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Epson ES Series Manipulator Manual

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SCARA ROBOT
ES/EL series
MANIPULATOR MANUAL
Rev.9
EM019R893F

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  • Page 1 SCARA ROBOT ES/EL series MANIPULATOR MANUAL Rev.9 EM019R893F...
  • Page 3 SCARA ROBOT ES / EL series Manipulator manual Rev.9 Copyright  1997-2001 SEIKO EPSON CORPORATION. All rights reserved.
  • Page 4 WARRANTY The robot and its optional parts are shipped to our customers only after being subjected to the strictest quality controls, tests and inspections to certify its compliance with our high performance standards. Product malfunctions resulting from normal handling or operation will be repaired free of charge during the normal warranty period.
  • Page 5 We ask that you please notify us if you should find any errors in this manual or if you have any comments regarding its content. Please direct any inquiries about the use of this manual to: ES / EL series manipulator manual SEIKO EPSON CORPORATION Sales Engineering Group TEL : 81-266-24-2004 FAX : 81-266-24-2017...
  • Page 6 SAFETY PRECAUTIONS Please carefully read this and other related manuals before and while using the equipment. Keep this manual in a handy location for easy access at all times.   This sign indicates that a danger of serious WARNING injury or death will exist if theses instructions are not followed.
  • Page 7 This manual contains information that you need to know to use the ES / EL series manipulator correctly. Please thoroughly read this and other related manuals before using the equipment. This manipulator can be used with the following EPSON robot controllers: • EPSON RC+ •...
  • Page 8 If service center information is not indicated here, please contact the supplier office for your region as listed in the following SUPPLIERS section. SUPPLIERS Japan & Others SEIKO EPSON CORPORATION Okaya Plant No. 2 1-16-15, Daiei-cho Okaya-shi, Nagano-ken, 394-0025...

  • Page 9: Table Of Contents

    (2) Changing motion range using mechanical stops ........46 (3) Changing motion range using X, Y limits ..........54 9. Emergency Stop................. 57 10. Specifications ................59 10.1 ES series Standard model specifications ...........60 10.2 EL series Standard model specifications..........61 10.3 Model settings..................62 11. Clean Model................63 11.1 Manipulator part names ..............63...
  • Page 10 12. Protected Model ..............69 12.1 Manipulator part names ..............70 12.2 Environmental conditions ..............71 General environmental conditions............... 71 Special environmental conditions ............... 72 12.3 Connecting the cables................ 73 12.4 User wires and pneumatic tubes............74 12.5 External dimensions................76 12.6 Additional specifications ..............
  • Page 11 11. Calibration ................179 11.1 Calibration for EPSON RC+ Controller ..........180 Common procedure for calibration............180 Calibrating Joint #3 ...................182 Calibrating Joint #1, #2, and #4 ..............183 Accurate calibration of Joint #2 ..............184 11.2 Calibration for SPEL 95 / SRC-5** Controller ........186 Common procedure for calibration............186...

  • Page 13: Part 1: Setup & Operation

    Part 1 Setup & Operation Part 1 contains information for setup and operation of the EPSON ES and EL Series Manipulators, including: • Installation • Safety • User wiring and pneumatics • Attaching external devices • Motion range adjustments • Specifications...

  • Page 15: Manipulator Part Names

    Part 1: Setup & Operation 1. Manipulator Part Names 1. Manipulator Part Names The model name of the ES / EL series Manipulator is specified as follows: ES 55 1 S Option S: Standard model C: Clean model * P: Protected model * Joint #3 stroke 1: 170 mm 3: 320 mm...
  • Page 16 1. Manipulator Part Names Part 1: Setup & Operation...

  • Page 17: Installation Requirements

    Part 1: Setup & Operation 2. Installation Requirements 2. Installation Requirements 2.1 Environmental conditions A suitable environment is necessary for the manipulator to function properly and safely. Please install the robot in a place that meets the following requirements. Ambient temperature 5 to 40°C (with minimum temperature variation) Ambient relative humidity...

  • Page 18: Base Table

    2. Installation Requirements Part 1: Setup & Operation 2.3 Base Table A base table for anchoring the manipulator is not supplied. Users must make or obtain such a table independently. The size and shape of the base table differs depending on the robot’s application.
  • Page 19 Part 1: Setup & Operation 2. Installation Requirements Maximum space in Figure 2 shows the radius of end effector equal to or less than 60 mm. NOTE If the radius of the end effector exceeds 60 mm, such as when using a camera or electromagnetic valve, increase the radius to allow proper clearance.

  • Page 20: Pre-Installation Safety Precautions

    Relocating the manipulator.) Safeguard design For safety reasons, it is necessary to equip robot systems with safeguards. Refer to the Safety chapter in the EPSON RC+ User’s Guide. SPEL 95 Refer to the Safety section of the SRC5**/SPEL 95 Introduction manual.

  • Page 21: Installation

    Part 1: Setup & Operation 3. Installation 3. Installation 3.1 Unpacking Contents Manipulator Standard accessories Power cable Signal cable Connector and clamp hood for user wiring (2 sets) Ball screw spline grease (70g) Transport the manipulator in the delivered condition. After unpacking, to prevent the manipulator from falling, secure the manipulator to a transporter such as a cart or lift, or have it carried by two or more people.

  • Page 22: Installation Method

    3. Installation Part 1: Setup & Operation 3.2 Installation method If the manipulator is a Clean model, refer to the chapter Clean Model. (1) Anchor the base of the manipulator to the base table using the four steel bolts. Use the steel bolts (M8 for ES or M12 for EL) conform to “ISO898-1 property class 10.9 or 12.9”.
  • Page 23 Part 1: Setup & Operation 3. Installation (3) Push Arm #1 slowly in the direction shown by the arrow in Figure 6. Remove the arm retaining bracket and bolt (ES: M8×10, EL: M12×20) from the base. If they are not removed, the motion range of Joint #1 will be limited.

  • Page 24: Connecting The Cables

    3. Installation Part 1: Setup & Operation 3.3 Connecting the cables Cable connections are shown in Figure 7. This figure shows the minimum connections necessary for operating the robot. Refer to the controller manual for information on how to connect the cables. * If the manipulator is a Clean model, refer to chapter 11.
  • Page 25 Part 1: Setup & Operation 3. Installation M/C power cable   M/C power Manipulator M/C signal cable   M/C signal MOTION interface cable   SPEL 95 MOTION   Drive unit D-I/O   D-I/O (STD) I/O equipment EMERGENCY   E-STOP switch EMERGENCY PC power cable  ...

  • Page 26: Safety Precautions After Installation

    3. Installation Part 1: Setup & Operation 3.4 Safety precautions after installation Carefully read the Safety section of the User’s manual before operation. Do not enter the motion range of the manipulator when the power is ON even if the manipulator seems to be stopped. It is extremely hazardous to put any part of WARNING your body in the motion range.
  • Page 27 Part 1: Setup & Operation 3. Installation Other safety recommendations Perform daily inspections carefully before starting operation. (Refer to Part 2: Maintenance.) Perform inspections and maintenance periodically in accordance with the instructions in Part 2: Maintenance. Joint #3, with an end effector mounted to it, descends under its own weight while the joint #3 brake release button is pushed.

  • Page 28: Relocating The Manipulator

    3. Installation Part 1: Setup & Operation 3.5 Relocating the manipulator Please follow the procedures below when moving the manipulator to a new location. NOTE The arms of the manipulator must be secured to prevent them from moving when transporting the manipulator.

  • Page 29: User Wires And Pneumatic Tubes

    Part 1: Setup & Operation 4. User Wires and Pneumatic Tubes 4. User Wires and Pneumatic Tubes Electrical wires and pneumatic tubes have been incorporated into the cable unit for your use. Electrical wires Rated Allowable Number of Nominal sectional Outer diameter Note voltage...
  • Page 30 4. User Wires and Pneumatic Tubes Part 1: Setup & Operation...

  • Page 31: End Effectors

    Part 1: Setup & Operation 5. End Effectors 5. End Effectors 5.1 Attaching an end effector Users are responsible for making their own end effector(s). Here, we point out some precautions to adhere to when attaching an end effector. Install an end effector to the lower end of the shaft. Figure 10 shows the dimensions around the shaft.
  • Page 32 5. End Effectors Part 1: Setup & Operation NOTE Do not move the upper-limit mechanical stop which is on the lower side of the shaft. Use a split muff coupling with an M4 bolt or larger to attach an end effector to the shaft. You can use the flat cut and conical hole on the end of the shaft to orient Joint #4 by tightening a setscrew.

  • Page 33: Wire And Tube Layout

    Part 1: Setup & Operation 5. End Effectors Wire and tube layout The Joint #3 shaft has a through-hole to the end effector for supplying air and electricity. The diameter of the through-hole is 14 mm. The lower limit mechanical stop of Joint #3 has two φ...

  • Page 34: The End Effector And Acceleration / Deceleration

    Enter their combined total weight into the [Weight:] text box on the WEIGHT tab of the Project | Robot Parameters dialog. (Refer to the chapter EPSON RC+ GUI in the EPSON RC+ User’s Guide.) You may also execute the WEIGHT command from the EPSON RC+ Monitor Window.
  • Page 35 Part 1: Setup & Operation 5. End Effectors SPEL 95 * The percentage in the graph is based on the speed at rated weight (2kg) as 100%. * The percentage in the graph is based on the speed at rated weight (2kg) as 100%.
  • Page 36 5. End Effectors Part 1: Setup & Operation SPEL 95 * The percentage in the graph is based on the speed at rated weight (2kg) as 100%. * The percentage in the graph is based on the speed at rated weight (2kg) as 100%.

  • Page 37: Precautions For Auto Acceleration / Deceleration

    Part 1: Setup & Operation 5. End Effectors Precautions for auto acceleration / deceleration When you move the manipulator horizontally with Joint #3 (Z) at a high position, the motion time will be faster. When Joint #3 gets below a certain point (-60mm in figure 13 below), then auto acceleration/deceleration is used to reduce acceleration/deceleration.

  • Page 38: Moment Of Inertia And The Accel Setting

    5. End Effectors Part 1: Setup & Operation If you move the manipulator horizontally when the position of Joint #3 is low, it may cause over shoot at the time of final positioning. We recommend that the height of the Joint #3 be as high as possible when you move the manipulator horizontally.

  • Page 39: Calculating The Moment Of Inertia

    Part 1: Setup & Operation 5. End Effectors Calculating the moment of inertia The moment of inertia is defined as “the ratio of the torque applied to a rigid body free to rotate about a given joint to the angular acceleration thus produced about that joint”. This value is typically referred to as “the moment of inertia”, “inertia”, or “GD ”.
  • Page 40 5. End Effectors Part 1: Setup & Operation + m × L (a) Moment of inertia of a rectangular parallelepiped = m Rectangular parallelepiped’s Rotation center center of gravity Mass m  L  b  h  Figure 16 (a). Rectangular parallelepiped + m × L (b) Moment of inertia of cylinder = m Cylinder’s center of gravity...

  • Page 41: Eccentricity Of Joint #4

    Part 1: Setup & Operation 5. End Effectors Eccentricity of Joint #4 The eccentricity of Joint #4 (rotation center) and the position of a load’s center of gravity should not be more than 50 mm. Rotation center Position of load’s center of gravity Amount of eccentricity (50 mm or less) Figure 17.
  • Page 42 5. End Effectors Part 1: Setup & Operation...

  • Page 43: Attaching A Camera, Valve, And Other Devices

    Part 1: Setup & Operation 6. Attaching a Camera, Valve, and Other Devices 6. Attaching a Camera, Valve, and Other Devices Arm #2 has eight threaded holes. Use these holes for attaching cameras, valves, and other equipment. See Figure 10 in 7. External Dimensions for information on dimensions. B:4-M4 depth 8 A:6-M4 depth 8 72(ES)
  • Page 44 6. Attaching a Camera, Valve, and Other Devices Part 1: Setup & Operation...

  • Page 45: External Dimensions

    Part 1: Setup & Operation 7. External Dimensions 7. External Dimensions ES series * If the manipulator is a Clean model, refer to chapter 11. Clean Model. * If the manipulator is a Protected model, refer to chapter 12. Protected Model.
  • Page 46 7. External Dimensions Part 1: Setup & Operation EL series * If the manipulator is a Clean model, refer to chapter 11. Clean Model. * If the manipulator is a Protected model, refer to chapter 12. Protected Model. Signal cable connector Duct support (for EL853S only) Power cable connector...

  • Page 47: Motion Range And Robot Coordinates

    Part 1: Setup & Operation 8. Motion Range and Robot Coordinates 8. Motion Range and Robot Coordinates 8.1 Standard motion range The motion range and the robot coordinate of the ES / EL series is described below. The following motion range shows the standard (maximum) specification. When each axis motor is engaged, the center of Joint #3’s lowest point moves in the area shown below.
  • Page 48 8. Motion Range and Robot Coordinates Part 1: Setup & Operation Center of Joint #3 Maximum space Motion range Point P Area limited by Space for cables mechanical stops Maintenance space ES45*S ES45*C ES45*P 5° 5° 3° Value of dimensions in ( ) of Z stroke is option. Figure 21-1.
  • Page 49 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates Center of Joint #3 Maximum space Motion range Point P Area limited by mechanical stops Space for cables Maintenance space ES55*S ES55*C ES55*P 5° 5° 3° Value of dimensions in ( ) of Z stroke is option. Figure 21-2.
  • Page 50 8. Motion Range and Robot Coordinates Part 1: Setup & Operation Center of Joint #3 Maximum space Motion range Point P Area limited by mechanical stops Maintenance space Space for cables ES65*S ES65*C ES65*P 5° 5° 3° Value of dimensions in ( ) of Z stroke is option. Figure 21-3.
  • Page 51 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates Center of Joint #3 Maximum space Motion range Point P Area limited by mechanical stops Space for cables Maintenance space Figure 22-1. Motion range of EL65** [unit : mm]...
  • Page 52 8. Motion Range and Robot Coordinates Part 1: Setup & Operation Center of Joint #3 Maximum space Motion range Point P Area limited by mechanical stops Maintenance space Space for cables Figure 22-2. Motion range of EL85** [unit : mm]...

  • Page 53: Pulse Range

    X-coordinate axis. The pulse value is positive (+) in the counterclockwise direction from the 0 pulse position and negative (-) in the clockwise direction. A° A° +X 0 pulse C pulse B pulse ES series EL series A° 125° 130° B pulse -31858...
  • Page 54 8. Motion Range and Robot Coordinates Part 1: Setup & Operation The 0 pulse position of Joint #2 is the position at which Joint #2 is parallel to Joint #1. A positive (+) pulse value is taken in the counterclockwise direction from the 0 pulse position, and a negative (-) pulse value is taken in the clockwise direction.
  • Page 55 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates The 0 pulse position of Joint #4 is the position at which the flat cut surface of the Joint #4 shaft faces the positive direction of the X-coordinate axis when Joint #1 and #2 are parallel to the X-coordinate axis.

  • Page 56: Changing The Motion Range

    8. Motion Range and Robot Coordinates Part 1: Setup & Operation 8.3 Changing the Motion Range Both the mechanical stop and the software settings must always be set at the same time when a motion range is being set up. WARNING * The motion ranges of Joint #3 of Clean model manipulator and all joints of Protected model manipulator cannot be changed with mechanical stops.

  • Page 57: Changing Motion Range Using Pulse Range

    You can set the pulse range by using the RANGE tab in the Project | Robot Parameters dialog. (Refer to the chapter EPSON RC+ GUI in the EPSON RC+ User’s Guide.) You may also execute the RANGE command from the EPSON RC+ Monitor Window.

  • Page 58: Changing Motion Range Using Mechanical Stops

    8. Motion Range and Robot Coordinates Part 1: Setup & Operation (2) Changing motion range using mechanical stops Mechanical stops physically limit the absolute area that the manipulator can move. You can change the angle of the stops to the angles shown in the following table to limit motion range for Joints #1 to #3 of Standard model and Joints #1 and #2 of the Clean model.
  • Page 59 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates (1) Exit EPSON RC+, shut down the SPEL Runtime Drivers, and turn OFF the Drive Unit. SPEL 95 (1) Exit SPEL 95, and turn OFF the Drive Unit. (1) Turn OFF the controller.
  • Page 60 Set the pulse range corresponding to the new positions of the mechanical stops using the RANGE tab in the Project | Robot Parameters dialog. (Refer to the chapter EPSON RC+ GUI in the EPSON RC+ User’s Guide.) You may also execute the RANGE or JRANGE from the EPSON RC+ Monitor Window.
  • Page 61 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates <Example> Joint #1 of the ES series manipulator is set from -65° to +95°and Joint #2 is set from -120° to +95°. ' Sets the pulse range of Joint #1 >JRANGE 1,22756,168392...
  • Page 62 If the arm is touching a mechanical stop or if it has hit a stop and an error has occurred, either reset the pulse range to a narrower setting or extend the position of the mechanical stop within limits. Turn ON the Drive Unit, and start EPSON RC+. Turn ON the Drive Unit, and start SPEL 95. SPEL 95...
  • Page 63 Joint #3 brake release button shaft  Figure 30. Mechanical stop for Joint #3 (2) Exit EPSON RC+, shut down the SPEL Runtime Drivers, and turn OFF the Drive Unit. (2) Exit SPEL 95, and turn OFF the Drive Unit. SPEL 95 (2) Turn OFF the controller.
  • Page 64 (5) Firmly tighten the bolt of the split muff coupling once it is in the appropriate position. Recommended tightening torque is 490N⋅cm (50kgf⋅cm). (6) Turn ON the Drive Unit, and start EPSON RC+. SPEL 95 Turn ON the Drive Unit, and start SPEL 95.
  • Page 65 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates (10) Move Joint #3 slowly using the PULSE command to the position of the lower-limit value of the pulse range. If the mechanical stop is being hit, or if it is hit and an error occurs, either narrow the pulse range just enough to eliminate interface, or widen the position of the mechanical stop.

  • Page 66: Changing Motion Range Using X, Y Limits

    Set the X Y range by using the XYLIM tab in the Project | Robot Parameters dialog. (Refer to the chapter EPSON RC+ GUI in the EPSON RC+ User’s Guide.) You may also execute the XYLIM command from the EPSON RC+ Monitor Window.
  • Page 67 Part 1: Setup & Operation 8. Motion Range and Robot Coordinates Refer to the User’s manual for SRC-300/320 11. Set up, Set the robot parameters in Function volume. For ES45**, at the factory shipping, it is set as follows: XYLIM -90,90,-450,0 (Refer to Figure 21-1 in this chapter.) For EL65**, at the factory shipping, it is set as follows: XYLIM -120,120,-650,0...
  • Page 68 8. Motion Range and Robot Coordinates Part 1: Setup & Operation...

  • Page 69: Emergency Stop

    Part 1: Setup & Operation 9. Emergency Stop 9. Emergency Stop If the manipulator moves abnormally during operation, immediately press the emergency stop switch. By pressing the emergency stop switch, the motor power is cut and the dynamic brake activates and stops the rotation of motor as inertia. However, you should not press the emergency stop switch during normal operation unnecessarily.
  • Page 70 9. Emergency Stop Part 1: Setup & Operation...

  • Page 71: Specifications

    Part 1: Setup & Operation 10. Specifications 10. Specifications The tables on the following pages show the standard specifications for the ES and EL series manipulators. If the manipulator is a Clean model, refer to the section 11.5 Additional Specifications in chapter 11.

  • Page 72: Series Standard Model Specifications

    10. Specifications Part 1: Setup & Operation 10.1 ES series Standard model specifications Model ES45** ES55** ES65** Arm length Arm #1 + #2 215 + 235 mm 315 + 235 mm 415 + 235 mm Weight 20kg Driving method All joints...

  • Page 73: El Series Standard Model Specifications

    Temperature: 5 to 40 °C (No drastic change is allowed.) Environmental requirements Humidity: 10 to 80 % (No condensation is allowed.) Equivalent continuous A-weighted = 70 dB (A) or under sound pressure level EPSON RC+, SRC5**, SRC-3** Applicable controller SPEED ACCEL 10, 10 SPEEDS...

  • Page 74: Model Settings

    At the front of manipulator, 100 mm apart from the motion range, 50 mm above the base-installed surface. 10.3 Model settings To set the manipulator model using the EPSON RC+ system, use the Setup | System Configuration | Robots tab. Refer to the chapter “Robot Configuration” in the EPSON RC+ User’s Guide.

  • Page 75: Clean Model

    Part 1: Setup & Operation 11. Clean Model 11. Clean Model The Clean models for the ES / EL series include extra features that reduce dust emitted by the manipulator to enable use in clean room environments (See NOTE). This chapter describes the differences between the Standard and Clean models for the ES / EL series.

  • Page 76: Installation Method

    11. Clean Model Part 1: Setup & Operation 11.2 Installation method Chapter 3. Installation contains instructions and safety precautions for unpacking and installing the manipulator. (1) After unpacking the manipulator outside of the clean room, use bolts to fasten it down so that it will not tip over.

  • Page 77: External Dimensions

    Part 1: Setup & Operation 11. Clean Model 11.4 External dimensions ES series Clean model [unit : mm] Signal cable connector Power cable connector by the mechanical stop ES45*C ES55*C ES65*C ES**1C ES**3C The shaft of ES**3C will reach lower than the bottom of the manipulator base when it is fully lowered.
  • Page 78 11. Clean Model Part 1: Setup & Operation EL series Clean model [unit : mm] Duct support (for EL853C only) by mechanical stop EL653C EL853C Signal cable connector (including the duct support) The shaft of EL**3C will reach lower than the bottom of the manipulator base when it is fully lowered.

  • Page 79: Additional Specifications

    Part 1: Setup & Operation 11. Clean Model 11.5 Additional specifications For standard specifications, refer to chapter 10. Specifications in Part 1. Model ES***C EL***C Max. motion range of Joint #3 150mm (300mm) 300mm Value in ( ) is option Maximum of 10 particles (0.13 µm or more in diameter) Cleanliness level in 28317 cm...
  • Page 80 11. Clean Model Part 1: Setup & Operation...

  • Page 81: Protected Model

    Part 1: Setup & Operation 12. Protected Model 12. Protected Model The protected models for the ES / EL series include shielding on the manipulator specifically for use in a dusty, wet or oily environment. The degree of the protective shielding is equivalent to IP65.

  • Page 82: Manipulator Part Names

    12. Protected Model Part 1: Setup & Operation 12.1 Manipulator part names For information on standard manipulator parts, refer to 1. Manipulator Part Names. Model names that end with a “P” indicate Protected models. ES 55 1 P Option ....Protected model Joint #3 stroke ...

  • Page 83: Environmental Conditions

    Part 1: Setup & Operation 12. Protected Model 12.2 Environmental conditions General environmental conditions For basic environmental information, refer to 2.1 Environmental conditions. A suitable environment is necessary for the manipulator to function properly and safely. Please install the robot in a location that meets the following requirements: Ambient temperature 5 to 40°C (with minimum temperature variation) Ambient relative humidity 10 to 80 % (no condensation)

  • Page 84: Special Environmental Conditions

    To store the controller unit* in a protective box, it is imperative to use a heat exchanger to keep the calorific value generated from the controller under 300W. * The controller unit: : EPSON RC+ (PC Control unit / Drive Unit) SPEL 95/SRC5**...

  • Page 85: Connecting The Cables

    Part 1: Setup & Operation 12. Protected Model 12.3 Connecting the cables For basic information about cabling, refer to section 3.3 Connecting the cables. Do not expose the manipulator or connectors to water or dust when connecting or disconnecting cables. WARNING Do not place a manipulator without a power cable connector in an environment where it is exposed to water or dust.

  • Page 86: User Wires And Pneumatic Tubes

    12. Protected Model Part 1: Setup & Operation 12.4 User wires and pneumatic tubes For basic information about user wiring and pneumatics, refer to chapter 4. User Wires and Pneumatic tubes. Electrical wires and air tubes have been incorporated into the cable unit for your use. Since the outlets for the user wires and the air tubes lead to the inside of the CAUTION arm, they need to be sealed completely after the wiring to the end effector is...
  • Page 87 Part 1: Setup & Operation 12. Protected Model Fitting (black) for φ 6 mm pneumatic tube Connect to φ 4 mm (black) pneumatic tube on the end effector Fitting (white) for φ 6 mm pneumatic tube Connect to φ 4 mm (blue) pneumatic tube on the end effector Fitting for φ...

  • Page 88: External Dimensions

    12. Protected Model Part 1: Setup & Operation 12.5 External dimensions ES series Protected model [unit : mm] Waterproof cover 1 diameter Bellows diameter Ф4-10 Through hole Flange diameter Signal cable connector Power cable connector (*) indicates the stroke margin or more by mechanical stop.
  • Page 89 Part 1: Setup & Operation 12. Protected Model EL series Protected model [unit : mm] Waterproof cover 1 diameter Bellows diameter Ф4-16 Through hole Flange diameter Duct support (for EL853P only) Signal cable connector Power cable connector or more Space for cable (*) Indicates the stroke margin by mechanical stop.

  • Page 90: Additional Specifications

    12. Protected Model Part 1: Setup & Operation 12.6 Additional specifications For standard specifications, refer to section 10. Specifications. The table below contains additional information about protected models. Model ES *** P EL *** P Max. motion range of Joint #3 150 mm (300 mm) 300 mm Value in parentheses is optional...

  • Page 91: Part 2 Maintenance

    Part 2 Maintenance Part 2 contains maintenance information for the ES and EL Series Manipulators, including instructions for: • Maintenance schedules • Connection diagrams • How to replace parts • Calibration • Parts list...

  • Page 93: Maintenance Safety Precautions

    Part 2: Maintenance Maintenance Safety Precautions Maintenance Safety Precautions Please read this manual and other relevant manuals carefully before performing any routine maintenance. Keep this manual in a handy location for easy access at all times. *If the manipulator is a Protected model, refer to chapter 13. Protected Model Maintenance. WARNING Only trained personnel should be allowed to operate, test, and maintain this robot and the robot system.
  • Page 94 Maintenance Safety Precautions Part 2: Maintenance...

  • Page 95: General Maintenance

    Part 2: Maintenance 1. General Maintenance 1. General Maintenance Proper inspection steps are essential to preventing trouble and maintaining safety. This section describes maintenance inspection schedule and procedures. Be sure to perform inspection and maintenance as described in this chapter. 1.1 Maintenance Inspection Schedule Inspection procedures are divided into five stages: daily, monthly, quarterly, biannually and annually.

  • Page 96: Inspections

    1. General Maintenance Part 2: Maintenance 1.2 Inspections Inspection while the power is OFF (Be sure to turn off the power) Inspection item Point of inspection Daily Monthly Quarterly Biannual Annual Grease condition Refer to the next page End effector installing bolts Check looseness of bolts/screws and Manipulator installing bolts...
  • Page 97 Part 2: Maintenance 1. General Maintenance Inspection while the power is ON, or while manipulator is moving Inspection item Point of inspection Daily Monthly Quarterly Biannual Annual Check motion range Motion range of each joint Check disconnection External cables by swinging cables. (including cable unit) Check backlash by pushing arms during...

  • Page 98: Lubrication

    1. General Maintenance Part 2: Maintenance 1.3 Lubrication For this manipulator, reduction gears and ball screw spline shaft are used. These parts require lubrication or replacing grease periodically. If lubrication is not done properly, and the manipulator is operated with insufficient grease, sliding parts will be damaged and the efficiency of the manipulator will be reduced.

  • Page 99: Matching Mechanical And Electrical Origins

    [Joint #3 pulse value] [Joint #4 pulse value] 1.6 Differences between ES and EL Series Though the size of reduction gears and motors, and length of the arms for the ES series and EL series are different, the methods for maintenance are almost the same.

  • Page 100: Internal Layout

    1. General Maintenance Part 2: Maintenance 1.7 Internal Layout * If the manipulator is a Protected model, refer to chapter 13. Protected Model. The outline and name of internal configuration are shown below. Joint #3 motor Joint #4 motor Joint #4 counter Ball screw shaft...

  • Page 101: Opening The Covers

    Part 2: Maintenance 2. Opening the Covers 2. Opening the Covers The methods for removing the various covers that are related to the maintenance of each part are explained here. Do not expose the manipulator to water or dust when you open the covers for WARNING maintenance.

  • Page 102: Arm Bottom Cover

    2. Opening the Covers Part 2: Maintenance 2.2 Arm Bottom Cover × The arm bottom cover is fastened to the lower position of Arm #2 with three bolts (M4 Remove these bolts, then pull the arm bottom cover downward. The cover may be unable to be removed when an end effector is installed.

  • Page 103: Base Connector Plate

    Part 2: Maintenance 2. Opening the Covers 2.4 Base Connector Plate × The base connector plate is fastened to the rear panel of the manipulator with four M4 bolts (with six bolts for Protected model). The base connector plate is separated from the base when these bolts are removed. However, the base connector plate is internally connected to connectors and ground wires.
  • Page 104 2. Opening the Covers Part 2: Maintenance...

  • Page 105: Replacing The Cable Unit

    Part 2: Maintenance 3. Replacing the Cable Unit 3. Replacing the Cable Unit When connecting or disconnecting the cables, make sure the power is turned OFF and pull out the power plug from the power source. Failure to turn OFF the power can result in a robot may malfunction.

  • Page 106: Cable Unit Replacement Procedure

    3. Replacing the Cable Unit Part 2: Maintenance 3.1 Cable Unit Replacement Procedure * If the manipulator is a Protected model, refer to section 13.4 Replacing the Cable Unit in the chapter 13. Protected Model Maintenance. Removal (1) Turn OFF the PC Control Unit / Control Unit / Controller power. (2) Disconnect all the connectors and tubes from the base connector plate located at the rear of the manipulator.
  • Page 107 Part 2: Maintenance 3. Replacing the Cable Unit (6) Remove the four bolts (M3×8) from the receptacle and remove the receptacle from the base connector plate. Receptacle 4-M3×8 Pneumatic tube joints Ground wires (7) Disconnect the ground wires and pneumatic tubes from the base connector plate. Each pneumatic tube can be pulled out by first pushing the fitting release ring.
  • Page 108 3. Replacing the Cable Unit Part 2: Maintenance (10) Referring to the Wiring Schematic 1 in this chapter, disconnect the ground wires and pneumatic tubes from the arm. To disconnect each pneumatic tube, pull it out by first pushing the fitting release ring. The ground wire terminals are secured by bolts ×...
  • Page 109 Part 2: Maintenance 3. Replacing the Cable Unit Installation (1) Pass the cables of the new cable unit through the cable bracket and nut. Fasten the duct joint to the cable bracket. (2) Pass the cables through the base connector plate and fasten the main cable elbow ×...

  • Page 110: Wiring Schematic 1

    3. Replacing the Cable Unit Part 2: Maintenance 3.2 Wiring Schematic 1 To remove the cable unit, remove the connectors in the arm top cover and base. These connectors are connected as shown in the figure below. For more information, refer to the next page and the wiring list in 4.

  • Page 111: Wiring Schematic 2

    Part 2: Maintenance 3. Replacing the Cable Unit 3.3 Wiring Schematic 2 * If the manipulator is a Protected model, refer to chapter 13. Protected Model.
  • Page 112 3. Replacing the Cable Unit Part 2: Maintenance...

  • Page 113: Connector Pin Assignments

    Part 2: Maintenance 4. Connector Pin Assignments 4. Connector Pin Assignments X10 Signal connector X11 Motor signal connector Line color Connect to Line color Connect to FGND shield BLU/(WHT) N.C. WHT/(BLU) BLU/(WHT) X11-1 YLW/(WHT) WHT/(BLU) X11-2 WHT/(YLW) YLW/(WHT) X11-3 GRN/(WHT) WHT/(YLW) X11-4 WHT/(GRN)
  • Page 114 4. Connector Pin Assignments Part 2: Maintenance X20 Signal connector X21 Motor signal connector Line color Connect to Line color Connect to FGND shield BLU/(WHT) N.C. WHT/(BLU) BLU/(WHT) X21-1 YLW/(WHT) WHT/(BLU) X21-2 WHT/(YLW) YLW/(WHT) X21-3 GRN/(WHT) WHT/(YLW) X21-4 WHT/(GRN) Joint #2 GRN/(WHT) X21-5 RED/(WHT)
  • Page 115 Part 2: Maintenance 4. Connector Pin Assignments X30 Signal connector X31 Motor signal connector Line color Connect to Line color Connect to FGND shield BLU/(WHT) N.C. WHT/(BLU) BLU/(WHT) X31-1 YLW/(WHT) WHT/(BLU) X31-2 WHT/(YLW) YLW/(WHT) X31-3 GRN/(WHT) WHT/(YLW) X31-4 WHT/(GRN) Joint #3 GRN/(WHT) X31-5 RED/(WHT)
  • Page 116 4. Connector Pin Assignments Part 2: Maintenance X40 Signal connector X41 Motor signal connector Line color Connect to Line color Connect to FGND shield BLU/(WHT) N.C. WHT/(BLU) BLU/(WHT) X41-1 YLW/(WHT) WHT/(BLU) X41-2 WHT/(YLW) YLW/(WHT) X41-3 GRN/(WHT) WHT/(YLW) X41-4 WHT/(GRN) Joint #4 GRN/(WHT) X41-5 RED/(WHT)
  • Page 117 Part 2: Maintenance 4. Connector Pin Assignments X50 Signal connector X51 Signal connector Line color Connect to Line color Connect to BLU/(WHT) X51-1 BLU/(WHT) X53-1 WHT/(BLU) X51-2 WHT/(BLU) X53-2 YLW/(WHT) X51-3 YLW/(WHT) X53-3 WHT/(YLW) X51-4 WHT/(YLW) X53-4 GRN/(WHT) X51-5 GRN/(WHT) X53-5 WHT/(GRN) X51-6...
  • Page 118 4. Connector Pin Assignments Part 2: Maintenance X100 Receptacle X110 Motor power connector Line color Connect to Line color Connect to X110-1 Joint #1 X110-2 motor X110-3 (POWER) X121-1 FGND GRN/YLW X121-2 X121-3 X121 Motor power connector X131-1 Line color Connect to X131-2 Joint #2...

  • Page 119: Replacing The Motors

    Part 2: Maintenance 5. Replacing the Motors 5. Replacing the Motors Only trained personnel should be allowed to maintain this unit. WARNING When replacing the motors, make sure the power is turned OFF and pull out the power plug from the power source. Failure to turn OFF the power can result in electric shock and malfunction.

  • Page 120: Replacing The Joint #1 Motor

    (4) Remove the four bolts (M4×15 for the ES series; M5×15 for the EL series) from the motor flange and pull the motor downward. In this case, insert a hexagon head wrench from the maintenance hole and remove the two bolts at the maintenance hole side.
  • Page 121 Part 2: Maintenance 5. Replacing the Motors (5) Using a hexagon head wrench (2.5mm wide) in the screw holes of the waveform generator, remove the two flat point setscrews (M5×6). Remove the waveform generator from the motor. One of the setscrews has a brass bush inside which must not be lost.
  • Page 122 5. Replacing the Motors Part 2: Maintenance Installation : Joint #1 × (1) Attach a new motor to the motor flange with four bolts (M5 12). (2) Mount the waveform generator to the motor shaft with two flat point setscrews ×...
  • Page 123 Part 2: Maintenance 5. Replacing the Motors (3) Install the motor flange in the manipulator base with four bolts (M4×15 for the ES series; M5×15 for the EL series) so that the motor faces the main set by 45 degrees and the motor cable faces the base connector plate.

  • Page 124: Replacing The Joint #2 Motor

    (5) Remove the four bolts (M4×10 for the ES series; M4×15 for the EL series) from the motor flange and pull the motor unit upward. If it is difficult to extract the motor, extract it while moving Arm #2 slightly.
  • Page 125 Waveform generator Bush Bush × × Motor flange (7) Remove the bolts (2-M4×10 for the ES series; 4-M5×12 for the EL series) from the motor and remove the motor flange.   × ×...
  • Page 126 End face of motor shaft form generator (3) Fasten the Joint #2 motor unit in Arm #2 with the four bolts (M4×10 for the ES series; M4×15 for the EL series). If the wave generator does not fit into the arm easily, move Arm #2 slowly by hand while pushing the waveform generator into place.
  • Page 127 Part 2: Maintenance 5. Replacing the Motors × (4) Install the duct plate (3-M4 ∗ If the manipulator is a Protected model, seal the duct plate. Refer to the section Sealing the Manipulator in chapter 13. Protected Model Maintenance. M4×8 Duct plate (5) Connect the connectors, X121 and X21.

  • Page 128: Replacing The Joint #3 Motor

    5. Replacing the Motors Part 2: Maintenance 5.3 Replacing the Joint #3 Motor A brake is provided for the Joint #3 motor. If the motor is replaced, it is necessary to adjust the brake, but be careful not to stretch the board spring of CAUTION the brake.
  • Page 129 Part 2: Maintenance 5. Replacing the Motors (5) Cut off the wire ties which fasten the brake cable to the motor. (6) Using a hexagon head wrench in the screw holes of the pulley, remove the two flat point setscrews (M4×8) that secure the pulley to the motor shaft. One of the setscrews has a brass bush inside which must not to be lost.
  • Page 130 5. Replacing the Motors Part 2: Maintenance Installation : Joint #3 (1) Slide the pulley and rotor hub horizontally to remove them from the brake so as not to cause damage to the leaf spring. The rotor hub, which is screwed on the pulley, is attracted to the brake magnet.
  • Page 131 Part 2: Maintenance 5. Replacing the Motors (3) Place the new motor on the motor plate so that the motor cables turn to the direction of × the figure and fasten it with two bolts (M4 8). The direction of the motor shaft flat face should face one of the screw holes of the pulley.
  • Page 132 5. Replacing the Motors Part 2: Maintenance (8) Place the Z belt around the Z1 and Z2 pulleys. Ensure that the gear grooves of the belt and pulleys engage properly. Be careful not to slip the Z belt from the pulleys while maintaining proper interval between the pulleys.
  • Page 133 Part 2: Maintenance 5. Replacing the Motors (12) Install the arm top cover and arm bottom cover. (Refer to chapter 2. Opening the Covers.) (13) If the manipulator is a Protected model, seal the arm top cover and arm bottom covers. Refer to the section Sealing the Manipulator in chapter 13.

  • Page 134: Replacing The Joint #4 Motor

    5. Replacing the Motors Part 2: Maintenance 5.4 Replacing the Joint #4 Motor Removal : Joint #4 (1) Open the arm top cover and arm bottom cover. (Refer to chapter 2. Opening the Covers.) (2) Cut off the wire ties which fasten the Joint #4 motor and cables. (3) Disconnect connectors ,X141 and X41.
  • Page 135 Part 2: Maintenance 5. Replacing the Motors (5) Using a hexagon head wrench in the screw holes of the pulley, remove the two flat point setscrews (M4×8) that secure the pulley to the motor shaft. Remove the pulley from the motor. One of the setscrews has a brass bush inside which must not to be lost.
  • Page 136 5. Replacing the Motors Part 2: Maintenance Installation : Joint #4 (1) Attach the new motor onto the motor plate with two bolts (M4×8). × (2) Secure the pulley to the motor shaft with two flat point setscrews (M4 8). Match the end face of the pulley to the end face of the motor shaft.
  • Page 137 Part 2: Maintenance 5. Replacing the Motors × (5) Fasten the Joint #4 motor plate roughly for the time being with four bolts (M4 10). × 4-M4 Joint #4 motor plate (6) Pass a cord or string near the Joint #4 motor plate. Loosen the bolts for the Joint #4 motor plate fastened in the step (5) and pull the string using a force gauge or similar tool.
  • Page 138 5. Replacing the Motors Part 2: Maintenance...

  • Page 139: Replacing The Reduction Gear Units

    Part 2: Maintenance 6. Replacing the Reduction Gear Units 6. Replacing the Reduction Gear Units Only trained personnel should be allowed to maintain this unit. WARNING When replacing the reduction gear units, make sure the power is turned OFF and pull out the power plug from the power source. Failure to turn OFF the power can result in electric shock or malfunction.
  • Page 140 6. Replacing the Reduction Gear Units Part 2: Maintenance Location of reduction gear units Joint #1 reduction gear unit Joint #2 reduction gear unit...
  • Page 141 Part 2: Maintenance 6. Replacing the Reduction Gear Units Structure of reduction gear unit The reduction gear unit consists of the following three parts: 1. Waveform generator An ellipsoid cam with ball bearings around the outer circumference. The inner ring of bearings is secured to the cam, while the outer ring is capable of flexible deformation through the ball bearings.

  • Page 142: Replacing The Joint #1 Reduction Gear Unit

      (2) Support the arm with more than one person. While the arm is being supported, have another person unscrew the eight fastening bolts (M4×40 for the ES series; M5×55 for the EL series) and remove Arm #1. When removing or installing Arm #1, there must be two or more people to work...
  • Page 143 Base connector plate X110 (5) Remove the four bolts (M8×20 for the ES series; M8×25 for the EL series) from the reduction gear flange. Reduction gear flange ES: M8×20...
  • Page 144 (6) Lift up the reduction gear unit.    (7) Remove the four bolts (M4×15 for the ES series; M5×15 for the EL series) from the motor flange and pull the motor flange out of the reduction gear flange. Joint #1 motor...
  • Page 145 Part 2: Maintenance 6. Replacing the Reduction Gear Units (8) Remove the twelve bolts (M4×18 for the ES series; M5×25 for the EL series) from the reduction gear flange and remove the flange from the circular spline.  Reduction gear flange ES: M4×18...
  • Page 146 6. Replacing the Reduction Gear Units Part 2: Maintenance Installation : Joint #1 (1) A new reduction gear unit contains the parts shown below when it is unpacked. However, the oil-sealing ring (L) will not be used here. The circular spline and fleck spline (at the gear grooves) are greased as well as the waveform generator (at the bearings).
  • Page 147 Part 2: Maintenance 6. Replacing the Reduction Gear Units (3) Fit the circular spline (with the convex side facing down) into the fleck spline.    (4) As shown below, match the screw holes on the inner ring unit (of the cross roller bearing unit) and the through holes of the circular spline. ...
  • Page 148 6. Replacing the Reduction Gear Units Part 2: Maintenance (6) Secure the waveform generator to the motor shaft with two flat point setscrews × 6). Match the end face of the waveform generator to the end face of the motor shaft.
  • Page 149 6. Replacing the Reduction Gear Units (7) Secure the motor to the reduction gear unit with four bolts (M4×15 for the ES series; M5×15 for the EL series). Be sure that the motor cable is at the opposite side of the joint label on the reduction gear flange when secured. ...
  • Page 150 (10) Secure Arm #1. Support the arm with more than one person. While the arm is being supported, have another person fasten eight bolts (M4×40 for the ES series; M5×55 for the EL series) to attach Arm #1. Be careful not to drop or hit the arm. ...

  • Page 151: Replacing The Joint #2 Reduction Gear Unit

    (5) Support Arm #2 with more than one person. While the arm is being supported, have another person unscrew the four fastening bolts (M6×18 for the ES series; M8×18 for the EL series) and remove Arm #2 from Arm #1.
  • Page 152 6. Replacing the Reduction Gear Units Part 2: Maintenance When removing or installing Arm #2, there must be two or more people to work on it so that at least one of them can support the arm while others remove the CAUTION bolts and so on.
  • Page 153 Part 2: Maintenance 6. Replacing the Reduction Gear Units (6) Remove the four bolts (M4×10 for the ES series; M4×15 for the EL series) from the Joint #2 motor flange.  Motor flange ES: M4×10 EL: M4×15   (7) Remove the Joint #2 motor unit from Arm #1. ...
  • Page 154   (10) Remove the twelve bolts (M3×18 for the ES series; M4×18 for the EL series) from the reduction gear flange and remove the flange from the circular spline. Reduction gear flange ES: M3×18...
  • Page 155 (11) Using a hexagon head wrench in the screw holes of the waveform generator, remove the two flat point setscrews (M4×6 for ES series; M5×6 for the EL series). Remove the waveform generator from the motor. One of the setscrew holes has a brass bush inside which must be paid attention so as not to be lost.
  • Page 156 6. Replacing the Reduction Gear Units Part 2: Maintenance Installation : Joint #2 (1) A new reduction gear unit contains the parts shown below when it is unpacked. However, the oil-sealing ring (L) will not be used here. The circular spline and fleck spline (at the gear grooves) are greased as well as the waveform generator (at the bearings).
  • Page 157 Part 2: Maintenance 6. Replacing the Reduction Gear Units (3) Fit the circular spline (with the convex side facing down) into the fleck spline. (4) As shown below, match the screw holes on the inner ring unit (of the cross roller bearing unit) and the through holes of the circular spline.
  • Page 158 (6) Mount the waveform generator to the motor shaft with two flat point setscrews (M4 × for ES series; M5 6 for EL series). Match the end face of the waveform generator to the end face of the motor shaft. One of the setscrews should touch the flat face in the motor shaft perpendicularly.
  • Page 159 (8) Place the Joint #2 reduction gear unit back inside Arm #1 and secure it with eight bolts (M3×40 with plain washer for the ES series; M4×45 for the EL series). (9) As shown below, grease inside the reduction gear unit (ES: 16g; EL: 40g) and build the motor unit inside Joint #2. ...
  • Page 160 (11) Secure Arm #2. Support the arm with more than one person. While the arm is being supported, have another person fasten four bolts (M6×18 for the ES series; M8×18 for the EL series) to attach Arm #2. Be careful not to drop or hit the arm.
  • Page 161 Part 2: Maintenance 6. Replacing the Reduction Gear Units (12) Connect the connectors, X121 and X21 of the Joint #2 motor.  Power connector X121 Signal connector X21   (13) Fasten the motor cables with wire ties in their original positions. Do not allow unnecessary strain on the cables. ...
  • Page 162 6. Replacing the Reduction Gear Units Part 2: Maintenance...

  • Page 163: Replacing The Brake

    Part 2: Maintenance 7. Replacing the Brake 7. Replacing the Brake Only trained personnel should be allowed to maintain this unit. WARNING When replacing the brake, make sure the power is turned off and pull out the power plug from the power source. Failure to turn off the power can result in electric shock and malfunction.
  • Page 164 7. Replacing the Brake Part 2: Maintenance (4) Remove four bolts (M3×5) that fasten the brake to the brake plate, then remove the brake from the brake plate. × Brake Brake plate (5) Remove the rotor hub from the end of the pulley. (3-M2×3 machine screw) M2×3 Rotor hub...
  • Page 165 Part 2: Maintenance 7. Replacing the Brake Installation (1) Fasten the rotor hub of the new brake to the surface of the pulley securely with three machine screws (M2×3). (2) Fasten the new brake to the brake plate with four bolts (M3×5). (3) Fasten the brake cable to the brake plate with a wire tie to prevent interference with the pulley.
  • Page 166 7. Replacing the Brake Part 2: Maintenance (8) Place the Joint #3 motor unit in the arm. The motor cables should be facing Joint #2. (9) Fit the Z belt around the Z1 and Z2 pulleys. Ensure that the gear grooves of the belt and pulleys engage properly.

  • Page 167: Replacing The Timing Belts

    Part 2: Maintenance 8. Replacing the Timing Belts 8. Replacing the Timing Belts Only trained personnel should be allowed to maintain this part. WARNING When replacing the timing belts, make sure the power is turned OFF and pull out the power plug from the power source. Failure to turn OFF the power can result in electric shock and malfunction.

  • Page 168: Replacing The Z Belt

    8. Replacing the Timing Belts Part 2: Maintenance 8.1 Replacing the Z belt Removal : Z belt (1) Remove the Joint #3 motor unit as described in 5.3 Replacing the Joint #3 Motor steps (1) through (4). (2) Remove the bolts (3-M4×10) from the spline plate. M4×10 Spline plate (3) Lift the spline plate and draw the Z belt up, make it through under the spline plate, and...
  • Page 169 Part 2: Maintenance 8. Replacing the Timing Belts Installation : Z belt (1) Place a new Z belt on the shaft from above, and lift the spline plate to allow the belt to be positioned under it. (2) Fit the spline plate (with the belt attached on the spline plate pulley) on the arm. Spline plate Spline plate pulley Z belt...
  • Page 170 8. Replacing the Timing Belts Part 2: Maintenance (6) Pass a suitable cord or string around the Joint #3 motor near its motor mounting plate. Loosen the bolts for the Joint #3 motor plate fastened in the step (5) and pull the cord using a force gauge or similar tool.

  • Page 171: Replacing The U1 Belt

    Part 2: Maintenance 8. Replacing the Timing Belts 8.2 Replacing the U1 Belt Removal : U1 Belt (1) Open the arm top cover and arm bottom cover. (Refer to chapter 2. Opening the Covers.) (2) Loosen the four bolts (M4×10) holding the Joint #4 motor plate. ×...
  • Page 172 8. Replacing the Timing Belts Part 2: Maintenance Installation : U1 Belt (1) Fit a new U1 belt around the U1 and the large U2 pulleys. And then, fit the U2 belt to the U2 small pulley. Ensure that the gear grooves of the belts and pulleys engage properly.
  • Page 173 Part 2: Maintenance 8. Replacing the Timing Belts (3) Pass a suitable cord or string around the Joint #4 motor near the countershaft plate. Loosen the bolts for the Joint #4 countershaft plate fastened in the step (2) and pull the cord using a force gauge or similar tool.

  • Page 174: Replacing The U2 Belt

    8. Replacing the Timing Belts Part 2: Maintenance 8.3 Replacing the U2 Belt Removal : U2 Belt (1) Remove the Joint #3 motor unit as described in 5.3 Replacing the Joint #3 Motor steps (1) through (4). (2) Loosen the four bolts (M4×10) holding the Joint #4 motor plate. ×...
  • Page 175 Part 2: Maintenance 8. Replacing the Timing Belts (5) Remove the bolts (3-M4×10) from the spline plate. × Spline plate (6) Lift the spline plate, and then extract the Z belt and the U2 belt from the shaft upward. Z belt...
  • Page 176 8. Replacing the Timing Belts Part 2: Maintenance Installation : U2 Belt (1) Pass a new U2 belt and the Z belt through the shaft from above, and lift the spline plate to make those belts through. (2) Place the Joint #3 motor unit in the arm. The motor cables should be facing Joint #2. (3) Fit the new U2 belt around the U3 and the small U2 pulleys.
  • Page 177 Part 2: Maintenance 8. Replacing the Timing Belts (6) Pass a suitable cord or string around the Joint #4 countershaft unit near its mounting plate. Loosen the bolts for the Joint #4 countershaft plate fastened in the step (5) and pull the cord using a force gauge or similar tool.
  • Page 178 8. Replacing the Timing Belts Part 2: Maintenance (8) Pass a suitable cord or string around the Joint #3 motor near its mounting plate. Loosen the bolts for the Joint #3 motor plate fastened in the step (5) and pull the cord using a force gauge or similar tool.

  • Page 179: Replacing The Ball Screw Spline Unit

    Part 2: Maintenance 9. Replacing the Ball Screw Spline Unit 9. Replacing the Ball Screw Spline Unit Only trained personnel should be allowed to maintain this unit. WARNING When replacing this unit, make sure the power is turned OFF and pull out the power plug from the power source.

  • Page 180: Replacing The Ball Screw Spline Unit

    9. Replacing the Ball Screw Spline Unit Part 2: Maintenance 9.1 Replacing the Ball Screw Spline Unit Removal (1) Remove the end effector from the shaft. ∗ If the manipulator is a Clean model, remove the bellows. Refer to the section 12.2 Replacing the Bellows in chapter 12.
  • Page 181 Part 2: Maintenance 9. Replacing the Ball Screw Spline Unit Installation (1) Fit the U2 and Z belts into the shaft of a new ball screw spline unit. Place the ball screw spline unit inside the arm. (2) Tighten four bolts (M4×10) at the ball screw spline unit under the arm. Beware so that the timing belts will not be pinched between the nut and arm.
  • Page 182 9. Replacing the Ball Screw Spline Unit Part 2: Maintenance (6) Fit the U2 belt around the U3 and small U2 pulleys. Fit the Z belt around the Z2 and Z1 pulleys. Ensure that the gear grooves of the belts and pulleys engage properly. Also, for the U1 belt around the U1 and rage U2 pulleys, ensure that the gear groves of the belt and pulleys are engaging properly.
  • Page 183 Part 2: Maintenance 9. Replacing the Ball Screw Spline Unit (8) Pass a suitable cord or string around the Joint #4 countershaft unit near its mounting plate. Loosen the bolts for the Joint #4 countershaft plate fastened in the step (7) and pull the cord using a force gauge or similar tool.
  • Page 184 9. Replacing the Ball Screw Spline Unit Part 2: Maintenance (10) Pass a suitable cord or string around the Joint #3 motor near its mounting plate. Loosen the bolts for the Joint #3 motor plate fastened in the step (7) and pull the cord using a force gauge or similar tool.

  • Page 185: Greasing The Ball Screw Spline Unit

    Part 2: Maintenance 9. Replacing the Ball Screw Spline Unit 9.2 Greasing the Ball Screw Spline Unit When greasing the ball screw spline unit, follow the procedure on this page. ∗ If the manipulator is a Clean model, refer to the section Greasing the Ball Screw Spline Unit in chapter 12.
  • Page 186 9. Replacing the Ball Screw Spline Unit Part 2: Maintenance...

  • Page 187: Replacing The Signal Relay Board

    Part 2: Maintenance 10. Replacing the Signal Relay Board 10. Replacing the Signal Relay Board Only trained personnel should be allowed to maintain this board. WARNING When replacing this board, make sure the power is turned off and pull out the power plug from the power source.
  • Page 188 10. Replacing the Signal Relay Board Part 2: Maintenance Installation (1) Install a new signal relay board onto the base connector plate with four M3×6 screws. Signal relay board × (2) Securely connect the connectors, X10, X20, X30, X40, and X50. Be sure to connect the signal connectors securely.

  • Page 189: Replacing The Lithium Battery

    10. Replacing the Signal Relay Board 10.2 Replacing the Lithium Battery When the lithium battery power is low, an error will occur when EPSON RC+ / SPEL 95(SRC5**) / SRC-3** starts to warn the user about the low battery status. When this happens, the position data of the motors will be lost and all the joints need to be calibrated all over again (refer to chapter 11.
  • Page 190 10. Replacing the Signal Relay Board Part 2: Maintenance Installation (1) Connect the X4 connector of the new battery unit. (2) Using two wire ties, secure the battery unit to the board. Wire ties (3) Using four screws (M3×6), install the signal relay board onto the base connector plate. (4) Mount the base connector plate to the manipulator base.

  • Page 191: Calibration

    The process of realigning the origin position is called “origin calibration”. This chapter includes calibration instructions for three different controller types, designated by the following icons: Procedure when using EPSON RC+ Robot Control System. Procedure when using SPEL 95 / SRC5** controllers. SPEL 95 Procedure when using SRC-3** controllers.

  • Page 192: Calibration For Epson Rc+ Controller

    Part 2: Maintenance 11.1 Calibration for EPSON RC+ Controller Refer to the EPSON RC+ on-line help for details of commands used in this section. During the following steps, you may have to open the safeguard to gain access to the NOTE manipulator, depending on the system setup.
  • Page 193 Part 2: Maintenance 11. Calibration (3) Open the acrylic plate on the sensor monitor on the base connector plate. Sensor monitor Reset switch DIP switch For protected models, remove four bolts (M3×8) from the encoder reset cover and open the NOTE cover on the base connector plate.

  • Page 194: Calibrating Joint #3

    11. Calibration Part 2: Maintenance Calibrating Joint #3 First, perform steps (1) to (10) in the Common procedure for calibration section. (11) Select a current teach point, which is easy to verify for accuracy, and move the robot to that point using servo control. Because of the error due to origin offset, the same position will not be obtained.

  • Page 195: Calibrating Joint #1, #2, And #4

    Part 2: Maintenance 11. Calibration Calibrating Joint #1, #2, and #4 Joint #1, #2 and #4 are all calibrated by the same method. Calibrating two or more joints at the same time can affect accuracy. For best accuracy, calibrate each joint one at a time. First, perform steps (1) to (10) in the Common procedure for calibration section.

  • Page 196: Accurate Calibration Of Joint #2

    11. Calibration Part 2: Maintenance (17) Display the number of pulses in this position using the PULSE command and check that they match the values obtained in step (12) on previous page. <Example> >PULSE PULSE: 16000 pls 10000 pls pls. (18) Restore servo control to the calibrated joint with the SLOCK command.
  • Page 197 Part 2: Maintenance 11. Calibration (4) Switch positioning of left and right orientation and move to the same point. <Example> > MOTOR ON > JUMP P1:Z(0)/L ' To change from right to left orientation. ' (Use /R at end of statement for left to right) >...

  • Page 198: Calibration For Spel 95 / Src5** Controller

    11. Calibration Part 2: Maintenance 11.2 Calibration for SPEL 95 / SRC5** Controller Refer to the on-line help of SPEL 95 for details of commands used in this section. Common procedure for calibration For both the ES and EL series manipulators, calibration steps (1) to (10) are the same for all SPEL 95 four joints.
  • Page 199 Part 2: Maintenance 11. Calibration (3) Open the acrylic plate on the sensor monitor on the base connector plate. Sensor monitor Reset switch DIP switch For protected models, remove four bolts (M3×8) from the encoder reset cover and open the NOTE cover on the base connector plate.

  • Page 200: Calibrating Joint #3

    11. Calibration Part 2: Maintenance Calibrating Joint #3 First, perform steps (1) to (10) in the Common procedure for calibration section. SPEL 95 (11) Select a current teach point, which is easy to verify for accuracy, and move the robot to that point using servo control.

  • Page 201: Calibrating Joint #1, #2, And #4

    Part 2: Maintenance 11. Calibration Calibrating Joint #1, #2, and #4 Joint #1, #2, and #4 are all calibrated by the same method. Calibrating two or more joints SPEL 95 at the same time can affect accuracy. For best accuracy, calibrate each joint one at a time. First, perform steps (1) to (10) in the Common procedure for calibration section.

  • Page 202: Accurate Calibration Of Joint #2

    11. Calibration Part 2: Maintenance (18) Use the SLOCK command to put the free joints back under servo control. <Example> ' Joints #1 and #3 are under servo control >SLOCK 1,3 (19) Move to another teach point and check the position. Accurate calibration of Joint #2 For accurate calibration of Joint #2, calculation of robot working point coordinates is most SPEL 95...
  • Page 203 Part 2: Maintenance 11. Calibration (5) The position in left orientation mode is different from the position in right orientation mode. This gap must be adjusted manually after lowering Joint #3 to P1 position. In order to lower Joint #3 to P1, push Joint #3 down while pressing the brake release button.

  • Page 204: Calibration For Src-3** Controllers

    11. Calibration Part 2: Maintenance 11.3 Calibration for SRC-3** Controllers Refer to the SPEL for Windows online help for details on the commands used in this section. Common procedure for calibration For both the ES and EL series manipulator, calibration steps (1) to (10) are the same for all four axes.
  • Page 205 Part 2: Maintenance 11. Calibration (4) Set the DIP switch bits corresponding to the axes to be calibrated to the ON position. (5) Hold down the reset switch for at least one second. (The error display does not change.) (6) Turn the controller power OFF and ON again. Error 165 will be displayed. Repeat power cycle.

  • Page 206: Calibrating Axis #3

    11. Calibration Part 2: Maintenance Calibrating Axis #3 First, perform steps (1) to (10) in the Common procedure for calibration section. (11) Select a current teach point, which is easy to verify for accuracy, and move the robot to that point using servo control. Because of the error due to origin offset, the same position will not be obtained.

  • Page 207: Calibrating Axes #1, #2, And #4

    Part 2: Maintenance 11. Calibration Calibrating Axes #1, #2, and #4 Axes #1, #2, and #4 are all calibrated by the same method. Calibrating two or more Axes at the same time can affect accuracy. For best accuracy, calibrate each axis one at a time. First, perform steps (1) to (10) in the Common procedure for calibration section.

  • Page 208: Accurate Calibration Of Axis #2

    11. Calibration Part 2: Maintenance (17) Display the number of pulses in this position using the PULSE command and check that they match the values obtained in step (12) on previous page. <Example> > PULSE ' Axes #1 and #2 pulses. 16000 10000 ' Axes #3 and #4 pulses.
  • Page 209 Part 2: Maintenance 11. Calibration (4) Switch the arm mode from right to left and move to the same point. <Example> > MOTOR ON >JUMP P1:Z0/L ' To change from right to left arm. ' (/R at end of statement for left to right) ' All axes can now be moved manually.
  • Page 210 11. Calibration Part 2: Maintenance...

  • Page 211: Clean Model Maintenance

    Part 2: Maintenance 12. Clean Model Maintenance 12. Clean Model Maintenance The Clean models for the ES / EL series includes additional features that reduce dust emitted by the manipulator to enable use in clean room environments (See NOTE). This chapter describes the differences between Standard and Clean models for the ES / EL series.
  • Page 212 12. Clean Model Maintenance Part 2: Maintenance (4) Fill the groove of the ball screw spline shaft with grease. Apply it directly by hand. Wipe off excess grease from the shaft. (5) Push the shaft all the way down to the lower limit while pressing the brake release button.

  • Page 213: Replacing The Bellows

    Part 2: Maintenance 12. Clean Model Maintenance 12.2 Replacing the Bellows If the bellows should become damaged, follow the steps described below for replacing the bellows. The specification and replacement method are the same for the upper and lower bellows. However, detach the end effector from the shaft beforehand when you remove the lower bellows.
  • Page 214 12. Clean Model Maintenance Part 2: Maintenance...

  • Page 215: Protected Model Maintenance

    Part 2: Maintenance 13. Protected Model Maintenance 13. Protected Model Maintenance The Protected model for ES / EL series features shielding on the manipulator specifically for use in a dusty, wet or oily environment. The degree of the protective shielding is equivalent to IP65.

  • Page 216: Sealing The Manipulator

    13. Protected Model Maintenance Part 2: Maintenance 13.2 Sealing the Manipulator The following figure shows all parts of the manipulator that must be sealed to prevent moisture and dust. The figure also specifies the type of sealing for each part as types A, B, C, and D.
  • Page 217 Part 2: Maintenance 13. Protected Model Maintenance Name Specification NOTE Silicon Rubber A sheet of 1 mm-thick silicon Make sure the rubber sheet has Sheet rubber to be used for sealing been sealed up with the cover all covers with liquid gasket around by tightening the bolts on the cover.

  • Page 218: Internal Layout

    13. Protected Model Maintenance Part 2: Maintenance 13.3 Internal Layout The outline and name of internal configuration are shown below. User cable duct Upper Cable unit bellows Joint #3 motor Extension shaft Joint #4 middle axis Ball screw Joint #4 motor spline shaft Joint #2 motor...

  • Page 219: Replacing The Cable Unit

    Part 2: Maintenance 13. Protected Model Maintenance 13.4 Replacing the Cable Unit When connecting or disconnecting the cables, make sure the power is turned OFF and pull out the power plug from the power source. Failure to turn OFF the power can result in a robot may malfunction. WARNING When replacing the cable unit, remove the cable (the power cable, signal cable, and user’s wiring and piping) connected to the manipulator before replacing the...
  • Page 220 13. Protected Model Maintenance Part 2: Maintenance Removal (1) Turn OFF the Drive Unit power. SPEL 95 (1) Turn OFF the Controller power. (2) Disconnect all the connectors and tubes from the base connector plate. (3) Remove the six bolts (4-M4×8 and 2-M4×16) from the base connector plate and open the cover forward.
  • Page 221 Part 2: Maintenance 13. Protected Model Maintenance (9) Referring to the Wiring Schematic 1 in this chapter, disconnect the ground wires and pneumatic tubes off the arm. To disconnect each pneumatic tube, pull it out by first pushing the fitting release ring. The ground wire terminals are secured with bolts (M4×8).
  • Page 222 13. Protected Model Maintenance Part 2: Maintenance Installation For maintenance, the cable unit is provided with an elbow fitting on one end. The other end has a sealed duct rotating mechanism on the mounting bracket. (1) Let the wires go through the base connector box. Secure the main cable elbow fitting using four bolts (M6×12).

  • Page 223: Wiring Schematic 1

    Part 2: Maintenance 13. Protected Model Maintenance 13.5 Wiring Schematic 1 To remove the cable unit, remove the connectors in the arm top cover and base. These connectors are connected as shown in the figure below. For more information, see the block diagram on the next page and the wiring list in 4.

  • Page 224: Wiring Schematic 2

    13. Protected Model Maintenance Part 2: Maintenance 13.6 Wiring Schematic 2...

  • Page 225: Greasing The Ball Screw Spline Unit

    Part 2: Maintenance 13. Protected Model Maintenance 13.7 Greasing the Ball Screw Spline Unit For basic information about the ball screw spline unit, refer to chapter 9. Replacing the Ball Screw Spline Unit. Follow the standards specifications concerning the type of grease to use and the areas to be greased.
  • Page 226 13. Protected Model Maintenance Part 2: Maintenance (4) Fill the groove of the ball screw spline shaft with grease. Apply it directly by hand. Wipe off excess grease from the shaft. (5) Push the shaft all the way down to the lower limit while pushing the brake release button.

  • Page 227: Replacing The Bellows

    Part 2: Maintenance 13. Protected Model Maintenance 13.8 Replacing the Bellows If the bellows are damaged, follow the steps described below to replace the bellows. The specifications are the same for the upper and lower bellows. Removal Remove the wiring and piping to the end effector and the end effector itself after turning OFF the power.
  • Page 228 13. Protected Model Maintenance Part 2: Maintenance (5) Lift up the lower bellows and loosen the bolt (M4×18) on the upper-limit mechanical stop. Slide the stop upward about 50 mm. Upper-limit mechanical stop M4×18 bolt (6) Lift up the flange and loosen the bolt (M6×18) on the set-ring. Remove the set-ring, flange, O-rings, lower bellows, and mounting rings from the shaft.
  • Page 229 Part 2: Maintenance 13. Protected Model Maintenance (8) Remove the six bolts (M4×6) from the mounting ring on the bottom of the upper bellows. There is an O-ring between the bellows and flange that is fitted into a groove of the flange. Flange Upper bellows Mounting rings...
  • Page 230 13. Protected Model Maintenance Part 2: Maintenance Installation (1) Attach the mounting rings to both ends of the new bellows. (2) Pass the shaft through the O-ring, bellows, and O-ring. (3) Pass the wiring and tubes through the shaft. Mount the extension shaft to the main shaft with two bolts (M4×15).
  • Page 231 Part 2: Maintenance 13. Protected Model Maintenance (7) Place the flange on the set-ring. Lower the bearing, spacer and upper-limit mechanical stop to the bottom. (8) Secure the upper-limit mechanical stop with a bolt (M4×18). Upper-limit mechanical stop M4×18 bolt (9) Fit the O-ring into the groove of the flange.

  • Page 232: Replacing The Signal Relay Board

    13. Protected Model Maintenance Part 2: Maintenance 13.9 Replacing the Signal Relay Board For basic information, refer to chapter 10. Replacing the Signal Relay Board. Before turning OFF the power for the replacement, keep the power of the manipulator ON NOTE for more than 30 minutes.

  • Page 233: Maintenance Part Lists

    Part 2: Maintenance 14. Maintenance Part Lists 14. Maintenance Part Lists 14.1 Maintenance Parts for All Models (S/N: Serial No.) Parts Name New code Old code Standard Note S/N: 0**** R13ZA00061400 ZA000614 Common to Joint #1 200W-ABS Joint #2 of EL S/N: 1**** R13ZA00062500 ZA000625 S/N: 0**** R13ZA00061300 ZA000613 Common to Joint...

  • Page 234: Maintenance Parts For Standard-Model

    14. Maintenance Part Lists Part 2: Maintenance 14.2 Maintenance Parts for Standard-model Parts Name New code Old code Standard Note For 170 mm stroke ES**1S R13ZA00120800 ZA001208 BNS2020A-385B Only for ES Ball screw spline unit ES**3S R13ZA00120900 ZA001209 BNS2020A-535B For 320 mm stroke EL**3S ES45*S ES55*S...

  • Page 235: Maintenance Parts For Protected-Model

    Seal unit R13ZA00371600 ZA003716 ELP_SEAL Liquid gasket R13ZA00370300 ZA003703 1212 The bellows used in the following Manipulators have the same structure as that in the Clean-model. Use the bellows (round-type), R13ZA00370400. ·ES451P S/N 00540 (EPSON OKAYA) ·ES651P S/N 00419 (EDG)
  • Page 236 14. Maintenance Part Lists Part 2: Maintenance...

This manual is also suitable for:

El series

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