Epson ProSix S5 Series User manual

Rev.5 EM133R2483F
EPSON ProSix
S5 series
MANIPULATOR MANUAL

Manipulator manual
S5 series Rev. 5

S5 Rev.5i
EPSON ProSix
S5 series Manipulator Manual
Rev. 5
Copyright  2010-2013 SEIKO EPSON CORPORATION. All rights reserved.

ii S5 Rev.5
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 robot and its optional parts are shipped to our customers only after being subjected to
the strictest quality controls, tests, and inspections to certify its compliance with our high
performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (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 robot 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.

S5 Rev.5iii
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
INQUIRIES
Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier office for
your region.
Please prepare the following items before you contact us.
- Your controller model and its serial number
- Your manipulator model and its serial number
- Software and its version in your robot system
- A description of the problem
SERVICE CENTER

iv S5 Rev.5
MANUFACTURER
Toyoshina Plant
Industrial Solutions Division
6925 Toyoshina Tazawa,
Azumino
-shi, Nagano, 399-8285
JAPAN
TEL
: [phone]
FAX
: [phone]
SUPPLIERS
North & South
America
EPSON AMERICA, INC.
Factory
Automation/Robotics
18300 Central Avenue
Carson, CA 90746
USA
TEL
: [phone]
FAX
: [phone]
E-MAIL
: [e-mail]
Europe
EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto
-Hahn-Str.4
D
-40670 Meerbusch
Germany
TEL
: [phone]
FAX
: [phone]
E-MAIL
: [e-mail]
China
EPSON China Co., Ltd
Factory Automation Division
7F, Jinbao Building No. 89 Jinbao Street
Dongcheng District, Beijing,
China, 100005
TEL
: [phone]
FAX
: [phone]
Taiwa n
EPSON Taiwan Technology & Trading Ltd.
Factory Automation Division
14F, No.7, Song Ren Road, Taipei 110
Taiwan, ROC
TEL
: [phone]
FAX
: [phone]

S5 Rev.5v
Southeast Asia
Epson Singapore Pte Ltd.
India
Factory Automation System
1 HarbourFrontPlace, #03
-02
HarbourFront Tower one, Singapore
098633
TEL
: [phone]
FAX
: [phone]
Korea
EPSON Korea Co, Ltd.
Marketing Team (Robot
Business)
27F DaeSung D-Polis A, 606,
Seobusaet-gil, Geumcheon-gu, Seoul, 153-803
Korea
TEL
: [phone]
FAX
: [phone]
Japan
EPSON SALES JAPAN CORPORATION
Factory Automation Systems Department
Nishi
-Shinjuku Mitsui Bldg.6-24-1
Nishishinjuku. Shinjuku
-ku. Tokyo. 160-8324
JAPAN
TEL
: [phone]

vi S5 Rev.5
For Customers in the European Union
The crossed out wheeled bin label that can be found on your product indicates that this
product and incorporated batteries should not be disposed of via the normal household
waste stream. To prevent possible harm to the environment or human health please
separate this product and its batteries from other waste streams to ensure that it can be
recycled in an environmentally sound manner. For more details on available collection
facilities please contact your local government office or the retailer where you purchased
this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used
in the battery.
This information only applies to customers in the European Union, according to
DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and
accumulators and repealing Directive 91/157/EEC and legislation transposing and
implementing it into the various national legal systems.
For other countries, please contact your local government to investigate the possibility of
recycling your product.
The battery removal/replacement procedure is described in the following manuals:
Controller manual / Manipulator manual (Maintenance section)

S5 Rev.5vii
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
S5 series Manipulators can be used with the following combinations of Controllers and
software.
Controller
Software
Type
Composition (Hardware)
RC180 Controller EPSON RC+ 5.0
RC620 Control Unit
Drive Unit EPSON RC+ 6.0
For details on commands, refer to “EPSON RC+ User’s Guide” or “Online Help”.
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to
turn ON/OFF all the hardware components. For the hardware components, see the table
above.
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.

viii S5 Rev.5

S5 Rev.5ix
Table of Contents
Before Reading This Manual ............................................................................ v
Setup & Operation
1. Safety ··········································································· 3
1.1 Conventions .......................................................................................... 3
1.2 Design and Installation Safety .............................................................. 4
1.3 Operation Safety ................................................................................... 5
1.4 Emergency Stop .................................................................................... 6
1.5 How to Move Arms the Electromagnetic Brake is Applied to ............... 7
1.5.1 Moving the Arm Using the Brake Release Unit ........................ 8
1.5.2 Moving the Arm Using the Software ........................................ 13
1.6 Precaution for Operation in Low Power Status ................................... 14
1.7 Manipulator Labels .............................................................................. 15
2. Specifications ································································ 18
2.1 Features of Manipulators .................................................................... 18
2.2 Model Number ..................................................................................... 19
2.3 Appearance ......................................................................................... 20
2.4 Specifications ...................................................................................... 25
2.4.1 Table ........................................................................................ 25
2.4.2 Option Table ............................................................................ 26
2.5 How to Set the Model .......................................................................... 27
3. Environment and Installation ············································· 28
3.1 Environmental Conditions ................................................................... 28
3.2 Unpacking, Transportation, and Relocation ........................................ 30
3.2.1 Using a Crane ......................................................................... 31
3.2.2 Using a Forklift ........................................................................ 32
3.2.3 Removing / Attaching the Shipping Bolts and Jigs ................. 32
3.2.4 Relocating ............................................................................... 33
3.3 Mounting Dimensions ......................................................................... 34
3.4 Installation ........................................................................................... 35
3.4.1 Base Table Mounting ............................................................... 36
3.4.2 Floor Mounting ........................................................................ 37
3.4.3 Cleanroom-model .................................................................... 38
3.4.4 Protection-model ....................................................................... 38
3.5 Connecting the Cables ........................................................................ 39
3.5.1 Cable Connections .................................................................. 40
3.5.2 Grounding ................................................................................ 41
3.6 Setting the Basic Pose for Calibration ................................................ 42
3.7 User Wires and Pneumatic Tubes ...................................................... 44

x S5 Rev.5
4. End Effectors ································································· 46
4.1 Attaching an End Effector .................................................................... 46
4.2 Attaching Valves .................................................................................. 47
4.3 WEIGHT and INERTIA Settings .......................................................... 47
4.3.1 WEIGHT Setting ...................................................................... 50
4.3.2 INERTIA Setting ....................................................................... 54
4.4 Precautions for Auto Acceleration / Deceleration ................................ 58
5. Motion Range ································································ 59
5.1 Motion Range Setting by Pulse Range (for All Arms) .......................... 60
5.1.1 Max. Pulse Range of Arm #1 ................................................... 61
5.1.2 Max. Pulse Range of Arm #2 ................................................... 62
5.1.3 Max. Pulse Range of Arm #3 ................................................... 63
5.1.4 Max. Pulse Range of Arm #4 ................................................... 64
5.1.5 Max. Pulse Range of Arm #5 ................................................... 65
5.1.6 Max. Pulse Range of Arm #6 ................................................... 66
5.2 Restriction of Manipulator Operation by Joint Angle Combination ...... 67
5.3 Coordinate System .............................................................................. 69
5.4 Setting the Cartesian (Rectangular) Range in
the XY Coordinate System of the Manipulator ...................................... 69
Maintenance
1. Safety Maintenance ························································ 73
2. Periodic Inspection ························································· 75
2.1 Schedule for Maintenance Inspections ............................................... 75
2.2 Inspection Tasks .................................................................................. 76
2.3 Grease Replenishment ........................................................................ 78
2.3.1 Joint #1 Reduction Gear Unit ................................................... 80
2.3.2 Joint #1 Gear ........................................................................... 81
2.3.3 Joint #2 Reduction Gear Unit ................................................... 82
2.3.4 Joint #3 Reduction Gear Unit ................................................... 83
2.3.5 Joint #4 Reduction Gear Unit ................................................... 84
2.3.6 Joint #5 Reduction Gear Unit ................................................... 85
2.3.7 Joint #6 Reduction Gear Unit ................................................... 86
2.4 Tightening Hexagon Socket Head Cap Bolts ...................................... 87
2.5 Removing Condensation (Only protection-model) ................................ 88
3. Covers ········································································· 89
3.1 Arm #1 Cover ......................................................................................... 90
3.2 Arm #2 Cover ....................................................................................... 91
3.3 Arm #3 Cover ....................................................................................... 92
3.4 Arm #4 Cover ....................................................................................... 93
3.5 Connector Plate ..................................................................................... 94
3.6 Connector Sub Plate ............................................................................. 95

S5 Rev.5xi
4. Joint #1 ········································································ 96
4.1 Replacing the Joint #1 Motor .............................................................. 96
4.2 Replacing the Joint #1 Reduction Gear Unit .................................... 102
4.2.1 Greasing the Reduction Gear Unit ........................................ 103
4.2.2 Replacing the Reduction Gear Unit ...................................... 104
5. Joint #2 ······································································ 110
5.1 Replacing the Joint #2 Motor ............................................................. 110
5.2 Replacing the Joint #2 Reduction Gear Unit ..................................... 114
5.2.1 Greasing the Reduction Gear Unit ......................................... 116
5.2.2 Replacing the Reduction Gear Unit ....................................... 117
5.3 Replacing the Joint #2 Timing Belt ................................................... 124
6. Joint #3 ······································································ 126
6.1 Replacing the Joint #3 Motor ............................................................ 126
6.2 Replacing the Joint #3 Reduction Gear Unit .................................... 130
6.2.1 Greasing the Reduction Gear Unit ........................................ 131
6.2.2 Replacing the Reduction Gear Unit ...................................... 133
6.3 Replacing the Joint #3 Timing Belt ................................................... 140
7. Joint #4 ······································································ 142
7.1 Replacing the Joint #4 Motor ............................................................ 142
7.2 Replacing the Joint #4 Reduction Gear Unit .................................... 145
7.2.1 Greasing the Reduction Gear Unit ........................................ 146
7.2.2 Replacing the Reduction Gear Unit ...................................... 147
7.3 Replacing the Joint #4 Timing Belt ................................................... 153
8. Joint #5 & Joint #6 ························································ 155
8.1 Replacing the Joint #5 & Joint #6 Motor ........................................... 155
8.2 Replacing the Joint #5 & Joint #6 Timing Belt .................................. 160
8.3 Replacing the Joint #5 & Joint #6 Brake ............................................ 162
9. Cable Unit ··································································· 163
9.1 Replacing the Cable Unit .................................................................. 163
9.2 Wiring Diagrams .............................................................................. 175
9.2.1 Signal Cable .......................................................................... 175
9.2.2 Power Cable .......................................................................... 176
9.2.3 User Cable ............................................................................ 177
9.3 Replacing the M/C Cable .................................................................... 178
10. Battery Unit (Lithium Battery) ········································ 181
10.1 Precautions of the Data .................................................................. 181
10.2 Replacing the Battery Unit ............................................................ 182
10.3 Data Recovery ............................................................................... 184
11. Replacing the LED Lamp ·············································· 186

xii S5 Rev.5
12. Calibration ································································· 188
12.1 Overview ........................................................................................ 188
12.2 Calibration Procedure .................................................................... 190
12.3 Calibration Jig .................................................................................. 193
13. Maintenance Parts List ················································ 195
13.1 Standard ........................................................................................... 195
13.2 Option ............................................................................................... 197

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

Setup & Operation 1. Safety
S5 Rev.5 3
1. Safety
Installation and transportation of robots and robotic equipment shall be performed by
qualified personnel and should conform to all national and local codes.
Please read this manual and other related manuals before installing the robot system or
before connecting cables.
Keep this manual handy for easy access at all times.
1.1 Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
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 harm to people
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 S5 Rev.5
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 or the Safety 1.3 Design Precautions in
the SPEL CT 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 or the Safety part in the
SPEL CT
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 saf
ety
requirements is extremely hazardous,
and 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. Environment and Installation. Please read this chapter carefully to understand
safe installation procedures before installing the robots and robotic equipment.

Setup & Operation 1. Safety
S5 Rev.5 5
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
EPSON RC+ User’s Guide or the Safety 1.1 Safety-related Requirements in
the SPEL CT
User’s Guide before operating the robot system. Operating the
robot
system without understanding the safety requirements is extremely
hazardous and may result in serious bodily injury and/or sever
e equipment
damage to the robot system.
■
Do not enter the operating area of the Manipulator while the power to the robot
s
ystem 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
status (low speeds and low
power) 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
unexpec
tedly.
■
Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally while the robot system is operated.
Continuing the operating the
robot system while
the Manipulator moves abnormally is extremely hazardous
and may result in serious bodily injury and/or severe equipment change to the
robot system.
WARNING
■
Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power
to the robot system, pull
out the power plug from the power source. Performing any work while
connecting the AC power ca
ble to a factory power source is extremely hazardous
and may result in
electric shock and/or malfunction of the robot system.
■
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 rob
ot system.
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 necessary safety precautions.

Setup & Operation 1. Safety
6 S5 Rev.5
1.4 Emergency Stop
If the Manipulator moves abnormally during operation, immediately press the Emergency
Stop switch. It stops the power supply to the motor, and the arm stops in the shortest
distance with the dynamic brake and mechanical brake.
However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator
is running normally. Otherwise, the Manipulator may hit the peripheral equipment since
the operating trajectory while the robot system stops is different from that in normal
operation. It may also reduce the life of the reduction gear unit by the shock, or reduce
the life of the electromagnetic brake by worn friction plate.
To place the robot 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 press the Emergency Stop switch unnecessarily while the Manipulator is operating.
Pressing the switch during the operation makes the brakes work. This will shorten the
life of the brakes due to the worn friction plates.
Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)
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
To check brake problems, refer to the following manuals.
Manipulator Manual Maintenance 2.2.2 Inspection While the Power is ON
(Manipulator is operating)
Safety and Installation 5.2 Inspection Point - Inspection While the
Power is ON (Manipulator is operating)