
To pull out the lead line smoothly, bind the connectors with a tape as shown in the
picture below.
(13) Remove the connectors of power cable and signal cable.
Connector: For Joint #2 (L), For Joint #3 (U)
(14) Cut off all wire ties that secure the lead line inside the Arm #2.
(15) Remove the saddle.
Hexagon socket head cap bolt
: 2-M4×8
(with disc spring 2H-4, M4 washer)
S5
Rev.4
161
Maintenance
9. Cable Unit
(16) Remove the saddle.
Hexagon socket head cap bolt
: 2-M4×6
(with disc spring 2H-4, M4 washer,
and rubber plate)
(17) Pull out the lead line toward the Arm #2.
(18) Remove the supporting plate.
GT-SA bolt : 2-M4×12
(19) Remove the saddle.
GT-SA bolt : 2-M5×10
(with M5 washer)
(20) Remove the connectors of power cable and signal cable.
Connector: For Joint #1 (S)
(21) Pull out the lead line by pulling the connector plate.
162
S5
Rev.4
Maintenance
NOTE
)
Cable Unit
Installation
9. Cable Unit
Double-check the bolts to make sure that you have not forgotten to tighten any of
them.
(1) Pass the lead line (with the connector plate attached) through the back of the Base
and Arm #1 to Arm #4.
(2) Connect the Joint #1 motor connector to the lead line.
Remove the backup battery.
(3) Press the lead line into the Base and mount the Connector
Plate.
Hexagon socket button head bolt : 8-M4×10
Tightening torque : 1.4 N·m (0.14 kgf·m)
NOTE
)
Be careful not to catch the cables between the Base and
the Connector Plate.
(4) Put the lead line around the Arm #3 as shown in the
picture.
(5) Pass a wire tie through the supporting plate.
S5
Rev.4
163
Maintenance
9. Cable Unit
(6) Secure the wire tie as shown in the picture.
(7) Mount the saddle to the supporting plate.
GT-SA bolt
: M4×10
Tightening torque : 2.8 N·m (0.29 kgf·m)
(8) Secure the cables to the supporting plate as shown in the picture.
(9) Loosely secure the cables in the Arm #3 with a wire
tie.
(10) Secure the supporting plate to the Arm #3.
GT-SA bolt
: 2-M4×10
Tightening torque : 2.8 N·m (0.29 kgf·m)
(11) Mount the saddle to the spring (some winds from the end) of the lead line.
164
S5
Rev.4
Maintenance
9. Cable Unit
(12) Mount the supporting plate inside the Arm #1.
(13) Secure the supporting plate and saddle.
(14) Connect the connector to the lead line.
Remove the backup battery.
Connector: For Joint #2 (L), For Joint #3 (U)
(15) Mount the rubber plate and saddle to the spring (some winds from the end) of the
lead line.
(16) Secure the saddle to the Arm #2.
Hexagon socket head cap bolt
: 2-M4×6
(with disc spring 2H-4, M4 washer)
Tightening torque
: 2.8 N·m (0.29 kgf·m)
S5
Rev.4
165
Maintenance
9. Cable Unit
(17) Set a wire tie in the area marked in white.
(18) Mount another saddle to the spring (some winds
from the end) of the Arm #3 side.
Hexagon socket head cap bolt
: 2-M4×8
(with disc spring 2H-4, M4 washer)
Tightening torque: 2.8 N·m (0.29 kgf·m)
(19) Set a wire tie in the area marked in white.
(20) Bind the signal connectors with a wire tie as
shown in the picture.
Connector: For Joint #2 (L), For Joint #3 (U)
(21) Bind the power connectors with a wire tie as shown in the picture.
Connector: For Joint #2 (L), For Joint #3 (U)
166
S5
Rev.4
Maintenance
9. Cable Unit
(22) Put the cable in the position in the Arm #4 as shown in the picture below, with the
white marking on the cable as the guide.
(23) Connect the connector to the lead line.
Remove the backup battery.
Connector: For Joint #5 (B), For Joint #6 (T)
(24) Bind the signal connectors with a wire tie as
shown in the picture.
Connector: For Joint #5 (B), For Joint #6 (T)
(25) Bind the power connectors with a wire tie as
shown in the picture.
Connector: For Joint #5 (B), For Joint #6 (T)
(26) Put the connector of the signal cable in the
position shown in the picture.
(27) Pass the wire tie through the cable fixing plate.
S5
Rev.4
167
Maintenance
9. Cable Unit
(28) Secure the cable fixing plate to the Arm #4.
GT-SA bolt
: 2-M4×12
Tightening torque : 2.8 N·m (0.29 kgf·m)
(29) Set a wire tie in the area marked in white.
(30) Mount two air hoses to the Arm #4.
Air Hose: A – Black, B – Blue
NOTE
)
Make sure to mount the air hoses in the right position. Otherwise, the air lines
change inside the manipulator and the equipment such as the hand cannot function
normally.
(31) Press the power connectors into the Arm #4.
(32) Connect the connector to the lead line. Remove the backup battery.
Connector: For Joint #4 (R)
(33) Mount the LED lamp to the Arm #3.
168
S5
Rev.4
Maintenance
9. Cable Unit
(34) Mount the connector of the LED lamp to the lead line.
(35) Remove the following covers:
Arm #1 Cover
Arm #4 Cover
Arm #2 Cover
Arm #3 Cover
Base Connector Plate
For details, refer to Maintenance: 3. Covers.
S5
Rev.4
169
170
Green
Gray
Blue
Orange
Red
Violet
White
Yellow
G
L
O
R
V
W
Y
Brown
BR
GR
Black
B
Cable color
Resolver Board
Gyro Board
Brake Switch
Brake
9.2.1
Azure
9.2
A
Code
Maintenance
9. Cable Unit
Wiring Diagrams
Signal Cable
S5
Rev.4
S5
Rev.4
Cable color
Black
Brown
Green
Gray
Blue
Orange
Red
Violet
White
Yellow
B
BR
G
GR
L
O
R
V
W
Y
Azure
9.2.2
A
Code
Maintenance
9. Cable Unit
Power Cable
171
Maintenance
9. Cable Unit
9.2.3 User Cable
Code
A
B
BR
G
GR
L
O
R
V
W
Y
172
Cable color
Azure
Black
Brown
Green
Gray
Blue
Orange
Red
Violet
White
Yellow
S5
Rev.4
Maintenance
10.
10. Battery Unit (Lithium Battery)
Battery Unit (Lithium Battery)
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ 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.
CAUTION
<Improper Handling>
Attempting to charge
Disassembling
Connecting batteries improperly
Exposing to fire
Forcing discharge
Deforming by pressure
Short-circuit (Polarity; Positive/Negative)
Heating (100°C or more)
Soldering the terminal of the lithium battery
directly
The life span of the lithium battery is three years. Even if the Manipulator is constantly
connected to power, the lithium battery needs to be replaced every three years.
10.1
NOTE
)
S5
Rev.4
Precautions of the Data
- Always connect the new battery unit before disconnecting the old battery unit. If you
disconnect the old battery unit before connecting the new one, all position data for
each arm will be lost and you will need to execute the recovery procedure. Refer to
10.3 Data Recovery Procedure to recover the data.
When battery replacement is executed in the properly, the recovery procedure is not
required.
173
Maintenance
10. Battery Unit (Lithium Battery)
If the position data has been lost because the low lithium battery power
The following error that warns the voltage reduction appears at starting the Controller
(staring up the software). After replacing the battery unit, recover the position data using
the procedures described in 10.3. Data Recovery Procedure.
EPSON RC+ 5.0 / EPSON RC+ 6.0
: Error 5016 [Power supply failure of the absolute encoder.] occurs.
When the motor or gears are removed from the robot for parts replacement
You cannot recover by 10.3. Data Recovery Procedure. For calibration after parts
replacement, refer to Maintenance 12. Calibration.
10.2
Replacing the Battery Unit
Name
Maintenance Parts
Battery Unit
Removal
Quantity
Battery unit
Liquid Gasket
Note
1
R13B060005
Proper quantity
R13B031201
(1) Turn OFF the power for the Controller.
(2) Remove the connector plate.
Button bolt: 8-M4×10
(3) Remove the grease supply tube for the Joint #1
reduction gear unit.
(4) Pull out the connectors.
Connector: OBT1, OBT4
(5) Cut off the wire tie binding the battery unit.
Pull out the battery unit.
174
S5
Rev.4
Maintenance
Battery Unit
Installation
10. Battery Unit (Lithium Battery)
(6) Two connectors are paralleled, so make sure to connect a new battery unit to another
available connector.
NOTE
)
- Make sure to connect a new battery unit before disconnecting the old battery unit.
If you disconnect the old battery unit without connecting new one, all position data
for each arm will be lost and all arms need to be calibrated again.
- Make sure to use our specified battery unit (Code: R13B060005).
(7) As shown in the picture, use wire ties to secure the battery unit.
(8) Mount the grease supply tube for the Joint #1
reduction gear unit.
(9) Mount the connector plate.
Button bolt
: 8-M4×10
Apply liquid gasket.
Tightening torque : 1.4 N·m (0.14 kgf·m)
S5
Rev.4
175
Maintenance
10.3
10. Battery Unit (Lithium Battery)
Data Recovery
In this section, there are steps to execute some commands. The dialogs and startup
procedures used in the following sections depend on which software you are using.
Please follow the instructions for the software you are using.
EPSON RC+ 5.0 / EPSON RC+ 6.0
: Select menu-[Tools]-[Command Window] to display [Command] window.
(1) Turn ON the Controller with all joints in the motion range.
(2) Reset the encoder.
(3) Execute the following command.
> EncReset 1,2,3,4,5,6
(4) Select menu-[Tools]-[Controller] and click the <Reset Controller> button to restart
the Controller.
(5) Move the robot to the origin position (0 pulse position).
Release the electromagnetic brake and move the arms manually, or set the jog mode
to “Joint” from the [Jog & Teach] and operate the Manipulator in jog motion to
match the home position of the joint accurately.
Make sure to match the home position of the joint as accurate as possible visually.
CAUTION
■ The Arm #4 does not have a mechanical stop. The used of Arm #4 in motion
exceeding the maximum pulse range may cause inner wiring damage to and/or
malfunction of the Manipulator.
(6) Reset the encoder again by the procedure in step (2).
(7) Restart.
EPSON RC+ 5.0 / EPSON RC+ 6.0
: Select menu-[Tools]-[Controller] and click the <Reset Controller> button
to restart the Controller.
(8) Execute the following command to move to 0 pulse position.
> Go Pulse(0,0,0,0,0,0)
(9) Be sure to check that all joints have moved to their home positions (0 pulse position).
If no differences are found, recovery is complete.
Joint(s) that did not move to the proper home position will be out of position in
multiples of degrees shown in the following table.
S5
Joint
Difference
#1
3.76 deg.
#2
3.37 deg
#3
4.05 deg
#4
4.5 deg
#5
4.5 deg
#6
7.2 deg
#1
2.74 deg
#2
2.7 deg
#3
3.24 deg
#4
4.5 deg
#5
4.5 deg
#6
7.2 deg
S5L
Joint
Difference
176
S5
Rev.4
Maintenance
10. Battery Unit (Lithium Battery)
Specify the joint that is out of the home position and the direction of the difference,
then change the Hofs values as follows.
Joint #1 out of home position in + direction
> Hofs Hofs(1) − 131072, Hofs(2), Hofs(3), Hofs(4), Hofs(5), Hofs(6)
Joint #1 out of home position in − direction
> Hofs Hofs(1) + 131072, Hofs(2), Hofs(3), Hofs(4), Hofs(5), Hofs(6)
Joint #2 out of home position in + direction
> Hofs Hofs(1), Hofs(2) − 131072, Hofs(3), Hofs(4), Hofs(5), Hofs(6)
Joint #2 out of home position in − direction
> Hofs Hofs(1),Hofs(2) + 131072, Hofs(3), Hofs(4), Hofs(5), Hofs(6)
:
:
:
Joint #6 out of home position in + direction
> Hofs Hofs(1), Hofs(2), Hofs(3), Hofs(4), Hofs(5), Hofs(6) − 131072
Joint #6 out of home position in − direction
> Hofs Hofs(1), Hofs(2), Hofs(3), Hofs(4), Hofs(5), Hofs(6) + 131072
(10) Move to 0 pulse position again.
> Go Pulse(0,0,0,0,0,0)
(11) Be sure to check that all joints have moved to their home positions (0 pulse position).
If no differences are found, recovery is complete.
Otherwise, repeat step (7) and (8) until no differences are found.
Now, the recovery of the home position is complete.
When you change the Hofs values, make sure to write down the new Hofs values.
S5
Rev.4
177
Maintenance 11. Replacing the LED Lamp
11. Replacing the LED Lamp
■ 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.
WARNING
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Carefully use alcohol, liquid gasket, and adhesive following respective
instructions and also instructions below. Careless use of alcohol, liquid gasket,
or adhesive may cause a fire and/or safety problems.
CAUTION
- Never put alcohol, liquid gasket, or adhesive close to fire.
- Use alcohol, liquid gasket, or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.
- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your
eyes or wash out your mouth with clean water thoroughly, and then see a
doctor immediately.
Name
Maintenance Parts
178
LED lamp
Quantity
1
Note
R13B030006
S5
Rev.4
Maintenance 11. Replacing the LED Lamp
Removal
(1) Remove the Arm #3 Cover.
For details, refer to the Maintenance 3.3 Arm #3 Cover.
(2) Remove the LED lamp connectors from
inside of the manipulator.
(3) Loosen the nut and remove the LED
lamp.
Installation
(1) Mount the LED lamp and fasten it with
the nut.
(Adjust the LED lamp so that the CE
label is in the front side.)
(2) Mount the LED lamp connector.
(3) Mount the Arm #3 Cover.
For details, refer to the Maintenance 3.3 Arm #3 Cover.
For protection-model
NOTE
)
When the Manipulator is a protection-model, liquid gasket (R13B031201) was
applied on the LED mounting surface.
Removal
The LED lamp is secured with liquid gasket. There is a risk that the LED lamp
gets broken in removal. Replace the LED lamp with great caution.
Installation
Before installing the LED lamp, apply liquid gasket on the contact surfaces of the
LED lamp and Arm #3.
Wipe excess liquid gasket with a wiping cloth treated with alcohol.
S5
Rev.4
179
Maintenance 12. Calibration
12.
Calibration
12.1
Overview
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot perform positioning properly because a mismatch exists between the
origin stored in each motor encoder and its corresponding origin stored in the Controller.
After replacing the parts, it is necessary to match (correct) these origins.
The process of aligning the two origins is called “Calibration”.
same as teaching*.
The calibration is not the
* “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 the Installation and Design Precautions in
the Safety chapter of the EPSON RC+ User’s Guide.
WARNING
■ Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
The motion of the Manipulator is always in restricted (low speeds and low power)
status to secure the safety of an operator. However, operating the robot system
while someone is inside the safeguarded area is extremely hazardous and may
result in serious safety problems in case that the Manipulator moves
unexpectedly.
For EPSON RC+, a coordinate point including the arm pose is defined as “point”.
data is called “point data”.
The
There are two methods to move the Manipulator during calibration.
- Releasing the electromagnetic brake and moving the arms manually
For details, refer to the Setup & Operation 1.5 How to Move Arms the Electromagnetic
Brake is Applied to.
- Moving the Manipulator in the Jog & Teach mode.
For details, refer to EPSON RC+ 5.0 User’s Guide - 5.11.1 Robot Manager Command
Tools: Robot Manager: Jog and Teach Page.
Normally move the Manipulator in the Jog & Teach mode since moving the Manipulator
while releasing the electromagnetic brake involves risk.
■ Normally, release the brake of a single joint at a time. Take extra care to release
the brakes of two or more joints simultaneously from necessity. Releasing the
brakes of two or more joints simultaneously may cause hands and fingers to be
caught, serious bodily injury and/or severe equipment damage to the Manipulator
as the arms of the Manipulator may move in unexpected directions.
CAUTION
180
■ Be careful of the arm falling when releasing the brake.
While the brake release switch is pressed, the Manipulator’s arm falls by its own
weight. The arm falling may cause hands and fingers to be caught and/or may
cause equipment damage to or malfunction of the Manipulator.
S5
Rev.4
Maintenance 12. Calibration
NOTE
)
- For details about the basic pose, refer to the Setup & Operation 3.6 Setting the Basic
Pose for Calibration.
- Whenever possible, calibrate the origin one joint at a time. (Replace parts one joint at a
time whenever possible.) If you calibrate the origins for multiple joints simultaneously,
it will be more difficult to verify their origins and obtain the origin positions.
However, joint #5 cannot be calibrated alone according to the structure of the
Manipulator. Make sure you calibrate joint #6 at the same time.
Calibration Flowchart
Start
1. Basic Pose
Confirmation
2. Part Replacement
3. Encoder
Initialization
4. Temporary
Calibration
5. Calibration
Calibrate the Manipulator roughly
to avoid unexpected contact with
························
peripheral equipment.
Accurate calibration
························
6. Accuracy Testing
Yes
Re-calibrate?
No
End
S5
Rev.4
181
Maintenance 12. Calibration
12.2
Calibration Procedure
Command Input
Calibration procedures include command execution.
Select the EPSON RC+ menu-[Tools]-[Command Window].
The information above is omitted in the calibration procedure.
Jog Motion
The process to set the jog motion is included in the calibration procedures.
Select the EPSON RC+menu-[Tools]-[Robot Manager] and select the [Jog & Teach]
page.
The panel, window, and page above are indicated as [Jog & Teach] in the calibration
procedure.
Follow steps 1 to 7 described below in order to calibrate the origin.
1.
Basic Pose Confirmation
Verify the recorded pulse values of the basic pose obtained in the Setup & Operation
3.6 Setting the Basic Pose for Calibration.
2.
Part Replacement
Replace parts as dictated by this manual.
parts during part replacement.
3.
Be careful not to injure yourself or damage
Encoder Initialization
Turn ON the Controller when all joints are in the motion range.
The message “Encoder alarm has occurred. Check robot battery. EPSON RC+ must be
restarted.” is displayed.
Initialize the encoder at the current position and reset the error.
Initialize the encoder using one of the following procedures.
Execute the following command at the [Monitor Window].
>Encreset [The joint number (1 to 6) corresponding to the encoder will be reset]
Select the EPSON RC+ menu-[Tools]-[Maintenance], then click the [Restart
Controller] button.
After resetting the error, the motor encoder of the parts replaced joint is initialized.
Set the jog mode to “Joint” from the [Jog & Teach] and operate the Manipulator in jog
motion to match the home position of the joint accurately.
When the joint does not move to the home position, operate the Manipulator to match
the tram mark placed in Setup & Operation 3.6 Setting the Basic Pose for Calibration
as accurate as possible.
Initialize the joint encoder when the joint matches the home position or the tram mark.
For the encoder initialization, refer to the procedure indicated above.
182
S5
Rev.4
Maintenance 12. Calibration
NOTE
- When the origin of Joint #5 is calibrated, Joint #6 will be out of position.
(Due to the structure of the Manipulator, any offset in the position of Joint #5 affects
Joint #6.)
Calibrate the origin of Joint #6 at the same time when calibrating Joint #6.
)
4.
NOTE
Rough Calibration
Calibrate the origin of Joint #5 at the same time when calibrating Joint #6.
)
Select either the points of the basic pose you previously set in the Setup & Operation
3.6 Setting the Basic Pose for Calibration or the currently registered point data that
makes it easy to verify the accuracy of the joint whose origin you want to calibrate.
Move the Manipulator to the selected point while avoiding interference with
peripheral equipment.
To perform temporary calibration, input the pulse value of the specified point data.
For example, when the specified point data is “P1,” execute the following command.
> Calpls Ppls(P1,1), Ppls(P1,2), Ppls(P1,3), Ppls(P1,4), Ppls
(P1,5), Ppls(P1,6)
Perform the temporary calibration.
to the joint being calibrated.
Joint #1
Joint #2
Joint #3
Joint #4
Joint #5
Joint #6
5.
S5
Rev.4
: >Calib
: >Calib
: >Calib
: >Calib
: >Calib
: >Calib
Input one of the following commands according
1
2
3
4
5,6
6
Calibration (Accurate Positioning)
183
Maintenance 12. Calibration
Move the joint* being calibrated to the specified point by motion command.
* You must also move Joints #1 - #4 to the position when calibrating Joint #5.
For example, when the specified point data is “P1”, “Motor On” is executed from
[Control Panel], and “Go P1” is executed from [Jog & Teach].
Accurately conform the calibrating joint* to the specified point data by jog command.
* You must also move Joint #5 and #6 to the position when calibrating Joint #5.
Select the Joint jog mode from the [Jog & Teach] to execute the jog motion.
Perform the calibration.
being calibrated.
Joint #1
Joint #2
Joint #3
Joint #4
Joint #5
Joint #6
6.
: >Calib
: >Calib
: >Calib
: >Calib
: >Calib
: >Calib
Input one of the following commands according to the joint
1
2
3
4
5,6
6
Accuracy Testing
Move the Manipulator into a different point to verify the reproducibility of the
position. If accuracy is inadequate, it may be necessary to re-calibrate the origin
using a different point. You must set the point again if reproducibility cannot be
assured through calibration.
184
S5
Rev.4
Maintenance 12. Calibration
12.3
Calibration Jig
Jigs such as the one described in this section are necessary in order to set the reference
points for calibration when installing the Manipulator. (In practice, there are instances
where your end effector can be used.)
(B)
(C)
(A)
S5
Rev.4
185
Maintenance 12. Calibration
[Unit: mm]
°: deg.
(A) × 1
14
11
50
28
15
25
(B) × 1
20
ø12H7
4-C1
ø70
60
8
3
20
Ø12h6
28
14
25
ø5H7
ø12H7
20
8
2-ø5.5
40
ø20
5
40
4-C3
45°
(C) × 2
2-M4
ø31.5
ø28
ø12h6
10
24
6 3
2-ø4.5
(ø8 depth5)
4-ø5.5
14
7
PCD20
ø12h6
186
S5
Rev.4
Maintenance
13.
13. Maintenance Parts List
Maintenance Parts List
Be sure to specify the proper codes when ordering maintenance parts.
13.1
Standard
Part Name
AC Servo Motor
R13B000626
400 W with brake
For Joint #3
R13B000627
200 W with brake
For Joint #4
R13B000628
50 W with brake
For Joints #5, #6
R13B000629
50 W
R13B010030
S5-A701**
R13B010031
S5-A901**
R13B010032
S5-A701**
R13B010033
S5-A901**
R13B010034
S5-A701**
R13B010035
S5-A901**
For Joint #2
Electromagnetic Brake
M/C Cable
Cable Unit
Battery Unit
S5
Rev.4
For Joint #4
R13B010036
For Joint #5
R13B010037
For Joint #6
R13B010038
For Joints #5, #6
R13B030508
For Joint #2
R13B030228
R13B030229
S5-A701**
R13B030230
S5-A901**
For Joint #4
R13B030231
For Joints #5, #6
R13B030232
Reduction gear For ALL Joints
R13ZA00330100 SK-1A (500 g)
Base
For Joint #1
R13B030303
Multemp SRL
For ALL Joints
R13B031201
1206C
Liquid Gasket
LED Lamp
For Joint #3
For Joint #3
Timing Belt
Grease
*1
Note
For Joints #1, #2
For Joint #1
Reduction Gear Unit
Code
R13B030006
R12B020440
3m
R12B020441
5m
R12B020442
10 m
R13B020056
S5-A701**
R13B020057
S5-A901**
R13B060005
Lithium battery ER6V LY
(TOSHIBA)
187
Maintenance
13. Maintenance Parts List
Part Name
Code
For motor shafts For Joint #1
For Reduction
Gear Unit
For Joint #2
For Joint #5
For Joint #1
Oil Seal
For Joint #2
For rotator
For Joint #5
For Joint #6
O-ring
Radiating sheet
For Cleanroom-model
R13B031260
R13B031266
For Cleanroom-model
R13B031257
R13B031259
R13B031265
For Cleanroom-model
R13B031261
R13B031267
For Cleanroom-model
R13B031262
R13B031268
R13B031263
R13B031269
For Cleanroom-model
For Cleanroom-model
R13B031275
R13B031270
For Cleanroom-model
S5-A701C* R13B031271
For Cleanroom-model
S5-A901C* R13B031272
For Cleanroom-model
Arm #3
R13B031273
For Cleanroom-model
Arm #4
R13B031274
For Cleanroom-model
For Joint #1, #2, #3
R13B031910
Arm #2
*2
Joints #5, #6 Unit (Motor NOT included)
188
R13B031264
For Joint #6
Battery for backing up motor encoder
Brake Release Unit
R13B031258
R13B031255
Arm #1
Gasket
R13B031256
For Joint #1
Base
Note
R13B060006
Lithium battery ER6V LY
(TOSHIBA)
R13B080204
Arm #4 is included
R12B120803
For Europe
R12B120804
For USA and Japan
S5
Rev.4
Maintenance
13. Maintenance Parts List
*1 Reduction Gear Unit
A reduction gear unit consists of the following three parts. When replacing the reduction gear unit, be sure
to always replace the waveform generator, flexspline, and circular spline all together as one set.
Waveform generator
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
Circular spline
Flexspline
A rigid, ring-shaped body with gear teeth on the inner
circumference.
The circular spline has two more teeth than the flexspline does.
*2 Battery for backing up motor encoder
The battery for backing up a motor encoder is only used for retaining the motor position data during
maintenance (cable replacement, etc.). It is not used for the Manipulator itself.
Even storing a battery consumes battery power. When three years have passed since you purchased a spare
battery, replace it with a new one or measure the battery voltage before using it.
13.2
Option
Part Name
Brake release unit
(with Cable, short connector)
Brake release unit
Code
R12B120805
For Europe
R12B120806
For USA and Japan
R12B120803
For Europe
R12B120804
For USA and Japan
Camera Plate
R12B031930
PS Compatible Plate
R12B031931
PS Installation Compatible Plate
R12B031932
Mechanical stop for Arm #1, #2, #3
R12B031933
S5
Rev.4
Note
189
Maintenance
190
13. Maintenance Parts List
S5
Rev.4
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