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SCARA ROBOT
G1 series
MANIPULATOR MANUAL
Rev.4
EM111R2119F
MANIPULATOR MANUAL
G1 series Rev.4
SCARA ROBOT
G1 series
Manipulator Manual
Rev.4
Copyright © 2009-2011 SEIKO EPSON CORPORATION. All rights reserved.
G1 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 Manipulator and its optional parts are shipped to our customers only after being
subjected to the strictest quality controls, tests, and inspections to certify its compliance
with our high performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1. Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2. Malfunctions caused by customers’ unauthorized disassembly.
3. Damage due to improper adjustments or unauthorized repair attempts.
4. Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1. If the Manipulator or associated equipment is used outside of the usage conditions and
product specifications described in the manuals, this warranty is void.
2. If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3. We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.
ii
G1 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
G1 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
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]
iv
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
G1 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)
G1 Rev.4
v
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
The G1 series Manipulators can be used with the following combinations of Controllers and
software.
The operating methods and descriptions are different depending on which software you are
using. The following icons are put beside appropriate text as necessary. Use the
descriptions that pertain to the software you are using.
Controller
Name
RC180
RC620
Structure
Controller
Control Unit
Drive Unit
Software
EPSON RC+ 5.0
EPSON RC+ 6.0
For details on commands, refer to User’s Guide or “On-line help”.
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to
turn ON/OFF all the hardware components. For the Controller composition, refer to the
table above.
Shape of Motors
The shape of the motors used for the Manipulator that you are using may be different from
the shape of the motors described in this manual because of the specifications.
Setting by Using Software
This manual contains setting procedures by using software.
following icon.
They are marked with the
EPSON
RC+
Figures in this Manual
The figures of manipulators indicated in this manual are basically Standard-model
Manipulator. Unless special instruction is provided, the specifications of Standard-model,
Cleanroom-model, and Protected-model (IP54 / IP65) are the same.
vi
G1 Rev.4
TABLE OF CONTENTS
TABLE OF CONTENTS
Before Reading This Manual ..........................................................................v
Setup & Operation
1.
Safety
1.1
1.2
1.3
1.4
1.5
1.6
2.
Conventions ...........................................................................................3
Design and Installation Safety ...............................................................4
Operation Safety ....................................................................................5
Emergency Stop ....................................................................................6
Emergency Movement Without Drive Power .........................................7
Manipulator Labels .................................................................................8
Specifications
2.1
2.2
2.3
2.4
2.5
4.3
22
Environmental Conditions ....................................................................22
Base Table ...........................................................................................22
Mounting Dimensions ..........................................................................24
Unpacking and Transportation .............................................................27
Installation Procedure ..........................................................................28
Connecting the Cables .........................................................................28
User Wires and Pneumatic Tubes .......................................................29
Relocation and Storage ........................................................................30
4. Setting of End Effectors
4.1
4.2
10
Features of G1 series Manipulators .....................................................10
Model Number and Model Differences ..................................................10
Part Names and Outer Dimensions ..................................................... 11
Specifications .......................................................................................19
How to Set the Model ...........................................................................21
3. Environments and Installation
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3
31
Attaching an End Effector ....................................................................31
Weight and Inertia Settings ..................................................................32
4.2.1 Weight Setting ..........................................................................32
4.2.2 Inertia Setting ...........................................................................34
Precautions for Auto Acceleration/Deceleration of Joint #3 ..................37
5. Motion Range
38
5.1 Motion Range Setting by Pulse Range (for All Joints) ..........................38
5.2 Motion Range Setting by Mechanical Stops .........................................40
5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate
System of the Manipulator (for Joints #1 and #2) ..............................45
5.4 Standard Motion Range .......................................................................45
G1 Rev.4
vii
TABLE OF CONTENTS
Maintenance
1.
Safety Maintenance
49
2.
General Maintenance
50
2.1
2.2
2.3
2.4
2.5
2.6
Schedule for Maintenance Inspection ................................................. 50
Inspection Point ................................................................................... 51
2.2.1 Inspection While the Power is OFF
(Manipulator is not operating) .................................................. 51
2.2.2 Inspection While the Power is ON
(Manipulator is operating) ........................................................ 51
Greasing .............................................................................................. 52
Tightening Hexagon Socket Head Cap Bolts ...................................... 53
Matching Origins ................................................................................. 53
Layout of Maintenance Parts ............................................................... 54
3. Covers
3.1
3.2
3.3
3.4
Arm Top Cover .................................................................................... 57
Connector Plate ................................................................................... 58
Connector Sub Plate ........................................................................... 59
User Plate ........................................................................................... 59
4. Cable Unit
4.1
4.2
viii
75
Motor ................................................................................................... 76
Reduction Gear Unit ............................................................................ 78
7. Arm #3
7.1
7.2
7.3
70
Motor ................................................................................................... 71
Reduction Gear Unit ............................................................................ 74
6. Arm #2
6.1
6.2
60
Replacing Cable Unit ........................................................................... 61
Wiring Diagrams .................................................................................. 67
4.2.1 Signal Cable ............................................................................ 67
4.2.2 Power Cable ............................................................................ 68
4.2.3 User Cable ............................................................................... 69
5. Arm #1
5.1
5.2
56
81
Motor ................................................................................................... 82
Timing Belt .......................................................................................... 86
Brake ................................................................................................... 88
G1 Rev.4
TABLE OF CONTENTS
8. Arm #4
8.1
8.2
89
Motor ....................................................................................................90
Timing Belt ...........................................................................................94
9. Bellows
9.1
9.2
96
4-axis spec ...........................................................................................97
3-axis spec ...........................................................................................99
10. Ball Screw Spline Unit
101
10.1
Greasing the Ball Screw Spline Unit ................................................101
10.1.1 Standard-model ....................................................................102
10.1.2 Cleanroom-model / Protected-model ....................................103
10.2 Replacing the Ball Screw Spline Unit ...............................................104
10.2.1 4-axis spec.............................................................................105
10.2.2 3-axis spec.............................................................................108
11.
Lithium Battery
11.1
11.2
Replacing the Battery Unit (Lithium Battery) .................................... 112
Replacing the Battery Board ............................................................ 113
12. LED Lamp
115
13.
117
Calibration
13.1
13.2
13.3
13.4
About Calibration ............................................................................. 117
Calibration Procedure ......................................................................118
Accurate Calibration of Joint #2 .......................................................128
Calibration Procedure without using Calibration Wizard ..................130
14. Maintenance Parts List
14.1
14.2
G1 Rev.4
111
134
Common Parts .................................................................................134
Parts by Environment Model ............................................................135
ix
TABLE OF CONTENTS
x
G1 Rev.4
Setup & Operation
This volume contains information for setup and operation of the
G1 series 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.
WARNING
WARNING
CAUTION
G1 Rev.4
This symbol indicates that a danger of possible serious injury or
death exists if the associated instructions are not followed
properly.
This symbol indicates that a danger of possible serious injury or
death caused by electric shock exists if the associated
instructions are not followed properly.
This symbol indicates that a danger of possible harm to people
or physical damage to equipment and facilities exists if the
associated instructions are not followed properly.
3
Setup & Operation
1. Safety
1.2 Design and Installation Safety
Only trained personnel should design and install the robot system. Trained
personnel are defined as those who have taken robot system training and
maintenance training classes held by the manufacturer, dealer, or local
representative company, or those who understand the manuals thoroughly and
have the same knowledge and skill level as those who have completed the training
courses.
To ensure safety, a safeguard must be installed for the robot system. For details
on the safeguard, refer to the Installation and Design Precautions in the Safety
chapter of the EPSON RC+ User’s Guide.
The following items are safety precautions for design personnel:
■ Personnel who design and/or construct the robot system with this product must
read the Safety chapter in the EPSON RC+ User’s Guide to understand the
safety requirements before designing and/or constructing the robot system.
Designing and/or constructing the robot system without understanding the safety
requirements is extremely hazardous, may result in serious bodily injury and/or
severe equipment damage to the robot system, and may cause serious safety
problems.
WARNING
■ The Manipulator and the Controller must be used within the environmental
conditions described in their respective manuals. This product has been
designed and manufactured strictly for use in a normal indoor environment.
Using the product in an environment that exceeds the specified environmental
conditions may not only shorten the life cycle of the product but may also cause
serious safety problems.
■ The robot system must be used within the installation requirements described in
the manuals. Using the robot system outside of the installation requirements
may not only shorten the life cycle of the product but also cause serious safety
problems.
Further precautions for installation are mentioned in the chapter Setup &
Operation: 3. Environments and Installation. Please read this chapter carefully to
understand safe installation procedures before installing the robots and robotic
equipment.
4
G1 Rev.4
Setup & Operation
1. Safety
1.3 Operation Safety
The following items are safety precautions for qualified Operator personnel:
■ Please carefully read the Safety-related Requirements in the Safety chapter of
the EPSON RC+ User’s Guide before operating the robot system. Operating
the robot system without understanding the safety requirements is extremely
hazardous and may result in serious bodily injury and/or severe equipment
damage to the robot system.
■ Do not enter the operating area of the Manipulator while the power to the robot
system is turned ON. Entering the operating area with the power ON is
extremely hazardous and may cause serious safety problems as the Manipulator
may move even if it seems to be stopped.
WARNING
■ Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
The motion of the Manipulator is always in restricted (low speeds and low power)
status to secure the safety of an operator. However, operating the robot system
while someone is inside the safeguarded area is extremely hazardous and may
result in serious safety problems in case that the Manipulator moves
unexpectedly.
■ Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally while the robot system is operated.
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
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
G1 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. Safety
1.4 Emergency Stop
If the Manipulator moves abnormally during operation, immediately press the Emergency
Stop switch. Stops the power supply to the motor, and the arm stops in the shortest
distance with the dynamic brake and mechanical brake.
However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator
is running normally. Otherwise, the Manipulator may hit the peripheral equipment since
the operating trajectory while the robot system stops is different from that in normal
operation.
To place the system in emergency mode during normal operation, press the Emergency
Stop switch when the Manipulator is not moving.
Refer to the Controller manual for instructions on how to wire the Emergency Stop switch
circuit.
Free running distance in emergency
The operating Manipulator cannot stop immediately after the Emergency Stop switch is
pressed.
The free running time/angle/distance of the Manipulator are shown below. However,
remember that the values vary depending on following conditions.
Weight of the end effector Weight of work piece Operating pose
Weight Speed Accel etc.
Conditions for measurement
Accel setting
100
Speed setting
100
Load [kg]
1
Weight setting
1
Start point of
operation
Point where the
emergency stop
signal is input
Joint #1
Target point
Stop point
Joint #2
Controller
Manipulator
Free running
time
Free running
angle
Free running
distance
6
RC180 / RC620
G1-171*/ G1-171*Z
G1-221*/ G1-221*Z
Joint #1 + Joint #2
[sec.]
0.4
Joint #3
[sec.]
0.3
Joint #1
[deg.]
40
50
Joint #2
[deg.]
40
45
Joint #1 + Joint #2
[deg.]
80
95
Joint #3
[mm]
50
G1 Rev.4
Setup & Operation
1. Safety
1.5 Emergency Movement Without Drive Power
When the system is placed in emergency mode, push the arm or joint of the
Manipulator by hand as shown below:
Arm #1 .............Push the arm by hand.
Arm #2 .............Push the arm by hand.
Joint #3 ............The joint cannot be moved up/down by hand until the
electromagnetic brake applied to the joint has been released.
Move the joint up/down while pressing the brake release
button.
Joint #4........... Rotate the shaft by hand.
Joint #3 brake release button
Joint #2
(rotating)
Arm #2
Joint #1
(rotating)
Arm #1
Joint #3
(up/down)
Shaft
Base
Joint #4
(rotating)
NOTE
)
G1 Rev.4
When the brake release button is pressed in emergency mode, the brake for Joint #3 is
released. Be careful of the shaft while the brake release button is pressed because the
shaft may be lowered by the weight of an end effector.
7
Setup & Operation
1. Safety
1.6 Manipulator Labels
The following labels are attached near the locations of the Manipulator where specific
dangers exist.
Be sure to comply with descriptions and warnings on the labels to operate and maintain
the Manipulator safely.
Do not tear, damage, or remove the labels. Use meticulous care when handling those
parts or units to which the following labels are attached as well as the nearby areas:
Labels
NOTE
A
Before loosening the base mounting screws, hold the arm
and secure it tightly with a band to prevent hands or fingers
from being caught in the Manipulator.
B
Be careful to avoid collision.
C
Hazardous voltage exists while the Manipulator is ON.
To avoid electric shock, do not touch any internal electric
parts.
D
Only authorized personnel should perform sling work and
operate a crane and a forklift.
When these operations are performed by unauthorized
personnel, it is extremely hazardous and may result in
serious bodily injury and/or severe equipment damage to
the robot system.
E
Be careful of the hand falling while the brake release
button is being pressed.
F
G
8
G1 Rev.4
Setup & Operation
1. Safety
Location of Labels
G1 Rev.4
9
Setup & Operation
2.
2. Specifications
Specifications
2.1 Features of G1 series Manipulators
The G1 series Manipulators are high-performance manipulators intended to space saving,
achieve high speed, high DUTY, and high rigidity.
The features of the G1 series Manipulators are as follows:
High Accuracy & High Speed & High Rigidity
Repeating positioning accuracy is ± 0.005 mm
Æ Optimum for precision assembling production line
Cycle time under 0.3 seconds (with 175 mm arm)
* When moving 100 mm in horizontally, 25 mm in vertically with load 0.5 kg
Small body yet powerful (Press force: 50N)
Space Saving
Achieves the motion area equivalent to the upper class robot with 225 mm arm
Easy-to-Use
You can easily operate the Light & Compact body
3-Axis Spec
Optimum for screw driving and pressing work using the hand offset
2.2 Model Number
G1-17 1 S Z-UL
UL specification
UL : UL compliant
□ : Non UL compliant
Axis
□
: 4-axis spec
Z
: 3-axis spec
Environment
S
C
: Standard
: Cleanroom &ESD
Joint #3 stroke
1
: 100 mm
Arm length
17 : 175 mm
22 : 225 mm
For details of the specifications, refer to Setup & Operation: 2.4 Specifications.
10
G1 Rev.4
Setup & Operation
2. Specifications
2.3 Part Names and Outer Dimensions
2.3.1 4-axis spec
Part Names : Standard-model (G1-***S)
Fitting (black)
for ø6 mm pneumatic tube
Fitting (black)
for ø4 mm pneumatic tube
User connector
(15-pin D-sub connector)
Joint #3
Brake release switch
Fittings (white) for ø6 mm pneumatic tube
LED
User connector
(9-pin D-sub connector)
Cable
MT label
(only for special order)
UR label
Shaft
Base
CE label
Face plate (Manipulator serial No.)
Signal cable
User connector
(9-pin D-sub connector)
User connector
(15-pin D-sub connector)
Power cable
Fittings (white)
for ø6 mm pneumatic tube
NOTE
)
Fitting (black) for ø4 mm pneumatic tube
Fitting (black) for ø6 mm pneumatic tube
- The brake release button affects only Joint #3. When the brake release button is
pressed in emergency mode, the brake for Joint #3 is released simultaneously.
- When the LED lamp is lighting or the controller power is on, the current is being
applied to the manipulator. Performing any work with the power ON is extremely
hazardous and it may result in electric shock and/or improper function of the robot
system. Make sure to turn OFF the controller power before the maintenance work.
G1 Rev.4
11
Setup & Operation
2. Specifications
Part Dimension : Standard-model (G1-***S)
a
b
G1-171S
G1-221S
75
Max.515
125
Max.545
1mm flat cut
shaft diameter
mechanical stop
diameter
Detail of “A”
(Calibration point position of
Joints #3 and #4)
90 or more
Space for cables
(*) indicates the stroke margin
by mechanical stop.
not penetrable
Reference through hole
(View from the bottom of the base)
12
G1 Rev.4
Setup & Operation
2. Specifications
Part Names : Cleanroom-model (G1-***C)
Fitting (black)
for ø6 mm pneumatic tube
Fitting (black)
for ø4 mm pneumatic tube
User connector
(15-pin D-sub connector)
Joint #3
Brake release switch
Fittings (white) for ø6 mm pneumatic tube
LED
User connector
(9-pin D-sub connector)
Cable
MT label
(only for special order)
UR label
Belows
Shaft
Base
CE label
Face plate (Manipulator serial No.)
Signal cable
User connector
(9-pin D-sub connector)
User connector
(15-pin D-sub connector)
Power cable
Fittings (white)
for ø6 mm pneumatic tube
NOTE
)
Exhaust port
Fitting (black) for ø4 mm pneumatic tube
Fitting (black) for ø6 mm pneumatic tube
- The brake release button affects only Joint #3. When the brake release button is
pressed in emergency mode, the brake for Joint #3 is released simultaneously.
- When the LED lamp is lighting or the controller power is on, the current is being
applied to the manipulator. Performing any work with the power ON is extremely
hazardous and it may result in electric shock and/or improper function of the robot
system. Make sure to turn OFF the controller power before the maintenance work.
G1 Rev.4
13
Setup & Operation
2. Specifications
Part Dimension : Cleanroom-model (G1-***C)
a
b
G1-171C
G1-221C
75
Max.515
125
Max.545
1mm flat cut
shaft diameter
mechanical stop
diameter
Detail of “A”
(Calibration point position of
Joints #3 and #4)
(*) indicates the stroke margin
by mechanical stop.
90 or more
Space for cables
not penetrable
Reference through hole
(View from the bottom of the base)
14
G1 Rev.4
Setup & Operation
2. Specifications
2.3.2 3-axis spec
Part Names : Standard-model (G1-***Z)
Fitting (black)
for ø6 mm pneumatic tube
Fitting (black)
for ø4 mm pneumatic tube
User connector
(15-pin D-sub connector)
Joint #3
Brake release switch
Fittings (white) for ø6 mm pneumatic tube
LED
User connector
(9-pin D-sub connector)
Cable
MT label
(only for special order)
UR label
Shaft
Base
CE label
Face plate (Manipulator serial No.)
Signal cable
User connector
(9-pin D-sub connector)
User connector
(15-pin D-sub connector)
Power cable
Fittings (white)
for ø6 mm pneumatic tube
NOTE
)
Fitting (black) for ø4 mm pneumatic tube
Fitting (black) for ø6 mm pneumatic tube
- The brake release button affects only Joint #3. When the brake release button is
pressed in emergency mode, the brake for Joint #3 is released simultaneously.
- When the LED lamp is lighting or the controller power is on, the current is being
applied to the manipulator. Performing any work with the power ON is extremely
hazardous and it may result in electric shock and/or improper function of the robot
system. Make sure to turn OFF the controller power before the maintenance work.
G1 Rev.4
15
Setup & Operation
2. Specifications
Part Dimension : Standard-model (G1-***Z)
a
b
G1-171Z
G1-221Z
75
Max.515
125
Max.545
1mm flat cut
shaft diameter
Detail of “A”
(Calibration point position of
Joints #3 and #4)
90 or more
Space for cables
(*) indicates the stroke margin
by mechanical stop.
2-M3
Through hole
not penetrable
Reference through hole
(View from the bottom of the base)
16
G1 Rev.4
Setup & Operation
2. Specifications
Part Names : Cleanroom-model (G1-***CZ)
Fitting (black)
for ø6 mm pneumatic tube
Fitting (black)
for ø4 mm pneumatic tube
User connector
(15-pin D-sub connector)
Joint #3
Brake release switch
Fittings (white) for ø6 mm pneumatic tube
LED
User connector
(9-pin D-sub connector)
Cable
Belows
MT label
(only for special order)
UR label
Belows
Shaft
Base
CE label
Face plate (Manipulator serial No.)
Signal cable
User connector
(9-pin D-sub connector)
User connector
(15-pin D-sub connector)
Power cable
Fittings (white)
for ø6 mm pneumatic tube
NOTE
)
Exhaust port
Fitting (black) for ø4 mm pneumatic tube
Fitting (black) for ø6 mm pneumatic tube
- The brake release button affects only Joint #3. When the brake release button is
pressed in emergency mode, the brake for Joint #3 is released simultaneously.
- When the LED lamp is lighting or the controller power is on, the current is being
applied to the manipulator. Performing any work with the power ON is extremely
hazardous and it may result in electric shock and/or improper function of the robot
system. Make sure to turn OFF the controller power before the maintenance work.
G1 Rev.4
17
Setup & Operation
2. Specifications
Part Dimension : Cleanroom-model (G1-***CZ)
a
b
G1-171CZ
G1-221CZ
75
Max.515
125
Max.545
1mm flat cut
shaft diameter
Detail of “A”
(Calibration point position of
Joints #3 and #4)
(*) indicates the stroke margin
by mechanical stop.
90 or more
Space for cables
not penetrable
Reference through hole
(View from the bottom of the base)
18
G1 Rev.4
Setup & Operation
2. Specifications
2.4 Specifications
Item
4-axis spec
G1-171*
G1-221*
G1-171*
G1-221*
175 mm
75 mm
Table Top
225 mm
175 mm
125 mm
75 mm
225 mm
125 mm
Mounting type
Arm #1, #2
Arm length
Arm #1
#1, #2
Arm #2
Weight (cables not included)
Driving method
All joints
Joints #1, #2
Max.
Joints #3 (Z)
operating speed *1
Joints #4 (U)
Joints #1, #2
Repeatability
Joints #3 (Z)
Joints #4 (U)
Joints #1
Joints #2
(Cleanroom model)
Max.
motion range
Z stroke
(Cleanroom model)
Joints #4
Joints #1
Joints #2
Max.
(Cleanroom model)
pulse range
Joints #3
(pulse)
(Cleanroom model)
Joints #4
Joints #1
Joints #2
Resolution
Joints #3
Joints #4
Motor power consumption
Rated
Payload
Maximum
Joint #4 allowable
Rated
moment of inertia *2
Maximum
Shaft diameter
Mounting hole
Joint #3 down force
Installed wire for customer use
Installed pneumatic tube for customer use
Environmental
requirements
Ambient temperature
Ambient relative humidity
Vibration level
Noise level *3
Installation environment
Applicable Controller
G1 Rev.4
3-axis spec
100 mm
8 kg
100 mm
8 kg
AC servo motor
2630 mm/s
3000 mm/s
2630 mm/s
3000 mm/s
1200 mm/s
1200 mm/s
3000 deg/s
± 0.005 mm
± 0.008 mm
± 0.005 mm
± 0.008 mm
± 0.01 mm
± 0.01 mm
± 0.01 deg.
± 125 deg.
± 125 deg
± 140 deg.
± 152 deg.
± 135 deg.
± 135 deg.
(± 140 deg.)
(±149 deg.)
(±123 deg.)
(±132 deg.)
± 100 (80) mm
± 100 (80) mm
± 360 deg
− 1019449 ∼ 6262329 pulse
± 2548623
± 2767076
± 2457600
± 2457600
(± 2548623)
(± 2712463)
(± 2239147)
(± 2402987)
− 1092267 ∼ 0
(－873813 ∼ 0)
− 393216 ∼ 393216
3.43322E-05 deg/pulse
5.49316E-05 deg/pulse
9.15527E-05 mm/pulse
9.15527E-04 deg/pulse
All joints: 50 W
0.5 kg
0.5 kg
1 kg
1.5 kg
0.0003 kg·m2
2
0.004 kg·m
ø 8 mm
125×88 (4-M6)
50 N
24 pin (9 + 15)
1 pneumatic tube (ø 4 mm): 0.59 Mpa (6 kgf/cm2 : 86 psi)
2 pneumatic tubes (ø 6 mm): 0.59 Mpa (6 kgf/cm2 : 86 psi)
5 to 40 degree C (with minimum temperature variation)
10 to 80 % RH (no condensation)
4.9 m/s2 (0.5G) or less
65dB
Standard / Cleanroom + ESD (ISO Class 3) *4
RC180, RC620
19
Setup & Operation
2. Specifications
4-axis spec
Item
Assignable Value
( ) Default values
MTBF
Safety standard
G1-171*
Speed
Accel *5
SpeedS
AccelS
Fine
Weight
G1-221*
3-axis spec
G1-171*Z
G1-221*Z
1 ∼ (5) ∼ 100
1 ∼ (10) ∼ 120
1 ∼ (50) ∼ 2000
1 ∼ (200) ∼ 25000
0 ∼ (10000) ∼ 65000
0,100 ∼ (0.5,100) ∼ 1,100
0,100 ∼ (0.5,100) ∼ 1.5,100
3 years
UL1740 (Third Edition, Dated December 7, 2007)
ANSI/RIA R15.06-1999
NFPA 79 (2007 Edition)
CSA/CAN Z434-03 (February 2003)
CE Marking − Machinery Directive,
Low Voltage Directive, EMC Directive
*1: In the case of PTP command. Maximum operating speed for CP command is 2000 mm/s on horizontal
plane.
*2: In the case where the center of gravity is at the center of Joint #4. If the center of gravity is not at the
center of Joint #4, set the parameter using Inertia command.
*3: Conditions of Manipulator during measurement as follows:
Operating conditions : Under rated load, 4-joints simultaneous motion, maximum speed, maximum
acceleration, and duty 50%.
Measurement point : In front of the Manipulator, 1000 mm apart from the motion range, 50 mm above
the base-installed surface.
*4: The exhaust system in the Cleanroom-model Manipulator draws air from the base interior and arm cover
interior.
A crack or other opening in the base unit can cause loss of negative air pressure in the outer part of the
arm, which can cause increased dust emission.
Seal firmly the exhaust port and the exhaust tube with vinyl tape.
If the exhaust flow is not sufficient, dust particle emission may exceed the specified maximum level.
Cleanliness level : Class ISO 3 (ISO14644-1)
In previous criteria; Clean Class: 10 or its equivalent
Amount of Dust (0.1 µm diameter or larger) in 28317 cm3 (1cft)
sample-air around the center of the motion rang: 10 particles or
less.)
Exhaust System : Exhaust port
: Inner diameter: ø8 mm
Exhaust tube
: Polyurethane tube
Outer diameter ø8 mm
or Inner diameter ø16mm or larger
Recommended exhaust flow rate: approx. 1000 cm3/s (Normal)
*5: In general use, Accel setting 100 is the optimum setting that maintains the balance of acceleration and
vibration when positioning.
However, you may require an operation with high acceleration to shorten the cycle time by decreasing the
vibration at positioning. In this case, set Accel to larger than 100.
If you specify a larger Accel value, the frequency of the overload error and over heat may rise during
continuous operation. The use of large Accel setting is recommended only for necessary motions.
20
G1 Rev.4
Setup & Operation
2. Specifications
2.5 How to Set the Model
The Manipulator model for your system has been set before shipment from the factory.
is normally not required to change the model when you receive your system.
CAUTION
NOTE
)
It
■ 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.
The custom specifications may require a different configuration
procedure; check the custom specifications number described on the MT label and contact
us when necessary.
The Manipulator model can be set from software.
Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide.
G1 Rev.4
21
Setup & Operation
3.
3. Environments and Installation
Environments and Installation
3.1 Environmental Conditions
A suitable environment is necessary for the robot system to function properly and safely.
Be sure to install the robot system in an environment that meets the following conditions:
Item
Conditions
Ambient temperature *1
5 to 40°C
(with minimum temperature variation)
Ambient relative humidity
10 to 80% (no condensation)
First transient burst noise
2 kV or less
(Power supply wire)
1 kV or les
(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 and oil.
· Keep away from shocks or vibrations.
· Keep away from sources of electric noise.
NOTE
)
Manipulators are not suitable for operation in harsh environments such as painting areas,
etc. When using Manipulators in inadequate environments that do not meet the above
conditions, please contact us.
*1 The ambient temperature conditions are for the Manipulators only.
the Manipulators are connected to, refer to the Controller manual.
22
For the Controller
G1 Rev.4
Setup & Operation
3. Environments and Installation
3.2 Base Table
A base table for anchoring the Manipulator is not supplied. Please make or obtain the
base table for your Manipulator. The shape and size of the base table differs depending
on the use of the robot system. For your reference, we list some Manipulator table
requirements here.
The base table must not only be able to bear the weight of the Manipulator but also be able
to withstand the dynamic movement of the Manipulator when the Manipulator operates at
maximum acceleration. Ensure that there is enough strength on the base table by
attaching reinforcing materials such as crossbeams.
The torque and reaction force produced by the movement of the Manipulator are as
follows:
Max. Reaction torque on the horizontal plate : 100 Nm
Max. Horizontal reaction force
: 200 N
Max. Vertical reaction force
: 300 N
The threaded holes required for mounting the Manipulator base are M6. Use mounting
bolts with specifications conforming to ISO898-1 property class: 10.9 or 12.9.
For dimensions, refer to Setup & Operation: 3.3 Mounting Dimensions.
The plate for the Manipulator mounting face should be 15 mm thick or more and made of
steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or
less.
The table must be secured on the floor or wall to prevent it from moving.
The Manipulator must be installed horizontally.
When using a leveler to adjust the height of the base table, use a screw with M8 diameter
or more.
If you are passing cables through the holes on the base table, see the figures below.
[unit : mm]
47
53
26
M/C Cables
NOTE
)
Power Cable
Connector
18
Signal Cable
Connector
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.
■ To ensure safety, a safeguard must be installed for the robot system.
For details on the safeguard, refer to the EPSON RC+ User’s Guide.
WARNING
G1 Rev.4
23
Setup & Operation
3. Environments and Installation
3.3 Mounting Dimensions
The maximum space described in figures shows that the radius of the end effector is 30
mm or less. If the radius of the end effector exceeds 30 mm, define the radius as the
distance to the outer edge of maximum space.
If a camera or electromagnetic valve extends outside of the arm, set the maximum range
including the space that they may reach.
g
h-g
m
f
a
c
e
b
d
n
p
j
k
q
Length of Arm #1 (mm)
Length of Arm #2 (mm)
Stroke of Joint #3 (mm)
Motion range
Motion range of Joint #1 (degree)
Motion range of Joint #2 (degree)
Mechanical stop area
Joint #1 angle to hit mechanical stop (degree)
Joint #2 angle to hit mechanical stop (degree)
Joint #3 range to hit lower mechanical stop (mm)
Joint #3 range to hit upper mechanical stop (mm)
Range from center of axis to back end (mm)
Range from center of axis to back end after moved to mechanical stop (mm)
Joint #2 motion range + angle to hit mechanical stop (degree)
Be sure to allow for the following extra spaces in addition to the space required for
mounting the Manipulator, Controller, and peripheral equipment.
space for teaching
space for maintenance and inspection
(Ensure a space to open the rear side cover and the maintenance cover for maintenance.)
24
G1 Rev.4
Setup & Operation
3. Environments and Installation
3.3.1 4-axis spec
Standard-model (G1-***S)
Center of Joint#3
Maximum
space
Motion
range
Area limited by mechanical stop
Base mounting face
a
G1-171S
G1-221S
b
c
140°
125° 3°
152°
d
3°
4°
e
60.4
52.8
f
64.3
59.6
g
75
125
h
175
225
j
143
171.6
k
146.1
176.9
(unit: mm, ° = degree)
q
m
n
p
143°
2.5
100
6
154°
Cleanroom-model (G1-***C)
Center of Joint#3
Maximum
space
Motion
range
Area limited by mechanical stop
Base mounting face
a
G1-171C
G1-221C
G1 Rev.4
b
c
140°
125° 3°
149°
d
3°
5°
e
62.6
56.2
f
64.3
64.8
g
75
125
h
175
225
j
143
171.6
k
146.1
176.9
(unit: mm, ° = degree)
q
n
p
143°
2.5
80
3
154°
m
25
Setup & Operation
3. Environments and Installation
3.3.2 3-axis spec
Standard-model (G1-***SZ)
Center of Joint#3
Maximum
space
Motion
range
Area limited by mechanical stop
Base mounting face
a
b
c
d
G1-171SZ
1.3°
125° 3° 135°
G1-221SZ
4°
e
69.2
82.2
f
70.9
89.2
g
75
125
h
175
225
j
143
171.6
k
146.1
176.9
(unit: mm, ° = degree)
q
n
p
136.3°
2.5
100
6
139°
m
Cleanroom-model (G1-***CZ)
Center of Joint#3
Maximum
space
Motion
range
Area limited by mechanical stop
Base mounting face
a
c
G1-171CZ
123°
125° 3°
G1-221CZ
132°
26
b
d
3°
7°
e
82.5
82.2
f
86.4
94.4
g
75
125
h
175
225
j
143
171.6
k
146.1
176.9
(uinit mm, ° = degree)
q
n
p
126°
2.5
80
3
139°
m
G1 Rev.4
Setup & Operation
3. Environments and Installation
3.4 Unpacking and Transportation
THE INSTALLATION SHALL BE PREFORMED BY QUALIFIED INSTALLATION
PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL
CODES.
■
WARNING
Only authorized personnel should perform sling work and operate a crane and a
forklift. When these operations are performed by unauthorized personnel, it is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.
■ Using a cart or similar equipment, transport the Manipulator in the same manner
as it was delivered.
■
To carry the Manipulator, secure the Manipulator to the delivery equipment or
hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the
base) by hand. Never hold the duct to carry the Manipulator. There are the
possibility such as the damage of cable and duct.
Duct
DO NOT hold here
for carrying
Hold here for carrying
CAUTION
G1-171S
approx. 8 kg :18 lb.
■ Be careful not to get hands or fingers caught when holding the bottom of the base
by hand.
■ Stabilize the Manipulator with your hands when hoisting it.
■ When transporting the Manipulator for a long distance, secure it to the delivery
equipment directly so that the Manipulator never falls.
If necessary, pack the Manipulator in the same style as it was delivered.
G1 Rev.4
27
Setup & Operation
3. Environments and Installation
3.5 Installation
■ Be careful not to get hands, fingers, or feet caught and/or have equipment
damaged by a fall of the Manipulator when installing or transporting it.
Manipulator weight: approx. 8 kg: 18 lb.
■ 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.
CAUTION
■ Do not allow unnecessary strain on the arm.
The unnecessary strain on the arm may result in damage to the bearing and/or
the arm.
Max. press force: 50N (Arm tip)
Secure the base to the base table.
bolt (4-M6×25) + spring washer + flat washer
NOTE
)
Use bolts with specifications conforming to ISO898-1 Property Class: 6.9.
3.6 Connecting the Cables
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
WARNING
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the
cables. (Do not put heavy objects on the cables. Do not bend or pull the cables
forcibly.) The unnecessary strain on the cables may result in damage to the
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
or contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
■ Grounding the manipulator is done by connecting with the controller. Ensure
that the controller is grounded and the cables are correctly connected.
If the
ground wire is improperly connected to ground, it may result in the fire or electric
shock.
28
G1 Rev.4
Setup & Operation
3. Environments and Installation
3.7 User Wires and Pneumatic Tubes
CAUTION
■ Only authorized or certified personnel should be allowed to perform wiring.
Wiring by unauthorized or uncertified personnel may result in bodily injury and/or
malfunction of the robot system.
User electrical wires and pneumatic tubes are contained in the cable unit.
Electrical Wires
Rated Voltage
Allowable
Current
Wires
Nominal Sectional Area
Outer Diameter
Note
AC/DC30 V
1A
9+15
0.211 mm2
ø8.3±0.3 mm
Twist pair
Suitable Connector
Clamp Hood
Suitable Connector
15 pin
Clamp Hood
9 pin
Maker
JAE
JAE
JAE
JAE
DE-9PF-N
DE-C8-J9-F2-1R
DA-15PF-N
DA-C8-J10-F2-1
Standard
(Solder type)
(Connector setscrew: #4-40 NC)
(Solder type)
(Connector setscrew: #4-40 NC)
Pins with the same number, indicated on the connectors on both ends of the cables, are
connected.
Prepare D-sub connectors for wiring.
Pneumatic Tubes
Max. Usable Pneumatic Pressure
Pneumatic Tubes
Outer Diameter × Inner Diameter
0.59 MPa (6 kgf/cm2 : 86 psi)
2
1
ø6 mm × ø4 mm
ø4 mm × ø2.5 mm
Fittings for ø4 mm / ø6 mm (outer diameter) pneumatic tubes are supplied on both ends of
the pneumatic tubes.
Fitting (black)
for ø6 mm pneumatic tube
Fitting (black)
for ø4 mm pneumatic tube
User connector
(15-pin D-sub connector)
Joint #3
Brake release switch
Fittings (white) for ø6 mm pneumatic tube
LED
User connector (9-pin D-sub connector)
Signal cable
User connector
(9-pin D-sub connector)
User connector
(15-pin D-sub connector)
Power cable
Fittings (white)
for ø6 mm pneumatic tube
G1 Rev.4
Exhaust port (only Cleanroom-model)
Fitting (black) for ø4 mm pneumatic tube
Fitting (black) for ø6 mm pneumatic tube
29
Setup & Operation
3. Environments and Installation
3.8 Relocation and Storage
3.8.1
Precautions for Relocation and Storage
Observe the following when relocating, storing, and transporting the Manipulators.
THE INSTALLATION SHALL BE PREFORMED BY QUALIFIED INSTALLATION
PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL
CODES.
WARNING
■ Only authorized personnel should perform sling work and operate a crane and a
forklift. When these operations are performed by unauthorized personnel, it is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.
■ Before relocating the Manipulator, fold the arm and secure it tightly with a wire tie
to prevent hands or fingers from being caught in the Manipulator.
■ When removing the anchor bolts, support the Manipulator to prevent falling.
Removing the anchor bolts without support may result in a fall of the Manipulator,
and then get hands, fingers, or feet caught.
CAUTION
■ To carry the Manipulator, secure the Manipulator to the delivery equipment or
hold the bottom of Arm #1, the bottom of the main cable fitting, and the bottom of
the base by hand. When holding the bottom of the base by hand, be very
careful not to get hands or fingers caught.
Do not hold the duct joint on the back of the base.
■ Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is
extremely hazardous and may result in fall of the Manipulator.
When transporting the Manipulator for a long distance, secure it to the delivery
equipment so that the Manipulator cannot fall.
If necessary, pack the Manipulator in the same way as it was delivered.
When the Manipulator is used for a robot system again after long-term storage,
perform a test run to verify that it works properly, and then operate it thoroughly.
Transport and store the Manipulator in the range of -25 to +55 degree C.
Humidity within 10 to 80 % is recommended.
When condensation occurs on the Manipulator during transport or storage, turn
ON the power only after the condensation dries.
Do not shock or shake the Manipulator during transport.
■ Be careful not to get hands, fingers, or feet caught and/or have equipment
damaged by a fall of the Manipulator.
CAUTION
Manipulator weight: approx. 8 kg: 18 lb.
(1) Turn OFF the power on all devices and unplug the cables.
(2) Hold the bottom of Arm #1 by hand to unscrew the anchor bolts.
Then, remove the Manipulator from the base table.
30
G1 Rev.4
Setup & Operation
4.
4. Setting of End Effectors
Setting of End Effectors
4.1 Attaching an End Effector
Users are responsible for making their own end effector(s).
effector, observe these guidelines.
CAUTION
Before attaching an end
■ If you use an end effector equipped with a gripper or chuck, connect wires and/or
pneumatic tubes properly so that the gripper does not release the work piece
when the power to the robot system is turned OFF. Improper connection of the
wires and/or pneumatic tubes may damage the robot system and/or work piece
as the work piece is released when the Emergency Stop switch is pressed.
I/O outputs are configured at the factory so that they are automatically shut off (0)
by power disconnection, the Emergency Stop switch, or the safety features of the
robot system.
Shaft
- Attach an end effector to the lower end of the shaft.
For the shaft dimensions, and the overall dimensions of the Manipulator, refer to Setup
& Operation: 2. Specifications.
- Do not move the upper limit mechanical stop on the lower side of the shaft.
Otherwise, when “Jump motion” is performed, the upper limit mechanical stop may hit
the Manipulator, and the robot system may not function properly.
- Use a split muff coupling with an M4 bolt or larger to attach the end effector to the
shaft.
Brake release button
Joint #3 brake release button
- Joint #3 cannot be moved up/down by hand because the electromagnetic brake is
applied to the joint while power to the robot system is turned OFF. This prevents the
shaft from hitting peripheral equipment in the case that the shaft is lowered by the
weight of the end effector when the power is disconnected during operation, or when
the motor is turned OFF even though the power is turned ON.
- To move Joint #3 up/down while attaching an end effector, turn ON the Controller and
move the joint with the brake release button pressed.
- This button switch is a momentary-type; the brake is released only while the button
switch is being pressed.
- Be careful of the shaft while the brake release button is being pressed because the shaft
may be lowered by the weight of the end effector.
Layouts
- When you operate the manipulator with an end effector, the end effector may interfere
with the Manipulator because of the outer diameter of the end effector, the size of the
work piece, or the position of the arms. When designing your system layout, pay
attention to the interference area of the end effector.
G1 Rev.4
31
Setup & Operation
4. Setting of End Effectors
4.2 Weight and Inertia Settings
To ensure optimum Manipulator performance, it is important to make sure that the load
(weight of the end effector and work piece) and moment of inertia of the load are within
the maximum rating for the Manipulator, and that Joint #4 does not become eccentric.
If the load or moment of inertia exceeds the rating or if the load becomes eccentric, follow
the steps below, “4.2.1Weight Setting” and “4.2.2 Inertia Setting” to set parameters.
Setting parameters makes the PTP motion of the Manipulator optimal, reduces vibration to
shorten the operating time, and improves the capacity for larger loads. In addition, it
reduces persistent vibration produced when the moment of inertia of the end effector and
work piece is larger that the default setting.
4.2.1
CAUTION
Weight Setting
■ The total weight of the end effector and the work piece must not exceed 1 kg
(3-axis spec: 1.5 kg).
The G1 series Manipulators (4-axis spec) are not designed to work with loads
exceeding 1 kg (3-axis spec: 1.5 kg).
Always set the Weight parameters according to the load. Setting a value that is
smaller than the actual load may cause errors, excessive shock, insufficient
function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.
The acceptable weight capacity (end effector and work piece) in G1 series
4-axis spec
3-axis spec
Default rating
Maximum
0.5 kg
0.5 kg
1 kg
1.5 kg
When the load (weight of the end effector and work piece) exceeds the rating, change the
setting of Weight parameter.
After the setting is changed, the maximum acceleration/deceleration speed of the robot
system at PTP motion corresponding to the “Weight Parameter” is set automatically.
Load on the Shaft
The load (weight of the end effector and work piece) on the shaft can be set by Weight
parameter.
EPSON
RC+
32
Enter a value into the [Load:] text box on the [Inertia] panel ([Tools] - [Robot Manager]).
(You may also execute the Inertia command from the [Command Window].)
G1 Rev.4
Setup & Operation
4. Setting of End Effectors
Load on the Arm
When you attach a camera or other devices to the arm, calculate the weight as the
equivalent of the shaft. Then, add this to the load and enter the total weight to the Weight
parameter.
Equivalent Weight Formula
WM = M (L1)2/(L1+L2)2
When you attach the equipment near Arm #2:
2
2
When you attach the equipment to the end of Arm #2: WM = M (LM) /(L2)
WM : equivalent weight
M
: weight of air valves etc.
L1
: length of Arm #1
L2
: length of Arm #2
LM : distance from rotation center of Joint #2 to center of gravity
of camera etc.
Automatic speed setting by Weight
(%) 140
120
100
100
100
100
100
* The percentage in the graph is
based on the speed at rated
weight (0.5 kg) as 100%.
80
* 1.5 kg is only for 3-axis spec.
60
4-axis spec is up to 1.0 kg.
40
20
0
0.5
1.0
1.5
(kg) Weight setting
Automatic acceleration/deceleration setting by Weight
(%) 140
120
100
* The percentage in the graph is
110
based on the acceleration
100
80
/ deceleration at rated weight
70
(0.5 kg) as 100%.
60
60
* 1.5 kg is only for 3-axis spec.
40
4-axis spec is up to 1.0 kg.
20
0
G1 Rev.4
0.5
1.0
1.5
(kg) Weight setting
33
Setup & Operation
4. Setting of End Effectors
4.2.2 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 additional objects (such as an
end effector) attached to the shaft, the moment of inertia of load must be considered.
■ The moment of inertia of the load (weight of the end effector and work piece)
must be 0.004 kgwm2 or less. The G1 series Manipulators (4-axis spec) are not
designed to work with a moment of inertia exceeding 0.004 kgwm2.
Always set the moment of inertia parameter to the correct moment of inertia.
Setting a value that is smaller than the actual moment of inertia may cause
errors, excessive shock, insufficient function of the Manipulator, and/or shorten
the life cycle of parts/mechanisms.
CAUTION
The acceptable moment of inertia of load for G1 series Manipulator (4-axis spec) is 0.0003
kgwm2 at the default rating and 0.004 kgwm2 at the maximum. When the moment of
inertia of the load exceeds the rating, change the setting of the moment of inertia
parameter of the Inertia command. After the setting is changed, the maximum
acceleration/deceleration speed of Joint #4 at PTP motion corresponding to the “moment
of inertia” value is set automatically.
Moment of inertia of load on the shaft
The moment of inertia of load (weight of the end effector and work piece) on the shaft can
be set by the “moment of inertia” parameter of the Inertia command.
EPSON
RC+
Enter a value into the [Load inertia:] text box on the [Inertia] panel ([Tools] - [Robot
Manager]). (You may also execute the Inertia command from the [Command Window].)
Automatic acceleration/deceleration setting of Joint #4 by Inertia (moment of inertia)
(%) 140
120
120
100
80
60
40
40
20
20
10
0
34
0.001
0.002
0.003
0.004
(kg･m2) Moment of inertia setting
G1 Rev.4
Setup & Operation 4. Setting of End Effectors
Eccentric Quantity and the Inertia Setting
CAUTION
■ The eccentric quantity of load (weight of the end effector and work piece) must be
50 mm or less. The G1 series Manipulators are not designed to work with
eccentric quantity exceeding 50 mm.
Always set the eccentric quantity parameter according to the eccentric quantity.
Setting a value that is smaller than the actual eccentric quantity may cause
errors, excessive shock, insufficient function of the Manipulator, and/or shorten
the life cycle of parts/mechanisms.
The acceptable eccentric quantity of load in G1 series is 0 mm at the default rating and 50
mm at the maximum. When the eccentric quantity of load exceeds the rating, change the
setting of eccentric quantity parameter of Inertia command. After the setting is changed,
the maximum acceleration/deceleration speed of the Manipulator at PTP motion
corresponding to the “eccentric quantity” is set automatically.
Rotation center
Position of load’s center of gravity
Eccentric quantity (50 mm or less)
Eccentric Quantity
Eccentric quantity of load on the shaft
The eccentric quantity of load (weight of the end effector and work piece) on the shaft can
be set by “eccentric quantity” parameter of Inertia command.
EPSON
RC+
Enter a value into the [Eccentricity:] text box on the [Inertia] panel ([Tools] - [Robot
Manager]). (You may also execute the Inertia command from the [Command Window].)
Automatic acceleration/deceleration setting by Inertia (eccentric quantity)
(%) 120
100
* The percentage in the graph is
100
based on the acceleration /
80
deceleration at rated eccentricity
65
(0 mm) as 100%.
60
40
30
20
20
0
10
20
30
40
50 (mm) Eccentricity setting
* Please contact EPSON for over 50 mm.
G1 Rev.4
35
Setup & Operation 4. Setting of End Effectors
Calculating the Moment of Inertia
Refer to the following examples of formulas to calculate the moment of inertia of load
(end effector with work piece).
The moment of inertia of the entire load is calculated by the sum of each part (a), (b), and
(c).
Rotation center
Joint #3 shaft
End effector (a)
Work piece (c)
Work piece (b)
Whole moment
of inertia
=
Moment of inertia
of end effector (a)
+
Moment of inertia
of work piece (b)
+
Moment of inertia
of work piece (c)
The methods for calculating the moment of inertia for (a), (b), and (c) are shown below.
Calculate the total moment of inertia using the basic formulas.
(a) Moment of inertia of a rectangular parallelepiped
Rotation center
Rectangular parallelepiped’s center of gravity
2
Mass (m)
L
2
m
b +h
12
m
r
2
+m×L
2
+m×L
2
b
h
(b) Moment of inertia of a cylinder
Cylinder’s center of gravity
Rotation center
r
2
Mass (m)
L
36
G1 Rev.4
Setup & Operation 4. Setting of End Effectors
(c) Moment of inertia of a sphere
Sphere’s center of gravity
Rotation center
r
m
2 2
2
r +m×L
5
Mass (m)
L
4.3
Precautions for Auto Acceleration/Deceleration of Joint #3
When you move the Manipulator in horizontal PTP motion with Joint #3 (Z) at a high
position, the motion time will be faster.
When Joint #3 gets below a certain point, then auto acceleration/deceleration is used to
reduce acceleration/deceleration. (Refer to the figure below.) The higher the position of
the shaft is, the faster the motion acceleration/deceleration is. However, it takes more
time to move Joint #3 up and down. Adjust the position of Joint #3 for the Manipulator
motion after considering the relation between the current position and the destination
position.
The upper limit of Joint #3 during horizontal motion using Jump command can be set by
the LimZ command.
Automatic acceleration/deceleration vs. Joint #3 position
(%)120
100
* Figures on the graph (%) are
100
the proportion to the
100
acceleration/deceleration speed
80
at the shaft upper limit position.
60
30
40
20
0
NOTE
)
G1 Rev.4
-30
-60
-90
-120
-150 (mm) Shaft height
When moving the Manipulator horizontally while the shaft is being lowered, it may cause
over-shoot at the time of final positioning.
37
Setup & Operation 5. Motion Range
5.
Motion Range
■ When setting up the motion range for safety, both the pulse range and
mechanical stops must always be set at the same time.
CAUTION
The motion range is preset at the factory as explained in Setup & Operation: 5.4 Standard
Motion Range. That is the maximum motion range of the Manipulator.
There are three methods for setting the motion range described as follows:
1. Setting by pulse range (for all joints)
2. Setting by mechanical stops (fix or change is not available)
3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the
Manipulator (for Joints #1 and #2)
Rectangular range setting
Mechanical
stop
Motion range
Mechanical
stop
Pulse range
When the motion range is changed due to layout efficiency or safety, follow the
descriptions in 5.1 to 5.3 to set the range.
5.1 Motion Range Setting by Pulse Range (for All Joints)
Pulses are the basic unit of Manipulator motion. The motion range of the Manipulator is
controlled by the pulse range between the pulse lower limit and upper limit of each joint.
Pulse values are read from the encoder output of the servo motor.
For the maximum pulse range, refer to the following sections.
The pulse range must be set inside of the mechanical stop range.
5.1.1 Max. Pulse Range of Joint #1
5.1.2 Max. Pulse Range of Joint #2
5.1.3 Max. Pulse Range of Joint #3
5.1.4 Max. Pulse Range of Joint #4.
38
NOTE
)
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.
EPSON
RC+
The pulse range can be set on the [Range] panel shown by selecting
[Tools]-[Robot Manager]. (You may also execute the Range command from the
[Command Window].)
G1 Rev.4
Setup & Operation 5. Motion Range
5.1.1
Max. Pulse Range of Joint #1
The 0 (zero) pulse position of Joint #1 is the position where Arm #1 faces toward the
positive (+) direction on the X-coordinate axis.
When the 0 pulse is a starting point, the counterclockwise pulse value is defined as the
positive (+) and the clockwise pulse value is defined as the negative (-).
+Y
A
A
+X 0 pulse
B
B
All models
± 125 deg.
− 1019449 ～ + 6262329
A Max. Motion Range
B Max. Pulse Range
5.1.2
Max. Pulse Range of Joint #2
The 0 (zero) pulse position of Joint #2 is the position where Arm #2 is in-line with Arm #1.
With the 0 pulse as a starting point, the counterclockwise pulse value is defined as the
positive (+) and the clockwise pulse value is defined as the negative (-).
0 pulse
A
B
G1 Rev.4
A
B
4-axis spec
A Max. Motion Range
B Max. Pulse Range
G1-171S
G1-171C
±140 deg.
± 2548623
G1-221S
±152 deg.
± 2767076
G1-221C
±149 deg.
± 2712463
3-axis spec
A Max. Motion Range
B Max. Pulse Range
G1-171SZ
±135 deg.
± 2457600
G1-171CZ
±135 deg.
± 2457600
G1-221CZ
±132 deg.
± 2402987
G1-171CZ
±123 deg.
± 2239147
39
Setup & Operation 5. Motion Range
5.1.3
Max. Pulse Range of Joint #3
The 0 (zero) pulse position of Joint #3 is the position where the shaft is at its upper limit.
The pulse value is always negative because Joint #3 always moves lower than the 0 pulse
position.
Maximum Limit
:0 pulse
Type
Standard-model
Cleanroom-model
5.1.4
G1-**1S
G1-**1C
Joint #3 Stroke
100 mm
80 mm
Minimum Limit
− 1092267
－873813
Max. Pulse Range of Joint #4
The 0 (zero) pulse position of Joint #4 is the position where the flat near the end of the
shaft faces toward the end of Arm #2. With the 0 pulse as a starting point, the
counterclockwise pulse value is defined as the positive (+) and the clockwise pulse value
is defined as the negative (-).
+Y
Counterclockwise (+value)
+X 0 pulse ± 393216 pulse
Clockwise (-value)
5.2 Motion Range Setting by Mechanical Stops
Mechanical stops physically limit the absolute area that the Manipulator can move.
Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for
the mechanical stop settings. Install the bolts in the holes corresponding to the angle that
you want to set.
Joints #3 can be set to any length less than the maximum stroke.
Mechanical stop of Joint #3
(Lower limit mechanical stop)
Mechanical stop of
Joint #2 (Adjustable)
(Do not move the upper
limit mechanical stop.)
Mechanical stop of Joint #1
(Adjustable)
40
G1 Rev.4
Setup & Operation 5. Motion Range
5.2.1
Setting the Mechanical Stops of Joints #1 and #2
Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for
the mechanical stop settings. Install the bolts in the holes corresponding to the angle that
you want to set.
Joint #1
C
B
A
Model
All
D
A
+125°
B
-125°
C
+120°
( ° = degree )
D
-120°
Joint #2
G1-221*
G1-171CZ
G1-171*
E
D B
C
B
C
D
E
Top
Model
G1-171S
G1-171C
4-axis spec
G1-221S
G1-221C
G1-171SZ
G1-171CZ *2
3-axis spec
G1-221SZ
G1-221CZ
D B
A
C E
Top
Bottom
A
±152
±149
-
B *1
+140°
+140°
+140°
+140°
+135°
+123°
+135°
+132°
C *1
−140°
−140°
−140°
−140°
−135°
−123°
−135°
−132°
D
+130°
+130°
+125°
+125°
+125°
+115°
+120°
+120°
( ° = degree )
E
−130°
−130°
−125°
−125°
−125°
−115°
−120°
−120°
*1 Standard position of the mechanical stop
*2 Limits the motion range using the bolts in the Arm #2 bottom to prevent the
bellows from contacting the manipulator body.
G1 Rev.4
41
Setup & Operation 5. Motion Range
(1) Turn OFF the Controller.
(2) Install a hexagon socket head cap bolt into the hole corresponding to the setting angle,
and tighten it.
Hexagon socket head cap
bolt (fully threaded)
1
M6×10
2
M5×10
(3) Turn ON the Controller.
Joint
NOTE
The number
of bolts
2
2
Recommended
tightening torque
1760 N⋅cm (180kgf⋅cm)
980 N⋅cm (100kgf⋅cm)
(4) Set the pulse range corresponding to the new positions of the mechanical stops.
)
Be sure to set the pulse range inside the positions of the mechanical stop range.
Example: Using G1-171S*
The angle of Joint #1 is set from –120 degrees to +120 degrees.
The angle of Joint #2 is set from -130 degrees to +130 degrees.
EPSON
RC+
Execute the following commands from the [Command Window].
>JRANGE 1,-873814,6116694
'the pulse range of Joint #1
>JRANGE 2,-2366578,2366578
'the pulse range of Joint #2
>RANGE
'Checks the setting using Range
-873814, 6116694,-2366578,2366578, −1092267
,0, −393216, 393216
(5) Move the arm by hand until it touches the mechanical stops, and make sure that the
arm does not hit any peripheral equipment during operation.
(6) Operate the joint changed at low speeds until it reaches the positions of the minimum
and maximum pulse range. Make sure that the arm does not hit the mechanical
stops. (Check the position of the mechanical stop and the motion range you set.)
Example: Using G1-171S*
The angle of Joint #1 is set from -120 degrees to +120 degrees.
The angle of Joint #2 is set from -130 degrees to +130 degrees.
EPSON
Execute the following commands from the [Command Window].
RC+
>MOTOR ON
' Turns ON the motor
>LP ON
' Enters low-power mode
>SPEED 5
' Sets at low speeds
>PULSE -873814,0,0,0
' Moves to the min. pulse position of Joint #1
>PULSE 6116694,0,0,0
' Moves to the max. pulse position of Joint #1
>PULSE 2621440,-2366578,0,0 ' Moves to the min. pulse position of Joint #2
>PULSE 2621440,2366578,0,0 ' Moves to the max. pulse position of Joint #2
The Pulse command (Go Pulse command) moves all joints to the specified positions
at the same time. Specify safe positions after considering motion of not only the
joints whose pulse range have been changed, but also other joints.
In this example, Joint #1 is moved to the center of its motion range (pulse value:
2621440) when checking Joint #2.
If the arm is hitting the mechanical stops or if an error occurs after the arm hits the
mechanical stops, either reset the pulse range to a narrower setting or extend the
positions of the mechanical stops within the limit.
42
G1 Rev.4
Setup & Operation 5. Motion Range
5.2.2
NOTE
)
Setting the Mechanical Stop of Joint #3
This method applies only to the Standard-model Manipulator (G1-***S*).
For the Cleanroom-model (G1-***C*), the motion range set with the Joint #3 mechanical
stop cannot be changed.
(1) Turn ON the Controller and turn OFF the motors using the Motor OFF command.
(2) Push up the shaft while pressing the brake release
button.
Brake
release
button
When you press the brake release button, the shaft
may lower due to the weight of the end effector.
Be sure to hold the shaft by hand while pressing
the button.
NOTE
)
Shaft
(3) Turn OFF the Controller.
(4) Remove the Arm Top Cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(5) Loosen the lower limit mechanical stop screw. (2-M3×4 set screws)
A mechanical stop is mounted on both the top and bottom of Joint #3. However,
only the position of the lower limit mechanical stop on the top can be changed.
Do not remove the upper limit mechanical stop on the bottom because the
calibration point of Joint #3 is specified using the stop.
NOTE
)
(6) The upper end of the shaft defines the
maximum stroke. Move the lower limit
mechanical stop down by the length you
want to limit the stroke.
For example, when the lower limit
mechanical stop is set at “100 mm”
stroke, the lower limit Z coordinate value
is “-100”. To change the value to
“-80”, move the lower limit mechanical
stop down “20 mm”. Use calipers to
measure the distance when adjusting the
mechanical stop.
(7)
G1 Rev.4
Measure this
distance.
2-M3×4
set screw
Firmly tighten the lower limit mechanical stop screw (2-M3×4 set screws) not to let it
enter the shaft groove.
Recommended tightening torque: 147 N⋅cm (15 kgf⋅cm)
(8)
Mount the Arm top cover to the base.
For details, refer to Maintenance: 3.1 Arm Top Cover
(9)
Turn ON the Controller.
43
Setup & Operation 5. Motion Range
(10) Move Joint #3 to its lower limit while pressing the brake release button, and then check
the lower limit position. Do not lower the mechanical stop too far. Otherwise, the
joint may not reach a target position.
(11) Calculate the lower limit pulse value of the pulse range using the formula shown below
and set the value.
The result of the calculation is always negative because the lower limit Z coordinate
value is negative.
Lower limit of pulse (pulse)
= lower limit Z coordinate value (mm) / Resolution (mm/pulse)
** For the Joint #3 resolution,
refer to the section Setup & Operation 2.4 Specifications.
EPSON
RC+
Execute the following command from the [Command Window].
calculated value in X.
>JRANGE 3,X,0
' Sets the pulse range of Joint #3
Enter the
(12) Using the Pulse command (Go Pulse command), move Joint #3 to the lower limit
position of the pulse range at low speed. If the mechanical stop range is less than
the pulse range, Joint #3 will hit the mechanical stop and an error will occur. When
the error occurs, either change the pulse range to a lower setting or extend the position
of the mechanical stop within the limit.
NOTE
)
EPSON
RC+
44
If it is difficult to check whether Joint #3 hits a mechanical stop, turn OFF
the Controller and lift the arm top cover to check the condition causing the
problem from the side.
Execute the following commands from the [Command Window]. Enter the value
calculated in Step (10) in X.
>MOTOR ON
' Turns ON the motor
>SPEED 5
' Sets low speed
>PULSE 0,0,X,0
' Moves to the lower limit-pulse position of Joint #3.
(In this example, all pulses except those for Joint #3 are
“0”. Substitute these “0s” with the other pulse values
specifying a position where there is no interference even
when lowering Joint #3.)
G1 Rev.4
Setup & Operation 5. Motion Range
5.3 Setting the Cartesian (Rectangular) Range in the XY
Coordinate System of the Manipulator (for Joints #1 and #2)
Use this method to set the upper and lower limits of the X and Y coordinates.
This setting is only enforced by software. Therefore, it does not change the physical
range. The maximum physical range is based on the position of the mechanical stops.
EPSON
RC+
Set the XYLim setting on the [XYZ Limits] panel shown by selecting [Tools]-[Robot
Manager].
(You may also execute the XYLim command from the [Command Window].)
5.4 Standard Motion Range
The following “motion range” diagrams show the standard (maximum) specification.
When each Joint motor is under servo control, the center of Joint #3’s (shaft’s) lowest
point moves in the areas shown in the figure.
“Area limited by mechanical stop” is the area where the center of Joint #3’s lowest point
can be moved when each joint motor is not under servo control.
“Mechanical stop” sets the limited motion range so that the center of Joint #3 cannot move
beyond the area mechanically.
“Maximum space” is the area that contains the farthest reach of the arms. If the
maximum radius of the end effector is over 60 mm, add the “Area limited by mechanical
stop” and “radius of the end effector”. The total value is specified as the maximum area.
For the motion area figures, refer to Setup & Operation 3.3 Mounting Dimensions.
G1 Rev.4
45
Setup & Operation 5. Motion Range
46
G1 Rev.4
Maintenance
This volume contains maintenance procedures with safety
precautions for G1 series Manipulators.
48
Maintenance
1.
1. Safety Maintenance
Safety Maintenance
Please read this chapter, this manual, and other relevant manuals carefully to understand
safe maintenance procedures before performing any routine maintenance.
Only authorized personnel who have taken safety training should be allowed to
maintain the robot system.
Safety training is the program for industrial robot operators that follows the laws
and regulations of each nation.
The personnel who have taken safety training acquire knowledge of industrial
robots (operations, teaching, etc.), knowledge of inspections, and knowledge of
related rules/regulations.
The personnel who have completed the robot system-training and maintenancetraining classes held by the manufacturer, dealer, or locally-incorporated
company are allowed to maintain the robot system.
■ Do not remove any parts that are not covered in this manual. Follow the
maintenance procedure strictly as described in this manual. Improper removal
of parts or improper maintenance may not only cause improper function of the
robot system but also serious safety problems.
■ Keep away from the Manipulator while the power is ON if you have not taken the
training courses. Do not enter the operating area while the power is ON.
Entering the operating area with the power ON is extremely hazardous and may
cause serious safety problems as the Manipulator may move even it seems to be
stopped.
WARNING
■ When you check the operation of the Manipulator after replacing parts, be sure to
check it while you are outside of the safeguarded area. Checking the operation
of the Manipulator while you are inside of the safeguarded area may cause
serious safety problems as the Manipulator may move unexpectedly.
■ Before operating the robot system, make sure that both the Emergency Stop
switches and safeguard switch function properly. Operating the robot system
when the switches do not function properly is extremely hazardous and may
result in serious bodily injury and/or serious damage to the robot system as the
switches cannot fulfill their intended functions in an emergency.
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
WARNING
G1 Rev.4
■ 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.
49
Maintenance
CAUTION
2.
1. Safety Maintenance
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the
cables. (Do not put heavy objects on the cables. Do not bend or pull the cables
forcibly.) The unnecessary strain on the cables may result in damage to the
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
or contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
General Maintenance
This chapter describes maintenance inspections and procedures. Performing maintenance
inspections and procedures properly is essential for preventing trouble and ensuring safety.
Be sure to perform the maintenance inspections in accordance with the schedule.
2.1 Schedule for Maintenance Inspection
Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and
annual. The inspection points are added every stage.
If the Manipulator is operated for 250 hours or longer per month, the inspection points
must be added every 250 hours, 750 hours, 1500 hours, and 3000 hours operation.
Monthly
inspection
√
2 months (500 h)
√
3 months (750 h)
√
4 months (1000 h)
√
5 months (1250 h)
√
8 months (2000 h)
9 months (2250 h)
√
√
11 months (2750 h)
√
12 months (3000 h)
√
13 months (3250 h)
√
…
√
…
√
√
10 months (2500 h)
…
√
√
√
√
√
…
7 months (1750 h)
√
Annual
inspection
√
…
6 months (1500 h)
Inspect every day
1 month (250 h)
Inspection Point
Quarterly
Biannual
inspection
inspection
…
Daily
inspection
h = hour
50
G1 Rev.4
Maintenance
2. General Maintenance
2.2 Inspection Point
2.2.1
Inspection While the Power is OFF (Manipulator is not operating)
Inspection Point
Inspection Place
Daily Monthly Quarterly Biannual Annual
Check looseness or backlash of
End effector mounting bolts
√
√
√
√
√
bolts/screws.
Manipulator mounting bolts
√
√
√
√
√
Tighten them if necessary.
Each arm locking bolts
√
√
√
√
√
(For the tightening torque, refer to
Bolts/screws around shaft
Maintenance: 2.4 Tightening
Bolts/screws securing motors,
Hexagon Socket Head Cap Bolts.)
reduction gear units, etc.
Check looseness of connectors.
If the connectors are loosen, push it
securely or tighten.
√
√
External connectors on
Manipulator (on the connector
√
Clean up if necessary.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
plates etc.)
Manipulator cable unit
Visually check for external defects.
√
External appearance of
Manipulator
√
External cables
Check for bends or improper
location. Repair or place it properly Safeguard etc.
√
if necessary.
Check tension of timing belts.
Tighten it if necessary.
Grease conditions
2.2.2
Inside of Arm #2
Refer to Maintenance: 2.3 Greasing.
Inspection While the Power is ON (Manipulator is operating)
Inspection Point
Inspection Place
Check motion range
Each joint
Move the cables back and forth
External cables
lightly to check whether the cables
(including cable unit of the
are disconnected.
Manipulator)
Daily Monthly Quarterly Biannual Annual
√
√
√
Push each arm in MOTOR ON
status to check whether backlash
Each arm
√
exists.
Check whether unusual sound or
vibration occurs.
Measure the accuracy repeatedly by
a gauge.
G1 Rev.4
Whole
Whole
√
√
√
√
√
√
51
Maintenance
2. General Maintenance
2.3 Greasing
The ball screw spline and reduction gear units need greasing regularly.
grease specified in the following table.
CAUTION
Only use the
■ Keep enough grease in the Manipulator. Operating the Manipulator with
insufficient grease will damage sliding parts and/or result in insufficient function of
the Manipulator. Once the parts are damaged, a lot of time and money will be
required for the repairs.
Greasing part
Joint #3
Joint #1
Joint #2
Ball screw spline shaft
Reduction gear units
Greasing Interval
First time: after 50 km operation
2nd or more: after 100 km operation
In the replacement of motor*
Grease
AFB
SK-2
* Under normal conditions, the reduction gear units shall be greased only when the motor is
replaced. However, in case of severe working conditions (such as high duty, high speeds,
large payloads, etc.), the reduction gear units must be greased every 10,000 hours.
■ If grease gets into your eyes, mouth, or on your skin, follow the instructions
below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and then see a doctor
immediately.
If grease gets into your mouth
CAUTION
: If swallowed, do not induce vomiting. See a doctor immediately.
: If grease just gets into your mouth, wash out your mouth with water
thoroughly.
If grease gets on your skin
: Wash the area thoroughly with soap and water.
52
G1 Rev.4
Maintenance
2. General Maintenance
2.4 Tightening Hexagon Socket Head Cap Bolts
Hexagon socket head cap bolts are used in places where mechanical strength is required.
(A hexagon socket head cap bolt will be called a “bolt” in this manual.) These bolts are
fastened with the tightening torques shown in the following table.
When it is necessary to refasten these bolts in some procedures in this manual (except
special cases as noted), use a torque wrench so that the bolts are fastened with the
appropriate tightening torques as shown below.
Bolt
Tightening Torque
M3
245 N⋅cm (25 kgf⋅cm)
Set Screw
M4
490 N⋅cm (50 kgf⋅cm)
M3
147 N⋅cm (15 kgf⋅cm)
M5
980 N⋅cm (100 kgf⋅cm)
M4
245 N⋅cm (25 kgf⋅cm)
M6
1,760 N⋅cm (180 kgf⋅cm)
Refer below for the set screw.
Tightening Torque
We recommend that the bolts aligned on a circumference should be fastened in a crisscross
pattern as shown in the figure below.
1
5
8
Bolt hole
3
4
6
7
Do not fasten all bolts securely at one time.
Divide the number of times that the bolts are
fastened into two or three and fasten the bolts
securely with a hexagonal wrench. Then, use a
torque wrench so that the bolts are fastened with
tightening torques shown in the table above.
2
2.5 Matching Origins
After parts have been replaced (motors, reduction gear units, a brake, timing belts, a ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller. After replacing the parts, it is necessary to match these origins.
For calibration, the pulse values for a specific position must be recorded in advance.
Before replacing parts, select easy point (pose) data from the registered point data to check
the accuracy. Then, follow the steps below to display the pulse values and record them.
EPSON
RC+
G1 Rev.4
Execute the following command from the [Command Window].
>PULSE
PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value]
pls [Joint #4 Pulse value] pls
53
Maintenance
2. General Maintenance
2.6 Layout of Maintenance Parts
2.6.1 4-axis spec
G1-***S : Standard-model
Brake release button switch
Arm top cover
Cable unit
LED lamp
Ball screw spline unit
Joint #2 motor
Joint #4 motor
Joint #2 reduction gear unit
Joint #3 motor
Power cable
Zbelt
U belt
Signal cable
Joint #3 brake
Joint #1 reduction gear unit
Joint #1 motor
Lithium battery and Battery board
G1-***C : Cleanroom-model
Gasket
Gasket
Bellows
54
G1 Rev.4
Maintenance
2. General Maintenance
2.6.2 3-axis spec
G1-***SZ : Standard-model
Arm top cover
Cable unit
LED lamp
Ball screw spline unit
Joint #2 motor
Joint #2 reduction gear unit
Joint #3 motor
Power cable
Zbelt
Signal cable
Joint #3 brake
Joint #1 reduction gear unit
Joint #1 motor
Lithium battery and Battery board
G1-***CZ : Cleanroom-model
Gasket
Bellows
Gasket
Bellows
G1 Rev.4
55
Maintenance
3.
3. Covers
Covers
All procedures for removing and installing covers in maintenance are described in this
chapter.
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle.
connect it directly to a factory power source.
WARNING
DO NOT
■ Before performing any replacement procedure, turn OFF the Controller and related
equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
foreign substances exist in them is extremely hazardous and may result in electric
shock and/or malfunction of the robot system.
Maintenance Parts and Tools
Name
Maintenance
parts
Tools
Quantity
Arm Top Cover
1
Arm Top Cover for Cleanroom-model
Gasket unit
Hexagonal wrench (width across flats: 3 mm)
1
1
1
Cross-point screwdriver
1
Wiping cloth
1
Note
Only for Cleanroom-model
For M4 screw
For bellows removal
Only for Cleanroom-model
For wiping adhesive
User plate
Arm top cover
Connector plate
Connector sub plate
56
G1 Rev.4
Maintenance
3. Covers
3.1 Arm Top Cover
■ Do not remove the arm top cover forcibly. Removing the cover forcibly may
result in damage to the cables, disconnection, and/or contact failure. Damaged
cables, disconnection, or contact failure is extremely hazardous and may result in
electric shock and/or improper function of the robot system.
CAUTION
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the
cover. Unnecessary strain on cables may result in damage to the cables,
disconnection, and/or contact failure. Damaged cables, disconnection, or
contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
When routing the cables, observe the cable locations after removing the cover.
Be sure to place the cables back to their original locations.
Unscrew the arm top cover mounting bolts, and
then lift the cover.
When bellows are installed to the manipulator,
remove / install the arm top cover and then remove
/ install the upper bellows.
G1 Rev.4
4-M4×12
: Truss
4-M4×8
: Hexagonal
57
Maintenance
3. Covers
3.2 Connector Plate
■ Do not remove the connector plate forcibly. Removing the connector plate
forcibly may result in damage to the cables, disconnection, and/or contact failure.
Damaged cables, disconnection, or contact failure is extremely hazardous and
may result in electric shock and/or improper function of the robot system.
CAUTION
■ When installing the connector plate, be careful not to allow the cables to interfere
with the plate mounting and do not bend these cables forcibly to push them into
the cover.
Unnecessary strain on cables may result in damage to the cables, disconnection,
and/or contact failure. Damaged cables, disconnection, or contact failure is
extremely hazardous and may result in electric shock and/or improper function of
the robot system.
When routing the cables, observe the cable locations after removing the
connector plate. Be sure to place the cables back to their original locations.
Unscrew the connector plate mounting bolts and
remove the plate.
4-M4×12
58
G1 Rev.4
Maintenance
3. Covers
3.3 Connector Sub Plate
■ Do not remove the connector sub plate forcibly. Removing the connector sub
plate forcibly may result in damage to the cables, disconnection, and/or contact
failure.
Damaged cables, disconnection, or contact failure is extremely
hazardous and may result in electric shock and/or improper function of the robot
system.
CAUTION
■ When installing the connector sub plate, be careful not to allow the cables to
interfere with the plate mounting and do not bend these cables forcibly to push
them into the cover.
Unnecessary strain on cables may result in damage to the cables, disconnection,
and/or contact failure. Damaged cables, disconnection, or contact failure is
extremely hazardous and may result in electric shock and/or improper function of
the robot system.
When routing the cables, observe the cable locations after removing the
connector sub plate. Be sure to place the cables back to their original locations.
Unscrew the connector sub plate mounting bolts and
remove the plate.
4-M4×5
3.4 User Plate
(1) Remove the Arm top cover.
For detail, refer to Maintenance 3.1 Arm top
cover.
(2) Unscrew the user plate mounting bolts and
remove the plate.
G1 Rev.4
2-M4×8
59
Maintenance
4.
4. Cable Unit
Cable Unit
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
WARNING
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
foreign substances exist in them is extremely hazardous and may result in
electric shock and/or malfunction of the robot system.
CAUTION
60
■ 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.
G1 Rev.4
Maintenance
4. Cable Unit
4.1 Replacing Cable Unit
Since the power is supplied to each motor from the lithium battery installed on the battery
board via the battery connector, the position data will not be lost when the Controller is
turned OFF. When the battery connectors are disconnected, the position data will be lost,
and EPSON RC+ will display an error when the Controller is turned ON.
If the error occurs, execute the calibration of all joints and axes.
calibration, refer to Maintenance 13. Calibration.
For details of the
Maintenance parts, Tools and Materials
Maintenance
parts
Tools
Name
Quantity
Cable unit
Battery Unit (Lithium battery)
Hexagonal wrench (width across flats: 3 mm)
Spanner
(width across flats: 5 mm)
Nut screwdriver
(width across flats: 5 mm)
Cross-point screwdriver
Torque wrench
Nippers
1
1
1
1
1
1
1
1
Proper
quantity
1
Alcohol
Wiping cloth
Note
R13ZA00600300
For M4 screw
For D-sub connector removal
For D-sub connector removal
For cutting wire tie
For wiping grease
For wiping grease
Cable unit
G1 Rev.4
61
Maintenance
4. Cable Unit
■ If the connectors have been disconnected during the replacement of the cable
unit, be sure to reconnect the connectors to their proper positions. Refer to the
block diagrams.
Improper connection of the connectors may result in improper function of the
robot system.
For details on the connections, refer to Maintenance: 4.2 Wiring Diagrams.
CAUTION
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the
cover. Unnecessary strain on cables may result in damage to the cables,
disconnection, and/or contact failure. Damaged cables, disconnection, or
contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
When routing the cables, observe the cable locations after removing the cover.
Be sure to place the cables back to their original locations.
■ 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.
62
G1 Rev.4
Maintenance
Cable unit
Removal
4. Cable Unit
(1) Turn ON the Controller and change the motor to OFF status (MOTOR OFF).
(2) Press and hold the brake release button switch to let the shaft down. Be sure to keep
enough space and prevent the end effector hitting any peripheral equipment.
The brake release button switch affects only Joint #3.
button switch is pressed, the brake for Joint #3 is released.
When the brake release
Be careful of the shaft falling while the brake release button switch is being pushed
because it may be lowered by the weight of an end effector.
(3) Turn OFF the Controller and disconnect the power cable and signal cable connectors
from thee controller.
(4) Remove the arm top cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(5) Connect the spare battery to connector X60C.
- Use the battery unit as the spare battery.
-
The position data of Joint #2, #3, #4 motor is stored with the battery on base.
Connect the spare battery otherwise the Joint #2, #3, #4 position data will be lost.
(6) Cut off the wire tie binding cables on the arm side.
(7) Remove the 10 connectors and ground wire on the arm side.
Connector: X21, X22, X31, X32, X33, X41, XB10, X221, X231, X241
-
Remember the cable layout so that the cables can be reconnected correctly after
replacement.
(8) Remove the screw securing the user plate and remove the user plate from Arm #2.
For details, refer to Maintenance: 3.4 User Plate.
(9) Remove the connectors of the following from the user plate.
D-sub cable, Air tube, Brake release switch
NOTE
)
Be careful not to lose the set screws of D-sub cable because they are so small.
To pull out the air tube, press the ring of fittings. (ø6×2, ø4×2)
-
Remember the cable layout so that the cables can be reconnected correctly after
replacement.
(10) Remove the duct fitting from the user plate and pull
out the cables.
Duct fittings
User plate
(11) Remove the connector plate.
For details, refer to Maintenance: 3.2 Connector Plate.
G1 Rev.4
63
Maintenance
4. Cable Unit
(12) Remove the cables from the connector plate.
Air tube, D-sub cable
6 connectors : X10, X20, X30, X111, X121, X131
NOTE
)
Be sure to keep the connectors of the battery board connected while replacing the
cables. Otherwise, you will lose the position data and must execute the calibration
again.
-
Remember the cable layout so that the cables can be reconnected correctly after
replacement.
(13) Remove the ground wire from the base.
(14) Remove the mounting plate of the cable unit.
Mounting plate
of cable unit
4-M4×12
(15) Remove the wire tie binding the cables on the base side.
(16) Pull out the connector X62 from the battery board.
(X62: lower of two connectors)
Be sure to keep the connector X61 (upper one) of the
battery board connected. Otherwise, you will lose
the position data of the Joint #1 motor and must
execute the calibration again. Do not remove the
connector X61.
-
X62
Remember the cable layout so that the cables can
be reconnected correctly after replacement.
(17) Remove the duct fittings from the mounting plate of
the cable unit.
Mounting plate of
cable unit
Duct fittings
64
G1 Rev.4
Maintenance
Cable unit
Installation
4. Cable Unit
(1) Pass the cables through the user plate and secure the
duct fittings.
Duct fittings
Be careful of the cable support direction.
User plate
(2) Mount the air tube, ground wire, and D-sub cable to the user plate.
(3) Pass the cables though the mounting plate of the cable
unit and secure the duct fittings.
Mounting plate of
cable unit
Duct fittings
(4) Connect the connector X62 to the battery board.
X62
(5) Secure the ground wire to the base.
(6) Re-bundle the wire tie removed in the removal step (16).
(7) Mount the cable unit to the J1 flange.
Be careful of the cable support direction.
Cable
support
(8) Mount the following to the inner side of connector plate, connector sub plate.
Air tube, ground wire, D-sub cable
Joint #1 signal cable connector, power cable connector: X10, X111
4 connectors: X20, X30, X121, X131
(9) Mount the user plate to Arm #2.
For details, refer to Maintenance: 3.4 User Plate.
(10) Mount the ground wire to Arm #2.
(11) Connect the following connectors on the arm side.
X21, X22, X31, X32, X33, X41, XB10, X221, X231, X241
(12) Remove the spare battery connected to X60C.
(13) Re-bundle the wire tie removed in the removal step (6).
G1 Rev.4
65
Maintenance
4. Cable Unit
(14) Mount the connector plate to the base.
For details, refer to Maintenance: 3.2 Connector Plate.
(15) Set the Arm #2 cover without cables caught and secure it.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(16) If a connector falls out from the battery board, you must execute the calibration for all
axes.
66
G1 Rev.4
G1 Rev.4
Cable color
Black
Brown
Green
Blue
Orange
Code
P
R
V
W
Y
Cable color
Pink
Red
Violet
White
Yellow
4.2.1
Code
B
BR
G
L
O
Detail Board Diagram
Maintenance
4. Cable Unit
4.2 Wiring Diagrams
Signal Cable
67
Code
B
BR
G
L
O
GR
Cable color
Black
Brown
Green
Blue
Orange
Gray
Code
P
R
V
W
Y
Cable color
Pink
Red
Violet
White
Yellow
Maintenance
68
4. Cable Unit
4.2.2
Power Cable
G1 Rev.4
Maintenance
4. Cable Unit
4.2.3 User Cable
Code
B
BR
G
L
G1 Rev.4
Cable color
Black
Brown
Green
Blue
Code
R
V
W
Y
Cable color
Red
Violet
White
Yellow
69
Maintenance
5. Arm #1
5. Arm #1
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
WARNING
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be careful not to apply excessive shock to the motor shaft when replacing the
motors. The shock may shorten the life cycle of the motors and encoder and/or
damage them.
CAUTION
■ Never disassemble the motor and encoder. A disassembled motor and encoder
will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance: 13. Calibration to perform the calibration.
Joint #1 reduction gear
Joint #1 motor
70
G1 Rev.4
Maintenance
5. Arm #1
5.1 Replacing Joint #1 Motor
Maintenance parts and Tools
Maintenance parts
Tools
Joint #1 motor
Removal
Name
Quantity
AC Servo Motor (50 W)
Hexagonal wrench (width across flats: 1.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Hexagonal wrench (width across flats: 5 mm)
Torque wrench
Wiping cloth
1
1
1
1
1
1
Note
R13B000621
For M3 set screw
For M4 screw
For M6 screw
For wiping grease
(1) Remove Arm #1 from the base.
Put Arm #1 softly on the floor to avoid a shock to the arm.
(2) Remove the connector plate.
For details, refer to Maintenance: 3.4 Connector Plate.
(3) Disconnect the following connectors.
Connectors X111, X10 (Hold the claw to remove.)
Connector X61
(4) Remove the Joint #1 flange with the Joint #1
unit from the base.
4-M6×15
2-M4×45
The base and Joint #1 flange has been aligned
to the assembly position with the positioning
pin. Be careful not to lose the positioning pin.
(5) Loosen the screw of motor flange on the Joint
#1 flange. Remove the Joint #1 unit.
Joint #1 motor unit
4-M4×40
G1 Rev.4
71
Maintenance
5. Arm #1
(6) Loosen the screw fixing the motor flange and
reduction gear and remove the motor unit.
Reduction gear
There is an O-ring in the assembly position of
motor flange and reduction gear. Be careful
not to lose the O-ring.
Joint #1 motor
4-M4×12
(7) Remove the wave generator from the Joint
#1motor.
Wave generator
2-M4×6 set screw
There is a brass bushing in one of the set
screws. Be careful not to lose it.
Joint #1 motor
(8) Remove the motor flange from the Joint #1
motor.
Motor flange
Joint #1 motor
2-M4×12
72
G1 Rev.4
Maintenance
Joint #1 motor
Installation
5. Arm #1
(1) Mount the motor flange on the Joint #1 motor.
Motor flange
Joint #1 motor
2-M4×12
(2) Mount the waveform generator on the Joint #1
motor.
Edge of wave generator
Press the edge of waveform generator lightly to
the edge of spacer on the motor shaft.
Tighten one of the set screws on the flat face of
the motor shaft until the screw just touches the
surface. Insert a bushing into the other set
screw hole to prevent damage to the motor shaft.
Then, tighten both set screws.
CAUTION
Edge of motor
Screw hole
Joint #1 motor
■ See the figures above for the orientation of the waveform generator. Be sure to
install the waveform generator properly. Improper installation of the waveform
generator will result in improper function of the Manipulator.
(3)
Insert the O-ring to the groove in the Joint #1 reduction gear unit and assemble the
Joint #1 motor unit.
(4)
Mount the Joint #1 flange on the Joint #1 unit.
Make sure that the motor cable faces toward the Joint #1 flange lengthy side.
(5)
(6)
Mount the Joint #1 flange to the base.
The assembly position of the Joint #1 flange and the base has been set by the
positioning pin.
Attach the connectors.
Connector: X110, X10, X61
(7)
Mount the connector plate.
For details, refer to Maintenance: 3.4 Connector Plate.
(8)
Perform the calibration of Joint #1.
For details refer to Maintenance: 14. Calibration.
G1 Rev.4
73
Maintenance
5. Arm #1
5.2 Replacing Joint #1 Reduction Gear Unit
Maintenance Parts and Tools
Maintenance Parts
Tools
Name
Quantity
Reduction Gear Unit
Grease
Hexagonal wrench (width across flats: 1.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Hexagonal wrench (width across flats: 5 mm)
Nippers
1
R13B010026
1
1
1
1
For M3 set screw
For M4 screw
For M6 screw
1
Wiping cloth
1
Note
For wiping grease
(motor flange)
For wiping grease (bolt)
Removal
(1) Follow the steps in Maintenance: 5.1 Replacing Joint #1 Motor, Removal (1) to (8)
and remove the Joint #1 motor unit and waveform generator.
Installation
(1) A new reduction gear unit contains the parts shown in the picture.
The grease has been applied to the bearing are of waveform generator.
grease from the mounting surface.
Reduction gear
Wave
generator
Wipe the
O-ring
■ Never adjust the bolt fixing the reduction gear.
by the manufacturer.
If you did, it needs the alignment
CAUTION
(2) Follow the steps in Maintenance: 5.1 Replacing Joint #1 Motor, Installation (2) to (8).
74
G1 Rev.4
Maintenance
6. Arm #2
6. Arm #2
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
WARNING
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be careful not to apply excessive shock to the motor shaft when replacing the
motors. The shock may shorten the life cycle of the motors and encoder and/or
damage them.
CAUTION
■ Never disassemble the motor and encoder. A disassembled motor and encoder
will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance: 13. Calibration to perform the calibration.
Joint #2 motor
Joint #2 reduction gear
G1 Rev.4
75
Maintenance
6. Arm #2
6.1 Replacing Joint #2 Motor
Maintenance Parts and Tools
Name
Maintenance
Parts
Tools
Joint #2 motor
Removal
Quantity
Note
AC Servo Motor (50W)
1
R13B000607
Hexagonal wrench (width across flats: 1.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Hexagonal wrench (width across flats: 4 mm)
Cross-point screwdriver
Nippers
Wiping cloth
1
1
1
1
1
1
For M3 set screw
For M4 screw
For M5 screw
For cutting wire tie
For wiping grease
(1) Remove the arm top cover.
For details, refer to Maintenance: 3.1 Arm Top
Cover.
(2) Cut off the wire tie binding the Joint #2 motor
cables.
(3) Unscrew the bolts from the user plate and remove
the user plate.
4-M4×5
(5) Disconnect the following connectors.
Connectors: X221, X21，X22，XB20 (Hold the claw to remove.)
(6) Remove the Joint #2 motor unit.
2-M4×12
Motor
(7) Remove the wave generator and motor spacer.
2-M3×3
Wave
generator
Spacer
76
G1 Rev.4
Maintenance
Joint #2 motor
Installation
(1) Mount the motor spacer and wave generator on the
Joint #2 motor.
Be sure to fit the edge of the waveform generator to
the edge of the motor shaft.
Tighten one of the set screws on the flat face of the
motor shaft until the screw just touches the surface.
Insert a bushing into the other set screw hole to
prevent damage to the motor shaft. Then, tighten
both set screws.
CAUTION
6. Arm #2
2-M3×3
Wave
generator
Spacer
■ See the figures above for the orientation of the waveform generator. Be sure to
install the waveform generator properly. Improper installation of the waveform
generator will result in improper function of the Manipulator.
(2) Mount the Joint #2 motor unit on Arm #2.
If it is difficult to mount the motor, push it while
moving Arm #2 slowly by hand.
2-M4×12
Motor
(3) Connect the connectors X221, X21, X22, XB20.
(4) Mount the user plate. (4-Ｍ4×5)
(5) Put the wire tie cut in the removal step (4) to the original position.
Do not allow unnecessary strain on the cables.
(6) Mount the arm top cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(7) Perform the calibration of Joint #2.
For details refer to Maintenance: 13. Calibration.
G1 Rev.4
77
Maintenance
6. Arm #2
6.2 Replacing Joint #2 Reduction Gear Unit
Maintenance Parts
Name
Reduction Gear Unit
Grease (SK-2)
Hexagonal wrench (width across flats: 1.5 mm)
Hexagonal wrench (width across flats: 2.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Hexagonal wrench (width across flats: 4 mm)
Cross-point screwdriver
Nippers
Wiping cloth
78
Quantity
1
4g
1
1
1
1
1
1
1
1
Note
R13B010027
R13ZA00330400
For M3 set screw
For M3 screw
For M4 screw
For M5 screw
For wiping grease (Motor flange)
For wiping grease (Bolt)
G1 Rev.4
Maintenance
Joint #2
reduction gear
unit
Removal
6. Arm #2
(1) Follow the steps in Maintenance: 6.1 Replacing Joint #2 Motor, removal (1) to (7).
Remove the waveform generator from the Joint #2 motor.
(2) Remove the Arm #2 spacer.
2-M4×25
Spacer
(3) Loosen the screw fixing the Joint #2
reduction gear unit and loosely secure.
Arm #2
Reduction gear unit
2-M4×40
2-M5×40
(4) Remove the Arm #2 unit.
6-M4×12
Arm #2
unit
(5) Remove the screw secured loosely in the
step(3) and also remove the Joint #2 motor
flange, reduction gear, and Joint #2 spacer.
Hold the Joint #2 spacer upward and pull
it out sideways.
Joint #2
motor flange
Joint #2
reduction gear
Joint #2 spacer
G1 Rev.4
79
Maintenance
Joint #2
reduction gear
unit
Installation
6. Arm #2
(1) A new reduction gear unit contains the parts shown in the picture.
The grease has been applied to the bearing are of waveform generator.
grease from the mounting surface.
Reduction gear
Wave
generator
Wipe the
O-ring
(2) Put the O-ring into the groove in the reduction gear top surface.
(3) Mount the Joint #2 motor flange, reduction gear,
and Joint #2 spacer.
Hold the Joint #2 spacer and mount by reverse
procedure to remove it.
Joint #2
motor flange
Joint #2
reduction gear
Joint #2 spacer
(4) Loosely secure the Joint #2 reduction gear unit.
Arm #2
Reduction gear unit
Make sure the O-ring between the reduction
gear and motor flange has not moved and secure
the unit loosely.
2-M4×40
2-M5×40
(5) Mount the Arm #2 unit.
6-M4×12
(6) Tighten the screw secured loosely in the step
(4).
Arm #2
unit
(7) Mount the Arm #2 spacer.
2-M4×25
Spacer
(8) Follow the steps in Maintenance: 6.1 Replacing
Joint #2 Motor,
installation step (1) to (7).
80
G1 Rev.4
Maintenance
7. Arm #3
7. Arm #3
■ 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
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be careful not to apply excessive shock to the motor shaft when replacing the
motors. The shock may shorten the life cycle of the motors and encoder and/or
damage them.
CAUTION
■ Never disassemble the motor and encoder. A disassembled motor and encoder
will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance: 13. Calibration to perform the calibration.
Joint #3 motor
Z belt
Joint #3 brake
G1 Rev.4
81
Maintenance
7. Arm #3
7.1 Replacing Joint #3 Motor
Maintenance parts, Tools and Material
Name
Maintenance parts
Tools
Material
Quantity
AC Servo Motor (50W)
Hexagonal wrench (width across flats: 1.5 mm)
Hexagonal wrench (width across flats: 2 mm)
Hexagonal wrench (width across flats: 3 mm)
Hexagonal wrench (width across flats: 4 mm)
Torque wrench
Nippers
Force gauge
Suitable cord (Length about 800 mm)
Wire tie
1
1
1
1
1
1
1
1
1
2
Note
For M3 set screw
For M4 set screw
For M4 screw
For M5 screw
For cutting wire tie
Belt tension 30 N
For belt tension
A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to
the weight of the end effector while the power to the Controller is OFF or while the motor
is in OFF status (MOTOR OFF).
Note that the brake will not work during the replacement procedure.
Move the shaft down to its lower limit before starting the replacement procedure by
following the removal steps from (1) to (3).
Joint #3 motor
Removal
(1) Turn ON the Controller.
(2) Push down the shaft to its lower limit while pressing the brake release button switch.
Be sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
When the brake release button switch is pressed, the brake of the Joint #3 is released.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of an end effector.
(3) Turn OFF the Controller.
(4) Remove the arm top cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(5) Cut off the wire tie used for binding the motor cables to the Joint #3 motor.
(6) Disconnect the following connectors.
Connectors X231, X31, X32, X33, XB30 (Hold the claw to remove.)
(7) Remove the user plate.
For details, refer to Maintenance 3.4 User Plate.
82
G1 Rev.4
Maintenance
7. Arm #3
(8) Loosen the Z belt.
Loosen two bolts on the Joint #3 motor unit.
Slide the Joint #3 motor unit toward the arm
end.
(9) Remove the Joint #3 motor unit from Arm #2.
Motor
2-M4×10
Z belt
Z1 pulley
Unscrew the bolts securing the Joint #3 motor
unit. Remove the Z1 pulley from the Z belt.
Pull the Joint #3 motor unit upward to remove.
(10) Remove the Joint #3 motor from the Joint #3
motor unit.
Remove the brake hub and pulley from the
Joint #3 motor.
Loosen the screw of pulley and slide the pulley
toward the motor and then, loosen the screw of
brake hub.
2-M4×10
Motor
Pulley
There is a brass bushing in one of the set screw
holes. Be careful not to lose it.
G1 Rev.4
83
Maintenance
7. Arm #3
Joint #3 motor
Installation
(1) Mount the brake hub and pulley to the new motor
shaft.
Make sure to put a space of 1.5 mm between the
edges of the brake hub and motor shaft.
Brake hub
After the brake hub is mounted, press the pulley lightly to the brake hub and secure.
Both of the brake hub and pulley, tighten one of the set screws on the flat face of the
motor shaft until the screw just touches the surface.
Insert a bushing into the other set screw hole to prevent damage to the motor shaft.
Then, tighten both set screws.
(2) Mount the Z plate on the Joint #3 motor.
Align the brake disk with the hub and join them.
2-M4×10
If the brake disk position is not right, turn ON the
controller power supply, attach the connector X32,
release the brake by pressing the brake release
button, and move the hole to the center by hand.
Z plate
Disk
(3) Place the Joint #3 motor unit in the arm.
Motor unit
2-M4×12
(4) Place the Z belt around the Z1 pulley and the Z2
pulley so that the gear grooves of the belt are fit
into those of the pulleys completely.
Z belt
(5) Loosely secure the Joint #3 motor unit to Arm #2.
NOTE
)
84
Make sure the motor unit can be moved by hand, and it will not tilt when pulled.
If the unit is secured too loose or too tight, the belt will not have the proper tension.
G1 Rev.4
Maintenance
7. Arm #3
(6) Apply the proper tension to the Z belt, and then secure the Joint #3 motor unit.
Pass a suitable cord or string around the Joint #3 motor unit near its mounting plate.
Then, pull the cord using a force gauge or similar tool to apply the specified tension.
Make sure that the brake cables do not touch the pulley.
Z belt tension = 30N (3.0 kgf)
Joint #3
Motor unit
2-M4×12
(7) Connect the connectors: X231, X31, X32,
X33, XB30
Force gauge
(8) Mount the user plate.
For details, refer to Maintenance 3.4 User Plate.
(9) Re-bundle the cables in their original positions with a wire tie removed in step (5).
Do not allow unnecessary strain on the cables.
(10) Install the arm top cover and the arm bottom cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(11) Perform the calibration of Joint #3.
For details on the calibration method, refer to Maintenance: 13. Calibration.
G1 Rev.4
85
Maintenance
7. Arm #3
7.2 Replacing the Timing Belt
Maintenance part, Tools and Material
Maintenance part
Tools
Material
Name
Quantity
Note
Z belt
Hexagonal wrench (width across flats: 2.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Nippers
Force gauge
Suitable cord (Length about 800 mm)
Wire tie
1
1
1
1
1
1
2
R13B030226
For M3 screw
For M4 screw
For cutting wire tie
Belt tension 30 N (3.0 kgf)
For belt tension
A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to
the weight of the end effector while the power to the Controller is OFF or while the motor
is in OFF status (MOTOR OFF).
Note that the brake will not work during the replacement procedure.
Move the shaft down to its lower limit before starting the replacement procedure by
following the removal steps from (1) to (3).
Z belt
Removal
(1) Turn ON the Controller.
(2) Push down the shaft to its lower limit while pressing the brake release button switch.
Be sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
When the brake release button switch is pressed, the brake of the Joint #3 is released.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of an end effector.
(3) Turn OFF the Controller.
(4) Loosen the bolt securing the Joint #3 motor unit.
2-M4×12
(5) Remove the belt from the Z1 pulley and Z2 pulley.
(6) Remove the Z belt.
Remove the bolts securing the ball screw nut and
hold the ball screw nut up to pull out the Z belt
upward from the shaft.
4-M4×30
Z belt
86
G1 Rev.4
Maintenance
Z belt
Installation
7. Arm #3
(1) Pass a new Z belt through the shaft from above,
and then place it under the ball screw nut.
(2) Loosely secure the ball screw nut to Arm #2.
After moving the shaft up and down several
times, secure the ball screw nut to Arm #2.
4-M4×30
Z belt
(3) Place the belt around the Z1 pulley and the Z2 pulley so that the gear grooves of the
belt are fit into those of the pulleys completely.
(4) Apply the proper tension to the Z belt, and then secure the Joint #3 motor unit.
Z belt tension = 30 N (3.0 kgf)
Joint #3
Motor unit
2-M4×12
Force gauge
(5) Perform the calibration of Joint #3.
For details, refer to Maintenance: 13. Calibration.
G1 Rev.4
87
Maintenance
7. Arm #3
7.3 Replacing the Brake
Maintenance parts, Tools and Material
Name
Maintenance
Solenoid brake
parts
Hexagonal wrench (width across flats: 1.5 mm)
Hexagonal wrench (width across flats: 2.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Tools
Hexagonal wrench (width across flats: 4 mm)
Nippers
Force gauge
Suitable cord (Length about 800 mm)
Wire tie
Material
Quantity
Note
1
1
1
1
1
1
1
1
3
For M3 set screw
For M3 screw
For M4 screw
For M5 screw
For cutting wire tie
Belt tension 30 N (3.0 kgf)
For belt tension
A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to
the weight of the end effector while the power to the Controller is OFF or while the motor
is in OFF status (MOTOR OFF).
Note that the brake will not work during the replacement procedure.
Move the shaft down to its lower limit before starting the replacement procedure by
following the removal steps from (1) to (3).
Joint #3 brake
Removal
(1) Turn ON the Controller.
(2) Push down the shaft to its lower limit while pressing the brake release button switch.
Be sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
When the brake release button switch is pressed, the brake of the Joint #3 is released.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of an end effector.
(3) Turn OFF the Controller.
(4) Refer to Maintenance 7.1 Replacing Joint #3 Motor, Removal step (4) to (11) and
remove the brake hub from the Joint #3 motor.
(5) Remove the brake from the brake plate.
2-M2.6×6
Joint #3 brake
Installation
(1) Mount the brake on the brake plate.
(2) Refer to Maintenance 7.1 Replacing Joint #3 Motor, Installation step (1) to (11) and
mount the Joint #2 motor unit to Arm #2 after the brake hub is replaced.
(3) Perform the calibration of Joint #3.
For details, refer to Maintenance: 13. Calibration.
88
G1 Rev.4
Maintenance
8. Arm #4
8. Arm #4
■ 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
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Be careful not to apply excessive shock to the motor shaft when replacing the
motors. The shock may shorten the life cycle of the motors and encoder and/or
damage them.
CAUTION
■ Never disassemble the motor and encoder. A disassembled motor and encoder
will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance: 13. Calibration to perform the calibration.
Joint #4 motor
U belt
G1 Rev.4
89
Maintenance
8. Arm #4
8.1 Replacing Joint #4 Motor
Maintenance parts and Tools
Name
Maintenance
parts
Tools
Quantity
Note
AC Servo Motor (50 W)
1
R13B000619
Hexagonal wrench (width across flats: 2 mm)
Hexagonal wrench (width across flats: 2.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Cross-point screwdriver
Nippers
Force gauge
Suitable cord (Length about 800 mm)
1
1
1
1
For M4 set screw
For M3 screw
For M4 screw
1
1
1
For cutting wire tie
Belt tension 30 N (3.0 kgf)
For belt tension
A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to
the weight of the end effector while the power to the Controller is OFF or while the motor
is in OFF status (MOTOR OFF).
Note that the brake will not work during the replacement procedure.
Move the shaft down to its lower limit before starting the replacement procedure by
following the removal steps from (1) to (3).
Joint #4 motor
Removal
(1) Turn ON the Controller.
(2) Push down the shaft to its lower limit while pressing the brake release button switch.
Be sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
When the brake release button switch is pressed, the brake of the Joint #3 is released.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of an end effector.
(3) Turn OFF the Controller.
(4) Remove the arm top cover and the arm bottom cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(5) Cut off the wire tie used for binding the motor cables to the Joint #4 motor.
(6) Disconnect the following connectors.
Connectors X241, X41, X64 (Hold the claw to remove.)
(7) Remove the user plate.
For details, refer to Maintenance 3.4 User Plate.
90
G1 Rev.4
Maintenance
8. Arm #4
(8) Remove the Joint #4 motor unit from Arm #2.
Unscrew the bolts securing the Joint #4 motor
to the motor plate. Remove the U1 belt from
the pulley. Pull the motor unit upward to
remove.
(9) Remove the motor from the Joint #4 motor
housing.
Motor
2-M4×12
Pulley
U1 belt
Motor
2-M4×12
Motor
housing
(10) Remove the pulley from the Joint #4 motor.
There is a brass bushing in one of the set screw
holes. Be careful not to lose it.
Motor
2-M4×5
Pulley
G1 Rev.4
91
Maintenance
8. Arm #4
Joint #4 motor
Installation
(1) Mount the pulley to the new Joint #4 motor.
Be sure to fit the edge of the pulley to the edge of the motor shaft.
Tighten one of the set screws on the flat face of the motor shaft until the screw just
touches the surface.
Insert a bushing into the other set screw hole to prevent damage to the motor shaft.
Then, tighten both set screws.
(2) Mount the housing to the Joint #4 motor.
Motor
2-M4×12
Motor
housing
(3) Place the Joint #4 motor unit in the arm so that
the motor cable faces toward the back of the
arm.
(4) Place the belt around the U1 pulley and the U2
pulley so that the gear grooves of the belt are fit
into those of the pulleys completely.
NOTE
)
Motor
2-M4×12
Pulley
U1 belt
(5) Loosely secure the Joint #4 motor unit to Arm
#2.
Make sure the motor unit can be moved by
hand, and it will not tilt when pulled. If the
unit is secured too loose or too tight, the belt
will not have the proper tension.
U1 pulley
U2 pulley
(6) Apply the proper tension to the U1 belt, and
then secure the Joint #4 motor unit.
To do so, pass a suitable cord or string around
the Joint #4 motor unit near its mounting plate.
Then, pull the cord using a force gauge or
similar tool to apply the specified tension.
U belt tension = 30N (3.0 kgf)
Joint #4
Motor unit
4-M4×12 + washer
Force gauge
(7) Connect the connectors X241, X41, X64.
92
G1 Rev.4
Maintenance
8. Arm #4
(8) Mount the user plate.
For details, refer to Maintenance 3.4 User Plate.
(9) Re-bundle the cables in their original positions with a wire tie removed in step (5).
Do not allow unnecessary strain on the cables.
(10) Install the arm top cover and the arm bottom cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(11) Perform the calibration of Joint #4.
For details on the calibration method, refer to Maintenance: 13. Calibration.
G1 Rev.4
93
Maintenance
8. Arm #4
8.2 Replacing the Timing Belt
Maintenance parts and Tools
Name
Maintenance
parts
Tools
Quantity
Note
U1 belt
1
R13B030227
Hexagonal wrench (width across flats: 2.5 mm)
Hexagonal wrench (width across flats: 3 mm)
Cross-point screwdriver
Nippers
Force gauge
Suitable cord (Length about 800 mm)
1
1
1
1
1
1
For M3 screw
For M4 screw
For cutting wire tie
Belt tension: 30 N (3.0 kgf)
For belt tension
A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to
the weight of the end effector while the power to the Controller is OFF or while the motor
is in OFF status (MOTOR OFF).
Note that the brake will not work during the replacement procedure.
Move the shaft down to its lower limit before starting the replacement procedure by
following the removal steps from (1) to (3).
U belt
Removal
(1) Turn ON the Controller.
(2) Push down the shaft to its lower limit while pressing the brake release button switch.
Be sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
When the brake release button switch is pressed, the brake of the Joint #3 is released.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of an end effector.
(3) Turn OFF the Controller.
(4) Remove the arm top cover and the arm bottom cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(5) Loosen the bolts securing the Joint #4 motor unit.
(6) Remove the U belt from the U1 pulley.
2-M4×12
(7) Remove the Z belt.
For details, refer to Maintenance 7.2 Replacing the Timing Belt, Z belt Removal step
(4) to (6).
(8) Remove the U belt.
Hold the ball screw nut up and pull out the U belt
upward from the shaft.
94
4-M3×10
G1 Rev.4
Maintenance
U belt
Installation
8. Arm #4
(1) Pass a new U belt through the shaft from above, and then pass a new Z belt too.
Place them under the ball screw nut.
(2) Loosely secure the ball screw nut to Arm #2.
After moving the shaft up and down several times, secure the ball screw nut to Arm
#2.
(3) Place the U belt around the U1 pulley and the U2 pulley so that the gear grooves of
the belt are fit into those of the pulleys completely..
(4) Place the Z belt around the Z1 pulley and the Z2 pulley so that the gear grooves of
the belt are fit into those of the pulleys completely.
(5) Loosely secure the Joint #3 motor unit and Joint #4 motor unit to Arm #2.
Make sure the gear grooves of the belt are fit into those of the pulleys completely.
NOTE
)
Loosely secure the units to Arm #2 so that the motor unit can be moved by hand, and
it will not tilt when pulled. If the units are secured too loose or too tight, the belt will
not have the proper tension.
(6) Apply the proper tension to the Z belt,
and then secure the Joint #3 motor unit.
To do so, pass a suitable cord or string
around the Joint #3 motor unit near its
mounting plate. Then, pull the cord
using a force gauge or similar tool to
apply the specified tension.
Joint #3
motor unit
2-M4×12
Force gauge
Z belt tension = 30N (3.0 kgf)
(7) Apply the proper tension to the U belt,
and then secure the Joint #4 motor unit.
To do so, pass a suitable cord or string
around the Joint #4 motor unit near its
mounting plate. Then, pull the cord
using a force gauge or similar tool to
apply the specified tension.
U belt tension = 30N (3.0 kgf)
Joint #4
Motor unit
4-M4×12 + washer
Force gauge
(8) Install the arm top cover and the arm bottom cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(9) Perform the calibration of Joints #3 and #4.
For details on the calibration method, refer to Maintenance: 13. Calibration.
G1 Rev.4
95
Maintenance
9.
9.
Bellows
Bellows
NOTE
)
Two bellows make a set as maintenance parts.
bellows and lower bellows.
There is no difference between the upper
A large amount of dust is emitted when replacing the bellows.
Take the Manipulator to an outer room such as the room in front of the clean room’s
entrance, or take the necessary countermeasures to prevent dust emission before removing
the bellows.
Maintenance parts and Tools
Name
Maintenance
Quantity
Bellows
1
For each manipulator model
(Refer to Maintenance 14.
Maintenance Parts List.)
Liquid gasket
1
R13B031241
Cross-point screwdriver
1
parts
Tools
96
Note
G1 Rev.4
Maintenance
9.
Bellows
9.1 Replacing the Bellows (4-axis spec)
Bellows
Removal
(4-axis spec)
(1) Stop motor excitation. (MOTOR OFF)
(2) Remove the end effecter.
(3) Remove the wires and tubes from the end effector.
(4) Turn OFF the controller power.
(5) Loosen the two clamp bands on bellows.
(6) Remove the bearing case.
Clamp band
Bearing case
(7) Loosen the set screw of fixing ring.
Remove the fixing ring and bearing.
Bearing
Fixing ring
(8) Remove the bellows and the plate securing the
bellows.
(9) Pull out the bellows from the bellows plate.
Bellows plate
4-M3×6
G1 Rev.4
97
Maintenance
Bellows
Installation
(4-axis spec)
9.
Bellows
(1) Press the brake release switch and move the shaft to the point 10 mm ~ 20 mm down
from the upper limit.
(2) Insert the flat part of bellows into the bellows plate.
(3) Mount the bellows and bellows plate on the arm.
Bellows plate
4-M3×6
(4) Wipe off the old liquid gasket from the upper
limit mechanical stop, and then apply new liquid
gasket to it lightly.
Apply the liquid gasket to the whole bottom
surface of the mechanical stop.
Liquid gasket
(5) Insert the bearing and fixing ring from below the
shaft and secure the bearing fixing ring by
pressing it upward.
When securing the fixing ring, make sure the set
screw does not touch the spline groove.
(6) Wipe off the old liquid gasket from the inside
surface of bearing case, and then apply new
liquid gasket to it lightly.
Bearing
Bearing
case
Fixing ring
Liquid gasket
2-M13×3
Insert it into the shaft from below.
Apply the liquid gasket to the whole inside
surface of the bearing case.
(7) Insert the bellows lower part into the bearing case and secure with the clamp band.
98
G1 Rev.4
Maintenance
9.
Bellows
9.2 Replacing the Bellows (3-axis spec)
Bellows
Removal
(3-axis spec)
(1) Stop motor excitation. (MOTOR OFF)
(2) Remove the end effector.
(3) Detach the wires/tubes from the end effector.
Clamp band screw on upper bellows
(4) Loosen the two clamp bands on each
bellows.
(5) Remove the plate securing the lower bellows.
Bellows
plate
4-M3×8
(6) Pull out the lower bellows, bellows plate, and
clamp band from the shaft.
Clamp band
screw on
lower bellows
(7) Pull out the lower bellows from the bellows plate.
(8) Press the brake release switch and move the shaft to its lower limit.
(9) Remove the arm top cover.
For details, refer to Maintenance: 3. Covers.
(10) Remove the plate securing the upper bellows.
Remove the set screw from inside of the arm
top cover while pressing the nut.
Bellows plate
4-M3×8
4-M3 nut
(11) Pull out the upper bellows from the bellows plate.
G1 Rev.4
99
Maintenance
Bellows
Installation
(3-axis spec)
9.
Bellows
(1) Pass the flat part of the upper bellows
through the bellows plate and put the bellows
and arm top cover between two bellows plate
and secure them.
Bellows plate
4-M3×8
4-M3 nut
Press the nut and remove the set screw from
inside of the arm top cover.
(2) Mount the arm top cover.
For details, refer to Maintenance: 3. Covers.
(3) Pass the flat part of the lower bellows
through the bellows plate and put the
bellows between the bellows plate and Arm
#2 bottom surface and secure it.
Clamp band screw on upper bellows
(4) Secure the cylinder side of two bellows with
clamp bands.
Bellows
plate
4-M3×8
To attach the upper bellows, move the shaft
to its lower limit.
To attach the lower bellows, move the shaft
to its upper limit.
Press the brake release switch and move the
shaft up/down.
100
Clamp band
screw on
lower bellows
G1 Rev.4
Maintenance
10. Ball Screw Spline Unit
10. Ball Screw Spline Unit
■ Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
WARNING
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
NOTE
)
After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance: 13. Calibration to perform the calibration.
10.1 Greasing the Ball Screw Spline Unit
Maintenance parts and Tools
Name
Maintenance
parts
Tools
NOTE
)
G1 Rev.4
For Ball Screw Spline Unit (AFB grease)
Quantity
Proper
quantity
Wiping cloth
1
Cross-point screwdriver
1
Note
R13ZA00330200
For wiping grease (Spline shaft)
The brake release button switch is applied to Joint #3. When the brake release button
switch is pressed, the Joint #3 brake is released.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of the end effector.
101
Maintenance
10. Ball Screw Spline Unit
10.1.1
Standard-model (S type)
Cover the surrounding area such as the end effector and peripheral equipment in case the
grease drips.
(1) Turn ON the controller power.
Stop motor excitation. (MOTOR OFF)
(2) Move the arm to a position where Joint #3 can be moved in full stroke.
(3) Move the shaft to its upper limit manually
while pressing the brake release button switch.
(4) Turn OFF the controller power.
Brake release
switch
(5) Remove the arm top cover.
For details, refer to Maintenance: 3. Covers.
(6) Wipe off the old grease from the upper part of
the shaft, and then apply new grease to it.
When applying the new grease, directly fill the
grooves on the shaft by hand. Wipe off
excess grease from the shaft.
(7) Mount the arm top cover.
For details, refer to Maintenance: 3. Covers.
(8) Turn ON the controller power.
(9) Move the shaft to its lower limit while pressing the brake release button switch.
(10) Wipe off the old grease from the lower part of the shaft, and then apply new grease to
it.
When applying the new grease, directly fill the grooves on the shaft by hand.
off excess grease from the shaft.
Wipe
(11) Move the shaft up and down several times while pressing the brake release button
switch to smooth out the grease on the shaft. Wipe off excess grease from the shaft.
When wiping off the excess grease from the upper part of shaft, turn OFF the
controller power supply and remove the arm top cover.
For details, refer to Maintenance: 3. Covers.
102
G1 Rev.4
Maintenance
10.1.2
10. Ball Screw Spline Unit
Cleanroom-model (C type)
Cover the surrounding area such as the end effector and peripheral equipment in case the
grease drips.
(1) Turn ON the controller power.
Stop motor excitation. (MOTOR OFF)
(2) Move the arm to a position where Joint #3 can be moved in full stroke.
(3) Move the shaft to its upper limit manually
while pressing the brake release button switch.
(4) Turn OFF the controller power.
Brake release
switch
(5) Remove the arm top cover.
For details, refer to Maintenance: 3. Covers.
(6) Wipe off the old grease from the upper part of
the shaft, and then apply new grease to it.
Directly fill the grooves on the shaft inside the
bellows with grease by hand.
Wipe off excess grease from the shaft.
Clamp band
screw on
lower bellows
(7) Mount the arm top cover.
For details, refer to Maintenance: 3. Covers.
(8) Turn ON the controller power.
(9) Move the shaft to its lower limit while pressing the brake release button switch.
(10) Loosen the clamp band under the bellows, and then lift the bellows.
For the 3-axis spec, remove the set screw of the plate attached to the lower bellows
and lower the bellows.
(11) Wipe off the old grease from the lower part of the shaft, and then apply new grease
to it.
Directly fill the grooves on the shaft inside the bellows with grease by hand.
Wipe off excess grease from the shaft.
(12) Move the shaft up and down several times while pressing the brake release button
switch to smooth out the grease on the shaft. Wipe off excess grease from the shaft.
When wiping off the excess grease from the upper part of shaft, turn OFF the
controller power supply and remove the arm top cover.
For details, refer to Maintenance: 3.Covers.
(13) Put the lower part of bellows into the bearing case and secure with the clamp band.
For 3-axis spec, put the bellows into the Arm #2 bottom surface using the upper
bellows plate and secure the bellows.
G1 Rev.4
103
Maintenance
10. Ball Screw Spline Unit
10.2 Replacing the Ball Screw Spline Unit
A brake is mounted on the Joint #3 motor to prevent the shaft from moving down due to
the weight of the end effector while the power to the Controller is OFF or while the motor
is in OFF status (MOTOR OFF).
Note that the brake will not work during the replacement procedure.
Move the shaft down to its lower limit before starting the replacement procedure by
following the removal steps from (1) to (3).
Maintenance parts and Tools
Name
Maintenance
Ball Screw Spline Unit
parts
For Ball Screw Spline Unit (AFB grease)
Tools
Hexagonal wrench (width across flats: 2.5 mm)
Torque wrench
Nippers
Force gauge
Suitable cord (Length about 1000 mm)
Wiping cloth
104
Quantity
1
Proper
quantity
1
1
1
1
1
1
Note
For each manipulator model
(Refer to Maintenance:
14. Maintenance parts)
R13ZA00330200
For M3 screw
For cutting wire tie
Belt tension 30 N (3.0 kgf)
For belt tension
For wiping grease
(Spline shaft)
G1 Rev.4
Maintenance
10. Ball Screw Spline Unit
10.2.1 Replacing the ball screw spline unit (4-axis spec)
Ball screw
spline unit
Removal
(4-axis spec)
(1) Turn ON the controller power.
(2) Push down the shaft to its lower limit while pressing the brake release button switch.
Be sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
Be careful of the shaft falling while the brake release button switch is being pressed
because the shaft may be lowered by the weight of an end effector.
(3) Turn OFF the controller power.
(4) Detach the wires/tubes from the end effector, and remove the end effector.
(5) This step is only for Cleanroom-model.
Remove the bellows.
For details, refer to Maintenance: 9. Bellows.
(6) Remove the arm top cover.
For details, refer to Maintenance: 3. Covers.
(7) Remove the Joint #3 motor unit.
For details, refer to Maintenance: 7.1 Replacing Joint #3 Motor.
(8) Remove the Joint #4 motor unit from Arm #2.
For details, refer to Maintenance: 8.1 Replacing Joint #4 Motor.
(9) Remove the U belt and Z belt.
Remove the bolts securing the ball screw nut.
Hold the ball screw nut up and remove the U belt
and Z belt from the shaft by pulling them up.
4-M3×10
(10) Remove the nut mounting screws of the ball screw
spline shaft on the lower part of Arm #2.
4-M3×18
(11) Pull out the ball screw spline unit from Arm #2.
Remove the ball screw nut from the Arm #2 bottom plate and pull out the ball screw
spline unit toward the cutout of the Arm #2 upper plate (front).
G1 Rev.4
105
Maintenance
Ball screw
spline unit
Installation
(4-axis spec)
10. Ball Screw Spline Unit
(1) Pass the U belt and Z belt through the shaft and
mount the ball screw spline unit to Arm #2.
Attach the spacer to the lower part of spline unit
and align two holes in the spacer and in the Arm #2
bottom plate.
4-M3×10
(2) Secure the nut mounting screws of the ball screw
spline shaft on lower side of Arm #2.
4-M3×18
(3) Loosely secure the ball screw nut to Arm #2.
After moving the shaft up and down several times,
secure the spline plate to Arm #2.
4-M3×10
(4) Mount the Joint #3 motor unit.
For details, refer to Maintenance: 7.1 Replacing Joint #3 Motor.
(5) Mount the Joint #4 motor unit.
For details, refer to Maintenance: 8.1 Replacing Joint #4 Motor.
(6) If the position of the lower limit mechanical stop was changed for area limit, secure it
to the proper position.
(7) Grease the shaft.
For details, refer to Maintenance: 10.1. Greasing the Ball Screw Spline Unit.
(8) Mount the arm top cover.
For details, refer to Maintenance: 3. Covers.
(9) Turn OFF the controller power and peripheral equipments.
106
G1 Rev.4
Maintenance
10. Ball Screw Spline Unit
(10) This step is only for Cleanroom-model.
Install the bellows.
For details, refer to Maintenance: 9. Bellows.
(11) Mount the end effector, and connect wires and tubes to the end effector.
(12) Perform the calibration for the Joints #3 and #4.
For details, refer to Maintenance: 13. Calibration.
G1 Rev.4
107
Maintenance
10. Ball Screw Spline Unit
10.2.2 Replacing the ball screw spline unit (3-axis spec)
Ball screw
spline unit
Removal
(3-axis spec)
(1) This step is only for Cleanroom-model.
Loosen the screw of bellows fixing ring and pull it out to the lower shaft.
For details, refer to Maintenance: 9.2
removal step (1) to (8).
Replacing the Bellows (3-axis spec),
(2) Remove the arm top cover and Joint #3 motor unit.
For details, refer to Maintenance: 10.2.1 Replacing the ball screw spline unit
(4-axis spec), removal step (1) to (7).
(3) Remove the screw securing the upper side of
support shaft.
(4) Loosen the screw securing the lower support
guide to the shaft. Pull out the support guide and
support shaft downward.
(5) Remove the screw securing the ball screw nut and
spline nut.
Support
shaft
Shaft
2-M3×12
Support
guide
Ball screw nut
4-M3×10
Spline nut
4-M3×18
(6) Pull out the U belt and ball screw spline unit from Arm #2.
For details, refer to Maintenance: 10.2.1 Replacing the ball screw spline unit
(4-axis spec), removal step (9) to (11).
108
G1 Rev.4
Maintenance
Ball screw
spline unit
Installation
(3-axis spec)
10. Ball Screw Spline Unit
(1) Remove the screw securing the upper side of support shaft
and loosen the screw securing the lower support guide.
2-M3×12
Remove the lower support guide and support shaft from
the new ball screw spline shaft.
Make sure the spline nut will not fall out from the shaft.
(2) Mount the ball screw spline unit from which the support
shaft and lower support guide have been removed.
2-M3×12
For details, refer to Maintenance: 10.2.1 Replacing the
ball screw spline unit (4-axis spec), installation step (1)
to (4).
The U belt is not equipped for 3-axis spec.
(3) Mount the support shaft and lower support guide removed
in the step (1) through below Arm #2.
When inserting the support shaft into the arm, pass the
support shaft near the Joint #4 motor unit through the U
belt.
Loosely secure the upper side of support shaft to the
upper support guide. After moving the shaft up and
down several times, secure the set screw on the upper side
of shaft, and then secure the set screw of the lower
support guide.
(4) This step is only for Cleanroom-model.
Apply
liquid gasket here.
Apply the liquid gasket to the inside of bellows
fixing ring and insert it from below the shaft and
secure it.
When securing the bellows fixing ring, make
sure it does not touch the spline groove.
(5) Mount the Joint #3 motor unit.
For details, refer to Maintenance: 7.1 Replacing Joint #3 Motor.
(6) Grease the shaft.
For details, refer to Maintenance: 10.1. Greasing the Ball Screw Spline Unit.
(7) This step is only for Cleanroom-model.
Install the bellows.
For details, refer to Maintenance: 9. Bellows.
(8) Mount the arm top cover.
For details, refer to Maintenance: 3. Covers.
G1 Rev.4
109
Maintenance
10. Ball Screw Spline Unit
(9) Turn OFF the controller power and peripheral equipments.
(10) Mount the end effector, and connect wires and tubes to the end effector.
(11) Perform the calibration for the Joints #3 and #4.
For details, refer to Maintenance: 13. Calibration.
110
G1 Rev.4
Maintenance
11.
11. Lithium Battery
Lithium Battery
■ 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
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Use meticulous care when handling the lithium battery. Improper handling of
the lithium battery as mentioned below is extremely hazardous, may result in
heat generation, leakage, explosion, or inflammation, and may cause serious
safety problems.
<Improper Handling>
WARNING
・Battery Charge
・Disassembly
・Incorrect Installation
・Exposing to Fire
・Forced Discharge
・Deformation by Pressure
・Short-circuit (Polarity; Positive/Negative)
・Heating (85°C or more)
・Soldering the terminal of the lithium battery directly
■ When disposing of the battery, consult with the professional disposal services or
comply with the local regulation.
Spent battery or not, make sure the terminal is insulated. If the terminal contacts
with the other metals, it is extremely hazardous, may result in heat generation,
leakage, explosion, or inflammation, and may cause serious safety problems.
When the lithium battery power is low, an error will occur to warn the user about the low
battery status when the Controller is turned ON (when software is started up).
When the error occurs, the position data in motors will be lost and all joints need to be
completely calibrated again.
The life span of the lithium battery is 3 years. Even if the Manipulator is constantly
connected to power, the lithium battery needs to be replaced every 3 years.
If the error of the Power-low warning dose not occur, the calibration of the all joints is not
necessary. However, when the position is out of place after the battery replacement,
perform the calibration.
Be sure to use the specified lithium battery and the battery board.
(Refer to Maintenance: 14. Maintenance Parts List.)
Be sure to set the correct polar when installing the battery.
G1 Rev.4
111
Maintenance
11. Lithium Battery
Maintenance parts, Tools and Material
Name
Maintenance
parts
Tools
Material
Quantity
Note
Battery unit (Lithium battery)
Battery board (No Lithium battery)
Nippers
Hexagonal wrench (width across flats: 3 mm)
1
1
1
1
Wire tie
2
2
R13ZA00600300
R13B041203
For cutting wire tie
For M4 screw
(For replacing battery board)
For fixing battery unit (battery)
For fixing cable
11.1 Replacing the Battery Unit (Lithium Battery)
Battery unit
(lithium battery)
Removal
(1) Turn OFF the controller power.
(2) Remove the screw securing the battery plate.
(3) Lift the battery plate upward.
NOTE
)
2-M4×8
The lithium battery is fixed to the under the
battery plate.
(4) Connect the connector of the new lithium battery to the battery board.
User the unused connector of the two connectors X60A, X60B on the upper part of
the battery board.
Be sure to connect the connector of the new battery before disconnecting the old
battery. If the current battery is disconnected before connecting the new battery,
the robot will lose the home position data and the calibration must be executed
again.
NOTE
)
Except when the Power-Low warning is appearing.
(5) Cut off the wire tie binding the lithium battery to the battery plate and remove the
lithium battery.
Battery unit
(lithium battery)
Installation
(1) Mount the new lithium battery to the battery plate using wire tie.
(2 ) Mount the battery plate to the base.
(3) Turn ON the controller power.
(4) Check if the Manipulator moves to points (poses) correctly.
To do so, select 2 points (poses) or more from the registered points (poses) and move
the Manipulator to the points (poses).
(5) If the Manipulator does not move to the points (poses) correctly, perform the
calibration of all joints and axes.
For details, refer to Maintenance: 13. Calibration.
112
G1 Rev.4
Maintenance
11. Lithium Battery
11.2 Replacing the Battery Board
After battery board and parts have been replaced (motors, reduction gear units, brakes,
timing belts, ball screw spline unit, etc.), the Manipulator cannot operate properly because
a mismatch exists between the origin stored in each motor and its corresponding origin
stored in the Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance: 13. Calibration to perform the calibration.
Battery board
Removal
(1) Remove Arm #1 from the base.
Place the removed Arm #1 on the floor without
giving any shock.
6-M4×15
(2) Remove the connector plate.
For details, refer to Maintenance: 3.2 Connector Plate.
(3) Remove the Joint #1 flange by removing the
whole Joint #1 unit.
The base and Joint #1 flange are aligned by the
positioning pin. Be sure to keep the positioning
pin.
4-M6×15
2-M4×45
(4) Disconnect the connectors X61, X62, X63, and
X64 connected to the battery board.
X60B X60A
(5) Loosen the screws securing the battery board
and remove the battery board.
(6) Disconnect the connector X60 (Lithium battery)
connected to X60A or X60B.
G1 Rev.4
X63
X61
X64
X62
113
Maintenance
Battery board
Installation
11. Lithium Battery
(1) Mount the new battery board and connect the
connector X60 to X60A or X60B.
X60B X60A
Secure the board with screws.
(2) Connect the connectors X61, X62, X63, and X64.
X63
X61
X64
X62
(3) Mount the Joint #1 flange on the base.
4-M6×15
When mounting the base and Joint #1 flange, their
positions are determined by the positioning pin.
Be careful not to catch cables when mounting the
flange.
2-M4×45
(4) Mount the Arm #1 on the base.
6-M4×15
(5) Mount the connector plate.
For details, refer to Maintenance: 3.2 Connector Plate.
(6) Perform the calibration of all joints.
For details, refer to Maintenance: 13. Calibration.
114
G1 Rev.4
Maintenance
12.
12. LED Lamp
LED Lamp
■ 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
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.
Maintenance parts, Tools and Material
Name
Maintenance
parts
Tools
Material
LED Lamp
Removal
Quantity
Note
LED Lamp
1
R13B030004
Cross-point screwdriver
Nippers
Wire tie
1
1
1
For removing wire
(1) Turn OFF the controller power.
(2) Remove the arm top cover.
For details, refer to Maintenance: 3. Covers.
(3) Disconnect the connector X22.
(4) Remove the lens and lens holder.
Turn them counterclockwise to remove.
(5) Remove the LED and ring from the user
plate.
To remove the ring, turn it counterclockwise.
G1 Rev.4
Lens holder
Ring
115
Maintenance
LED Lamp
Installation
12. LED Lamp
(1) Mount the LED on the user plate.
(2) Put the arm top cover between the ring and lens holder, and then secure the LED to
the user plate.
(3) Mount the lens.
Connect the connector X22.
(4) Mount the arm top cover.
For details, refer to Maintenance: 3. Covers.
116
G1 Rev.4
Maintenance
13.
13. Calibration
Calibration
13.1 About Calibration
After parts have been replaced (motors, reduction gear units, timing belts, etc.), the
Manipulator cannot execute the positioning properly because a mismatch exists between
the origin stored in each motor and its corresponding origin stored in the Controller.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
not the same as teaching*.
Note that calibration is
*: “Teaching” means to teach the Controller coordinate points (including poses) anywhere
in the operating area of the Manipulator.
■ To ensure safety, a safeguard must be installed for the robot system.
For details on the safeguard, refer to EPSON RC+ User’s Guide: 2.4 Installation
and Design Precautions.
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.
Command Input
Calibration procedures include the process to input commands.
menu-[Tools]-[Command Window] to use the command window.
Select EPSON RC+
The information above is omitted in the calibration procedure.
Jog Motion
The process to set the jog motion is included in the [Jog & Teach] page of the Robot
Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog &
Teach] tab to use the [Jog & Teach] page.
The page above is indicated as [Jog & Teach] in the calibration procedure.
In the following calibration procedure, it uses EPSON RC+ 5.0. When the procedure is
different for each type of software, see your software type.
EPSON
EPSON
RC+ 5.0
G1 Rev.4
RC+ 6.0
117
Maintenance
13. Calibration
13.2 Calibration Procedure
EPSON RC+ has a wizard for calibration.
This section indicates the calibration using the calibration wizard of EPSON RC+.
EPSON
RC+ 5.0
You can also calibrate with option TP1 in TEACH mode. For details, refer to
RC170/RC180 option Teach pendant TP1 manual, Operation: 2.7 Calibrating Origin: E2
Series / G Series / RS series.
The same calibration procedure is used for each joint.
The follow the steps below are calibration using Joint #1.
calibrate other joints.
Follow the steps below to
When coordinates for the Manipulator working point require calculation, it is important
for Joint #2 to be calibrated accurately. Execute the procedure in “Calibration Using
Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to
Maintenance: 13.3 Accurate Calibration of Joint #2.
When calibrating Joint #4, you must calibrate Joint #3 and #4 at the same time.
cannot calibrate Joint #4 alone because of the structure of the Manipulator.
NOTE
)
You
If Err9716 or 5016 (Power supply failure of the absolute encoder. Replace the battery.
Check the robot internal wiring) occurs, apply the procedure of 14.4 Calibration
Procedure without using Calibration Wizard - 3. Encoder Initialization and then, start the
calibration wizard.
The reference point (a point to check the accuracy) needs to be specified for calibration.
(1) Start the calibration wizard.
EPSON
RC+ 5.0
i.
Select EPSON RC+ menu-[Setup]-[Controller] to display the [Controller]
dialog.
ii. Select [Robot]-[Calibration] to display [Robot Calibration].
iii. Select the joint and click the <Calibrate…> button.
118
G1 Rev.4
Maintenance
EPSON
RC+ 6.0
i.
13. Calibration
Select EPSON RC+ 6.0 menu-[Setup]-[System Configuration].
ii. Select the [Robot]-[Robot**]-[Calibration].
NOTE
)
Only selected robot can be calibrated.
iii. Select the joint and click the <Calibrate…> button.
(2) Confirm the warning message and click the <Yes> button.
(3) Move the joint to calibrate manually to approximate zero position, as shown in the
dialog. After moving the joint click the <Next> button.
G1 Rev.4
119
Maintenance
13. Calibration
0 pulse position of Joint #1:
position aligned with X-axis in
Robot coordinate system
0 pulse
0 pulse position of Joint #2:
position where Arms #1 and #2
are in a straight line
(Regardless of the Joint #1
direction.)
0 pulse
0 pulse position of Joint #3:
upper limit position in motion
range
The height of Joint #3 depends on manipulator model.
Standard model
0 pulse position of Joint #4:
position where the flat surface
(or screw hole 1) on the shaft
faces toward the tip of Arm #2
Screw hole 2
Screw hole 1
Flat surface
120
Cleanroom model
0 pulse
Screw hole 1 and flat surface are located
in the center of the shaft.
Screw hole 1 and 2 are located at right
angles to one another.
G1 Rev.4
Maintenance
13. Calibration
(4) Click the <Yes> button to reset the encoder.
* This window will disappear when the Controller starts up.
(5) Reboot the Controller.
* This window will disappear when the Controller starts up.
(6) Select the reference point to use for calibration, and click the <Next> button.
Select a point from the
current points to use for
checking the accuracy.
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Maintenance
13. Calibration
(7) Click the <Jog…> button to display the [Jog & Teach] dialog.
(8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for
rough calibration. Then click the <OK> button.
* Before operating the robot, open the [Jog & Teach] tab and click on the <Motor
ON> button.
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Maintenance
13. Calibration
(9) Click the <Next> button.
(10) The manipulator moves to the reference point.
Click the <Execute> button.
Input JUMP P0:z(0).
↑
Point selected in step (6)
(11) Confirm the message and click the <Yes> button.
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Maintenance
13. Calibration
(12) After the manipulator moves to the reference point, click the <Next> button.
JUMP P0:z(0 )
(13) Jog to the accurate reference position.
124
Click the <Jog> button.
G1 Rev.4
Maintenance
13. Calibration
(14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for
rough calibration. Then click the <OK> button.
* Position Joint #2 only and move Joint #3 to around 0 pulse.
(15) Click the <Next> button.
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Maintenance
13. Calibration
(16) Execute the procedure in “Calibration Using Right / Left Arm Orientations” to
accurately calibrate Joint #2 only.
* Go on to the step (17) for the other joints calibration.
i. Move to another point that has different pose (from righty to lefty) using Jump
command. Click the <Yes> button.
ii. Jog to the accurate reference position.
Click the <Jog> button.
iii. Jog to the accurate reference position and adjust the position. Click the <OK> button.
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13. Calibration
iv. Click the <Next> button.
(17) Calibration is complete.
Click the <Finish> button.
(18) Move the manipulator to other points and check if it can move without problems.
Teach points where appropriate.
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Maintenance
13. Calibration
13.3 Accurate Calibration of Joint #2
When coordinates for the Manipulator working point require calculation, it is important
for Joint #2 to be calibrated accurately.
NOTE
)
If the accuracy of Joint #2 is not obtained through the steps in the section 13.2 Calibration
Procedure, follow the steps below “Calibration Using Right / Left Arm Orientations” to
accurately calibrate Joint #2.
The reference point is the center of the ball
screw spline shaft during this calibration.
When there is a misalignment between the
center of the end effector and the center of the
ball screw spline shaft, remove the end effector
and perform the calibration of the shaft.
Make a calibration jig as shown in the right
figure and attach it on the end of the shaft to
make the center of the shaft clear.
The center of the shaft
There is a misalignment
between the center of
the end effector and the
center of the shaft.
The center
of the shaft
Decide a target point and mark a cross (×) on it
so that you can easily verify the center of the
shaft after switching the arm pose between
right and left.
Calibration jig at the
end of the shaft
(Example)
Target point
After removing the end effector and performing the calibration, install the end effector and
move the Manipulator to the teaching point to verify whether there is a positional gap. If
there is a positional gap, fine-tune the installation position of the end effector and teach the
point again.
Coordinates for the working point requires calculation in the following cases:
· Teaching the working point by entering the coordinate values (MDI teaching)
· Switching the arm orientation between right and left at a given point
· Using the Pallet command
· Executing CP control (such as liner or circular interpolation)
· Using the Local command
· Pose data specified with relative coordinates <Example: P1+X(100) >
· Vision Guide camera calibrations
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G1 Rev.4
Maintenance
13. Calibration
Calibration Using Right / Left Arm Orientations
(1) Check the point data for calibration
Use a pose (point) you can easily verify the accuracy within the work envelop
of both right and left arm. And then check the number of pose (point) you
want to use.
(2) Open the Tools menu | Robot Manager | Control Panel and click the MOTOR ON.
(3) Click the Free All to free all joints from servo control. Now, you can move arms by
hands.
(4) Move the arms to the position of point data for calibration in rightly arm orientation.
(5) From the current position, teach any point data number unused.
This pose (point) is now called P1.
Specify the point number “1” and click the <Teach> button in the [Jog & Teach].
(6) Click the Lock All in the [Control Panel] to lock all joints under servo control.
(7) Switch to the lefty arm orientation. Then, move the arm to the same point.
>Jump P1/L:Z(0) '
Change the arm orientation from righty to lefty
Z is the maximum position
* If any interference on the way from right to lefty, click the Free All in the [Control
Panel] and change the arm orientation to lefty by hands. Then, go to the step (6),
(7).
(8) The joints are slightly out of position.
Adjust the gap with the −Z in the Jogging group in the [Jog & Teach]. Then, teach
another point data number unused. This pose (point) is now called P2.
Specify point number “P2” and click the <Teach> button in [Jog & Teach].
(9) Input the new Hofs value.
> Hofs Hofs (1), Hofs (2) + (Ppls(P1,2) + Ppls(P2,2)) /
2, Hofs(3), Hofs(4)
(10) From the current lefty arm orientation (the position in the step (8)), teach the point
data number used in the step (8). This pose (point) is called P2.
Specify point number “P2” and click the <Teach> button in [Jog & Teach].
(11) Switch to the righty arm orientation.
correct position.
>Jump P2/R
Then, make sure the manipulator move to the
' Change the arm orientation from lefty to righty
* If there is any interference on the way from lefty to righty, click the Free All in the
[Control Panel] and change the arm orientation to righty by hands. Then, go to the
step (6), (11).
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Maintenance
13. Calibration
(12) Move the manipulator to other point data and make sure it moves to the correct
position. Teach some more points if required.
* Delete the two points taught for the Joint #2 calibration.
13.4 Calibration Procedure without using Calibration Wizard
NOTE
)
This section indicates the calibration without using the calibration wizard of EPSON RC+.
For details of calibration using the calibration wizard, refer to 13.2 Calibration Procedure.
When coordinates for the Manipulator working point require calculation, it is important
for Joint #2 to be calibrated accurately. Execute the procedure in “Calibration Using
Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to
Maintenance: 13.3 Accurate Calibration of Joint #2.
You cannot calibrate Joint #4 alone because of the structure of the Manipulator.
calibrating Joint #4, you must calibrate Joint #3 and #4 at the same time.
NOTE
)
When
The reference point (a point to identify the position of the manipulator) needs to be
specified for calibration.
Follow steps 1 to 6 described below in order to calibrate the origin.
1.
Basic Pose Confirmation
(1)-1 After the part replacement, perform the calibration using the point data
currently registered.
Confirm the point data number (P*) to reconstruct the correct manipulator
position.
* Point data before the parts replacement (motor, reduction gear, belt, etc.) is
necessary for the calibration.
2.
Part Replacement
(2)-1 Replace parts as dictated by this manual.
Be careful not to injure yourself or damage parts during part replacement.
3.
Encoder Initialization
(3)-1 Turn ON the Controller when all joints are in the motion range.
(3)-2 Manually move the joint that needs origin alignment to its approximate 0
pulse position.
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G1 Rev.4
Maintenance
13. Calibration
0 pulse position of Joint #1:
position aligned with X-axis in
Robot coordinate system
0 pulse
0 pulse position of Joint #2:
position where Arms #1 and #2
are in a straight line
(Regardless of the Joint #1
direction.)
0 pulse
0 pulse position of Joint #3:
upper limit position in motion
range
The height of Joint #3 depends on manipulator model.
Standard model
0 pulse position of Joint #4:
position where the flat surface
(or screw hole 1) on the shaft
faces toward the tip of Arm #2
Screw hole 2
Screw hole 1
Flat surface
G1 Rev.4
Cleanroom model
0 pulse
Screw hole 1 and flat surface are located
in the center of the shaft.
Screw hole 1 and 2 are located at right
angles to one another.
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Maintenance
13. Calibration
(3)-3 Connect EPSON RC+ to the Controller.
EPSON
RC+ 6.0
Select a robot to be calibrated. Input as below in the [Command
Window] and execute it.
(This example uses “robot 1”.)
> robot 1
(3)-4 Execute the absolute encoder initialization command.
Input one of the following commands to [Command Window] according to the
joint being calibrated.
Joint #1: >EncReset
Joint #2: >EncReset
Joint #3: >EncReset
Joint #4: >EncReset
1
2
3
3, 4
(3)-5 Reboot the Controller.
Select EPSON RC+ menu-[Tools]-[Controller] and click the <Reset
Controller> button.
* This window will be disappeared when the Controller starts up.
4.
Rough Calibration
(4)-1 Turn ON the motor from EPSON RC+ menu-[Tools]-[Robot Manager][Controller Panel].
(4)-2 Click the <Free All> button in the [Control Panel] page to free all joints and
move the arms manually.
(4)-3 Move the Manipulator to the approximate position and orientation.
(4)-4 To perform temporary calibration, input the pulse value of the specified point
data.
When the specified point data is “P1,” input and perform the following
command to [Command Window] according to the joint being calibrated.
> Calpls Ppls(P1,1), Ppls(P1,2), Ppls(P1,3), Ppls(P1,4)
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G1 Rev.4
Maintenance
13. Calibration
(4)-5 Perform the temporary calibration.
Input and perform one of the following commands to [Command Window]
according to the joint being calibrated.
Joint #1: >Calib 1
Joint #2: >Calib 2
Joint #3:: >Calib 3
Joint #4: >Calib 3, 4
5.
Calibration (Accurate Positioning)
(5)-1 Click the <Lock All> button in [Control Panel] to put all joints back under
servo control.
(5)-2 Move the joint to the specified point using a motion command.
For example, when the specified point data is “P1”, click <MOTOR ON>
button in [Control Panel] and execute “Jump P1:Z(0)” from [Jog & Teach].
* The joint NOT being calibrated moves to the original position.
(5)-3 Accurately align the joint* being calibrated to the specified point using jog
commands.
* You must move Joint #3 and #4 to the position when calibrating Joint #4.
Select the jog mode [Joint] from [Jog & Teach] to execute the jog motion.
(5)-4 Perform the calibration.
Input and perform one of the following commands to [Command Window]
according to the joint being calibrated.
Joint #1: >Calib
Joint #2: >Calib
Joint #3: >Calib
Joint #4: >Calib
6.
1
2
3
3, 4
Accuracy Testing
(6)-1 Move the Manipulator to another point to confirm that it moves to the same
position.
If it does not move to the same position, re-calibrate using another point.
You must set the point again if reproducibility cannot be assured through
calibration.
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133
Maintenance
14.
14. Maintenance Parts list
Maintenance Parts List
14.1 Common Parts
Code
Part Name
Joint #1
AC Servo Motor
R13B000621
Joint #2
Joint #3
Note
R13B000619
69
50 W
Electromagnetic Brake
R13B010026
72
Joint #2
R13B010027
76
Z axis
R13B030507
87
Joint #3
R13B030226
Z : width 6 mm
length 196 mm
85
Joint #4
R13B030227
U : width 6 mm
length 190 mm
93
175mm
R13B020039
12, 59
225mm
R13B020040
12, 59
M/C Cable
Battery Board
R12B020446
3m
23
R12B020447
5m
23
R12B020448
10 m
23
R13B041203
No lithium battery
Installed in Base
R13ZA00600300
Battery Unit
109
R13B031251
For Joint # motor flange
71
Joint #2
R13B031252
For Joint #2 motor flange
78
R13Z702640100
LED Lamp
R13B030004
113
Ball Screw Spline
R13ZA00330200
AFB grease (400 g)
52
Reduction Gear Unit
R13ZA00330400
SK-2 (500 g)
52
Cable
R13B030304
GPL-224 (227 g) in tube
Liquid gasket
134
111
Joint #1
Brake Release Button
Grease
Lithium battery for replacement
ER17330V (TOSHIBA)
O-ring
81
Joint #1
Timing Belt
Cable Unit
74
89
Joint #4
Reduction Gear Unit
Reference
page
R13B031241
108
G1 Rev.4
Maintenance
14. Maintenance Parts list
14.2 Parts by Environment Model
14.2.1 S: Standard-model
Code
Part Name
Ball Screw Spline
4-axis spec
3-axis spec
Arm Cover
R13B010224
R13B010226
R13B030441
Note
Reference
page
104
107
57
White
14.2.2 C: Cleanroom-model
Code
Part Name
Ball Screw Spline
4-axis spec
3-axis spec
Arm Cover
Bellows
Gasket Unit
G1 Rev.4
4-axis spec
3-axis spec
R13B010225
R13B010227
R13B030442
R13B030706
R13B030707
R13B031253
Note
Plating
Reference
page
102
108
57
96
98
135
Maintenance
136
14. Maintenance Parts list
G1 Rev.4

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