Epson LS20 User manual

Rev.4
EM179R3533F
SCARA ROBOT
LS20 series
MANIPULATOR MANUAL

MANIPULATOR MANUAL LS
20 series Rev.4

LS20 Rev.4 i
SCARA ROBOT
LS20 series Manipulator Manual
Rev.4
Copyright 2016-2017 SEIKO EPSON CORPORATION. All rights reserved.

ii LS20 Rev.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
with our high performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1.
Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2.
Malfunctions caused by customers’ unauthorized disassembly.
3.
Damage due to improper adjustments or unauthorized
repair attempts.
4.
Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1.
If the Manipulator or associated equipment is used outside of the usage conditions and
product specifications described in the manuals,
this warranty is void.
2.
If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3.
We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.

LS20 Rev.4 iii
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
MANUFACTURER

iv LS20 Rev.4
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. For more details on available collection
facilities please contact your local government office or the retailer where you purchased
this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used
in the battery.
This information only applies to customers in the European Union, according to
DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and
accumulators and repealing Directive 91/157/EEC and legislation transposing and
implementing it into the various national legal systems.
For other countries, please contact your local government to investigate the possibility of
recycling your product.
The battery removal/replacement procedure is described in the following manuals:
Controller manual / Manipulator manual (Maintenance section)

LS20 Rev.4 v
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
The LS20 series Manipulators can be used with the following combinations of Controllers
and software.
Robot Controller RC90 with the following label attached.
Label
Controller
Software
RC90 EPSON RC+ 7.0 Ver.7.1.4 or later
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to
turn ON/OFF all the hardware components. For the Controller composition, refer to the
table above.
Shape of Motors
The shape of the motors used for the Manipulator that you are using may be different from
the shape of the motors described in this manual because of the specifications.
Setting by Using Software
This manual contains setting procedures by using software. They are marked with the
following icon.
Figures in this Manual
The figures of manipulators indicated in this manual are basically Standard-model
Manipulator. Unless special instruction is provided, the specifications of Standard-model
and Cleanroom-model are the same.
Photos and Illustrations Used in This Manual
The appearance of some parts may differ from those on an actual product depending on
when it was shipped or the specifications. The procedures themselves, however, are
accurate.
EPSON
RC+

vi LS20 Rev.4

TABLE OF CONTENTS
LS20 Rev.4 vii
Setup & Operation
1. Safety 3
1.1 Conventions.............................................................................................. 3
1.2 Design and Installation Safety.................................................................. 4
1.2.1 Strength of Ball Screw Spline....................................................... 5
1.3 Operation Safety ...................................................................................... 6
1.4 Emergency Stop....................................................................................... 8
1.5 Emergency Movement Without Drive Power ......................................... 10
1.6 ACCELS Setting for CP Motions.............................................................11
1.7 Warning Labels....................................................................................... 12
2. Specifications 14
2.1 Features of LS20 series Manipulators ................................................... 14
2.2 Model Number........................................................................................ 15
2.3 Part Names and Outer Dimensions ....................................................... 16
2.3.1 LS20-804*................................................................................... 16
2.3.2 LS20-A04* .................................................................................. 20
2.4 Specifications ......................................................................................... 24
2.5 How to Set the Model............................................................................. 26
3. Environments and Installation 27
3.1 Environmental Conditions ...................................................................... 27
3.2 Base Table.............................................................................................. 28
3.3 Mounting Dimensions............................................................................. 29
3.3.1 LS20-804*................................................................................... 29
3.3.2 LS20-A04* .................................................................................. 31
3.4 Unpacking and Transportation ............................................................... 33
3.4.1 Precautions for Transportation...................................................... 33
3.4.2 Transportation ............................................................................... 34
3.5 Installation Procedure............................................................................. 35
3.5.1 Standard-Model.......................................................................... 35
3.5.2 Cleanroom-Model....................................................................... 36
3.6 Connecting the Cables........................................................................... 37
3.7 User Wires and Pneumatic Tubes.......................................................... 38
3.8 Relocation and Storage.......................................................................... 39
3.8.1 Precautions for Relocation and Storage .................................... 39
3.8.2 Relocation................................................................................... 40
4. Setting of End Effectors 41
4.1 Attaching an End Effector....................................................................... 41
4.2 Attaching Cameras and Valves .............................................................. 42
4.3 Weight and Inertia Settings .................................................................... 43
4.3.1 Weight Setting ............................................................................ 43
4.3.2 Inertia Setting ............................................................................. 45
4.4 Precautions for Auto Acceleration/Deceleration of Joint #3................... 49

TABLE OF CONTENTS
viii LS20 Rev.4
5. Motion Range 50
5.1 Motion Range Setting by Pulse Range (for All Joints)............................50
5.1.1 Max. Pulse Range of Joint #1 .....................................................51
5.1.2 Max. Pulse Range of Joint #2 .....................................................51
5.1.3 Max. Pulse Range of Joint #3 .....................................................52
5.1.4 Max. Pulse Range of Joint #4 .....................................................52
5.2 Motion Range Setting by Mechanical Stops...........................................53
5.2.1 Setting the Mechanical Stops of Joints #1 and #2......................54
5.2.2 Setting the Mechanical Stop of Joint #3 .....................................56
5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate
System of the Manipulator (for Joints #1 and #2) ..................................58
5.4 Standard Motion Range ..........................................................................58
Maintenance
1. Safety Maintenance 61
2. General Maintenance 62
2.1 Maintenance Inspection ..........................................................................62
2.1.1 Schedule for Maintenance Inspection.........................................62
2.1.2 Inspection Point...........................................................................63
2.2 Overhaul (Parts Replacement) ...............................................................64
2.3 Greasing..................................................................................................66
2.4 Tightening Hexagon Socket Head Cap Bolts .........................................68
2.5 Matching Origins .....................................................................................68
2.6 Layout of Maintenance Parts ..................................................................69
3. Covers 70
3.1 Arm Top Cover ........................................................................................71
3.2 Arm Bottom Cover...................................................................................72
3.3 Arm #1 Cover ..........................................................................................72
3.4 Connector Plate ......................................................................................73
3.5 Connector Sub Plate...............................................................................74
3.6 User Plate................................................................................................74
4. Cable 75
4.1 Replacing Cable Unit ..............................................................................75
4.2 Wiring Diagrams......................................................................................80
4.2.1 Signal Cable................................................................................80
4.2.2 Power Cable................................................................................81
4.2.3 User Cable ..................................................................................82
4.3 Replacing M/C Cable ..............................................................................83

TABLE OF CONTENTS
LS20 Rev.4 ix
5. Arm #1 86
5.1 Replacing Joint #1 Motor ....................................................................... 87
5.2 Replacing Joint #1 Reduction Gear Unit................................................ 90
6. Arm #2 93
6.1 Replacing Joint #2 Motor ....................................................................... 94
6.2 Replacing Joint #2 Reduction Gear Unit................................................ 98
7. Arm #3 102
7.1 Replacing Joint #3 Motor ..................................................................... 103
7.2 Replacing the Timing Belt .................................................................... 107
7.3 Replacing the Brake.............................................................................. 111
7.4 Checking the Timing Belt Tension.........................................................114
8. Arm #4 115
8.1 Replacing Joint #4 Motor ......................................................................116
8.2 Replacing the Timing Belt .................................................................... 120
8.3 Replacing the Brake............................................................................. 125
8.4 Replacing the Reduction Gear Unit ..................................................... 126
8.5 Checking the Timing Belt Tension........................................................ 128
9. Bellows 129
10. Ball Screw Spline Unit 131
10.1 Greasing the Ball Screw Spline Unit.................................................. 131
10.1.1 Standard-model (S type) ........................................................ 132
10.1.2 Cleanroom-model ................................................................... 133
10.2 Replacing the Ball Screw Spline Unit................................................. 135
11. Lithium Battery 138
11.1 Replacing the Battery Unit (Lithium Battery)...................................... 140
11.2 Replacing the Resolver Board............................................................ 141
11.3 Replacing the Control Board .............................................................. 143
12. LED Lamp 144
13. Calibration 145
13.1 About Calibration................................................................................ 145
13.2 Calibration Procedure......................................................................... 146
13.3 Accurate Calibration of Joint #2 ......................................................... 156
13.4 Calibration Procedure without using Calibration Wizard ................... 158
14. Maintenance Parts List 162

TABLE OF CONTENTS
x LS20 Rev.4

Setup & Operation
This volume
contains information for setup and operation of the
LS20
series Manipulators.
Please read this volume
thoroughly before setting up and
operating the Manipulators.

Setup & Operation 1. Safety
LS20 Rev.4 3
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.
Keep this manual handy for easy access at all times.
1.1 Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
This symbol indicates that a danger of possible serious injury or
death exists if the associated instructions are not followed
properly.
WARNING
This symbol indicates that a danger of possible serious injury or
death caused by electric shock exists if the associated
instructions are not followed properly.
CAUTION
This symbol indicates that a danger of possible harm to people
or physical damage to equipment and facilities exists if the
associated instructions are not followed properly.

Setup & Operation 1. Safety
4 LS20 Rev.4
1.2 Design and Installation Safety
Only trained personnel should design and install the robot system. Trained
personnel are defined as those who have taken robot system training and
maintenance training classes held by the manufacturer, dealer, or local
representative company, or those who understand the manuals thoroughly and
have the same knowledge and skill level as those who have completed the training
courses.
To ensure safety, a safeguard must be installed for the robot system. For details
on the safeguard, refer to the Installation and Design Precautions in the Safety
chapter of the EPSON RC+ User’s Guide.
The following items are safety precautions for design personnel:
WARNING
■
Personnel who design and/or construct the robot system with this product must
read the
Safety chapter in the EPSON RC+ User’s Guide to understand the
safety requirements before designing and/or constructing the robot system.
Designing and/or constructing the robot system without understanding the safety
requirements is extremely hazardous, may result in serious bodily injury and/or
sever
e equipment damage to the robot system, and may cause serious safety
problems.
■
The Manipulator and the Controller must be used within the environmental
conditions described in their respective manuals.
This product has been
designed and manufactured strictly for use in a normal indoor
environment. Using
the product in an environment that exceeds the specified environmental
conditions may not only shorten the life cycle of the product but may also cause
serious safety problems.
■
The robot system must be used within the installation requirements described in
the manuals.
Using the robot system outside of the installation requirements
may not only shorten the life cycle of the product but also cause serious safety
problems.
Further precautions for installation are mentioned in the chapter Setup &
Operation: 3. Environments and Installation.Please read this chapter carefully to
understand safe installation procedures before installing the robots and robotic
equipment.

Setup & Operation 1. Safety
LS20 Rev.4 5
1.2.1 Strength of 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.
The allowable loads differ depending on distance where the load is applied to. For
calculating the allowable load, see the calculation formula below.
[Allowable bending moment]
M=50,000 N
∙ mm
Calculation example:
110 N (11.2 kgf) load is placed at 400 mm from the end of the spline nut
[Moment]
M=F
∙ L ＝ 110∙400 ＝ 44,000 N ∙ mm
End of spline nut
F
L

Setup & Operation 1. Safety
6 LS20 Rev.4
1.3 Operation Safety
The following items are safety precautions for qualified Operator personnel:
WARNING
■
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 sever
e equipment
damage to the robot system.
■
Do not enter the operating area of the Manipulator while the power to the robot
system is turned ON.
Entering the operating area with
the power ON is
extremely hazardous and may cause serious safety problems as the Manipulator
may move even if it seems to be stopped.
■
Before operating the robot system, make sure that no one is inside the
safeguarded area.
The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
The motion of the Manipulator is
always in restricted (low speed and low power)
status to secure the safety of an operator.
However, operating the robot system
while someone is inside the safeguarded area is extremely hazardous and may
result in serious safety problems in case that the Manipulator moves
unexpectedly.
■
Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally while the robot system is operated.
Continuing the operation while
the Manipulator moves abnormally is extremely hazardous and may result in
serious bodily injury and/or
severe equipment damage to the robot system.
WARNING
■
To shut off power to the robot system, pull out the power plug from the power
source.
Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power
source.
■
Before performing any replacement procedure, turn OFF the
Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in
electric shock and/or malfunction of the robot
system.
■
Do not insert or pull out the motor connectors while the power to the robot system
is turned ON.
Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.

Setup & Operation 1. Safety
LS20 Rev.4 7
CAUTION
■
Whenever possible, only one person should operate the robot system.
If it is
necessary to operate the robot system with more than one person, ensure that all
people involved communicate with each other as to what they are doing and take
all nece
ssary safety precautions.
■
Joint #1, #2, and #4:
If the joints are operated
repeatedly with the operating angle less than 5 degrees,
they may get damaged early because the bearings are likely to cause oil film
shortage in such situation. To prevent early breakdown, move the joints larger
than 50 degrees for about five to ten times a day.
J
oint #3:
If the up
-and-down motion of the hand is less than 10 mm, move the joint a half of
the maximum stroke for five to ten times a day.
■
Oscillation (resonance) may
occur continuously in low speed Manipulator motion
(Speed:
approx. 5 to 20%) depending on combination of Arm orientation and end
effector load. Oscillation arises from natural oscillation frequency of the Arm
and can be controlled by following measures.
Changing Manipulator speed
Changing the teach points
Changing the end effector load

Setup & Operation 1. Safety
8 LS20 Rev.4
1.4 Emergency Stop
If the Manipulator moves abnormally during operation, immediately press the Emergency
Stop switch. Pressing the Emergency Stop switch immediately changes the manipulator
to deceleration motion and stops it at the maximum deceleration speed.
However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator
is running normally. Pressing the Emergency Stop switch locks the brake and it may
cause wear on the friction plate of the brake, resulting in the short life of the brake.
Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)
To place the system in emergency mode during normal operation, press the Emergency
Stop switch when the Manipulator is not moving.
Refer to the Controller manual for instructions on how to wire the Emergency Stop switch
circuit.
Do not turn OFF the Controller while the Manipulator is operating.
If you attempt to stop the Manipulator in emergency situations such as “Safeguard Open”,
make sure to stop the Manipulator using the E-Stop of the Controller.
If the Manipulator is stopped by turning OFF the Controller while it is operating,
following problems may occur.
Reduction of the life and damage of the reduction gear unit
Position gap at the joints
In addition, if the Controller was forced to be turned OFF by blackouts and the like while
the Manipulator is operating, make sure to check the following points after power
restoration.
Whether or not the reduction gear is damaged
Whether or not the joints are in their proper positions
If there is a position gap, perform calibration by referring to the Maintenance 16.
Calibration in this manual.
Before using the Emergency Stop switch, be aware of the followings.
-The Emergency Stop (E-STOP) switch should be used to stop the Manipulator only
in case of emergencies.
-To stop the Manipulator operating the program except in emergency, use Pause (halt)
or STOP (program stop) commands.
Pause and STOP commands do not turn OFF the motors. Therefore, the brake does
not function.
-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