Epson SCARA ROBOT Manipulator Manual
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Epson SCARA ROBOT Manipulator Manual

G6 series
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SCARA ROBOT
G6 series
MANIPULATOR MANUAL
Rev.21
EM183R3621F

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  • Page 1 SCARA ROBOT G6 series MANIPULATOR MANUAL Rev.21 EM183R3621F...
  • Page 3 SCARA ROBOT G6 series Manipulator Manual Rev.21 Copyright  2007-2018 SEIKO EPSON CORPORATION. All rights reserved. G6 Rev.21...
  • Page 4 FOREWORD Thank you for purchasing our robot products. This manual contains the information necessary for the correct use of the manipulator. Please carefully read this manual and other related manuals before installing the robot system. Keep this manual handy for easy access at all times. WARRANTY The Manipulator and its optional parts are shipped to our customers only after being subjected to the strictest quality controls, tests, and inspections to certify its compliance...
  • Page 5 TRADEMARKS Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Other brand and product names are trademarks or registered trademarks of the respective holders. NOTICE No part of this manual may be copied or reproduced without authorization. The contents of this manual are subject to change without notice.
  • Page 6 Regarding battery disposal The crossed out wheeled bin label that can be found on your product indicates that this product and incorporated batteries should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health please separate this product and its batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner.
  • Page 7 Controller EPSON RC+ 5.0 Control Unit RC700-A EPSON RC+ 7.0 Ver.7.1.2 or later Drive Unit The motions of the manipulators such as in emergency stops vary depending on the Controllers since they have different control methods. Details are described in the manual.
  • Page 8 G6 Rev.21...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS Setup & Operation 1. Safety 1.1 Conventions ..................3 1.2 Design and Installation Safety ............. 4 1.2.1 Strength of the Ball Screw Spline ..........5 1.3 Operation Safety.................. 6 1.4 Emergency Stop .................. 8 1.4.1 RC180 ..................8 1.4.2 RC700-A ................
  • Page 10 TABLE OF CONTENTS 4. Setting of End Effectors 4.1 Attaching an End Effector ..............59 4.2 Attaching Cameras and Valves ............60 4.3 Weight and Inertia Settings ..............61 4.3.1 Weight Setting ................ 61 4.3.2 Inertia Setting ................. 63 4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 ....66 5.
  • Page 11 TABLE OF CONTENTS 3.6 User Plate ..................104 3.7 Maintenance Plate ................104 3.8 Base Bottom Cover ................. 105 4. Cable 4.1 Replacing Cable Unit ............... 107 4.2 Wiring Diagrams ................118 4.2.1 Signal Cable ................ 118 4.2.2 Power Cable ................ 119 4.2.3 User Cable ................
  • Page 12 TABLE OF CONTENTS 13. Calibration 13.1 About Calibration ................183 13.2 Calibration Procedure ..............184 13.3 Accurate Calibration of Joint #2 ............. 194 13.4 Calibration Procedure without using Calibration Wizard ....196 14. Maintenance Parts List 14.1 Common Parts ................200 14.2 Parts by Environment Model ............

  • Page 13: Setup & Operation

    Setup & Operation This volume contains information for setup and operation of the G6 series Manipulators. Please read this volume thoroughly before setting up and operating the Manipulators.

  • Page 15: Safety

    Setup & Operation 1. Safety 1. Safety Installation and transportation of manipulators and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. Please read this manual and other related manuals before installing the robot system or before connecting cables.

  • Page 16: Design And Installation Safety

    The following items are safety precautions for design personnel: ■ Personnel who design and/or construct the robot system with this product must read the Safety chapter in the EPSON RC+ User’s Guide to understand the safety requirements before designing and/or constructing the robot system.

  • Page 17: Strength Of The Ball Screw Spline

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

  • Page 18: Operation Safety

    Setup & Operation 1. Safety 1.3 Operation Safety The following items are safety precautions for qualified Operator personnel: ■ Please carefully read the Safety-related Requirements in the Safety chapter of the Safety and Installation manual before operating the robot system. Operating the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.
  • Page 19 Setup & Operation 1. Safety ■ Whenever possible, only one person should operate the robot system. If it is necessary to operate the robot system with more than one person, ensure that all people involved communicate with each other as to what they are doing and take all necessary safety precautions.

  • Page 20: Emergency Stop

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

  • Page 22: Rc700-A

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

  • Page 24: Emergency Movement Without Drive Power

    Setup & Operation 1. Safety 1.5 Emergency Movement Without Drive Power When the system is placed in emergency mode, push the arm or joint of the Manipulator by hand as shown below: Arm #1 Push the arm by hand. Arm #2 Push the arm by hand.

  • Page 25: Accels Setting For Cp Motions

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

  • Page 26: Warning Labels

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

  • Page 28: Specifications

    Setup & Operation 2. Specifications 2. Specifications 2.1 Features of G6 series Manipulators The G6 series Manipulators are high-performance manipulators intended to achieve high speed, high accuracy, space saving, and high cost-performance. The features of the G6 series Manipulators are as follows: Compatibility with E2 series Manipulators The installation procedure and mounting dimensions of the end effector for the G6 series are compatible with those for the E2 series.

  • Page 29: Model Number And Model Differences

    Setup & Operation 2. Specifications 2.2 Model Number and Model Differences G6-45 1 S □ -UL UL specification UL : UL compliant □ : Non UL compliant Type □ : Table Top mounting : Wall mounting : Ceiling mounting Environment : Standard : Clean room &...

  • Page 30: Part Names And Outer Dimensions

    Setup & Operation 2. Specifications 2.3 Part Names and Outer Dimensions 2.3.1 Table Top Mounting Standard-model G6-***S Joint #2 (rotating) − Joint #1 (rotating) − Joint #3 and #4 brake release switch Arm #1 LED lamp Arm #2 Base Joint #3 Shaft (up and down) −...
  • Page 31 Setup & Operation 2. Specifications G6-45*S G6-55*S G6-65*S G6-**1S G6-**3S −31 (*) indicates the stroke margin by mechanical stop. 90 or more Space for cables 1 mm flat cut Conical hole ø4,90° Max.ø14 through hole ø20 h7 shaft diameter ø40 mechanical stop diameter Root both side chamfer C0.5 Detail of “A”...
  • Page 32 Setup & Operation 2. Specifications Cleanroom-model G6-***C The following figure shows the additional parts and specifications for the Table Top mounting Cleanroom-model when compared with the Standard-model in appearance. Upper bellows Plate cover (For static electricity countermeasure) Lower bellows Plate cover Cover (For static electricity for Table Top mounting surface...
  • Page 33 Setup & Operation 2. Specifications G6-45*C G6-55*C G6-65*C G6-**1C G6-**3C −34 (*) indicates the stroke margin by mechanical stop. 90 or more Space for cables 1 mm flat cut Conical hole ø4,90° Max.ø14 through hole Root both side chamfer C0.5 ø20 h7 shaft diameter ø40 mechanical stop diameter Reference through hole...
  • Page 34 Setup & Operation 2. Specifications Protected-model G6-***D/P The following figure shows the additional parts and specifications for the Table Top mounting Protected-model when compared with the Standard-model in appearance. Normal G6-***D* Manipulators do not have bellows. If necessary, select the bellows option at shipment.
  • Page 35 Setup & Operation 2. Specifications G6-45*D, P G6-55*D, P G6-65*D, P G6-**1D, P G6-**3D, P −34 795.5 945.5 (*) indicates the stroke margin by mechanical stop. 90 or more Space for cables 1 mm flat cut Conical hole ø4,90° Max.ø14 through hole ø20 h7 shaft diameter Root both side chamfer C0.5 ø40 mechanical stop diameter...

  • Page 36: Wall Mounting

    Setup & Operation 2. Specifications 2.3.2 Wall Mounting Standard-model G6-***SW Joint #2 (rotating) Signature label − (Serial No. of Manipulator) CE label Joint #3 and #4 brake release switch UR label LED lamp Base Arm #1 − Joint #1 (rotating) Joint #3 Arm #2 (up and down)
  • Page 37 Setup & Operation 2. Specifications (*) indicates the stroke margin by mechanical stop Detail of “B” Space for cables 90 or more 1 mm flat cut Conical hole ø4,90° Max.ø14 through hole ø20 h7 shaft diameter ø40 mechanical stop diameter Detail of “A”...
  • Page 38 Setup & Operation 2. Specifications Cleanroom-model G6-***CW The following figure shows the additional parts and specifications for the Wall mounting Cleanroom-model when compared with the Standard-model in appearance. Upper bellows Plate cover (For static electricity countermeasure) Lower bellows Plate cover (For static electricity countermeasure) Exhaust port...
  • Page 39 Setup & Operation 2. Specifications (*) indicates the stroke margin by mechanical stop G6-45*CW G6-55*CW G6-65*CW G6-**1CW G6-**3CW Detail of “B” Space for cables 90 or more 1 mm flat cut Conical hole ø4,90° Max.ø14 through hole ø20 h7 shaft diameter ø40 mechanical stop diameter Detail of “A”...
  • Page 40 Setup & Operation 2. Specifications Protected-model G6-***DW / PW The following figure shows the additional parts and specifications for the Wall mounting Protected-model when compared with the Standard-model in appearance. Normal G6-***DW Manipulators do not have bellows. If necessary, select the bellows option at shipment.
  • Page 41 Setup & Operation 2. Specifications (*) indicates the stroke margin by mechanical stop G6-45*DW, PW G6-55*DW, PW G6-65*DW, PW G6-**1DW, PW G6-**3DW, PW 102.5 252.5 Detail of “B” 529.5 679.5 Space for cables 90 or more 1 mm flat cut Conical hole ø4,90°...

  • Page 42: Ceiling Mounting

    Setup & Operation 2. Specifications 2.3.3 Ceiling Mounting Standard-model G6-***SR Joint #2 (rotating) − Joint #3 and #4 brake release switch Base LED lamp Arm #1 − Joint #1 (rotating) Joint #3 Arm #2 (up and down) Shaft − − Joint #4 (rotating) Fitting (black or blue)*...
  • Page 43 Setup & Operation 2. Specifications (*) indicates the stroke margin by mechanical stop Space for cables 90 or more Detail of “B” 1 mm flat cut Conical hole ø4,90° G6-45*SR G6-55*SR G6-65*SR G6-**1SR G6-**3SR Max.ø14 through hole −9 ø20 h7 shaft diameter ø40 mechanical stop diameter Detail of “A”...
  • Page 44 Setup & Operation 2. Specifications Cleanroom-model G6-***CR The following figure shows the additional parts and specifications for the Ceiling mounting Cleanroom-model when compared with the Standard-model in appearance. Cover for Ceiling mounting surface Upper bellows Plate cover (For static electricity countermeasure) Lower bellows Plate cover...
  • Page 45 Setup & Operation 2. Specifications Space for cables 90 or more (*) indicates the stroke margin by mechanical stop Detail of “B” 1 mm flat cut G6-45*CR G6-55*CR G6-65*CR Conical hole ø4,90° G6-**1CR G6-**3CR Max.ø14 through hole ø20 h7 shaft diameter ø40 mechanical stop diameter Detail of “A”...
  • Page 46 Setup & Operation 2. Specifications Protected-model G6-***DR / PR The following figure shows the additional parts and specifications for the Ceiling mounting Protected-model when compared with the Standard-model in appearance. Normal G6-***DR Manipulators do not have bellows. If necessary, select the bellows option at shipment.
  • Page 47 Setup & Operation 2. Specifications Space for cables 90 or more (*) indicates the stroke margin by mechanical stop Detail of “B” 1 mm flat cut G6-45*DR, PR G6-55* DR, PR G6-65* DR, PR Conical hole ø4,90° G6-**1 DR, PR G6-**3 DR, PR 102.5 252.5...

  • Page 48: Specifications

    Setup & Operation 2. Specifications 2.4 Specifications Item G6-**** G6-****R G6-****W Mount method Table Top Ceiling Wall Protected-model Environment Cleanroom-model + ESD *1, 450 mm 550 mm #1, #2 650 mm Arm length 180 mm : G6-**1S*, D* 150 mm : G6-**1C*, P*, D* with bellows option Arm #3 330 mm : G6-**3S*, D* 300 mm : G6-**3C*, P*, D* with bellows option...
  • Page 49 Setup & Operation 2. Specifications *a : G6-45*** Joint #2 Max. motion range Max. pulse range 147.5 deg ±2685156 pulse Z 0 to –270 G6-45*S* / D* 145 deg Z –270 to –330 ±2639645 pulse 147.5 deg ±2685156 pulse Z 0 to –240 G6-45*C*/ P* / D* with bellows option 142 deg Z –240 to –300...
  • Page 50 Setup & Operation 2. Specifications *1: The exhaust system in the Cleanroom-model Manipulator ( ) draws air from the base interior and G6-***C* 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.

  • Page 51: How To Set The Model

    The custom specifications may require a different configuration procedure; check the custom specifications number (MT***) and contact us when necessary. The Manipulator model can be set from software. Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide. G6 Rev.21...

  • Page 52: Environments And Installation

    Setup & Operation 3. Environments and Installation 3. Environments and Installation 3.1 Environmental Conditions A suitable environment is necessary for the robot system to function properly and safely. Be sure to install the robot system in an environment that meets the following conditions: Item Conditions Ambient temperature...
  • Page 53 Setup & Operation 3. Environments and Installation Special Environmental Conditions The protective seals are attached on the Protected-model Manipulator to prevent dust, water, etc. from the outside. Follow the precautions in use environment described below: The surface of the Manipulator has general oil resistance. However, if your requirements specify that the Manipulator must withstand certain kinds of oil, please consult your distributor.

  • Page 54: Base Table

    Setup & Operation 3. Environments and Installation 3.2 Base Table A base table for anchoring the Manipulator is not supplied. Please make or obtain the base table for your Manipulator. The shape and size of the base table differs depending on the use of the robot system.
  • Page 55 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 G6 Rev.21...

  • Page 56: Mounting Dimensions

    Setup & Operation 3. Environments and Installation 3.3 Mounting Dimensions The maximum space described in figures shows that the radius of the end effector is 60 mm or less. If the radius of the end effector exceeds 60 mm, define the radius as the distance to the outer edge of maximum space.
  • Page 57 Setup & Operation 3. Environments and Installation G6-65**W Wall Mounting G6-55**W G6-45**W G6-55* G6-45**W G6-65**W CW, PW, SW, DW DW bellows Length of Arm #1 (mm) Length of Arm #2 (mm) (Motion range) 195.5 161.2 172.1 Motion range of Joint #1 (degree) Motion range of Joint #2 (degree) 147.5 147.5...

  • Page 58: Unpacking And Transportation

    Setup & Operation 3. Environments and Installation 3.4 Unpacking and Transportation THE INSTALLATION SHALL BE PERFORMED BY QUALIFIED INSTALLATION PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL CODES. ■ Only authorized personnel should perform sling work and operate a crane and a forklift.

  • Page 59: Installation

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

  • Page 60: Wall Mounting

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

  • Page 61: Ceiling Mounting

    Setup & Operation 3. Environments and Installation 3.5.3 Ceiling Mounting ■ Install the Ceiling Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G6-45**R : Approximately 27 kg: 60 lb.

  • Page 62: Cleanroom-Model

    Setup & Operation 3. Environments and Installation 3.5.4 Cleanroom-model (1) Unpack it outside of the clean room. (2) Secure the Manipulator to delivery equipment such as a pallet with bolts so that the Manipulator does not fall. (3) Wipe off the dust on the Manipulator with a little alcohol or distilled water on a lint-free cloth.

  • Page 63: Connecting The Cables

    Setup & Operation 3. Environments and Installation 3.6 Connecting the Cables ■ To shut off power to the robot system, disconnect the power plug from the power source. Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source.
  • Page 64 Setup & Operation 3. Environments and Installation Cable Connections Connect the power connector and signal connector of the M/C cables to the Controller. Power Connector Signal Connector G6 Rev.21...

  • Page 65: User Wires And Pneumatic Tubes

    Setup & Operation 3. Environments and Installation 3.7 User Wires and Pneumatic Tubes ■ Only authorized or certified personnel should be allowed to perform wiring. Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system. CAUTION User electrical wires and pneumatic tubes are contained in the cable unit.
  • Page 66 Setup & Operation 3. Environments and Installation Table Top Mounting User connector (9-pin D-sub connector) User connector (15-pin D-sub connector) Fitting (white) for ø6 mm pneumatic tube Fitting (black or blue)* Fitting (white) for ø6 mm pneumatic tube for ø4 mm pneumatic tube Fitting (black or blue)* for ø4 mm pneumatic tube Wall Mounting...

  • Page 67: Relocation And Storage

    Setup & Operation 3. Environments and Installation 3.8 Relocation and Storage 3.8.1 Precautions for Relocation and Storage Observe the following when relocating, storing, and transporting the Manipulators. THE INSTALLATION SHALL BE PERFORMED BY QUALIFIED INSTALLATION PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL CODES.
  • Page 68 Setup & Operation 3. Environments and Installation 3.8.2 Table Top Mounting ■ Install or relocate the Table Top Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G6-45** : Approximately 27 kg: 60 lb.

  • Page 69: Wall Mounting

    Setup & Operation 3. Environments and Installation 3.8.3 Wall Mounting ■ Install or relocate the Wall Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G6-45**W : Approximately 29 kg: 64 lb.

  • Page 70: Ceiling Mounting

    Setup & Operation 3. Environments and Installation 3.8.4 Ceiling Mounting ■ Install or relocate the Ceiling Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G6-45**R : Approximately 27 kg: 60 lb.

  • Page 71: Setting Of End Effectors

    Setup & Operation 4. Setting of End Effectors 4. Setting of End Effectors 4.1 Attaching an End Effector Users are responsible for making their own end effector(s). Before attaching an end effector, observe these guidelines. ■ If you use an end effector equipped with a gripper or chuck, connect wires and/or pneumatic tubes properly so that the gripper does not release the work piece when the power to the robot system is turned OFF.

  • Page 72: Attaching Cameras And Valves

    Setup & Operation 4. Setting of End Effectors 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.

  • Page 73: Weight And Inertia Settings

    The load (weight of the end effector and work piece) on the shaft can be set by Weight parameter. Enter a value into the [Load inertia:] text box on the [Inertia] panel ([Tools] - [Robot EPSON Manager]). (You may also execute the Inertia command from the [Command Window].) Load on the Arm When you attach a camera or other devices to the arm, calculate the weight as the equivalent of the shaft.
  • Page 74 Setup & Operation 4. Setting of End Effectors <Example> A “1 kg” camera is attached to the end of the G6 series arm (450 mm away from the rotation center of Joint #2) with a load weight of “2 kg”. =350 =450 =1×450...

  • Page 75: Inertia Setting

    “moment of inertia” parameter of the Inertia command. Enter a value into the [Load inertia:] text box on the [Inertia] panel ([Tools]-[Robot EPSON Manager]). (You may also execute the Inertia command from the [Command Window].) Automatic acceleration/deceleration setting of Joint #4 by Inertia (moment of inertia) 0.02 0.04 0.06 0.08 0.10 0.12 (kg･m...
  • Page 76 “eccentric quantity” parameter of Inertia command. Enter a value into the [Eccentricity:] text box on the [Inertia] panel ([Tools]-[Robot EPSON Manager]). (You may also execute the Inertia command from the [Command Window].) Automatic acceleration/deceleration setting by Inertia (eccentric quantity)
  • Page 77 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).

  • Page 78: Precautions For Auto Acceleration/Deceleration Of Joint #3

    Setup & Operation 4. Setting of End Effectors (c) Moment of inertia of a sphere Sphere’s center of gravity Rotation center + m × L Mass (m) 4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 When you move the Manipulator in horizontal PTP motion with Joint #3 (Z) at a high position, the motion time will be faster.

  • Page 79: Motion Range

    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.

  • Page 80: Motion Range Setting By Pulse Range (For All Joints)

    Manipulator does not move. The pulse range can be set on the [Range] panel shown by selecting [Tools]-[Robot EPSON Manager]. (You may also execute the Range command from the [Command Window].) 5.1.1 Max. Pulse Range of Joint #1 The 0 (zero) pulse position of Joint #1 is the position where Arm #1 faces toward the positive (+) direction on the X-coordinate axis.

  • Page 81: Max. Pulse Range Of Joint #2

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

  • Page 82: Max. Pulse Range Of Joint #3

    Setup & Operation 5. Motion Range 5.1.3 Max. Pulse Range of Joint #3 The 0 (zero) pulse position of Joint #3 is the position where the shaft is at its upper limit. The pulse value is always negative because Joint #3 always moves lower than the 0 pulse position.

  • Page 83: Motion Range Setting By Mechanical Stops

    Setup & Operation 5. Motion Range 5.2 Motion Range Setting by Mechanical Stops Mechanical stops physically limit the absolute area that the Manipulator can move. Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for the mechanical stop settings.

  • Page 84: Setting The Mechanical Stops Of Joints #1 And #2

    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.
  • Page 85 Setup & Operation 5. Motion Range Joint #2 Mechanical Stops Joint #2 Model Arm Length Table Top, Ceiling, Wall 55, 65 +147.5° 45 (Z : 0 to –270) G6-45*S, D 45 (Z :–270 to –330) +145° -125° -100° Table Top +100°...
  • Page 86 The angle of Joint #1 is set from –135 degrees to +135 degrees. The angle of Joint #2 is set from -125 degrees to +125 degrees. Execute the following commands from the [Command Window]. EPSON >JRANGE 1,-1310720,6553600 ' Sets the pulse range of Joint #1 >JRANGE 2,-2275556,+2275556 ' Sets the pulse range of Joint #2...

  • Page 87: Setting The Mechanical Stop Of Joint #3

    Setup & Operation 5. Motion Range 5.2.2 Setting the Mechanical Stop of Joint #3 This method applies only to the Standard-model Manipulator ( G6-***S*)/Protected-model NOTE  Manipulator (G6-***D* without bellows option). For the Cleanroom-model ( G6-***C*) and Protected-model (G6-***D* with bellows option) the motion range set with the Joint #3 mechanical stop cannot be changed.
  • Page 88 Z coordinate value to “-100” in 150 mm stroke (-100) / 20 × 131072 × (62 / 37 ) = - 1098171 Execute the following command from the [Command Window]. EPSON >JRANGE 3,-1098171,0 ' Sets the pulse range of Joint #3 (10) Using the Pulse command (Go Pulse command), move Joint #3 to the lower limit position of the pulse range at low speed.

  • Page 89: Setting The Cartesian (Rectangular) Range In The Xy Coordinate System Of The Manipulator (For Joints #1 And #2)

    The maximum physical range is based on the position of the mechanical stops. Set the XYLim setting on the [XYZ Limits] panel shown by selecting [Tools]-[Robot EPSON Manager]. (You may also execute the XYLim command from the [Command Window].) 5.4 Standard Motion Range...
  • Page 90 Setup & Operation 5. Motion Range Table Top Mounting G6-65** Center of Joint#3 G6-55** Maximum space G6-45** Motion range Area limited by mechanical stop Base mounting face (°: degree) 147.5° 3° 134.8 Z 0 to –270 G6-45*S, D 145° 5.5° 143.5 Z –270 to –330 124.4...
  • Page 91 Setup & Operation 5. Motion Range Wall Mounting G6-65**W Center of Joint#3 G6-55**W Maximum space G6-45**W Motion range Center of Area limited by mechanical stop base reference hole (°: degree) G6-45**W 105° 130° 3.8° 182.4 195.5 G6-55*SW, DW 3.5° 147.5° 3.3°...
  • Page 92 Setup & Operation 5. Motion Range Ceiling Mounting G6-65**R Center of Joint#3 G6-55**R Maximum space G6-45**R Motion range Area limited by mechanical Base mounting face (°: degree) G6-45**R 120° 5.5° 130° 3.8° 182.4 195.5 366.1 G6-55*SR, DR 147.5° 3.3° 161.2 146.8 514.9 G6-55*CR, PR, DR bellows...

  • Page 93: Maintenance

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

  • Page 95: Safety Maintenance

    Maintenance 1. Safety Maintenance 1. Safety Maintenance Please read this chapter, this manual, and other relevant manuals carefully to understand safe maintenance procedures before performing any routine maintenance. Only authorized personnel who have taken safety training should be allowed to maintain the robot system.

  • Page 96: General Maintenance

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

  • Page 97: Inspection Point

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

  • Page 98: Overhaul (Parts Replacement)

    EPSON RC+ 7.0. For details, refer to the following manual. Robot Controller RC700 / RC700-A “Maintenance 6. Alarm” For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the NOTE  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 5.0.
  • Page 99 (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) For the parts subject to overhaul, refer to Maintenance 14. Maintenance Parts List.

  • Page 100: Greasing

    Maintenance 2. General Maintenance 2.3 Greasing The ball screw spline and reduction gear units need greasing regularly. Only use the grease specified in the following table. ■ Keep enough grease in the Manipulator. Operating the Manipulator with insufficient grease will damage sliding parts and/or result in insufficient function of the Manipulator.
  • Page 101 [Maintenance] dialog box of the EPSON RC+ 7.0. For details, refer to the following manual. Robot Controller RC700 / RC700-A “Maintenance 6. Alarm” For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the NOTE ...

  • Page 102: Tightening Hexagon Socket Head Cap Bolts

    Then, follow the steps below to display the pulse values and record them. Execute the following command from the [Command Window]. EPSON >PULSE PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value] pls [Joint #4 Pulse value] pls G6 Rev.21...

  • Page 103: Layout Of Maintenance Parts

    Maintenance 2. General Maintenance 2.6 Layout of Maintenance Parts 2.6.1 Table Top Mounting type G6-***S : Standard-model LED lamp Brake release switch Arm cover Ball screw spline unit Joint #2 motor Joint #2 reduction gear unit Joint #3 motor Cable unit Z belt U2 belt Joint #3 brake...

  • Page 104: Wall Mounting

    Maintenance 2. General Maintenance 2.6.2 Wall Mounting type G6-***SW : Standard-model Power cable Signal cable LED lamp Brake release switch Arm cover Ball screw spline unit Joint #3 motor Joint #1 motor Z belt Joint #1 reduction gear unit U2 belt Joint #3 brake Joint #2 motor Cable unit...

  • Page 105: Ceiling Mounting

    Maintenance 2. General Maintenance 2.6.3 Ceiling Mounting type G6-***SR : Standard-model LED lamp Brake release switch Power cable Arm cover Ball screw spline unit Signal cable Joint #3 motor Joint #1 motor Joint #1 Z belt reduction gear unit U2 belt Joint #3 brake Joint #2 motor Cable unit...

  • Page 106: Covers

    Maintenance 3. Covers 3. Covers All procedures for removing and installing covers in maintenance are described in this chapter. ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
  • Page 107 Maintenance 3. Covers Table Top mounting Arm top cover Side cover Arm cap Arm cap Side cover Arm bottom cover Connector plate Maintenance plate Connector sub plate Base bottom cover (Except G6-***S) Wall mounting Ceiling mounting Base bottom cover Connector sub plate (Except G6-***SR) Connector plate Maintenance plate...

  • Page 108: Arm Top Cover

    Maintenance 3. Covers 3.1 Arm Top Cover ■ Do not remove the arm top cover forcibly. Removing the cover forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.
  • Page 109 Maintenance 3. Covers G6-***C* (Cleanroom-model), G6-***S* (Standard-model) G6-***D*, P* (Protected-model) G6-***C* 4-M4×12 : 4-M4×12 G6-***D*, P* : 4-M4×15 (SUS) Gasket (G6-***P* only) Gasket (G6-***P* only) Gaskets are installed only to G6-***P*. (1) Set the arm top cover to the arm and secure with Arm Top Cover Brake release Lower limit...

  • Page 110: Arm Bottom Cover

    Maintenance 3. Covers 3.2 Arm Bottom Cover Unscrew the arm bottom cover mounting bolts, and then pull the cover downward and remove it. The arm bottom cover may not be removed from the shaft because the end effector is NOTE ...

  • Page 111: Arm #1 Cover

    Maintenance 3. Covers 3.3 Arm #1 Cover There are two sets of Arm #1 covers. - Arm caps - Side covers Unscrew the bolts mounting the covers and the caps to remove them. 3.3.1 G6-***S* (Standard-model), G6-***C* (Cleanroom-model) Arm side (Common part) Base side Table Top mounting For the arm cap...

  • Page 112: G6-***D*, P

    Maintenance 3. Covers 3.3.2 G6-***D*/P* (Protected-model) Arm side (Common part) Base side Table Top mounting For the arm cap : 4-M4×5 Gasket For the side cover : 4-M4×15 Gasket Gasket For the side cover For the arm cap : 4-M4×15 : 4-M4×5 Wall mounting For the side cover...

  • Page 113: Connector Plate

    Maintenance 3. Covers 3.4 Connector Plate ■ Do not remove the connector plate forcibly. Removing the connector plate forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.
  • Page 114 Maintenance 3. Covers Unscrew the connector plate mounting bolts and remove the plate. G6-***S* (Standard-model) G6-***C* (Cleanroom-model) G6-***D*, P* (Protected-model) Table Gasket 6-M4×10 mounting 4-M4×10 Part to apply silicon adhesive Wall 4-M4×10 4-M4×10 mounting Gasket Ceiling Gasket 4-M4×10 6-M4×10 mounting Part to apply silicon adhesive A gasket is installed to G6-***D*, P* (Protected-model).

  • Page 115: Connector Sub Plate

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

  • Page 116: User Plate

    Maintenance 3. Covers 3.6 User Plate Unscrew the user plate mounting bolts and remove the plate. Do not remove the nut by force. The nut for the user plate is combined with the user NOTE  plate. And if you try to remove the nut, it will damage the user plate. G6-***S* (Standard-model) G6-***C* (Cleanroom-model) G6-***D*, P* (Protected-model)

  • Page 117: Base Bottom Cover

    Maintenance 3. Covers 3.8 Base Bottom Cover The base bottom cover is removed only when replacing the gasket unit. Unscrew the base bottom cover mounting bolts and remove the cover. G6-***C* (Cleanroom-model) G6-***D*, P* (Protected-model) Table Top mounting Gasket 6-M3×8 6-M3×8 Ceiling mounting...

  • Page 118: Cable

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

  • Page 119: Replacing Cable Unit

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. If the error occurs, execute the calibration of all joints and axes.
  • Page 120 Maintenance 4. Cable Table Top mounting Cable Unit Wall mounting Cable Unit Ceiling mounting Cable Unit G6 Rev.21...
  • Page 121 Maintenance 4. Cable ■ If the connectors have been disconnected during the replacement of the cable unit, be sure to reconnect the connectors to their proper positions. Refer to the block diagrams. Improper connection of the connectors may result in improper function of the robot system.
  • Page 122 Maintenance 4. Cable When using Table Top mounting type or Ceiling mounting type (7)-1 Remove the saddle part mounting (8) 2-M4×10 cables inside the base. Wire tie (7)-2 Remove the spring plate. Saddle part (7)-3 Cut off the two wire ties binding cables. (7) 2-M4×10 Spring plate When using Wall mounting type...
  • Page 123 Maintenance 4. Cable (8) Remove the arm caps and side covers on Arm #1. For details, refer to Maintenance: 3.3 Arm #1 Cover. (9) Remove the arm top cover. For details, refer to Maintenance: 3.1 Arm Top Cover. (10) Remove the user plate. For details of user plate removal, refer to Maintenance 3.6 User Plate.
  • Page 124 Maintenance 4. Cable (18) Disconnect the Base side cables from Arm #1. Table Top mounting Cable Table Top mounting : Disconnect from the upper part of Arm #1 Wall mounting, Ceiling mounting : Disconnect from the lower part of Arm #1 Wall / Ceiling mounting NOTE When disconnecting the cables, first, disconnect...
  • Page 125 Maintenance 4. Cable Cable unit (1) Apply grease (GPL-224) to the cables. Applying positions Installation Grease volume: 5 g each (10 g in total) Each cable inside the spring Air tube 200 mm 200 mm Periphery of spring (shaded part) Greasing Greasing Spring...
  • Page 126 Maintenance 4. Cable When using Table Top mounting type or Ceiling mounting type (6)-1 Mount the spring for cable protection to Spring the spring plate with a wire tie. Wire tie Spring plate (6)-2 Mount the spring plate to the base. 2-M4×10 Spring plate (6)-3 Move Arm #1 to the right or left until...
  • Page 127 Maintenance 4. Cable When using Wall mounting type (6)-1 Pull out the spring and mount it to the spring plate with a wire tie. (6)-2 Mount the saddle part to mount the 2-M4×10 cables. Saddle part (6)-3 Loosely band the cables with a wire tie. Spring plate Be sure to keep the wire tie loose enough so that the cables move.
  • Page 128 Maintenance 4. Cable (7) Connect the connectors, air tubes, D-sub cable, and connectors to the connector plate (inner side). D-sub cable Spring washer Connector Plain washer Ground terminal Air tube D-sub Connector plate (8) Loosely mount the connector plate with two screws (M4). For details, refer to Maintenance: 3.4 Connector Plate.
  • Page 129 Maintenance 4. Cable (13) Mount the saddle part to the spring plate. Saddle part 2-M5×10 (14) Connect the connectors and the ground wire. For details, refer to Maintenance: 4.2 Wiring Diagrams. (15) Bind the excess cables with a wire tie. (16) Connect the D-sub cable, air tubes, and connector D-sub cable of the brake release switch cable to the user plate.

  • Page 130: Wiring Diagrams

    Maintenance 4. Cable 4.2 Wiring Diagrams 4.2.1 Signal Cable G6 Rev.21...

  • Page 131: Power Cable

    Maintenance 4. Cable 4.2.2 Power Cable RC180 G6 Rev.21...
  • Page 132 Maintenance 4. Cable RC700-A, RC700DU-A G6 Rev.21...

  • Page 133: User Cable

    Maintenance 4. Cable 4.2.3 User Cable Code Cable color Code Cable color Black Brown Violet Green White Blue Yellow The following table shows the types of the use cable. Environment Arm length Code Note 450 mm R13B020012 S, C 550 mm R13B020013 650 mm R13B020014...

  • Page 134: Replacing M/C Cable

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. NOTE If the connector connected to the battery was disconnected during cable replacement, ...
  • Page 135 Maintenance 4. Cable Table Top mounting M/C Cable Wall mounting M/C Cable Ceiling mounting M/C Cable G6 Rev.21...
  • Page 136 Maintenance 4. Cable M/C Cable (1) Turn OFF the Controller. Removal (2) Disconnect the power cable and signal cable connectors from the controller. (3) Remove the Connector Sub Plate. For details, refer to Maintenance: 3.5 Connector Sub Plate. NOTE Do not pull the Sub plate forcibly. ...

  • Page 137: Arm #1

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

  • Page 138: Replacing Joint #1 Motor

    Maintenance 5. Arm #1 5.1 Replacing Joint #1 Motor Name Quantity Note R13B000607 Maintenance AC Servo Motor (400 W) R13B000616 parts (For S/N:1**** or later) width across flats: 2.5 mm For M5 set screw, M3 screw Hexagonal wrench width across flats: 3 mm For M4 screw Tools width across flats: 4 mm...
  • Page 139 Maintenance 5. Arm #1 (1) Mount the motor flange on the Joint #1 motor. Joint #1 motor Installation Motor flange 4-M5×15 (2) Mount the waveform generator on the Joint #1 Wave generator motor. M5 brass bushing O-ring Apply grease without touching the motor axis. 2-M5×8 set screw Be sure to fit the end face of the waveform...

  • Page 140: Replacing Joint #1 Reduction Gear Unit

    Maintenance 5. Arm #1 5.2 Replacing Joint #1 Reduction Gear Unit A reduction gear unit consists of the following three parts and two attached parts. At replacing the reduction gear unit, be sure to always replace them all together as one set. Reduction gear unit : Waveform generator, Flexspline, Circular spline Attachment : Spacer, Grip ring...
  • Page 141 Maintenance 5. Arm #1 (1) Execute the removal steps from (1) to (5) in Maintenance: 5.1 Replacing Joint #1 Joint #1 Motor and remove the waveform generator. reduction gear unit (2) Remove the arm cap on the base side. Removal For details, refer to Maintenance: 3.3 Arm #1 Cover.
  • Page 142 Maintenance 5. Arm #1 (1) A new reduction gear unit contains the parts Joint #1 shown in the picture on the right when it is reduction gear unit unpacked. Installation Apply grease (SK-1A) to the waveform generator and flexspline so that the gear surface is filled with grease.

  • Page 143: Arm #2

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

  • Page 144: Replacing Joint #2 Motor

    Maintenance 6. Arm #2 6.1 Replacing Joint #2 Motor Name Quantity Note R13B000607 Maintenance AC Servo Motor (400W) R13B000616 Parts (For S/N：1**** or later) width across flats: 2 mm For M4 set screw Hexagonal wrench width across flats: 3 mm For M4 screw width across flats: 4 mm For M5 screw...
  • Page 145 Maintenance 6. Arm #2 (9) Remove the Joint #2 motor unit from Arm #2. 4-M4×15 To do so, unscrew the bolts from the Joint #2 motor flange. Pull the Joint #2 motor unit upward to remove. If the motor cannot be removed easily, pull it out while moving Arm #2 slowly by hand.
  • Page 146 Maintenance 6. Arm #2 (1) Mount the motor flange on the Joint #2 motor. Joint #2 motor Installation 4-M5×15 M5 small washer (2) Mount the waveform generator on the Joint #2 Waveform M4 bushing generator motor. 2-M4×8 set screw Apply grease without touching the motor axis. SK-1A Be sure to fit the end face of the waveform grease (6g)

  • Page 147: Replacing Joint #2 Reduction Gear Unit

    Maintenance 6. Arm #2 6.2 Replacing Joint #2 Reduction Gear Unit A reduction gear unit consists of the following three parts and two attached parts. At replacing the reduction gear unit, be sure to always replace them all together as one set. Reduction gear unit : Waveform generator, Flexspline, Circular spline Attachment : Spacer, Grip ring...
  • Page 148 Maintenance 6. Arm #2 Joint #2 (1) Turn ON the Controller. reduction gear (2) Push down the shaft to its lower limit while pressing the brake release switch. Be unit sure to keep enough space and prevent the end effector hitting any peripheral Removal equipment.
  • Page 149 Maintenance 6. Arm #2 (1) A new reduction gear unit contains the parts Joint #2 shown in the picture on the right when it is reduction gear unit unpacked. Installation Apply grease (SK-1A) to the waveform generator and flexspline so that the gear surface is filled with grease.

  • Page 150: Arm #3

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

  • Page 151: Replacing Joint #3 Motor

    Maintenance 7. Arm #3 7.1 Replacing Joint #3 Motor Name Quantity Note R13B000608 Maintenance AC Servo Motor (200W) R13B000614 parts (For S/N: 1**** or later) width across flats: 2.5 mm For M5 set screw Hexagonal wrench width across flats: 3 mm For M4 screw width across flats: 4 mm For M5 screw...
  • Page 152 Maintenance 7. Arm #3 Joint #3 motor (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 153 Maintenance 7. Arm #3 (1) Secure the pulley to the new motor shaft. Joint #3 motor 2-M3×4 Brake hub Set screw Installation 90° Be sure to fit the end face of the pulley to the end M5 bushing face of the motor shaft. 2-M5×6 0.5 ㎜...
  • Page 154 Maintenance 7. Arm #3 (6) Place the Z belt around the Z1 pulley and the Z2 pulley so that the gear grooves of the belt are fit Joint #3 motor unit into those of the pulleys completely. Z belt Z2 pulley Z1 pulley (7) Loosely secure the Joint #3 motor unit to Arm #2.

  • Page 155: Replacing The Timing Belt

    Maintenance 7. Arm #3 7.2 Replacing the Timing Belt Name Quantity Note Maintenance Z belt (width 10 mm) R13B030206 parts Hexagonal wrench (width across flats: 3 mm) For M4 screw Nippers For cutting wire tie Tools Force gauge Belt tension 80 N (8.2 kgf) Suitable cord (Length about 800 mm) For belt tension Wire tie...
  • Page 156 Maintenance 7. Arm #3 Z belt (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 157 Maintenance 7. Arm #3 3-M4×12 (1) Pass a new Z belt through the shaft from above, Z belt Z belt and then place it under the spline plate. Installation (2) Loosely secure the spline plate to Arm #2. After moving the shaft up and down several times, secure the spline plate to Arm #2.

  • Page 158: Replacing The Brake

    Maintenance 7. Arm #3 7.3 Replacing the Brake Name Quantity Note Maintenance Solenoid brake R13B030501 parts width across flats: 1.5 mm For M3 set screw width across flats: 2.5 mm For M3 screw Hexagonal wrench width across flats: 3 mm For M4 screw width across flats: 4 mm For M5 screw...
  • Page 159 Maintenance 7. Arm #3 Joint #3 brake (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 160 Maintenance 7. Arm #3 (1) Mount the brake to the brake plate. Joint #3 brake 2-M3×10 Installation Brake Brake plate Z plate (2) Mount the brake hub to the Z1 pulley. (3) 4-M5×12 For the brake hub mounting procedure, refer to Joint #3 motor the section 7.1 Replacing Joint #3 Motor - Joint Z1 pulley...

  • Page 161: Arm #4

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

  • Page 162: Replacing Joint #4 Motor

    Maintenance 8. Arm #4 8.1 Replacing Joint #4 Motor Name Quantity Note R13B000609 Maintenance AC Servo Motor (100 W) R13B000617 parts (For S/N:1**** or later) width across flats: 2 mm For M4 set screw Hexagonal wrench width across flats: 3 mm For M4 screw Nippers For cutting wire tie...
  • Page 163 Maintenance 8. Arm #4 Joint #4 motor (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 164 Maintenance 8. Arm #4 (1) Mount the motor plate to the Joint #4 motor. Joint #4 motor Motor plate Installation 2-M4×8 (2) Secure the pulley to the new Joint #4 motor. M4 bushing Be sure to fit the end face of the pulley to the 2-M4×8 end face of the motor shaft.
  • Page 165 Maintenance 8. Arm #4 (8) Re-bundle the cables in their original positions with a wire tie removed in step (5). Do not allow unnecessary strain on the cables. (9) Install the arm top cover and the arm bottom cover. For details, refer to Maintenance: 3. Covers. (10) Perform the calibration of Joint #4.

  • Page 166: Replacing The Timing Belt

    Maintenance 8. Arm #4 8.2 Replacing the Timing Belt Name Quantity Note U1 belt (width 9 mm) R13B030207 Maintenance parts U2 belt (width 20 mm) R13B030208 Hexagonal wrench (width across flats: 3 mm) For M4 screw Belt tension : 70N, 80N, 130N Force gauge (7.1 kgf, 8.2 kgf, 13.2 kgf) Tools...
  • Page 167 Maintenance 8. Arm #4 U1 belt (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 168 Maintenance 8. Arm #4 (1) Set the U1 belt around the U1 pulley and U2 U1 belt U1 belt large pulley (upper side) so that the gear Installation grooves of the belt are fit into those of the pulleys completely. U2 large pulley U1 pulley (2) Set the U2 belt around the U3 pulley and U2...
  • Page 169 Maintenance 8. Arm #4 (6) Install the arm top cover and the arm bottom cover. For details, refer to Maintenance: 3. Covers. (7) Perform the calibration of Joint #3. For details on the calibration method, refer to Maintenance: 13. Calibration. G6 Rev.21...
  • Page 170 Maintenance 8. Arm #4 U2 belt (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 171 Maintenance 8. Arm #4 (10) Remove the U2 belt from the U2 small pulley Joint #4 Joint #4 and remove the U1 belt from the U1 pulley and intermediate motor unit shaft unit U2 large pulley. U1 belt U2 belt Put the Joint #4 motor unit and the Joint #4 intermediate shaft unit to the shaft side and remove the belt from the pulley.
  • Page 172 Maintenance 8. Arm #4 (1) Pass the U2 belt through the shaft and mount the U2 belt 3-M4×12 ball screw spline unit to Arm #2. Installation U2 belt (2) Loosely secure the spline plate to Arm #2. After moving the shaft up and down several times, secure the spline plate to Arm #2.
  • Page 173 Maintenance 8. Arm #4 (8) Apply the proper tension to the U2 belt, and U2 belt tension = 130 N (13.2 kgf) then secure the Joint #4 intermediate shaft unit. Joint #4 Intermediate To do so, pass a suitable cord or string around shaft unit the Joint #4 intermediate shaft unit near its Force gauge...

  • Page 174: Replacing The Brake

    Maintenance 8. Arm #4 8.3 Replacing the Brake Name Quantity Note Maintenance Solenoid brake R13B030502 parts width across flats: 1.3 mm For M2.5 set screw Hexagonal wrench width across flats: 2 mm For M2.5 screw Tools Nippers For cutting wire tie Wire tie Material The brake for U axis is installed to G6-**3**.
  • Page 175 Maintenance 8. Arm #4 Joint #4 brake (1) Turn ON the Controller. Removal (2) Push down the shaft to its lower limit while pressing the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 176 Maintenance 8. Arm #4 (1) Mount the brake to the Joint #4 intermediate Joint #4 brake Brake hub 2-M2.5×25 shaft unit. Installation Brake (2) Mount the brake hub to the Joint #4 intermediate shaft unit. (3) Mount the rubber cap. Rubber cap Insert 9 mm to the brake.

  • Page 177: Bellows

    Maintenance 9. Bellows 9. Bellows NOTE The bellows are provided in a unit of two pieces. The shape varies between the upper  and lower bellows. A large amount of dust is emitted when replacing the bellows. Take the Manipulator to an outer room such as the room in front of the clean room’s entrance, or take the necessary countermeasures to prevent dust emission before removing the bellows.
  • Page 178 Maintenance 9. Bellows Bellows (1) To attach the upper bellows, move the shaft to its lower limit. Installation To attach the lower bellows, move the shaft to its upper limit. To move the shaft up/down, press and hold the brake release switch. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 179 Maintenance 9. Bellows (6) Turn OFF the Controller and peripheral equipment. (7) Attach the end effector. (8) Connect the wires and tubes to the end effector. G6 Rev.21...

  • Page 180: Ball Screw Spline Unit

    Maintenance 10. Ball Screw Spline Unit 10. Ball Screw Spline Unit ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.

  • Page 181: Greasing The Ball Screw Spline Unit

    Maintenance 10. Ball Screw Spline Unit 10.1 Greasing the Ball Screw Spline Unit Name Quantity Note Proper Grease For Ball Screw Spline Unit (AFB grease) quantity Wiping cloth For wiping grease (Spline shaft) For clamp band removal Tools Cross-point screwdriver Only for Cleanroom-model and Protected-model The brake release switch is applied to both Joints #3 and #4.

  • Page 182: Cleanroom-Model, Protected-Model

    Maintenance 10. Ball Screw Spline Unit 10.1.2 Cleanroom-model, Protected-model (C, D with bellows, P type) Cover the surrounding area such as the end effector and peripheral equipment in case the grease drips. Upper Part (1) Turn ON the Controller. Stop motor excitation. (MOTOR OFF) of the Shaft (2) Move the arm to a position where Joint #3 can be moved in full stroke.

  • Page 183: Replacing The Ball Screw Spline Unit

    Maintenance 10. Ball Screw Spline Unit 10.2 Replacing the Ball Screw Spline Unit A brake is mounted on the motor of Joints #3 and #4 to prevent the shaft from moving down due to the weight of the end effector while the power to the Controller is OFF or while the motor is in OFF status (MOTOR OFF).
  • Page 184 Maintenance 10. Ball Screw Spline Unit Ball screw (1) Turn ON the Controller. spline unit (2) Push down the shaft to its lower limit while pressing the brake release switch. Be Removal sure to keep enough space and prevent the end effector hitting any peripheral equipment.
  • Page 185 Maintenance 10. Ball Screw Spline Unit (12) Remove the U2 belt from the U2 small pulley Joint #4 Joint #4 and remove the U1 belt from the U1 pulley and Intermediate Motor unit shaft unit U2 large pulley. U1 belt U2 belt (13) Put the Joint #4 motor unit and the Joint #4 intermediate shaft unit to the shaft side and...
  • Page 186 Maintenance 10. Ball Screw Spline Unit (1) Pass the U2 belt and Z belt through the shaft and Ball screw U2 belt Z belt spline unit mount the ball screw spline unit to Arm #2. Installation (2) Secure the nut mounting screws of the ball screw spline shaft on lower side of Arm #2.
  • Page 187 Maintenance 10. Ball Screw Spline Unit (7) Set the U2 belt around the U3 pulley and U2 U2 belt small pulley so that the gear grooves of the belt are fit into those of the pulleys completely. U3 pulley U2 small pulley (8) Loosely secure the Joint #3 motor unit, Joint #4 Joint #4 Joint #4...
  • Page 188 Maintenance 10. Ball Screw Spline Unit (11) Apply the proper tension to the Z belt, and then Z belt tension = 80 N (8.1 kgf) secure the Joint #3 motor unit. Joint #3 To do so, pass a suitable cord or string around motor unit the Joint #3 motor unit near its mounting plate.

  • Page 189: Lithium Battery

    Maintenance 11. Lithium Battery 11. Lithium Battery ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
  • Page 190 EPSON RC+ 7.0. For details, refer to the following manual. Robot Controller RC700 / RC700-A “Maintenance 6. Alarm” For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the NOTE  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 5.0.

  • Page 191: Replacing The Battery Unit (Lithium Battery)

    Maintenance 11. Lithium Battery 11.1 Replacing the Battery Unit (Lithium Battery) (1) Turn OFF the Controller. Battery unit (lithium battery) (2) Push down the shaft to its lower limit while pressing the brake release switch. Be Removal sure to keep enough space and prevent the end effector hitting any peripheral equipment.

  • Page 192: Replacing The Battery Board

    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.
  • Page 193 Maintenance 11. Lithium Battery Battery board (1) Mount the new battery board and secure it with Battery screws. Installation board 2-M4×10 (2) Connect the connectors. Connectors X61, X62, X63, X64 Battery board (3) Fix the connector cable with wiring tie. Refer to procedure (4).

  • Page 194: Led Lamp

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

  • Page 195: Calibration

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

  • Page 196: Calibration Procedure

    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+. You can also calibrate with TP1 in TEACH mode. For details, refer to RC180/RC90 EPSON RC+ 5.0...
  • Page 197 Maintenance 13. Calibration i. Select EPSON RC+ menu-[Setup]-[System Configuration]. EPSON RC+ 7.0 ii. Select the [Robot]-[Robot**]-[Calibration]. NOTE Only selected robot can be calibrated.  iii. Select the joint and click the <Calibrate…> button. (2) Confirm the warning message and click the <Yes> button.
  • Page 198 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: 0 pulse position where Arms #1 and #2 are in a straight line (Regardless of the Joint #1 direction.) 0 pulse position of Joint #3: upper limit position in motion...
  • Page 199 Maintenance 13. Calibration (4) Click the <Yes> button to reset the encoder. (5) Reboot the Controller. * This window will disappear when the Controller starts up. (6) Select the reference point to use for calibration, and click the <Next> button. Select a point from the current points to use for checking the accuracy.
  • Page 200 Maintenance 13. Calibration (8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Before operating the robot, open the [Jog & Teach] tab and execute <Motor ON>. (9) Click the <Next>...
  • Page 201 Maintenance 13. Calibration (10) The manipulator moves to the reference point. Click the <Execute> button. Input JUMP P0:z(0). ↑ Point selected in step (6) (11) Confirm the message and click the <Yes> button. (12) After the manipulator moves to the reference point, click the <Next> button. JUMP P0:z(0) G6 Rev.21...
  • Page 202 Maintenance 13. Calibration (13) Jog to the accurate reference position. Click the <Jog> button. (14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Position Joint #2 only and move Joint #3 to around 0 pulse. G6 Rev.21...
  • Page 203 Maintenance 13. Calibration (15) Click the <Next> button. (16) Execute the procedure in “Calibration Using Right / Left Arm Orientations” to accurately calibrate Joint #2 only. Go on to the step (19) for the other joints calibration. i. Move to another point that has different pose (from righty to lefty) using Jump command.
  • Page 204 Maintenance 13. Calibration iii. Jog to the accurate reference position and adjust the position. Click the <OK> button. iv. Click the <Next> button. G6 Rev.21...
  • Page 205 Maintenance 13. Calibration (17) Calibration is complete. Click the <Finish> button. (18) Move the manipulator to other points and check if it can move without problems. Teach points where appropriate. G6 Rev.21...

  • Page 206: Accurate Calibration Of Joint #2

    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. If the accuracy of Joint #2 is not obtained through the steps in the section Maintenance: NOTE ...
  • Page 207 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. Then, check the number of pose (point) you want to use. (2) Open the Tools menu | Robot Manager | Control Panel and click the MOTOR ON.

  • Page 208: Calibration Procedure Without Using Calibration Wizard

    Maintenance 13. Calibration 13.4 Calibration Procedure without using Calibration Wizard This section indicates the calibration without using the calibration wizard of EPSON RC+. NOTE  For details of calibration using the calibration wizard, refer to Maintenance: 13.2 Calibration Procedure. When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately.
  • Page 209 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: 0 pulse position where Arms #1 and #2 are in a straight line (Regardless of the Joint #1 direction.) 0 pulse position of Joint #3: upper limit position in motion...
  • Page 210 Joint #3 >calib 3 Joint #4 >calib 3, 4 Calibration (Accurate Positioning) (5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools] -[Robot Manager]-[Control Panel]. (5)-2 Click the <Free All> button to free all joints from servo control. Now, you can move arms by hands.
  • Page 211 Maintenance 13. Calibration (5)-4 Create the data from the calibration point data. Enter and execute the following command in [Command Window]. (In this example, P1 is used as the calibration point data.) > Calpls Ppls(P1,1), Ppls(P1,2), Ppls(P1,3), Ppls(P1,4) (5)-5 Move the joint to the specified point using a motion command. For example, when the specified point data is “P1”, execute “Jump P1:Z(0)”...

  • Page 212: Maintenance Parts List

    Maintenance 14. Maintenance Parts List 14. Maintenance Parts List 14.1 Common Parts Overhaul Reference: Part Name Code Note Maintenance R13B000607 400 W Joint #1, 2 5.1, 6.1  R13B000616 400 W (For S/N: 1**** or later) R13B000608 200 W AC Servo Joint #3 ...
  • Page 213 Maintenance 14. Maintenance Parts List *2 Regarding purchase of grease Due to the chemicals regulations of individual countries (the UN GHS), we are requesting our customers to purchase the grease required for maintenance from the manufacturers listed in the table below as of April 2015.

  • Page 214: Parts By Environment Model

    Maintenance 14. Maintenance Parts List 14.2 Parts by Environment Model (S: Standard-model C: Cleanroom-model D, P: Protected-model) Reference: Overhaul Part Name Code Note Maintenance 180 mm R13B010202 S, D 10.1.1  (without bellows) 330 mm R13B010203 150 mm R13B010204 Ball Screw Spline 300 mm R13B010205...
  • Page 215 Maintenance 14. Maintenance Parts List Reference: Overhaul *5 Part Name Code Note Maintenance C, P, 150 mm R13B030701 *4 *6 Bellows D with bellows 300 mm R13B030702 option Gasket Unit D, P R13B031226 Arm #2 Gasket R13B031227 S, C R13Z702640100 *2 Brake Release Switch D, P...
  • Page 216 Maintenance 14. Maintenance Parts List G6 Rev.21...

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G6 series

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