Epson LS3-401 series User manual

Rev.10
EM16XR3299F
SCARA ROBOT
LS series
MANIPULATOR MANUAL

MANIPULATOR MANUAL LS series
Rev.10

SCARA ROBOT
LS series Manipulator Manual
Rev.10
Copyright 2011-2016 SEIKO EPSON CORPORATION. All rights reserved.

ii LS Rev.10
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 i
s 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.

LS Rev.10 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 LS Rev.10
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)

LS Rev.10 v
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
The LS series Manipulators can be used with the following combinations of Controllers and
software.
TYPE A:
Controller
Software
RC90 EPSON RC+ 5.0
LS3-401*, LS6-602*
RC90 Controller Firmware Version
Ver.3.0.*.*
EPSON RC+ 5.0
Before Ver.5.4.0
!!!
Ver.5.4.1 or later
OK
OK: Compatible All functions of the EPSON RC+ 5.0 and the Controller are
available.
!!!: Compatible Connection is OK. We recommend using EPSON RC+5.0 Ver.
5.4.1 or later. Controller firmware update cannot be executed.

vi LS Rev.10
TYPE B: Robot Controller RC90 with the following label attached.
Label
Controller
Software
RC90 EPSON RC+ 7.0
LS3-401*
RC90 controller firmware
Ver.7.0.2.0 or later
EPSON RC+ 7.0
Before Ver.7.0.1
!!!
Ver.7.0.2 or later
OK
OK: Compatible All functions of the EPSON RC+ 7.0 and the Controller are
available.
!!!: Compatible Connection is OK. We recommend using EPSON RC+ 7.0 Ver.
7.0.2 or later.
Manipulator serial No. : L6**00****
LS6-602*
RC90 controller firmware
Ver.7.0.2.0 or later
EPSON RC+ 7.0
Before Ver.7.0.1
!!!
Ver.7.0.2 or later
OK
OK: Compatible All functions of the EPSON RC+ 7.0 and the Controller are
available.
!!!: Compatible Connection is OK. We recommend using EPSON RC+ 7.0 Ver.
7.0.2 or later.
Manipulator serial No. : L6**01**** or later
LS6-502*, LS6-602*, LS6-702*
RC90 controller firmware
Ver.7.1.6.0 or later
EPSON RC+ 7.0
Before Ver.7.1.2
!!!
Ver.7.1.3 or later
OK
OK: Compatible All functions of the EPSON RC+ 7.0 and the Controller are
available.
!!!: Compatible Connection is OK. We recommend using EPSON RC+ 7.0 Ver.
7.1.3 or later.

LS Rev.10 vii
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.
EPSON
RC+

viii LS Rev.10

TABLE OF CONTENTS
LS Rev.10 ix
Setup & Operation
1. Safety 3
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 Controller Firmware Ver. 7.0.2.3 or earlier................................... 8
1.4.2 Controller Firmware Ver. 7.0.2.4 or later.................................... 10
1.5 Emergency Movement Without Drive Power......................................... 12
1.6 ACCELS Setting for CP Motions............................................................ 13
1.7 Warning Labels....................................................................................... 14
2. Specifications 16
2.1 Features of LS series Manipulators....................................................... 16
2.2 Model Number........................................................................................ 17
2.3 Part Names and Outer Dimensions....................................................... 18
2.3.1 LS3 ............................................................................................. 18
2.3.2 LS6 ............................................................................................. 22
2.4 Specifications......................................................................................... 26
2.5 How to Set the Model............................................................................. 28
3. Environments and Installation 29
3.1 Environmental Conditions...................................................................... 29
3.2 Base Table.............................................................................................. 30
3.3 Mounting Dimensions............................................................................. 31
3.3.1 LS3 ............................................................................................. 31
3.3.2 LS6 ............................................................................................. 33
3.4 Unpacking and Transportation............................................................... 35
3.5 Installation Procedure............................................................................. 36
3.5.1 Standard-Model.......................................................................... 37
3.5.2 Cleanroom-Model....................................................................... 38
3.6 Connecting the Cables........................................................................... 39
3.7 User Wires and Pneumatic Tubes.......................................................... 40
3.8 Relocation and Storage.......................................................................... 41
3.8.1 Precautions for Relocation and Storage.................................... 41
3.8.2 Relocation................................................................................... 42
4. Setting of End Effectors 43
4.1 Attaching an End Effector....................................................................... 43
4.2 Attaching Cameras and Valves.............................................................. 45
4.3 Weight and Inertia Settings.................................................................... 46
4.3.1 Weight Setting............................................................................ 46
4.3.2 Inertia Setting ............................................................................. 49
4.4 Precautions for Auto Acceleration/Deceleration of Joint #3................... 53

TABLE OF CONTENTS
x LS Rev.10
5. Motion Range 54
5.1 Motion Range Setting by Pulse Range (forAll Joints)............................54
5.1.1 Max. Pulse Range of Joint #1.....................................................55
5.1.2 Max. Pulse Range of Joint #2.....................................................55
5.1.3 Max. Pulse Range of Joint #3.....................................................56
5.1.4 Max. Pulse Range of Joint #4.....................................................56
5.2 Motion Range Setting by Mechanical Stops...........................................57
5.2.1 Setting the Mechanical Stops of Joints #1 and #2......................58
5.2.2 Setting the Mechanical Stop of Joint #3 .....................................60
5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate
System of the Manipulator (for Joints #1 and #2)..................................62
5.4 Standard Motion Range..........................................................................62
Maintenance 1. Safety Maintenance 65
2. General Maintenance 66
2.1 Maintenance Inspection..........................................................................66
2.1.1 Schedule for Maintenance Inspection.........................................66
2.1.2 Inspection Point...........................................................................67
2.2 Overhaul (Parts Replacement)...............................................................68
2.3 Greasing..................................................................................................70
2.4 Tightening Hexagon Socket Head Cap Bolts.........................................71
2.5 Matching Origins.....................................................................................72
2.6 Layout of Maintenance Parts..................................................................73
3. Covers 74
3.1 Arm Top Cover........................................................................................75
3.2 Arm Bottom Cover...................................................................................75
3.3 Connector Plate ......................................................................................76
3.4 Connector Sub Plate...............................................................................77
3.5 User Plate................................................................................................77
4. Cable 78
4.1 Replacing Cable Unit ..............................................................................79
4.2 Wiring Diagrams......................................................................................84
4.2.1 Signal Cable................................................................................84
4.2.2 Power Cable................................................................................86
4.2.3 User Cable ..................................................................................87
4.3 Replacing M/C Cable..............................................................................88
5. Arm #1 91
5.1 Replacing Joint #1 Motor........................................................................92
5.2 Replacing Joint #1 Reduction Gear Unit ................................................95

TABLE OF CONTENTS
LS Rev.10 xi
6. Arm #2 98
6.1 Replacing Joint #2 Motor ....................................................................... 99
6.2 Replacing Joint #2 Reduction Gear Unit.............................................. 103
7. Arm #3 107
7.1 Replacing Joint #3 Motor ..................................................................... 108
7.2 Replacing the Timing Belt .....................................................................112
7.3 Replacing the Brake..............................................................................116
7.4 Checking the Timing Belt Tension (Z Belt)........................................... 120
8. Arm #4 121
8.1 Replacing Joint #4 Motor ..................................................................... 122
8.2 Replacing the Timing Belt .................................................................... 126
8.2.1 U2 Belt...................................................................................... 127
8.2.2 U1 Belt...................................................................................... 132
8.3 Replacing the Brake (For LS6 series).................................................. 135
8.4 Checking the Timing Belt Tension (U1, U2 Belts)................................ 137
9. Bellows 138
10. Ball Screw Spline Unit 140
10.1 Greasing the Ball Screw Spline Unit.................................................. 140
10.1.1 Standard-model (S type)........................................................ 141
10.1.2 Cleanroom-model................................................................... 142
10.2 Replacing the Ball Screw Spline Unit................................................. 143
11. Lithium Battery and Boards 146
11.1 Replacing the Battery Unit (Lithium Battery)...................................... 148
11.2 Replacing the Resolver Board............................................................ 149
11.3 Replacing the Control Board.............................................................. 151
12. LED Lamp 152
13. Calibration 153
13.1 About Calibration................................................................................ 153
13.2 Calibration Procedure......................................................................... 154
13.3 Accurate Calibration of Joint #2......................................................... 164
13.4 Calibration Procedure without using Calibration Wizard ................... 166
14. Maintenance Parts List 170
14.1 LS3..................................................................................................... 170
14.2 LS6..................................................................................................... 171

TABLE OF CONTENTS
xii LS Rev.10

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

Setup & Operation 1. Safety
LS Rev.10 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 LS Rev.10
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
LS Rev.10 5
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.
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]
LS3: M=13,000 N ∙ mm
LS6: M=27,000 N ∙ mm
Example: If 100 N load is applied
at 200 mm from
the end of the spline nut
[Moment]
M=F ∙ L ＝ 100 ∙ 200 ＝ 20,000 N ∙ mm
End of the
spline nut
F
L

Setup & Operation 1. Safety
6 LS Rev.10
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 i
n 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.