Epson RS Series User manual

Original instructions
Rev.4 ENM226R5362F
Industrial Robot: SCARA ROBOT
RS series
MANUAL

RS
series MANUAL Rev.4

RS series Rev.4 i
Industrial Robot: SCARA ROBOT
RS series Manual
Rev.4
Seiko Epson Corporation 2021-2022

ii RS series 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.
The robot system 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. Please note that the basic performance of the product will
not be exhibited if our robot system is used outside of the usage conditions and product
specifications described in the manuals.
This manual describes possible dangers and consequences that we can foresee. Be sure to
comply with safety precautions on this manual to use our robot system safety and correctly.
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
CONTACT INFORMATION
Contact information is described in “SUPPLIERS” in the first pages of the following manual:
Robot System Safety Manual Read this manual first

RS series Rev.4 iii
DISPOSAL
When disposing this product, dispose in accordance with the laws and regulations of each
country.
Regarding battery disposal
The battery removal/replacement procedure is described in the following manuals:
Maintenance Manual
For European Union customers only
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.
For Taiwanese customers only
Please separate used 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.

iv RS series Rev.4
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
The RS series Manipulators can be used with the following combinations of Controllers and
software.
Controller
Software
Name
Structure
RC700-A Control Unit
Drive Unit
EPSON RC+ 7.0 Ver.7.1.2 or greater
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.
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.
EPSON
RC+

RS series Rev.4 v
The Manuals of This Product
The following are typical manual types for this product and an outline of the descriptions.
Safety Manual (book, PDF)
This manual contains safety information for all people who handle this product. The manual also
describes the process from unpacking to operation and the manual you should look at next.
Read this manual first.
-Safety precautions regarding robot system and residual risk
-Declaration of conformity
-Training
-Flow from unpacking to operation
RC700 series Manual (PDF)
This manual explains the installation of the entire robot system and the specifications and functions
of the controller. The manual is primarily intended for people who design robot systems.
-The installation procedure of the robot system (specific details from unpacking to operation)
-Daily inspection of the controller
-Controller specifications and basic functions
RS series Manual (PDF)
This manual describes the specifications and functions of the Manipulator. The manual is primarily
intended for people who design robot systems.
-Technical information, functions, specifications, etc. required for the Manipulator installation and
design
-Daily inspection of the Manipulator
Status Code/Error Code List (PDF)
This manual contains a list of code numbers displayed on the controller and messages displayed in
the software message area. The manual is primarily intended for people who design robot systems or
do programming.
RC700 series Maintenance Manual (PDF)
RS series Maintenance Manual (PDF)
This manual describes the details of maintenance etc. The manual is intended for people who perform
maintenance.
-Daily inspection
-Replacement and repair of maintenance parts
-The method of firmware update and controller setting backup etc.
EPSON RC+ 7.0 User’s Guide (PDF Manual)
This manual describes general information about program development software.
EPSON RC+ 7.0 SPEL+ Language Reference (PDF Manual)
This manual describes the robot programming language “SPEL+”.
Other Manual (PDF Manual)
Manuals for each option are available.

vi RS series Rev.4

TABLE OF CONTENTS
RS series Rev.4 vii
RS3, RS4 Manipulator
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 .................................................................................. 5
1.4 Emergency Stop................................................................................... 7
1.5 Safeguard............................................................................................. 8
1.6 Emergency Movement Without Drive Power ....................................... 9
1.7 ACCELS Setting for CP Motions........................................................ 11
1.8 Warning Labels .................................................................................. 12
1.9 Response for Emergency or Malfunction........................................... 16
1.9.1 Collision ...................................................................................... 16
1.9.2 Getting body caught in Manipulator ........................................... 16
2. Specifications 17
2.1 Model Number.................................................................................... 17
2.2 Part Names and Outer Dimensions ................................................... 18
2.2.1 RS3-351* .................................................................................... 18
2.3.2 RS4-551* .................................................................................... 22
2.3 Specifications ..................................................................................... 26
2.4 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......................................................................... 32
3.4 Unpacking and Transportation........................................................... 33
3.5 Installation .......................................................................................... 34
3.5.1 Standard-model.......................................................................... 34
3.5.2 Cleanroom-model....................................................................... 35
3.6 Connecting the Cables....................................................................... 36
3.7 User Wires and Pneumatic Tubes ..................................................... 37
3.8 Relocation and Storage...................................................................... 38
3.8.1 Precautions for Relocation and Storage .................................... 38
3.8.2 Relocation procedure ................................................................. 39
4. Setting of End Effectors 40
4.1 Attaching an End Effector .................................................................. 40
4.2 Attaching Cameras and Air valves..................................................... 42
4.3 Weight and Inertia Settings ................................................................ 42
4.3.1 Weight Setting ............................................................................ 42
4.3.2 Inertia Setting ............................................................................. 44
4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 .............. 48

TABLE OF CONTENTS
viii RS series Rev.4
5. Motion Range 49
5.1 Motion Range Setting by Pulse Range.............................................. 49
5.1.1 Max. Pulse Range of Joint #1..................................................... 50
5.1.2 Max. Pulse Range of Joint #2..................................................... 50
5.1.3 Max. Pulse Range of Joint #3..................................................... 51
5.1.4 Max. Pulse Range of Joint #4..................................................... 51
5.2 Motion Range Setting by Joint #3 Mechanical Stops ........................ 52
5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate
System of the Manipulator (for Joints #1 and #2) ............................... 53
5.4 Standard Motion Range..................................................................... 54
Regular Inspection
1. General Maintenance for RS3 RS4 57
1.1 Maintenance Inspection ..................................................................... 57
1.1.1 Schedule for Maintenance Inspection ........................................ 57
1.1.2 Inspection Point .......................................................................... 58
1.2 Overhaul (Parts Replacement) .......................................................... 59
1.3 Greasing............................................................................................. 59
1.4 Tightening Hexagon Socket Head Cap Bolts .................................... 62
Appendix
Appendix A: Specification 65
RS3 RS4 Specification ............................................................................... 65
Appendix B: Stopping Time and Stopping Distance in Emergency 67
RS3 Stopping Time and Stopping Distance in Emergency........................ 68
RS3-351*: J1 .......................................................................................... 68
RS3-351*: J2 .......................................................................................... 68
RS3-351*: J3 ................................................. ............. ...........................68
RS4 Stopping Time and Stopping Distance in Emergency........................ 69
RS4-551*: J1 .......................................................................................... 69
RS4-551*: J2 .......................................................................................... 69
RS4-551*: J3 .......................................................................................... 69
Appendix C: Stopping Time and Stopping Distance When Safeguard
Is Opened 70
RS3 Stopping Time and Stopping Distance When Safeguard Is Opened. 71
RS3-351*: J1 .......................................................................................... 71
RS3-351*: J2 .......................................................................................... 71
RS3-351*: J3 .......................................................................................... 71
RS4 Stopping Time and Stopping Distance When Safeguard Is Opened .72
RS4-551*: J1 .......................................................................................... 72
RS4-551*: J2 .......................................................................................... 72
RS4-551*: J3 .......................................................................................... 72

RS3, RS4
Manipulator
This volume contains information for setup and operation of the Manipulators.
Please read this volume thoroughly before setting up and operating the Manipulators.

RS3 RS4 Manipulator 1. Safety
RS series Rev.4 3
1. Safety
Unpacking and transportation of the Manipulators and robotic equipment shall be performed
by personnel who has taken robot system training held by us and suppliers 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 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.

RS3 RS4 Manipulator 1. Safety
4 RS series Rev.4
1.2 Design and Installation Safety
This product is intended for transporting and assembling parts in a safely isolated area.
Design and installation of robot system shall be performed by personnel who has taken robot
system training held by us and suppliers.
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 Manual” to understand the safety requirements before designing
and/or constructing the robot system. Designing and/or constructing the robot
system without under
standing 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.
■
When designing or installing a robot system, wear at least the following protective
gear. Working
without protective gear may cause serious safety problems.
Work clothes suitable for work
Helmet
Safety shoes
Further precautions for installation are mentioned in the chapter 3. Environments and
Installation. Please read this chapter carefully to understand safe installation procedures
before installing the robots and robotic equipment.

RS3 RS4 Manipulator 1. Safety
RS series Rev.4 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]
RS3/RS4: M=13,000 N ∙ mm
Example: If 130 N load is applied
at 100 mm from
the end of the spline nut
[Moment]
M=F ∙ L ＝ 100 ∙ 130 ＝ 13,000 N ∙ mm
End of the
spline nut
F
L
1.3 Operation Safety
The following items are safety precautions for qualified Operator personnel:
WARNING
■
Please carefully read the
Safety Requirements in the “Safety 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 speeds and low power)
status to secure the safety of an operator.
However, operating the robot system
while someone is inside the safeguarded are
a 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 Manipul
ator moves
abnormally while the robot system is operated.

RS3 RS4 Manipulator 1. Safety
6 RS series Rev.4
WARNING
■
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.
■
Before
performing any replacement procedure, turn OFF the Controller and
related equipment,
and then disconnect 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 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 mo
ve abnormally, and also may result in electric shock
and/or malfunction of the robot 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.
■
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 each joint larger
than 50 degrees
for about once an hour.
Joint #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
about once an hour.
■
Vibration
(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

RS3 RS4 Manipulator 1. Safety
RS series Rev.4 7
1.4 Emergency Stop
If the Manipulator moves abnormally during operation, immediately press the Emergency
Stop switch. Stops the power supply to the motor, and the arm stops in the shortest distance
with the dynamic brake and mechanical brake.
Avoid pressing the Emergency Stop switch unnecessarily while the Manipulator is running
normally.
- The Manipulator may hit the peripheral equipment.
When you press the Emergency Stop switch, the operating trajectory until the robot
system stops is different from that in normal operation.
- The life of the brakes will be shortened.
The brakes are locked and the brake friction plate is worn.
Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)
However, the rough normal relay life is approximately 20,000 times. If you press the
emergency stop switch unnecessarily, the life of the relay will be shortened.
- Impact is applied on the reduction gear unit, and it may result in the short life of the
reduction gear unit.
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 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)
Do not turn OFF the Controller while the Manipulator is operating.
If you attempt to stop the Manipulator in emergency situations, 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 RS series Maintenance
Manual 13. 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-S TO P.

RS3 RS4 Manipulator 1. Safety
8 RS series Rev.4
To check brake problems, refer to Regular Inspection.
Test pulse cannot be used with the emergency stop input of this model.
Stopping distance in emergency
The operating Manipulator cannot stop immediately after the Emergency Stop switch is
pressed. In addition, stopping time and stopping distance vary by following factors:
Hand weight WEIGHT Setting ACCEL Setting
Workpiece weight SPEED Setting Posture etc.
For stopping time and stopping distance of the Manipulator, refer to “Appendix B:
Stopping Time and Stopping Distance in Emergency”.
1.5Safeguard
To ensure safe operation, install a safety system using safety doors, light curtains, safety
floor mats, etc.
When a closed safeguard is open during robot motion, the safeguard interlock function
operates. The robot stops immediately and enters into pause state. Then, all robot motors are
turned OFF. The descriptions below explain how the safeguard input works.
Safeguard open
: The robot stops immediately, motors are turned OFF, and further
operation is impossible until either the safeguard is closed or
TEACH or TEST mode is turned ON and the enable circuit is
engaged.
Safeguard closed
: The robot can automatically operate in unrestricted (high power) state.
Do not open the safeguard unnecessarily while motor is ON. Frequent safeguard inputs
affect the life of the relay.
Rough normal relay life: Approximately 20,000 times
For the safeguard, do not use the E-STOP circuit.
For details of wiring instructions, refer to the following manual:
RC700 series Manual - Functions required for designing - 11. EMERGENCY
For details of Safeguard, refer to the following manual:
RC700 series Manual - Installation - 2.7.1 Connection to EMERGENCY Connector
Test pulse cannot be used with the safeguard input of this model.
WARNING
■
The EMERGENCY connector on the controller has a safeguard input circuit to
connect the safety device interlock switch. To protect operators working near the
robot, be sure to connect the interlock switch and make sure that it works
properly.
■ The time to stop the robot and the stopping distance by the safeguard interlock
function will change depending on the conditions of use. Be sure to confirm that
safety is ensured according to the installation environment of the robot.
Stopping distance when the safeguard is opened
The Manipulator in operation cannot stop immediately after the safeguard is opened. In
addition, stopping time and stopping distance vary by following factors:
Hand weight WEIGHT Setting ACCEL Setting
Workpiece weight SPEED Setting Posture etc.
For stopping time and stopping distance of the Manipulator, refer to “Appendix C: Stopping
Time and Stopping Distance When the Safeguard is Opened”.

NOTE

NOTE

RS3 RS4 Manipulator 1. Safety
RS series Rev.4 9
1.6Emergency 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.
Joint #3 ..........The joint cannot be moved up/down by hand until the
electromagnetic brake applied to the joint has been released.
Move the joint up/down while pressing the brake release switch.
Joint #4 ......... Rotate the shaft by hand.
RS3-351*
Joint #3
brake release switch
Joint #2
(rotating)
Joint #1
(rotating)
Joint #3
(up and down)
Joint #4
(rotating)
Arm #1
Arm #2
Base
+
−
+
−
+
−
+
−
Shaft
Base
Arm #1
Arm #2
Be careful of the shaft while the brake release switch is pressed,
because the shaft may be lowered by the weight of an end effector.

NOTE

RS3 RS4 Manipulator 1. Safety
10 RS series Rev.4
RS4-551*
Joint #2
(rotating)
+
−
Joint #3
brake release
switch
Joint #1
(rotating)
Joint #3
(up and down)
Joint #4
(rotating)
Arm #1
Arm #2
Base
+
−
+
−
+
−
Shaft
Base
Arm #1
Arm #2
Be careful of the shaft while the brake release switch is pressed,
because the shaft may be lowered by the weight of an end effector.

NOTE