Epson SCARA T3 Series Usermanuals 0

SCARA ROBOT
T series
MANIPULATOR MANUAL
Rev.4 EM178R3505F
MANIPULATOR MANUAL T series Rev.4
SCARA ROBOT
T series Manipulator Manual

Rev.4
Copyright  2017 SEIKO EPSON CORPORATION. All rights reserved.
T3 Rev.4 i
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.
ii T3 Rev.4
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
T3 Rev.4 iii
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:

T3 series manipulator manual Maintenance: 14.2 Replacing the Lithium Battery
iv T3 Rev.4
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Robot System

The T series Manipulators can be used with the following combinations of software.
Controller Firmware
T3-401S
Ver.7.3.51.1 or later
Before Ver.7.3.0 !!!
EPSON RC+ 7.0
Ver.7.3.1 or later OK
OK: Compatible All functions of the EPSON RC+ 7.0 and the robot system are
available.
!!!: Compatible Connection is OK. We recommend using EPSON RC+7.0
Ver.7.3.1 or later. Display or control may not be operated properly.
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+
T3 Rev.4 v
vi T3 Rev.4
TABLE OF CONTENTS
Setup & Operation

1. Safety 3
1.1 Conventions......................................................................................... 3
1.2 Design and Installation Safety............................................................. 3
1.2.1 Strength of the Ball Screw Spline ............................................ 4
1.3 Operation Safety.................................................................................. 5
1.4 Emergency Stop .................................................................................. 7
1.5 Emergency Movement Without Drive Power ...................................... 9
1.6 ACCELS Setting for CP Motions ....................................................... 10
1.7 Labels ................................................................................................ 11
2. Specifications 13
2.1 Features of T series Manipulators..................................................... 13
2.2 Model Number ................................................................................... 13
2.3 Part Names........................................................................................ 14
2.4 Outer Dimensions .............................................................................. 15
2.5 System Example................................................................................ 16
2.6 Specifications .................................................................................... 17
2.7 How to Set the Model ........................................................................ 20
3. Environments and Installation 21

3.1 Environmental Conditions ................................................................. 21
3.2 Base Table ........................................................................................ 22
3.3 Mounting Dimensions ........................................................................ 23
3.4 Unpacking and Transportation .......................................................... 24
3.5 Installation Procedure........................................................................ 25
3.6 Power Supply .................................................................................... 25
3.6.1 Specifications......................................................................... 25
3.6.2 AC Power Cable .................................................................... 26
3.6.3 Breaker .................................................................................. 27
3.6.4 Power Unit ............................................................................. 27
3.6.5 Grounding .............................................................................. 28
3.7 Connecting the Cables ...................................................................... 29
3.7.1 Connection Example ............................................................. 30
3.7.2 Noise Countermeasures ........................................................ 31
3.8 Pneumatic Tubes............................................................................... 32
3.9 Relocation and Storage ..................................................................... 33
3.9.1 Precautions for Relocation and Storage ............................... 33
3.9.2 Relocation .............................................................................. 34
T3 Rev.4 vii
TABLE OF CONTENTS
4. Setting of End Effectors 35

4.1 Attaching an End Effector .................................................................. 35
4.2 Attaching Cameras and Valves.......................................................... 36
4.3 Weight and Inertia Settings ................................................................ 37
4.3.1 Weight Setting ........................................................................ 37
4.3.2 Inertia Setting ......................................................................... 39
4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 .............. 42
5. Motion Range 43
5.1 Motion Range Setting by Pulse Range (for All Joints)....................... 43
5.1.1 Max. Pulse Range of Joint #1 ................................................ 44
5.2 Motion Range Setting by Mechanical Stops ...................................... 46
5.2.1 Setting the Mechanical Stops of Joints #1 and #2 ................. 46
5.2.2 Setting the Mechanical Stop of Joint #3................................. 48
5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate
System of the Manipulator .......................................................................... 50
5.4 Standard Motion Range ..................................................................... 50
6. Operation Mode & LED 51

6.1 Overview ............................................................................................51
6.2 Switch Operation Mode ...................................................................... 51
6.3 Program Mode (AUTO) ...................................................................... 52
6.3.1 What is Program Mode (AUTO)? ........................................... 52
6.3.2 Setup from EPSON RC+ 7.0.................................................. 52
6.4 Auto Mode (AUTO) ............................................................................ 53
6.4.1 What is Auto mode (AUTO)? ................................................. 53
6.4.2 Setup from EPSON RC+ 7.0.................................................. 53
6.4.3 Setup from Control Device ..................................................... 54
6.5 LED.....................................................................................................55
7. Development PC Connection Port 56

7.1 What is Development PC Connection Port ........................................ 56
7.2 Precaution ..........................................................................................57
7.3 Software Setup and Connection Check ............................................. 57
7.4 Disconnection of Development PC and Manipulator ......................... 58
viii T3 Rev.4
TABLE OF CONTENTS
8. Memory Port 59
8.1 What is Controller Status Storage Function? .................................... 59
8.2 Before Using Controller Status Storage Function ............................. 59
8.2.1 Precautions ............................................................................ 59
8.2.2 Adoptable USB Memory ........................................................ 59
8.3 Controller Status Storage Function ................................................... 60
8.3.1 Controller Status Storage with Trigger Button ...................... 60
8.3.2 Load Data with EPSON RC+ 7.0 .......................................... 61
8.3.3 Transfer with E-mail............................................................... 62
8.4 Details of Data ................................................................................... 63
9. LAN (Ethernet Communication) Port 64

9.1 What is the LAN (Ethernet Communication) Port ............................. 64
9.2 IP Address ......................................................................................... 64
9.3 Changing Manipulator IP Address .................................................... 65
9.4 Connection of Development PC and Manipulator with Ethernet ...... 66
9.5 Disconnection of Development PC and Manipulator with Ethrnet .... 67
10. TP Port 68
10.1 What is the TP Port? ....................................................................... 68
10.2 Teach Pendant Connection............................................................. 68
11. EMERGENCY 69
11.1 Safeguard Switch and Latch Release Switch ................................. 69
11.1.1 Safeguard Switch ................................................................ 70
11.1.2 Latch Release Switch .......................................................... 70
11.1.3 Checking Latch Release Switch Operation ......................... 71
11.2 Emergency Stop Switch Connection ............................................... 71
11.2.1 Emergency Stop Switch ...................................................... 71
11.2.2 Checking Emergency Stop Switch Operation ..................... 72
11.2.3 Recovery from Emergency Stop ......................................... 72
11.3 Pin Assignments .............................................................................. 73
11.4 Circuit Diagrams .............................................................................. 74
11.4.1 Example 1: External emergency stop switch typical application
........................................................................................................... 74
11.4.2 Example 2: External safety relay typical application ........... 75
T3 Rev.4 ix
TABLE OF CONTENTS
12. Standard I/O Connector 76

12.1 Input Circuit ......................................................................................76
12.1.1 Typical Input Circuit Application ........................................... 77
12.1.2 Typical Input Circuit Application 2 ........................................ 77
12.1.3 Pin Assignments of Input Circuit .......................................... 78
12.2 Output Circuit ...................................................................................78
12.2.1 Typical Output Circuit Application 1 ..................................... 79
12.2.3 Pin Assignments of Output Circuit ....................................... 80
12.3 I/O Cable Product Procedure ........................................................... 81
12.3.1 I/O Cable Connecting Method .............................................. 81
12.3.2 How to Fix the I/O Cable ...................................................... 81
13. Hand I/O Connector 82

13.1 Power Supply Specifications............................................................ 82
13.2 Input Circuit ......................................................................................83
13.3 Output Circuit ...................................................................................84
13.4 Pin Assignments .............................................................................. 85
13.5 How to Control Hand I/O .................................................................. 85
14. I/O Remote Settings 87

14.1 I/O Signal Description ...................................................................... 88
14.1.1 Remote Input Signals ........................................................... 88
14.1.2 Remote Output Signals ........................................................ 92
14.2 Timing Specifications ....................................................................... 95
14.2.1 Precautions for Remote Input Signals ................................. 95
14.2.2 Timing Diagram for Operation Execution Sequence ........... 95
14.2.3 Timing Diagram for Program Execution Sequence ............. 95
14.2.4 Timing Diagram for Safety Door Input Sequence ................ 96
14.2.5 Timing Diagram for Emergency Stop Sequence ................. 96
15. SD Card Slots 97
16. RESET Switch 98
17. Fieldbus I/O 99
x T3 Rev.4
TABLE OF CONTENTS
Maintenance
1. Safety Maintenance 103
2. General Maintenance 104

2.1 Maintenance Inspection .................................................................. 104
2.1.1 Schedule for Maintenance Inspection ................................. 104
2.1.2 Inspection Point ................................................................... 105
2.2 Overhaul (Parts Replacement)........................................................ 106
2.3 Greasing .......................................................................................... 108
2.4 Tightening Hexagon Socket Head Cap Bolts.................................. 109
2.5 Matching Origins.............................................................................. 109
2.6 Layout of Maintenance Parts .......................................................... 110
3. Manipulator Structure 111
4. Alarm 112
4.1 Maintenance .................................................................................... 113
4.1.1 Manipulator Maintenance Information ................................. 113
4.1.2 Manipulator Maintenance Information ................................. 113
4.2 Maintenance Information ................................................................. 114
4.2.1 How to View the Maintenance Information.......................... 114
4.2.2 How to Edit the Maintenance Information ........................... 115
4.2.3 Alarm Notifying Method ....................................................... 116
4.2.4 How to Cancel the Alarm ..................................................... 116
5. Backup and Restore 117
5.1 What is the Backup Controller Function .......................................... 117
5.2 Backup Data Types ......................................................................... 117
5.3 Backup ............................................................................................. 118
5.4 Restore ............................................................................................ 119
6. Firmware Update 121

6.1 Updating Firmware .......................................................................... 121
6.2 Firmware Upgrade Procedure ......................................................... 121
6.3 Manipulator Recovery ..................................................................... 124
6.4 Firmware Initialization Procedure .................................................... 125
7. Covers 127
7.1 Arm Top Cover ................................................................................ 128
7.2 Arm Bottom Cover ........................................................................... 129
7.3 Power Cable Cover ......................................................................... 129
7.4 Connector Plate ............................................................................... 130
7.5 Power Unit Cover ............................................................................ 131
T3 Rev.4 xi
TABLE OF CONTENTS
7.6 Base Side Cover ..............................................................................131

7.7 User Plate.........................................................................................132
8. Cable 133
8.1 Replacing Cable Unit .......................................................................133
8.2 Insert or Pull out of Power Cable .....................................................139
9. Joint #1 140
9.1 Replacing Joint #1 Motor .................................................................141
9.2 Replacing Joint #1 Reduction Gear Unit..........................................147
10. Joint #2 150

10.1 Replacing Joint #2 Motor ...............................................................151
10.2 Replacing Joint #2 Reduction Gear Unit........................................ 155
11. Joint #3 158

11.2 Replacing the Timing Belt ..............................................................163
11.3 Replacing the Brake .......................................................................164
11.4 Checking the Timing Belt Tension (Z Belt) .................................... 165
12. Joint #4 166

12.2 Replacing the Timing Belt ..............................................................171
12.3 Checking the Timing Belt Tension (U Belt) .................................... 173
13. Ball Screw Spline Unit 174

13.1 Greasing the Ball Screw Spline Unit ..............................................175
13.2 Replacing the Ball Screw Spline Unit ............................................176
14. Lithium Battery, SD Card, Boards, and Filter. 179

14.1 Replacing the CPU/DPB Boards....................................................181
14.2 Replacing the Lithium Battery ........................................................183
14.3 Replacing the SD Card ..................................................................184
14.4 Replacing the Power Board ...........................................................185
14.4.1 Replacing the Power Board Filter ......................................185
14.4.2 Replacing the Power Board ...............................................186
15. LED Lamp Unit 187
xii T3 Rev.4
TABLE OF CONTENTS
16. Calibration 189

16.1 About Calibration ........................................................................... 189
16.2 Calibration Procedure.................................................................... 190
16.3 Accurate Calibration of Joint #2 .................................................... 200
16.4 Reference: Calibration Procedure Without Using Calibration Wizard
.................................................................................................................. 202
17. Restrictions 206
17.1 Commands Cannot Use ................................................................ 206
17.2 Commands Cause Motion Error If Specifying RS-232C ............... 206
17.3 Commands Cause Error................................................................ 207
17.3.1 6-axis Robot Command ..................................................... 207
17.3.2 Conveyor Tracking Commands ......................................... 207
17.3.3 PG Commands .................................................................. 208
17.3.4 R-I/O Commands............................................................... 208
17.3.5 Force Sensing Commands ................................................ 208
17.3.6 Others (FineDist) ............................................................... 208
17.3.7 Others (HealthCalcPeriod) ................................................ 208
17.4 Restrictions of Functions ............................................................... 209
17.4.1 TP3 .................................................................................... 209
17.4.2 Loop Processing ................................................................ 209
17.4.3 Camera Searching by CV1/CV2........................................ 210
17.4.4 Restore the Data of Backup Controller Function .............. 210
18. Maintenance Parts List 211

Appendix A: Open Source Software License for T series ....................... 213
T3 Rev.4 xiii
TABLE OF CONTENTS
xiv T3 Rev.4
Setup & Operation
This volume contains information for setup and operation of the
T series Manipulators.
Please read this volume thoroughly before setting up and
operating the Manipulators.
Setup & Operation 1. Safety
1. Safety
Installation and transportation of manipulators and robotic equipment shall be performed
by qualified personnel and should conform to all national and local codes. Please read
this manual and other related manuals before installing the robot system or before
connecting cables.
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.
This symbol indicates that a danger of possible serious injury or

death exists if the associated instructions are not followed
WARNING properly.
This symbol indicates that a danger of possible serious injury or

death caused by electric shock exists if the associated
WARNING instructions are not followed properly.
This symbol indicates that a danger of possible harm to people

or physical damage to equipment and facilities exists if the
CAUTION associated instructions are not followed properly.
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:
■ 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
severe equipment damage to the robot system, and may cause serious safety
problems.
WARNING
■ The robot system 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.
T3 Rev.4 3
■ 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
WARNING
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.
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]

T3: M=13,000 N∙mm
Example: If 100 N load is applied

at 150 mm from
the end of the spline nut End of the L
spline nut F
[Moment]
M=F∙L＝100∙150＝15,000 N∙mm
4 T3 Rev.4
1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:
■ Please carefully read the 1.3 Safety-related Requirements in the Safety chapter
of the Safety and Installation manual before operating the robot system.
Operating the robot system without understanding the safety requirements is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.
■ 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
WARNING 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.
■ 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 Robot System 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
WARNING 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.
T3 Rev.4 5
■ 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 the joints larger
than 50 degrees for about five to ten times a day.
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 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
CAUTION 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
■ 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.
■ Manipulator may be warmed up due to motor heat or similar causes. Do not

touch the Manipulator until temperature falls. Also, make sure the temperature
of the Manipulator falls and you do not feel hot when you touch it. Then perform
teaching or maintenance.
6 T3 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 Setup & Operation: 11. EMERGENCY for instructions on how to wire the
Emergency Stop switch circuit.
Do not turn OFF the power 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 Emergency Stop switch.
If the Manipulator is stopped by turning OFF the power 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 manipulator 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. Also, the same troubles may occur if an error occurs and the
Manipulator stops in emergency during the operation. Check the Manipulator condition
and perform calibration if necessary.
Before using the Emergency Stop switch, be aware of the following.

- 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
T3 Rev.4 7
To check brake problems, refer to the following manuals.

Manipulator Manual Maintenance
2.1.2 Inspection Point - Inspection While the Power is ON
(Manipulator is operating)
Safety and Installation
5.1.1 Manipulator
- Inspection While the Power is ON (Manipulator is operating)
Free running distance in emergency

The operating Manipulator cannot stop immediately after the Emergency Stop switch is
pressed.
The free running time/angle/distance of the Manipulator are shown below. However,
remember that the values vary depending on following conditions.
Weight of the end effector Weight of work piece Operating pose
Weight Speed Accel etc.
Conditions for
T3-401S
Measurement
Accel Setting 100
Speed Setting 100
Load [kg] 3
Weight Setting 3
Start point of
operation
Point where the

emergency stop Joint #1 Target point
signal is input
Joint #2 Stop point
T3-401S
Joint #1 + Joint #2 [sec.] 0.5
Free running time
Joint #3 [sec.] 0.2
Joint #1 [deg.] 50
Free running angle Joint #2 [deg.] 50
Joint #1 + Joint #2 [deg.] 100
Free running distance Joint #3 [mm] 20
8 T3 Rev.4
1.5 Emergency Movement Without Drive Power

When the system is placed in emergency mode, push the arm or joint of the Manipulator
by hand as shown below:
Arm #1 Push the arm by hand.
Arm #2 Push the arm by hand.
Joint #3 The joint cannot be moved up/down by hand until the solenoid
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.
Joint #2 Joint #1
(rotating) (rotating)
− −
+ +
Joint #3
brake release switch
Arm #2
+
Joint #3 Arm #1
(up and down) − Shaft
− +
Joint #4
(rotating)
NOTE The brake release switch affects only Joint #3. When the brake release switch is pressed
 in emergency mode, the brake for Joint #3 is released.
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.
T3 Rev.4 9
1.6 ACCELS Setting for CP Motions

To make the Manipulator move in CP motion, see the following and set ACCELS properly
according to the tip load and the Z-axis height.
NOTE
Improper setting may cause following problems.
 - Decline in the life and damage of the ball screw spline
ACCELS setting values by Z-axis height and tip load: 10000 or less
Z-axis height 0
(Origin position)
Z
If the Manipulator is operated in CP motion with the wrong set values, make sure to check
the following points.
- Whether or not the ball screw spline shaft is deformed or bent
10 T3 Rev.4
1.7 Labels
The Manipulator has the following warning labels.
The warning labels are attached around the locations where specific dangers exist.
Be sure to comply with descriptions and warnings on the labels to operate and maintain
the Manipulator safely.
Do not tear, damage, or remove the warning labels. Use meticulous care when handling
those parts or units to which the following warning labels are attached as well as the
nearby areas.
Location Warning Label NOTE
Before loosening the base mounting screws, hold the

A arm and secure it tightly with a band to prevent hands
or fingers from being caught in the Manipulator.
Do not enter the operation area while the Manipulator

is moving. The robot arm may collide against the
B
operator. This is extremely hazardous and may
result in serious safety problems.
Hazardous voltage exists while the Manipulator is

C ON. To avoid electric shock, do not touch any
internal electric parts.
You can catch your hand or fingers between the shaft

D and cover when bringing your hand close to moving
parts.
Signature label
S/N (Serial Number) Label
T3 Rev.4 11
C C
E B
12 T3 Rev.4
Setup & Operation 2. Specifications
2. Specifications
2.1 Features of T series Manipulators
The T series Manipulators are controller integrated manipulators.
The features of the T series Manipulators are as follows:
For Device design and tooling
- There is no external controller
The controller is integrated with the robot.
No installation space required for external controller.
No design is required for external controller installation or tooling.
- No robot to controller cables
There are no external cables required between the robot and controller.
- Hand (end effector) can be controlled directly by Hand I/O
Wiring between controller and manipulator end effector is not necessary.
- Duct vibration reducing structure
Easy to route external cables.
For Maintenance
- There are no encoder batteries for the robot
No longer necessary to connect external devices for battery replacement.
- Easy to replace the manipulator
- Fan-less
No fan maintenance is required.
Others
- Power-saving (Approx. 2/3 of LS3/RC90)
2.2 Model Number

T3-40 1 S
Environment
S : Standard
Joint #3 stroke
1 : 150 mm
Arm length
40 : 400 mm
Payload
3 : 3 kg
For details on the specifications, refer to Setup & Operation: 2.6 Specifications.
T3 Rev.4 13
2.3 Part Names
Hand I/O Connecter
Joint #3 LED Lamp

Brake Release Switch
Power Unit
Arm #2
Base
Shaft Arm #1
TP Connector
EMERGENCY
Connector RESET Switch
MEMORY Port
CE label Port of PC for development
Fittings (blue)
for ø4 mm LAN (Ethernet)
Signature label Connector
pneumatic tube
(Serial No.
of Manipulator) Fittings (blue) I/O (Input) Connector
for ø6 mm
pneumatic tube I/O (Output) Connector
Fittings (white) Power Supply Cover
for ø6 mm (AC power connector inside)
pneumatic tube
NOTE - The brake release switch affects only Joint #3. When the brake release switch is
 pressed in emergency mode, the brake for Joint #3 is released.
- While the LED lamp is on, the current is being applied to the manipulator.
Performing any work with the power ON is extremely hazardous and it may result in
electric shock and/or improper function of the robot system. Make sure to turn OFF
the Manipulator power before the maintenance work.
14 T3 Rev.4
2.4 Outer Dimensions
T3 Rev.4 15
2.5 System Example
Standard T3
Standard I/O
Remote I/O
Ethernet
Hand I/O
USB (for save)
USB (for development)
ModBus
Option
Fieldbus
Slave
USB 2.0 *2
or
Ethernet Option: Teaching Pendant
*3
TP2
Windows *1
TP3
EPSON RC+ 7.0
Software
Option
*1 EPSON RC+ 7.0 supports the following OS

Windows XP Professional Service Pack 3 (before EPSON RC+7.0 Ver.7.2.0)
Windows Vista Business Service Pack 2
Windows 7 Professional Service Pack 1
Windows 8.1 Pro (EPSON RC+7.0 Ver.7.1.0 or later)
Windows 10 Pro (EPSON RC+7.0 Ver.7.2.0 or later)
*2 Either teaching pendant is available.
*3 When connecting to T3, specified convert cable is necessary.
16 T3 Rev.4
2.6 Specifications
Item T3-401S
Arm #1, #2 400 mm
Arm length Arm #1 225 mm
Arm #2 175 mm
Weight (cables not included) 16 kg : 35 lb.
Driving method All joints AC servo motor
Joints #1, #2 3700 mm/s
Max. operating speed*1 Joint #3 1000 mm/s
Joint #4 2600 deg/s
Joints #1, #2 ± 0.02 mm
Repeatability Joint #3 ± 0.02 mm
Joint #4 ± 0.02 deg
Joint #1 ± 132 deg
Max. Joint #2 ± 141 deg
motion range Joint #3 150 mm
Joint #4 ± 360 deg
Joint #1 − 95574 ~ 505174
Max. Joint #2 ± 320854
pulse range Joint #3 −187734 ~ 0
Joint #4 ± 71760
Joint #1 0.000439 deg/pulse
Joint #2 0.000439 deg/pulse
Resolution
Joint #3 0.000799 mm/pulse
Joint #4 0.005017deg/pulse
Joint #1 200 W
Motor Joint #2 100 W
energy consumption Joint #3 100 W
Joint #4 100 W
Rated 1 kg
Payload (Load)
Max. 3 kg
Joint #4 allowable Rated 0.003 kg·m2
moment of inertia*2 Max. 0.01 kg·m2
Shaft diameter ø 16 mm
Hand
Through hole ø 11 mm
Joint #3 down force 83 N
Hand I/O Connector 15 pin: D-sub
2 pneumatic tubes (ø6 mm):
Installed pneumatic 0.59 MPa (6 kgf/cm2 : 86 psi)
tube for customer use 1 pneumatic tubes (ø4 mm):
0.59 MPa (6 kgf/cm2 : 86 psi)
120 × 120 mm
Mounting hole
4-M8
5 to 40 degrees C
Ambient Temp.
Environmental (with minimum temperature variation)
requirements Ambient relative
20 to 80% (no condensation)
humidity
Noise level *3 LAeq = 80 dB (A)
T3 Rev.4 17
Item T3-401S
Speed 1 ~ (5) ~ 100
Assignable Accel *4 1 ~ (10) ~ 120
Value SpeedS 0.1 ~ (50) ~ 2000
( ) Default AccelS 0.1 ~ (200) ~ 10000
values Fine 0 ~ (1250) ~ 65000
Weight 0,175 ~ (1,175) ~ 3,175
Development
EPSON RC+ 7.0
Environment
Programming
SPEL+ (multi-tasking robot language)
Language
Standard 4 joints simultaneous control
Joint Control
Digital AC servo control
PTP (Point-To-Point control)
Motion
Positioning Control
CP (Continuous Path control)
Control PTP motion : Programmable in the range of
1 to 100%
Speed Control
CP motion : Programmable (Actual value to be
manually entered.)
PTP motion : Programmable in the range of
Acceleration/
1 to 100%; Automatic
Deceleration
CP motion : Programmable (Actual value to be
Control
manually entered.)
EMERGENCY STOP:
Redundant (Category 3) Supported for
internal/external power supply
EMERGENCY
Safeguard System:
Redundant (Category 3) Supported for external
power supply
Standard I/O Input: 18 points
(Rear side of Output: 12 points
Manipulator) Non-polar, Supported for both Sink and Source
External Input: 8 points
Interface Remote I/O
Program, 3 points
(Remote Start, Stop, Pause, Continue, Reset
functions are Output: 8 points
I/O
applied to Ready, Running, Paused, ErrorEStopOn,
Standard I/O) SafeguardOn, SError, Warning
Hand I/O Input: 6 points

Output: 4 points
(Upper side of Non-polar, Supported for both Sink and Source
Arm #2) Power supply: available up to 24V 500mA
Input: 256 points
Field bus Slave
Output: 256 points
(Option)
Enable to add only one more module
TP Connection Port Supported for teach pendant (Option: TP2, TP3)
USB B connector
External PC Connection Port
Supported for USB 2.0 High Speed / Full Speed
Interface
USB Memory USB A connector
Connection Port Supported for USB 2.0 High Speed / Full Speed
Supported for 10/100 Mbps
Ethernet Port
Available up to 8 ports
RESET Switch Enable to use for reset of system
18 T3 Rev.4
Item T3-401S
TEACH, AUTO, PROGRAM, TestMode, Error,
Display Mode Display LED
E-STOP
Save to USB memory
Controller Status Save
Save in RC+ (PC)
Voltage AC 100 V ~ AC 240 V
Phase Single phase
Frequency 50 / 60 Hz
Momentary Power Interrupt Less than 10 ms
Power Consumption 660 VA
When power is turned ON
Peak Current
: Max. 30A (Less than 2 ms.)
Leak Current Max. 10 mA
Ground Resistance Less than 100Ω
CE Mark
EMC Directive, Machinery Directive, RoHS Directive
Safety standard
ANSI/RIA R15.06-2012
NFPA 79 (2007 Edition)
*1: In the case of PTP command. Maximum operating speed for CP command is 2000
mm/s on horizontal plane.
*2: In the case where the center of gravity is at the center of Joint #4. If the center of
gravity is not at the center of Joint #4, set the parameter using Inertia command.
*3: Conditions of Manipulator during measurement as follows:
Operating conditions : Under rated load, 4-joints simultaneous motion, maximum
speed, maximum acceleration, and duty 50%.
Measurement point : Rear of the Manipulator, 1000 mm apart from the motion range,
50 mm above the base-installed surface.
*4: In general use, Accel setting 100 is the optimum setting that maintains the balance of
acceleration and vibration when positioning. Although values larger than 100 can be set
to Accel, it is recommended to minimize the use of large values to necessary motions
since operating the manipulator continuously with the large Accel setting may shorten
the product life remarkably.
T3 Rev.4 19
2.7 How to Set the Model

The Manipulator model for your system has been set before shipment from the factory. It
is normally not required to change the model when you receive your system.
■ When you need to change the setting of the Manipulator model, be sure to set the
Manipulator model properly. Improper setting of the Manipulator model may
result in abnormal or no operation of the Manipulator and/or cause safety
CAUTION problems.
NOTE If the custom specifications number (MT***) is described on MODEL of the signature
 label (S/N label), the Manipulator has custom specifications. The custom specifications
may require a different configuration procedure; check the custom specifications number
(MT***) and contact us when necessary.
The Manipulator model can be set from software.

Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide.
20 T3 Rev.4
Setup & Operation 3. Environments and Installation
3. Environments and Installation

3.1 Environmental Conditions
A suitable environment is necessary for the robot system to function properly and safely.
Be sure to install the robot system in an environment that meets the following conditions:
Item Conditions
Ambient temperature 5 to 40°C (with minimum temperature variation)
Ambient relative 20 to 80% (with no condensation)
humidity
First transient burst
2 kV or less
noise
Electrostatic noise 4 kV or less
Environment · Install indoors.
· Keep away from direct sunlight.
· Keep away from dust, oily smoke, salinity, metal
powder or other contaminants.
· Keep away from flammable or corrosive solvents
and gases.
· Keep away from water.
· Keep away from shocks or vibrations.
· Keep away from sources of electric noise.
NOTE Manipulators are not suitable for operation in harsh environments such as painting areas,
 etc. When using Manipulators in inadequate environments that do not meet the above
conditions, please contact us.
Special Environmental Conditions
Surface of the Manipulator has general oil resistance. However, if your requirements
specify that the Manipulator must withstand certain kinds of oil, please consult your
distributor.
Rapid change in temperature and humidity can cause condensation inside the Manipulator.
If your requirements specify that the Manipulator handles food, please consult your
distributor to check whether the Manipulator gives damage to the food or not.
The Manipulator cannot be used in corrosive environments where acid or alkaline is used.
In a salty environment where the rust is likely to gather, the Manipulator is susceptible to
rust.
■ Use an earth leakage breaker on the AC power cable of the Manipulator to avoid
electric shock and circuit breakdown caused by short circuit.
WARNING
■ When cleaning the Manipulator, do not rub it strongly with alcohol or benzene.
It may lose luster on the coated face.
CAUTION
T3 Rev.4 21
3.2 Base Table

A base table for anchoring the Manipulator is not supplied. Please make or obtain the
base table for your Manipulator. The shape and size of the base table differs depending
on the use of the robot system. For your reference, we list some Manipulator table
requirements here.
Base table is necessary for support not only the weight of the manipulator but also
dynamic motion when operating at the fastest speed. Provides enough beams to give
sufficient strength.
The torque and reaction force produced by the movement of the Manipulator are as
follows:
T3
Max. Reaction torque on the horizontal plate 150 Nm
Max. Horizontal reaction force 500 N
Max. Vertical reaction force 900 N
The threaded holes required for mounting the Manipulator base are M8. Use mounting
bolts with specifications conforming to ISO898-1 property class: 10.9 or 12.9.
For dimensions, refer to Setup & Operation: 3.3 Mounting Dimensions.
The plate for the Manipulator mounting face should be 20 mm thick or more and made of
steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or
less.
The table must be secured on the floor or wall to prevent it from moving.
The Manipulator must be installed horizontally.
When using a leveler to adjust the height of the base table, use a screw with M16 diameter
or more.
If you are passing cables through the holes on the base table, see the figures below.
54
ø26 37
11 13
I/O (Input) Connector EMERGENCY Connector

24 34
11 9 (Unit: mm)
TP Connector
I/O(Output) Connector AC Power Connector
■ To ensure safety, a safeguard must be installed for the robot system.

For details on the safeguard, refer to the EPSON RC+ User’s Guide.
WARNING
22 T3 Rev.4
3.3 Mounting Dimensions

The maximum space described in figures shows that the radius of the end effector is 60
mm or less. If the radius of the end effector exceeds 60 mm, define the radius as the
distance to the outer edge of maximum space.
If a camera or solenoid valve extends outside of the arm, set the maximum range including
the space that they may reach.
Be sure to allow for the following extra spaces in addition to the space required for
mounting the Manipulator and peripheral equipment.
Space for teaching
Space for maintenance and inspection
(Ensure a space to open the covers and plates for maintenance.)
Space for cables
The minimum bend radius of the power cable is 90 mm. When installing the cable, be
sure to maintain sufficient distance from obstacles. In addition, leave enough space for
other cables so that they are not bent forcibly.
Ensure distance to the safeguard from the maximum motion range is more than 100 mm.
Center of Joint #3
Maximum space
Motion range
Area limited by mechanical stop
Base mounting face
T3 Rev.4 23
3.4 Unpacking and Transportation

THE INSTALLATION SHALL BE PREFORMED BY QUALIFIED INSTALLATION
PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL
CODES.
■ Only authorized personnel should perform sling work and operate a crane and a
forklift. When these operations are performed by unauthorized personnel, it is
WARNING equipment damage to the robot system.
■ Using a cart or similar equipment, transport the Manipulator in the same manner
as it was delivered.
■ After removing the bolts securing the Manipulator to the delivery equipment, the
Manipulator can fall. Be careful not to get hands or fingers caught.
■ The arm is secured with a sheet. Leave the sheet secured until you finish the
installation so as not to get hands or fingers caught.
■ To carry the Manipulator, have two or more people to
work on it and secure the Manipulator to the delivery
equipment or hold the bottom of Arm #1 and or bottom of
the base areas (indicated in gray in the figure) by hand.
When holding the bottom of the base by hand, be very
careful not to get your hands or fingers caught.
CAUTION T3-401S : approx.16 kg :35 lb.
■ Stabilize the Manipulator with your hands when hoisting it.

■ When transporting the Manipulator for a long distance, secure it to the delivery
equipment directly so that the Manipulator never falls.
If necessary, pack the Manipulator in the same style as it was delivered.
24 T3 Rev.4
3.5 Installation Procedure

■ The Manipulator must be installed to avoid interference with buildings, structures,
utilities, other machines and equipment that may create a trapping hazard or
pinch points.
■ Oscillation (resonance) may occur during operation depending on rigidity of the

installation table.
If the oscillation occurs, improve rigidity of the table or change the speed or
acceleration and deceleration settings.
CAUTION
■ Install the Table Top Mounting Manipulator with two or more people.
The Manipulator weights are as follows. Be careful not to get hands, fingers, or
feet caught and/or have equipment damaged by a fall of the Manipulator.
T3-401S : approx.16 kg :35 lb.
Secure the base to the base table with four

bolts.
NOTE
Use bolts with specifications conforming to
 ISO898-1 Property Class: 10.9 or 12.9.
4-M8×30
Spring
Washer
Tightening torque: 32.0±1.6 N·m
Plane Washer
NOTE Make sure to remove wire tie for mechanical Screw Hole
 stop protector. (depth 20 mm
or more)
10 mm
3.6 Power Supply

■ There is no power switch on the Manipulator. Right after inserting power plug
to power, the Robot System turns ON.
WARNING Be careful about electric shock when inserting power plug.
3.6.1 Specifications
Ensure that the available power meets following specifications.
Item Specification
Voltage 100 VAC to 240 VAC
Phase Single phase
Frequency 50/60 Hz
Momentary Power Interrupt Less than10 msec.
Power Consumption 660 VA
When power is turned ON:
Peak Current
approximately 30A (Less than 2 ms.)
Voltage Max. 10 mA
Ground Resistance 100 Ω or less
T3 Rev.4 25
3.6.2 AC Power Cable

■ Make sure that cable manufacturing and connection are done by a qualified
personal.
■ When proceeding, be sure to connect the earth wire of the AC power cable
colored green/yellow on the Controller to the earth terminal of the factory
power supply.
Also, we recommend to ground directly via hole on the base to ground the
manipulator completely.
WARNING The equipment must be grounded properly at all times to avoid the risk of
electric shock.
■ Always use a power plug and receptacle for power connecting cable. Never
connect the Controller directly to the factory power supply.
■ Select the plug which conform safety standards for nations.
Plug
Connect this side to (Install by yourself)
Manipulator first
M4 round solderless terminal
The AC plug is the optional parts.

Attach a proper plug to the cable that is suitable for the factory power supply.
When connecting the plug of AC cable to the Manipulator, make sure to insert completely.
Connection Specification of Cable Wire Specification of Power plug (option)

Purpose Color Name Model Manufacturer
AC power wire
Black/White AC plug 4222R AMERICAN DENKI
(2 cables)
Ground wire Green/ Yellow
Cable length: 5 m (Standard)
NOTE
 Use cable clamp on rear side of the Manipulator to fix AC power cable.
AC Power Cable Clamp
26 T3 Rev.4
3.6.3 Breaker
Install an earth leakage circuit breaker or a circuit breaker in the AC power cable line at 10
A or less rated electric current. Both should be a two-pole disconnect type.
If you install an earth leakage circuit breaker, make sure to use an inverter type that does
not operate by induction of a 10 kHz or more leakage current.
If you install a circuit breaker, please select one that will handle the above mentioned
“peak current”.
The power receptacle shall be installed near the equipment and shall be easily accessible.
3.6.4 Power Unit

■ Before performing maintenance of power unit, turn OFF the Robot system and
system.
WARNING ■ Do not apply a load by applying weight to power unit. Doing so may result in
deformation or damage of parts.
■ NEVER connect deformed or damaged power unit to the Robot system or

related equipment. It may result in the fire or electric shock.
Power Unit
T3 Rev.4 27
3.6.5 Grounding
■ Ground resistance must be 100 Ω or less. Improper ground resistance may
result in fire and/or electric shock.
■ Do not use the ground line for the Manipulator in common with other ground lines
or grounding electrodes for other electric power, motor power, welding devices,
etc. Using the ground line for the Manipulator in common with other ground
lines or grounding electrodes may result in electric shock and/or malfunction of
WARNING the robot system.
■ When using metal ducts, metallic conduits, or distributing racks for cable, ground
in accordance with national and local electric equipment technical standards.
Grounding that does not meet the standards may result in electric shock and/or
malfunction of the robot system.
Follow local regulations for grounding. It is recommended that the core size of the
grounding wire be 5.5 mm2 or more.
Directly connect the ground line to the Manipulator using bolt hole in the figure below.
Bolt hole (for grounding)
28 T3 Rev.4
3.7 Connecting the Cables

■ Before performing any replacement procedure, turn OFF the Manipulator and
Performing any replacement procedure with the power ON is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the
cables. (Do not put heavy objects on the cables. Do not bend or pull the cables
WARNING
forcibly.) The unnecessary strain on the cables may result in damage to the
cables, disconnection, and/or contact failure.
Damaged cables, disconnection, or contact failure is extremely hazardous and
may result in electric shock and/or improper function of the robot system.
■ Grounding the manipulator is done by connecting with Power cable. Ensure that
the Power cable and ground wire are correctly connected. If the ground wire is
improperly connected to ground, it may result in the fire or electric shock.
■ Make sure that the serial numbers on each equipment match. Improper
connection between the Manipulator and Controller may not only cause
improper function of the robot system but also serious safety problems.
■ Before connecting the connector, make sure that the pins are not bent.
CAUTION
Connecting with the pins bent may damage the connector and result in
T3 Rev.4 29
3.7.1 Connection Example

Input/ Output device
(1) Hand I/O connector
Teach
(2) TP connector
Pendant
(3) EMERGENCY connector
Emergency stop, safety door
(4) Memory port
USB memory
(5) PC port for development
PC for development
(6) LAN (Ethernet)
Manipulator
(7) I/O (Input) connector
Output device
(8) I/O (Output) connector
Input device
(9) AC power connector
AC 100V-240V
Option
Fieldbus I/O
Accessible connector
Included cable when shipping

Not supplied cable (Prepare by yourself)
(1) Hand I/O connector
Connect input/output devices of the users.
When there are input/output devices, use this connector.
Be careful about allowable current when using hand I/O connector.
For details, refer to the Setup & Operation 13. Hand I/O connector.
(2) TP connector
Connect the option Teach Pendant.
For details, refer to the Setup & Operation 10.TP Port.
(3) EMERGENCY
The EMERGENCY connector has inputs to connect the Emergency Stop switch and
the Safety Door switch. For safety reasons, connect proper switches for these input
devices.
For details, refer to the Setup & Operation 11. EMERGENCY.
(4) Memory port
Connect to USB memory.
For details, refer to the Setup & Operation 8. Memory port.
(5) PC for development
Connect the PC for development.
For details, refer to the Setup & Operation 7. Development PC Connection Port
(6) LAN (EtherNet Communication)
Connect the EtherNet cable.
For details, refer to the Setup & Operation 9. LAN (Ethernet Communication) Port.
30 T3 Rev.4
(7) I/O (Input) connector

This input connector is for output device of the user.
When there is output device, use this connector.
For details, refer to the Setup & Operation 12. Standard I/O connector.
(8) I/O (Output) connector
This output connector is for input device of the user.
When there is input device, use this connector.
For details, refer to the Setup & Operation 12. Standard I/O connector.
(9) AC power connector
Connector for AC power supply to the manipulator.
3.7.2 Noise Countermeasures

To minimize electrical noise conditions, the following items must be observed in the
system’s cable wiring:
- The earth wire of the power supply should be grounded. (Ground resistance: 100 Ω or
less) It is important to ground the frame of Manipulator not only for prevention from
electric shock, but also for reducing the influence of electric noise around the
Manipulator. Therefore, be sure to connect the earth wire (yellow/green) of the
Manipulator’s power cable to the ground terminal of the factory power supply. For
details about the plug and AC power cable, refer to the Setup & Operation 3.6 Power
Supply.
- Do not tap power from a power line that connects to any equipment which may cause
noise.
- Do not run AC power lines and DC power lines in the same wiring duct, and separate
them as far as possible. For example, separate the AC motor power line and the
Manipulator power line as far as possible from the sensor or valve I/O lines; and do not
bundle both sets of wiring with the same cable tie. If more than one duct/cable must
cross each other, they should cross perpendicularly. The preferable example is shown
in the right figure.
AC Line duct
As far as possible
DC line duct
- Wire as short as possible to the I/O connector and EMERGENCY connector. Use a
shielded cable and clamp the shield to the attached connector interior. Make sure to
keep away from the peripheral noise source as far as possible.
- Make sure that the induction elements used to connect to the Manipulator’s I/O (such
as relays and solenoid valves) are noise suppression parts. If an induction element
without protection against noise is used, make sure to connect a noise suppression part
such as a diode located at the induction element in parallel with it. In selecting noise
suppression parts, make sure that they can handle the voltage and current incurred by
the induction load.
- As they are easily influenced by noise, keep cable such as USB, Ethernet, or fieldbus
away from peripheral noise sources.
T3 Rev.4 31
3.8 Pneumatic Tubes

Pneumatic tubes are contained in the cable unit.
Max. Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter × Inner Diameter
2 ø 6 mm × ø 4 mm
0.59 MPa (6 kgf/cm2 : 86 psi)
1 ø 4 mm × ø 2.5 mm
Fittings for ø6 mm and ø4 mm (outer diameter) pneumatic tubes are supplied on both ends
of the pneumatic tubes.
Detail view from A Detail view from B
Fitting (blue)
for ø6 mm pneumatic tube Fitting (blue)
for ø4 mm pneumatic tube
Fitting (blue)
Fitting (white) Fitting (blue)

for ø6 mm pneumatic tube for ø6 mm pneumatic tube
Fitting (white)
32 T3 Rev.4
3.9 Relocation and Storage

3.9.1 Precautions for Relocation and Storage
Observe the following when relocating, storing, and transporting the Manipulators.
THE INSTALLATION SHALL BE PREFORMED BY QUALIFIED INSTALLATION

PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL
CODES.
■ Only authorized personnel should perform sling work and operate a crane and a
forklift. When these operations are performed by unauthorized personnel, it is
WARNING equipment damage to the robot system.
■ Before relocating the Manipulator, fold the arm and secure it tightly with a sheet to
prevent hands or fingers from being caught in the Manipulator.
■ When removing the anchor bolts, support the Manipulator to prevent falling.
Removing the anchor bolts without support may result in a fall of the Manipulator,
and then get hands, fingers, or feet caught.
■ To carry the Manipulator, have two or more people to work on it and secure the
CAUTION Manipulator to the delivery equipment or hold the bottom of Arm #1, the bottom of
the main cable fitting, and the bottom of the base by hand. When holding the
bottom of the base by hand, be very careful not to get hands or fingers caught.
■ Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is
extremely hazardous and may result in fall of the Manipulator.
When transporting the Manipulator for a long distance, secure it to the delivery
equipment so that the Manipulator cannot fall.
If necessary, pack the Manipulator in the same way as it was delivered.
When the Manipulator is used for a robot system again after long-term storage,
perform a test run to verify that it works properly, and then operate it thoroughly.
Transport and store the Manipulator in the range of −25 deg.C to +55 deg.C.
Humidity within 10% to 90% is recommended.
When condensation occurs on the Manipulator during transport or storage, turn

ON the power only after the condensation dries.
Do not shock or shake the Manipulator during transport.
T3 Rev.4 33
3.9.2 Relocation
■ Install or relocate the Manipulator with two or more people. The Manipulator
weights are as follows. Be careful not to get hands, fingers, or feet caught and/or
have equipment damaged by a fall of the Manipulator.
CAUTION
T3-401* : approx.16 kg :35 lb.
(1) Turn OFF the power on all devices and unplug the cables.
NOTE Remove the mechanical stops if using them to limit the motion range of Joints #1 and
 #2. For details on the motion range, refer to Setup & Operation: 5.2 Motion Range
Setting by Mechanical Stops.
(2) Cover the Arm #2 and Power Supply Unit with a sheet so that the arm will not be
damaged.
Example of Arm Retaining Posture
Arm #2
Power Supply Unit
Arm #1
(3) Hold the bottom of Arm #1 by hand to unscrew the anchor bolts.
Then, remove the Manipulator from the base table.
34 T3 Rev.4
Setup & Operation 4. Setting of End Effectors
4. Setting of End Effectors

4.1 Attaching an End Effector
Users are responsible for making their own end effector(s). Before attaching an end
effector, observe these guidelines.
■ If you use an end effector equipped with a gripper or chuck, connect wires and/or
pneumatic tubes properly so that the gripper does not release the work piece
when the power to the robot system is turned OFF. Improper connection of the
wires and/or pneumatic tubes may damage the robot system and/or work piece
as the work piece is released when the Emergency Stop switch is pressed.
CAUTION I/O outputs are configured at the factory so that they are automatically shut off (0)
by power disconnection, the Emergency Stop switch, or the safety features of the
robot system.
Shaft
- Attach an end effector to the lower end of the shaft.
For the shaft dimensions, and the overall dimensions of the Manipulator, refer to Setup
& Operation: 2. Specifications.
- Do not move the upper limit mechanical stop on the lower side of the shaft. Otherwise,
when “Jump motion” is performed, the upper limit mechanical stop may hit the
Manipulator, and the robot system may not function properly.
- Use a split muff coupling with an M4 bolt or larger to attach the end effector to the shaft.
Brake release switch
- Joint #3 cannot be moved up/down by hand
because the solenoid brake is applied to the
joint while power to the robot system is turned Brake release switch
OFF.
This prevents the shaft from hitting peripheral
equipment in the case that the shaft is lowered
by the weight of the end effector when the
power is disconnected during operation, or
when the motor is turned OFF even though the
power is turned ON.
To move Joint #3 up/down while attaching
an end effector, turn ON the Manipulator
and press the brake release switch.
This button switch is a momentary-type; the

The shaft may be
brake is released only while the button lowered by the weight
switch is being pressed. of the end effector.
- Be careful of the shaft while the brake release switch is being pressed because the shaft
may be lowered by the weight of the end effector.
Layouts
- When you operate the manipulator with an end effector, the end effector may interfere
with the Manipulator because of the outer diameter of the end effector, the size of the
work piece, or the position of the arms. When designing your system layout, pay
attention to the interference area of the end effector.
T3 Rev.4 35
4.2 Attaching Cameras and Valves

The bottom of the Arm #2 has threaded holes as shown in the figure below. Use these
holes for attaching cameras, valves, and other equipment. [Unit: mm]
From the base mounting face
36 T3 Rev.4
4.3 Weight and Inertia Settings

To ensure optimum Manipulator performance, it is important to make sure that the load
(weight of the end effector and work piece) and moment of inertia of the load are within
the maximum rating for the Manipulator, and that Joint #4 does not become eccentric.
If the load or moment of inertia exceeds the rating or if the load becomes eccentric, follow
the steps below, Setup & Operation: 4.3.1Weight Setting and 4.3.2 Inertia Setting to set
parameters.
Setting parameters makes the PTP motion of the Manipulator optimal, reduces vibration to
shorten the operating time, and improves the capacity for larger loads. In addition, it
reduces persistent vibration produced when the moment of inertia of the end effector and
work piece is larger than the default setting.
4.3.1 Weight Setting

■ The total weight of the end effector and the work piece must not exceed 3 kg.
The T3 series Manipulators are not designed to work with loads exceeding 3 kg.
Always set the Weight parameters according to the load. Setting a value that is
CAUTION smaller than the actual load may cause errors, excessive shock, insufficient
function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.
The acceptable weight capacity (end effector and work piece) in T3 series is
1 kg at the default rating, 3 kg at the maximum.
When the load (weight of the end effector and work piece) exceeds the rating, change the
setting of Weight parameter.
After the setting is changed, the maximum acceleration/deceleration speed of the robot
system at PTP motion corresponding to the “Weight Parameter” is set automatically.
Load on the Shaft

The load (weight of the end effector and work piece) on the shaft can be set by Weight
parameter.
EPSON Enter a value into the [Load inertia:] text box on the [Inertia] panel ([Tools]-[Robot
RC+ Manager]). (You may also execute the Inertia command from the [Command Window].)
Load on the Arm

When you attach a camera or other devices to the arm, calculate the weight as the
equivalent of the shaft. Then, add this to the load and enter the total weight to the Weight
parameter
Equivalent Weight Formula

When you attach the equipment near Arm #2: WM = M (L1)2/(L1+L2)2
When you attach the equipment to the end of Arm #2: WM = M (LM)2/(L2)2
WM : equivalent weight
M : weight of camera etc.
L1 : length of Arm #1
L2 : length of Arm #2
LM : distance from rotation center of Joint #2 to center of gravity
of camera etc.
T3 Rev.4 37
<Example> A “1 kg” camera is attached to the end of the T3 series arm (180 mm away from the
rotation center of Joint #2) with a load weight of “1 kg”.
M=1 Shaft
L2=175
LM=225 Weight of
2 2 camera
WM=1×225 /175 M=1kg
=1.653  1.7 (round up) Joint #2
W+WM=1+1.7=2.7
Enter “2.7” for the Weight Parameter.

W=1kg L2=175 mm
LM=225 mm
Automatic speed setting by Weight
(%)120
100 100 100 100
100
80
60
40
20
0 1 2 3 (kg)
End effector weight parameter
* The percentage in the graph is based on the speed at rated weight (1 kg) as 100%.
Automatic acceleration/deceleration setting by Weight

(%) 120
110 110
100 100
80 80
60 60
40
20
0 1 2 3 (kg)
End effector weight parameter
* The percentage in the graph is based on the acceleration/deceleration at rated weight (1 kg) as 100%.
38 T3 Rev.4
4.3.2 Inertia Setting

Moment of Inertia and the Inertia Setting
The moment of inertia is defined as “the ratio of the torque applied to a rigid body and its
resistance to motion”. This value is typically referred to as “the moment of inertia”,
“inertia”, or “GD2”. When the Manipulator operates with additional objects (such as an
end effector) attached to the shaft, the moment of inertia of load must be considered.
■ The moment of inertia of the load (weight of the end effector and work piece)
must be 0.01 kg·m2 or less. The T3 series Manipulators are not designed to
work with a moment of inertia exceeding 0.01 kg·m2. Always set the moment of
inertia parameter to the correct moment of inertia. Setting a value that is smaller
CAUTION than the actual moment of inertia may cause errors, excessive shock, insufficient
function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.
The acceptable moment of inertia of load for a T3 series Manipulator is

0.003 kg·m2 at the default rating and, 0.01 kg·m2 at the maximum.
When the moment of inertia of the load exceeds the rating, change the setting of the
moment of inertia parameter of the Inertia command. After the setting is changed, the
maximum acceleration/deceleration speed of Joint #4 at PTP motion corresponding to the
“moment of inertia” value is set automatically.
Moment of inertia of load on the shaft

The moment of inertia of load (weight of the end effector and work piece) on the shaft can
be set by the “moment of inertia” parameter of the Inertia command.
EPSON Enter a value into the [Load inertia:] text box on the [Inertia] panel ([Tools]-[Robot
Automatic acceleration/deceleration setting of Joint #4 by Inertia (moment of inertia)
(%) 120
100 100
100
75
80
60
40 30
20
0 0.002 0.004 0.006 0.008 0.01 0.012 (kg·m2)

Moment of inertia setting
T3 Rev.4 39
Eccentric Quantity and the Inertia Setting
■ The eccentric quantity of load (weight of the end effector and work piece) must be
100 mm or less. The T3 series Manipulators are not designed to work with
eccentric quantity exceeding 100 mm.
Always set the eccentric quantity parameter according to the eccentric quantity.
CAUTION Setting a value that is smaller than the actual eccentric quantity may cause
errors, excessive shock, insufficient function of the Manipulator, and/or shorten
the life cycle of parts/mechanisms.
The acceptable eccentric quantity of load in T3 series is 0 mm at the default rating and 100
mm at the maximum. When the eccentric quantity of load exceeds the rating, change the
setting of eccentric quantity parameter of Inertia command. After the setting is changed,
the maximum acceleration/deceleration speed of the Manipulator at PTP motion
corresponding to the “eccentric quantity” is set automatically.
Eccentric Quantity Rotation center

Position of load’s center of gravity
Eccentric quantity (100mm or less)
Eccentric quantity of load on the shaft

The eccentric quantity of load (weight of the end effector and work piece) on the shaft can
be set by “eccentric quantity” parameter of Inertia command.
EPSON Enter a value into the [Eccentricity:] text box on the [Inertia] panel ([Tools]-[Robot
Automatic acceleration/deceleration setting by Inertia (eccentric quantity)
(%) 120
100
100
80
60
60
40
40
25
20
0 50 75 100 (mm)
Eccentricity setting
* The percentage in the graph is based on the acceleration / deceleration at rated eccentricity (0
mm) as 100%.
40 T3 Rev.4
Calculating the Moment of Inertia

Refer to the following examples of formulas to calculate the moment of inertia of load
(end effector with work piece).
The moment of inertia of the entire load is calculated by the sum of each part (a), (b), and
(c).
Rotation center
Joint #3 shaft
End effector (a)
Work piece (b) Work piece (c)
Whole moment Moment of inertia Moment of inertia Moment of inertia

= + +
of inertia of end effector (a) of work piece (b) of work piece (c)
The methods for calculating the moment of inertia for (a), (b), and (c) are shown below.
Calculate the total moment of inertia using the basic formulas.
(a) Moment of inertia of a rectangular parallelepiped

Rotation center Rectangular parallelepiped’s center of gravity
2 2
Mass (m) b +h 2
m +m×L
12
L
b
h
(b) Moment of inertia of a cylinder
Cylinder’s center of gravity Rotation center
r
2
r 2
m +m×L
Mass (m) 2
T3 Rev.4 41
(c) Moment of inertia of a sphere

Sphere’s center of gravity
Rotation center
2 2 2
r m r +m×L
5
Mass (m)
4.4 Precautions for Auto Acceleration/Deceleration of Joint #3

When you move the Manipulator in horizontal PTP motion with Joint #3 (Z) at a high
position, the motion time will be faster.
When Joint #3 gets below a certain point, then auto acceleration/deceleration is used to
reduce acceleration/deceleration. (Refer to the figures below) The higher the position of
the shaft is, the faster the motion acceleration/deceleration is. However, it takes more
time to move Joint #3 up and down. Adjust the position of Joint #3 for the Manipulator
motion after considering the relation between the current position and the destination
position.
The upper limit of Joint #3 during horizontal motion using Jump command can be set by
the LimZ command.
Automatic acceleration/deceleration vs. Joint #3 position
(%)120
100 100
100
80
60 50 50
40
20
0 -50 -100 -150 -200 (mm)

Shaft height
* Figures on the graph (%) are the proportion to the acceleration/deceleration speed
at the shaft upper limit position.
NOTE When moving the Manipulator horizontally while the shaft is being lowered, it may cause
 over-shoot at the time of final positioning.
42 T3 Rev.4
Setup & Operation 5. Motion Range
5. Motion Range
■ When setting up the motion range for safety, both the pulse range and
mechanical stops must always be set at the same time.
CAUTION
The motion range is preset at the factory as explained in Setup & Operation: 5.4 Standard
Motion Range. That is the maximum motion range of the Manipulator.
There are three methods for setting the motion range described as follows:
1. Setting by pulse range (for all joints)
2. Setting by mechanical stops (for Joints #1 to #3)
3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the
Manipulator (for Joints #1 and #2)
Rectangular range setting
Mechanical Mechanical
Motion range
stop stop
Pulse range
When the motion range is changed due to layout efficiency or safety, follow the
descriptions in 5.1 to 5.3 to set the range.
5.1 Motion Range Setting by Pulse Range (for All Joints)

Pulses are the basic unit of Manipulator motion. The motion range of the Manipulator is
controlled by the pulse range between the pulse lower limit and upper limit of each joint.
Pulse values are read from the encoder output of the servo motor.
For the maximum pulse range, refer to the following sections.
The pulse range must be set inside of the mechanical stop range.
5.1.1 Max. Pulse Range of Joint #1
5.1.4 Max. Pulse Range of Joint #4.
NOTE Once the Manipulator receives an operating command, it checks whether the target
 position specified by the command is within the pulse range before operating. If the
target position is out of the set pulse range, an error occurs and the Manipulator does not
move.
EPSON The pulse range can be set on the [Range] panel shown by selecting [Tools]-[Robot
RC+ Manager]. (You may also execute the Range command from the [Command Window].)
T3 Rev.4 43

The 0 (zero) pulse position of Joint #1 is the position where Arm #1 faces toward the
positive (+) direction on the X-coordinate axis.
When the 0 pulse is a starting point, the counterclockwise pulse value is defined as the
positive (+) and the clockwise pulse value is defined as the negative (-).
+Y
+A −A
+X 0 pulse
+B −B
A: Max. Motion Range B: Max. Pulse Range

± 132 deg. − 95574~505174 pulse

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

± 141 deg. ± 320854 pulse
44 T3 Rev.4

The 0 (zero) pulse position of Joint #3 is the position where the shaft is at its upper limit.
The pulse value is always negative because Joint #3 always moves lower than the 0 pulse
position.
Upper limit: 0 pulse
Joint #3 Stroke Lower Limit Pulse

150 mm −187734 pulse

The 0 (zero) pulse position of Joint #4 is the position where the flat near the end of the
shaft faces toward the end of Arm #2. With the 0 pulse as a starting point, the
counterclockwise pulse value is defined as the positive (+) and the clockwise pulse value
is defined as the negative (-).
+Y Counterclockwise (+value)
+X 0 ± 71760 pulse
Clockwise (-value)
T3 Rev.4 45
5.2 Motion Range Setting by Mechanical Stops

Mechanical stops physically limit the absolute area that the Manipulator can move.
Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for
the mechanical stop settings. Install the bolts in the holes corresponding to the angle that
you want to set.
Joints #3 can be set to any length less than the maximum stroke.
Mechanical stop of Joint #3

(Lower limit mechanical stop)
Mechanical stop of
Joint #2 (Adjustable)
Mechanical stop of
(Do not move the upper Joint #1 (Fixed)
limit mechanical stop.)
Mechanical stop of Joint #2

Mechanical stop of
(Fixed)
Joint #1 (Adjustable)
5.2.1 Setting the Mechanical Stops of Joints #1 and #2

Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for
the mechanical stop settings. Install the bolts in the holes corresponding to the angle that
you want to set.
Install the bolts for the mechanical stop to the following position.
Joint #1 Mechanical Stops (Views from the bottom of Arm #1)
a
b
a b
Setting Angle 110° −110°
Pulse Value 455112 pulse −45512 pulse
46 T3 Rev.4
Joint #2 Mechanical Stops (Views from the top of Arm #1)

b
a
a b
Setting Angle 120° −120°
Pulse Value 273066pulse −273066pulse
(1) Turn OFF the Manipulator.
(2) Install a hexagon socket head cap bolt into the hole corresponding to the setting angle,
and tighten it.
Joint #2 only Remove the user plate on the arm cover.
For details, refer to Maintenance: 7. Cover.
Hexagon socket
The number Recommended
Joint head cap bolt
of bolts tightening torque
(fully threaded)
M8×10 One for each
1 12.3 N⋅m (125 kgf⋅cm)
All screws One side
(3) Turn ON the Manipulator.
(4) Set the pulse range corresponding to the new positions of the mechanical stops.
NOTE Be sure to set the pulse range inside the positions of the mechanical stop range.
 Example: Using T3-401S

The angle of Joint #1 is set from –110 degrees to +110 degrees.
The angle of Joint #2 is set from -120 degrees to +120 degrees.
EPSON Execute the following commands from the [Command Window]

RC+
>JRANGE 1, -45512, 455112 ' Sets the pulse range of Joint #1
>JRANGE 2,- 273066, 273066 ' Sets the pulse range of Joint #2
>RANGE ' Checks the setting using Range
-45512, 455112, -273066, 273066, -187734
,0, -71760, 71760
(5) Move the arm by hand until it touches the mechanical stops, and make sure that the
arm does not hit any peripheral equipment during operation.
T3 Rev.4 47
(6) Operate the joint changed at low speeds until it reaches the positions of the minimum
and maximum pulse range. Make sure that the arm does not hit the mechanical
stops. (Check the position of the mechanical stop and the motion range you set.)
Example: Using T3-401S
The angle of Joint #1 is set from -110 degrees to +110 degrees.
The angle of Joint #2 is set from -120 degrees to +120
EPSON Execute the following commands from the [Command Window].
RC+ >MOTOR ON ' Turns ON the motor
>LP ON ' Enters low-power mode
>SPEED 5 ' Sets at low speeds
>PULSE -45512,0,0,0 ' Moves to the min. pulse position of Joint #1
>PULSE 455112,0,0,0 ' Moves to the max. pulse position of Joint #1
>PULSE 204800,-273066,0,0 ' Moves to the min. pulse position of Joint #2
>PULSE 204800,273066,0,0 ' Moves to the max. pulse position of Joint #2
The Pulse command (Go Pulse command) moves all joints to the specified positions
at the same time. Specify safe positions after considering motion of not only the
joints whose pulse range have been changed, but also other joints.
In this example, Joint #1 is moved to the center of its motion range (pulse value:
204800) when checking Joint #2.
If the arm is hitting the mechanical stops or if an error occurs after the arm hits the
mechanical stops, either reset the pulse range to a narrower setting or extend the
positions of the mechanical stops within the limit.
5.2.2 Setting the Mechanical Stop of Joint #3

(1) Turn ON the Manipulator and turn OFF the motors using the Motor OFF command.
(2) Push up the shaft while pressing the brake

release switch. Brake release switch
Do not push the shaft up to its upper limit or it

will be difficult for the arm top cover to be
Lower limit
removed. Push the shaft up to a position mechanical
where the Joint #3 mechanical stop can be stop screw
changed. M3×10
Shaft
NOTE
 When you press the brake release switch, the shaft may lower due to the weight of the
end effector. Be sure to hold the shaft by hand while pressing the button.
(4) Loosen the lower limit mechanical stop screw (M3×10).
48 T3 Rev.4
NOTE A mechanical stop is mounted on both the top and bottom of Joint #3. However, only
 the position of the lower limit mechanical stop on the top can be changed. Do not
remove the upper limit mechanical stop on the bottom because the calibration point of
Joint #3 is specified using the stop.
(5) The upper end of the shaft defines the

maximum stroke. Move the lower limit
mechanical stop down by the length you Measure
want to limit the stroke. this distance.
For example, when the lower limit

mechanical stop is set at “150 mm”
stroke, the lower limit Z coordinate value
is “-150”. To change the value to
“-130”, move the lower limit mechanical
stop down “20 mm”. Use calipers to
measure the distance when adjusting the
mechanical stop.
(6) Firmly tighten the lower limit mechanical stop screw (M3×10).
Recommended tightening torque: 2.4±0.1 N⋅m
(8) Move Joint #3 to its lower limit while pressing the brake release switch, and then
check the lower limit position. Do not lower the mechanical stop too far.
Otherwise, the joint may not reach a target position.
(9) Calculate the lower limit pulse value of the pulse range using the formula shown below
and set the value.
The result of the calculation is always negative because the lower limit Z coordinate
value is negative.
Lower limit of pulse (pulse)
= lower limit Z coordinate value (mm) / Joint #3 resolution (mm/pulse)**
** For the Joint #3 resolution,
refer to the section Setup & Operation 2.4 Specifications.
EPSON Execute the following command from the [Command Window]. Enter the
RC+ calculated value in X.
>JRANGE 3,X,0 ' Sets the pulse range of Joint #3
(10) Using the Pulse command (Go Pulse command), move Joint #3 to the lower limit
position of the pulse range at low speed. If the mechanical stop range is less than
the pulse range, Joint #3 will hit the mechanical stop and an error will occur. When
the error occurs, either change the pulse range to a lower setting or extend the position
of the mechanical stop within the limit.
NOTE If it is difficult to check whether Joint #3 hits a mechanical stop, turn OFF the
 Manipulator and lift the arm top cover to check the condition causing the problem from
the side.
T3 Rev.4 49
EPSON Execute the following commands from the [Command Window]. Enter the value
RC+ calculated in Step (9) in X.
>MOTOR ON ' Turns ON the motor
>SPEED 5 ' Sets low speed
>PULSE 0,0,X,0 ' Moves to the lower limit-pulse position of Joint #3.
(In this example, all pulses except those for Joint #3 are
“0”. Substitute these “0s” with the other pulse values
specifying a position where there is no interference even
when lowering Joint #3.)
5.3 Setting the Cartesian (Rectangular) Range in the XY

Coordinate System of the Manipulator (for Joints #1 and #2)
Use this method to set the upper and lower limits of the X and Y coordinates.
This setting is only enforced by software. Therefore, it does not change the physical
range. The maximum physical range is based on the position of the mechanical stops.
EPSON Set the XYLim setting on the [XYZ Limits] panel shown by selecting [Tools]-[Robot
RC+
Manager].
(You may also execute the XYLim command from the [Command Window].)
5.4 Standard Motion Range

The following “motion range” diagrams show the standard (maximum) specification.
When each Joint motor is under servo control, the center of Joint #3’s (shaft’s) lowest
point moves in the areas shown in the figure.
“Area limited by mechanical stop” is the area where the center of Joint #3’s lowest point
can be moved when each joint motor is not under servo control.
“Mechanical stop” sets the limited motion range so that the center of Joint #3 cannot move
beyond the area mechanically.
“Maximum space” is the area that contains the farthest reach of the arms. If the
maximum radius of the end effector is over 60 mm, add the “Area limited by mechanical
stop” and “radius of the end effector”. The total value is specified as the maximum area.
For the motion area figures, refer to Setup & Operation 3.3 Mounting Dimensions.
50 T3 Rev.4
Setup & Operation 6. Operation Mode & LED
6. Operation Mode & LED

6.1 Overview
The Robot system has three operation modes.
TEACH mode This mode enables point data teaching and checking close to the
Manipulator using the Teach Pendant.
In this mode the Manipulator operates in Low power status.
AUTO mode This mode enables automatic operation (program execution) of the
Robot system for the manufacturing operation, and also
programming, debug, adjustment, and maintenance of the Robot
system.
This mode cannot operate the Manipulators or run programs with the
Safety Door open.
TEST mode This mode enables program verification while the Enable Switch is
held down and the safeguard is open.
This is a low speed program verification function (T1: manual
deceleration mode) which is defined in Safety Standards.
This mode can operate the specified Function with multi-task /
single-task, multi-manipulator / single-manipulator at low speed.
6.2 Switch Operation Mode

Change the operation mode using the mode selector key switch on the Teach Pendant.
TEACH mode Turn the mode selector key switch to “Teach” for TEACH mode.
Switching to TEACH mode pauses the program if it was running.
The operating manipulator stops by Quick Pause.
AUTO mode Turn the mode selector key switch to “Auto” and turn on the latch
release input signal for AUTO mode.
TEST mode Turn the mode selector key switch to “Teach” for “TEACH” mode.
Push <F1> key-[Test Mode] in [Jog & Teach] dialog of TEACH
mode. The mode will be changed to TEST
T3 Rev.4 51
6.3 Program Mode (AUTO)

6.3.1 What is Program Mode (AUTO)?
Program mode is for programming, debug, adjustment, and maintenance of the Robot
system.
Follow the procedures below to switch to the Program mode.
6.3.2 Setup from EPSON RC+ 7.0
Switch the mode to Program mode from the EPSON RC+ 7.0.
(1) Select EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the [System
Configuration] dialog.
(5)
(2) (4)
(3)
(2) Select [Startup].

(3) Select [Start mode]-<Program> button.
(4) Click the <Apply> button.
(5) Click the <Close> button.
52 T3 Rev.4
6.4 Auto Mode (AUTO)
6.4.1 What is Auto mode (AUTO)?

Auto mode (AUTO) is for automatic operation of the Robot system.
Procedures for switching to the Auto mode (AUTO) are the following.
A : Set the start mode of the EPSON RC+ 7.0 to “Auto” and start the EPSON RC+
7.0.
(Refer to Setup & Operation 6.3.2 Setup from EPSON RC+ 7.0.)
B : Offline the EPSON RC+ 7.0.
Execute and stop the program from the control device specified by the EPSON RC+ 7.0.

NOTE
(Refer to Setup & Operation 6.4.3 Setup Control Device.)
6.4.2 Setup from EPSON RC+ 7.0

Switch the mode to Auto mode (AUTO) from the EPSON RC+ 7.0.
(5)
(2) (4)
(3)
(2) Select [Startup].

(3) Select [Start Mode]-<Auto> button.
T3 Rev.4 53
6.4.3 Setup from Control Device

Set the control device from EPSON RC+ 7.0.
(5)
(4)
(2)
(3)
(2) Select [Controller]-[Configuration].

(3) Select [Control Device] to select the control device from the following two types.
- PC
- Remote (I/O)
54 T3 Rev.4
6.5 LED
Six LEDs are located on the front panel of the Manipulator.
LEDs (ERROR, E-STOP, TEACH, AUTO, PROGRAM) turn ON according to the
Controller status (error, Emergency Stop, TEACH mode, Auto mode, Program mode).
LED
From turning ON the Robot System to completing startup

Three LEDs (TEACH, AUTO, PROGRAM) blink.
After the Robot System Startup

Controller status LED display
Execute Controller status
storage function to the TEACH AUTO, PROGRAM blink.
USB memory
TEACH, AUTO, PROGRAM turn ON
Complete Controller status
(for 2 seconds).
storage to USB memory
ERROR turns OFF even if an error occurs.
Failure of Controller status ERROR, TEACH, AUTO, PROGRAM turn ON
storage to USB memory (for 2 seconds).
Error ERROR turns ON
Warning ERROR blinks.
Emergency Stop E-STOP turns ON.
TEACH mode TEACH blinks.

Auto mode (AUTO mode) AUTO blinks.
Program mode (AUTO mode) PROGRAM blinks.
AC power supply drop TEACH, AUTO turn ON.
Test mode TEACH blinks.
T3 Rev.4 55
Setup & Operation 7. Development PC Connection Port
7. Development PC Connection Port
Development PC Connection Port
NOTE - For other details of development PC and Manipulator connection, refer to EPSON RC+
 7.0 User’s Guide 5.12.1 PC to Controller Communications Command.
- Be sure to install the EPSON RC+ 7.0 to the development PC first, then connect the
development PC and Manipulator with the USB cable.
If Manipulator and the development PC are connected without installing the EPSON
RC+ 7.0 to the development PC, [Add New Hardware Wizard] appears. If this wizard
appears, click the <Cancel> button.
7.1 What is Development PC Connection Port

The development PC connection port supports the following USB types.
- USB2.0 HighSpeed/FullSpeed (Speed auto selection, or FullSpeed mode)
- USB1.1 FullSpeed
Interface Standard : USB specification Ver.2.0 compliant
(USB Ver.1.1 upward compatible)
Connect the Manipulator and development PC by a USB cable to develop the robot system
or set the Manipulator configuration with the EPSON RC+ 7.0 software installed in the
development PC.
Development PC connection port supports hot plug feature. Cables insert and remove
from the development PC and the Manipulator are available when the power is ON.
However, stop occurs when USB cable is removed from the Manipulator or the
development PC during connection.
56 T3 Rev.4
7.2 Precaution
When connecting the development PC and the Manipulator, make sure of the following:
- Connect the development PC and the Manipulator with a 5 m or less USB cable.
Do not use the USB hub or extension cable.
- Make sure that no other devices except the development PC are used for development
PC connection port.
- Use a PC and USB cable that supports USB2.0 HighSpeed mode to operate in USB2.0
HighSpeed mode.
- Do not pull or bend the cable strongly.
- Do not allow unnecessary strain on the cable.
- When the development PC and the Manipulator are connected, do not insert or remove
other USB devices from the development PC. Connection with the Manipulator
may be lost.
7.3 Software Setup and Connection Check

Connection of the development PC and the Manipulator is indicated.
(1) Make sure that software EPSON RC+ 7.0 is installed to the Manipulator connected
to the development PC.
(Install the software when it is not installed. Refer to Robot System Safety and
Installation or EPSON RC+ 7.0 User’s Guide.
(2) Connect the development PC and the Manipulator using a USB cable.
(4) Start EPSON RC+ 7.0.
(5) Select the EPSON RC+ 7.0 menu-[Setup]-[PC to Controller Communications] to
display the [PC to Controller Communications] dialog.
(6) Select “No.1 USB” and click the <Connect> button.
T3 Rev.4 57
(7) After the development PC and the Manipulator connection has completed, “Connected”
is displayed at [Connection status]. Make sure that “Connected” is displayed and
click the <Close> button to close the [PC to Controller Communications] dialog.
The connection between the development PC and the Manipulator is completed. Now
the robot system can be used from EPSON RC+ 7.0.
7.4 Disconnection of Development PC and Manipulator

Disconnection of the development PC and the Manipulator communication.
(1) Select the EPSON RC+ 7.0 menu-[Setup]-[PC to Controller Communications] to
display the [PC to Controller Communications] dialog.
(2) Click the <Disconnect> button.
Communication between the Manipulator and the development PC is disconnected
and the USB cable can be removed.
If the USB cable is removed when the Manipulator and the development PC are connected,

NOTE
the Manipulator will stop. Be sure to click the <Disconnect> button in the [PC to
Controller Communications] dialog before USB cable is removed.
58 T3 Rev.4
Setup & Operation 8. Memory Port
8. Memory Port
Connect a commercial USB memory to the Manipulator memory port to use the Controller
status storage function to the USB memory.
8.1 What is Controller Status Storage Function?

This function saves various kinds of Manipulator data to the USB memory. Data saved
in USB memory is loaded to EPSON RC+ 7.0 to get the status of the Manipulator and the
program simply and accurately.
The saved data can also be used for restoring the Manipulator.
Unable to execute status storage to USB memory when operating the Manipulator.
8.2 Before Using Controller Status Storage Function
8.2.1 Precautions
■ Controller status storage function is available at any time and in any Manipulator
status after starting the Manipulator.
However, operations form the console including stop and pause are not available
while executing this function.
CAUTION Also, this function influences the Manipulator cycle time and the communication
with EPSON RC+ 7.0. Other than only when it is necessary, do not execute this
function when operating the Manipulator.
- Make sure that the USB port is used only for USB memory even though the port on
the Controller is a universal USB port.
- Insert the USB memory directly into the Manipulator memory port. Connection
with cables or hubs between the Manipulator and the USB memory is not assured.
- Make sure that the USB memory is inserted or removed slowly.
- Do not edit the saved files with an editor. Operation of the robot system after data
restoration to the Manipulator is not assured.
8.2.2 Adoptable USB Memory

Use USB memory that meets following conditions.
- USB2.0 supported
- Without security function
USB memory with password input function cannot be used.
- No installation of a driver or software is necessary for Windows XP, Windows Vista,
Windows 7, Windows 8, or Windows 10, Linux.
(For supported operating systems for the EPSON RC+ 7.0, refer to Setup &
Operation 2.5 System Example.)
T3 Rev.4 59
8.3 Controller Status Storage Function

8.3.1 Controller Status Storage with Trigger Button
■ Controller status storage function is available at any time and in any Manipulator
status after starting the Manipulator.
However, operations form the console including stop and pause are not available
while executing this function.
CAUTION Also, this function influences the Manipulator cycle time and the communication
with EPSON RC+ 7.0. Other than only when it is necessary, do not execute this
function when operating the Manipulator.
Use this procedure to save the status of the Manipulator to USB memory.
(1) Insert the USB memory into the memory port.
When the data transfer starts, the LED of TEACH, AUTO, and PROGRAM starts
blinking. Wait until the LED status changes.
(The data transfer time varies according to the data size such as of the projects.)
(2) When the Manipulator status storage is completed successfully, the LED of TEACH,
AUTO, and PROGRAM are turned ON for two seconds. Note that the LED of
ERROR turns OFF even in the error status.
If it ends in failure, the LED of ERROR, TEACH, AUTO, and PROGRAM are turned
ON for two seconds.
(3) Remove the USB memory from the Manipulator.
NOTE - USB memory with LED is recommended to check the status changes.
 - When storage is executed during Motor ON status, it may fail to store the status. Use
another USB memory or execute the storage during Motor OFF status.
60 T3 Rev.4
8.3.2 Load Data with EPSON RC+ 7.0

The following shows the procedure to load the data stored in the USB memory by EPSON
RC+ 7.0 and display the Controller status.
(1) Insert the USB memory into the PC with EPSON RC+ 7.0.
(2) Make sure that the following folder is indicated in the USB memory.
B_T_serial number_data status was saved
→ Exmaple:B_T_12345_2013-10-29_092951
(3) Copy the folder confirmed in procedure (2) to the “¥EpsonRC70¥Backup” folder.
(4) Select the EPSON RC+ 7.0 menu-[Tools]-[Controller] to display the [Controller Tools]
dialog.
(5) Click the <View Controller Status…> button.

(6) [Browse For Folder] dialog appears. Select the folder copied in procedure (3) and
click the <OK> button.
T3 Rev.4 61
(7) [Controller Status Viewer] dialog appears to confirm the Controller status.
For details, refer to View Controller Status in EPSON RC+ 7.0 User’s Guide 5.11.8
Controller Command (Tools Menu).
8.3.3 Transfer with E-mail

Follow this procedure to transfer the data by e-mail that was saved to the USB memory.
(1) Insert the USB memory to a PC that supports sending of e-mail.
(2) Make sure that the USB memory has following folders.
B_T_serial number_data status was saved
→ Exmaple:B_T_12345_2013-10-29_092951
(3) Send all the folders by e-mail.
NOTE
 Delete files that do not relate to the project before transfer.

This function is used to send the data to the system director and EPSON from the end
users for problem analysis.
62 T3 Rev.4
8.4 Details of Data

The following data files are created by the Controller status storage function.
File Name Outline

Backup.txt Information file File with information for Manipulator restore.
for restore
CurrentMnp01.PRM Robot parameter Saves information such as ToolSet.
CurrentStatus.txt Save status Saves program and I/O status.
ErrorHistory.csv Error history
InitFileSrc.txt Initial setting Saves various settings of the Controller.
MCSys01.MCD Robot setting Saves information of connected Manipulator.
SrcmcStat.txt Hardware Saves installation information of hardware.
information
ProjectName.obj OBJ file Result of project build.
Prg file is not included.
GlobalPreserves.dat Global Preserve Saves values of Global Preserve variables.
variables
WorkQueues.dat WorkQue Saves information of Queues information of the WorkQue.
information
MCSRAM.bin Inner information
MCSYSTEMIO.bin of Manipulator
MCTABLE.bin
MDATA.bin
SERVOSRAM.bin
VXDWORK.bin
All files related to Project When [Include project files when status exported] check
project except box is checked in EPSON RC+ 7.0 menu-[Setup]-
ProjectName.obj *1 [System Configuration]-[Controller]-
[Preference], the project file is stored.
Includes program files.
*1 Storage of “All files related to project except ProjectName.obj” can be specified by a setting.
T3 Rev.4 63
Setup & Operation 9. LAN (Ethernet Communication) Port
9. LAN (Ethernet Communication) Port

NOTE
- Refer to EPSON RC+ 7.0 User’s Guide 5.12.1 [PC to Controller Communications]
 Command (Setup Menu) for other details for the development PC and Manipulator
connection.
- For Ethernet (TCP/IP) communication with robot application software, refer to EPSON
RC+ 7.0 Online Help or User’s Guide 14. TCP/IP Communications.
9.1 What is the LAN (Ethernet Communication) Port

Ethernet communication port supports 100BASE-TX / 10 BASE-T.
This port is used for two different purposes.
Connection with development PC

LAN (Ethernet communication) port is used for connection of the Manipulator and the
development PC.
Equivalent operation is available to connect between the Manipulator and the
development PC with the development PC connection port.
(Refer to Setup & Operation 7. Development PC Connection Port)
Connection with other Manipulator, Controller, or PC

The LAN (Ethernet communication) port can be used as an Ethernet (TCP/IP)
communication port to communicate between multiple controllers from robot
application software.
9.2 IP Address
Set the proper IP address or subnet mask depending on the Manipulator and development
PC configuration to use the LAN port.
Do not input a random value for the IP address of the network configured TCP/IP. This
is the only address that specifies the computer using an Internet connection.
The IP address is assigned from the company or organization that has control of IP
address.
Use an address from the following Internet private environment such as P2P or line.
Make sure that the address is not redundantly assigned inside the closed network.
Private Address List

10.0.0.1 to 10.255.255.254
172.16.0.1 to 172.31.255.254
192.168.0.1 to 192.168.255.254
The following is the configuration of the controller Manipulator at delivery.

IP Address : 192.168.0.1
IP Mask : 255.255.255.0
IP Gateway : 0.0.0.0
64 T3 Rev.4
9.3 Changing Manipulator IP Address

In this section, the procedure to change the Manipulator IP address when connecting
Manipulator development PC connection port and the development PC by the USB cable
is indicated.
(1) For connection between the development PC and the Manipulator.
Refer to Setup & Operation: 7. Development PC Connection Port.
(2) Select the EPSON RC+ 7.0 menu-[Setup]-[Controller] to display the following dialog.
(3) Select [Controller]-[Configuration].
(4) Enter the proper IP address and subnet mask and click the <Apply> button.
(5) Click the <Close> button. The Manipulator reboots automatically.
IP address configuration is completed and the Manipulator reboot dialog disappears.
NOTE When the Manipulator and the development PC are connected via the Ethernet, the
 Manipulator IP address can also be changed. However, Manipulator and the
development PC do not connect automatically after rebooting the Manipulator at Ethernet
connection.
T3 Rev.4 65
9.4 Connection of Development PC and Manipulator with Ethernet

Connection between the development PC and the Manipulator is shown below.
(1) Connect the development PC and the Manipulator using the Ethernet cable.
(2) Turn on the Manipulator.
(3) Start EPSON RC+ 7.0.
(4) Display the [PC to Controller Communication] dialog from [Setup] in EPSON RC+
7.0 menu.
(5) Click the <Add> button.
(6) Connection “No.2” is added. Set the following and click the <Apply> button.
Name : Valid value to identify the Manipulator to connect
IP Address : IP address for Manipulator to connect
(7) [Name] and [IP Address] specified in procedure (6) is displayed.
66 T3 Rev.4
(8) Make sure that “No.2” is selected, and click the <Connect> button.
(9) After the development PC and Manipulator connection is completed, “Connected” is

displayed in the [Connection status:]. Make sure that “Connected” is displayed and
click the <Close> button to close the [PC to Controller Communications] dialog.
Connection between the development PC and the Manipulator is complete. Now the
robot system can be used via an Ethernet connection from EPSON RC+ 7.0.
9.5 Disconnection of Development PC and Manipulator with Ethrnet

Disconnection of the development PC and the Manipulator is shown below.
(1) Display [PC-Controller Connection] dialog from [Setup] in EPSON RC+ 7.0 menu.
(2) Click the <Disconnect> button.
Communication between the Manipulator and the development PC is disconnected
and the Ethernet cable can be removed.
NOTE If the Ethernet cable is removed when the Manipulator and the development PC is
 connected, Emergency Stop occurs and the Manipulator stops. Be sure to click the
<Disconnect> button in the [PC to Controller Communications] dialog before the Ethernet
cable is removed.
T3 Rev.4 67
Setup & Operation 10. TP Port
10. TP Port
10.1 What is the TP Port?
The TP port connects the Teach Pendant to the manipulator. You can connect the Teach
Pendant (TP2, TP3).
Dedicated convert cable* is necessary if connecting TP2 to T3 series manipulator.
Contact to regional office if only convert cable is necessary.
* TP Exchange Cable: R12NZ900L6
NOTE When nothing is connected to the TP port, Emergency Stop status occurs in the
 Manipulator. When the Teach Pendant is not connected, connect the TP bypass plug.
Do not connect the devices except TP2, TP3 to the TP port. Connecting these devices
may result in malfunction of the device since the pin assignments are different.
10.2 Teach Pendant Connection

A dedicated cable is attached to the Teach Pendant. Connect this cable connector to the
TP port.
Communication is set automatically. Enable the Teach Pendant by one of the following
procedures.
- Insert the Teach Pendant connector to the Manipulator and turn ON the Manipulator.
- Insert the Teach Pendant connector while the Manipulator is turned ON.
NOTE Teach Pendant connection and disconnection from the Controller are allowed when the
 Manipulator power is ON.
When the Teach Pendant connector is removed from the Manipulator with the mode
selector key switch of the Teach Pendant in the “Teach” position, the operation mode will
remain in the TEACH mode. The operation mode cannot be switched to AUTO mode.
Be sure to remove the Teach Pendant after switching the operation mode to “Auto” mode.
For details, refer to manual
Robot Contoroller RC700/RC90 Option Teach Pendant TP2.
Robot Contoroller RC700-A Option Teach Pendant TP3.
68 T3 Rev.4
Setup & Operation 11. EMERGENCY
11. EMERGENCY
NOTE The details of safety requirements for this section are described in EPSON RC+ 7.0 User’s
 Guide 2. Safety. Please refer to them to keep the robot system safe.
 Make sure that emergency stop or safeguard operate properly before operating,
not only booting but also usage changed such as options added or parts
replaced as maintenance.
 Before connecting the connector, make sure that the pins are not bent.
WARNING
Connecting with the pins bent may damage the connector and result in
Connect a safeguard switch or Emergency Stop switch to the EMERGENCY connector for
safety.
When nothing is connected to the EMERGENCY connector, the robot system does not
operate normally.
EMERGENCY Connector
11.1 Safeguard Switch and Latch Release Switch

The EMERGENCY connector has input terminals for the Safeguard switch and the
Emergency Stop switch. Be sure to use these input terminals to keep the system safe.
Connector Standard
EMERGENCY connector D-Sub 25 pin female (cable side)
(Manipulator side) D-Sub 25 pin male (board side)
* The E-STOP BOX, EMERGENCY connector cable, terminal block, and
EMERGENCY connector kit are offered as options.
T3 Rev.4 69
11.1.1 Safeguard Switch

 The interlock of the Safeguard must be functioning when the robot system is
operated. Do not operate the system under the condition that the switch cannot
be turned ON/OFF (e.g. The tape is put around the switch.). Operating the
robot system when the switch is not functioning properly is extremely hazardous
WARNING
and may cause serious safety problems as the Safeguard input cannot fulfill its
intended function.
In order to maintain a safe working zone, a safeguard must be erected around the
Manipulator. The safeguard must have an interlock switch at the entrance to the working
zone. The Safeguard that is described in this manual is one of the safeguards and an
interlock of the Safeguard is called a Safeguard switch. Connect the Safeguard switch to
the Safeguard input terminal on the EMERGENCY connector.
The Safeguard switch has safety features such as temporary hold-up of the program or the
operation-prohibited status that are activated whenever the Safeguard is opened.
Observe the following in designing the Safeguard switch and the Safeguard.
- For the Safeguard switch, select a switch that opens as the Safeguard opens, and not by
the spring of the switch itself.
- The signal from the Safeguard (Safeguard input) is designed to input to two redundant
signals. If the signals at the two inputs differ by two seconds or more, the system
recognizes it to be a critical error. Therefore, make sure that the Safeguard switch has
two separate redundant circuits and that each connects to the specified pins at the
EMERGENCY connector on the Controller.
- Make sure to design the safeguard to prevent the door from closing accidentally.
11.1.2 Latch Release Switch

The controller software latches these conditions:
- The safeguard is open.
- The operation mode is set to “TEACH”.
The EMERGENCY connector has an input terminal for a latch release switch that
cancels the latched conditions.
Open : The latch release switch latches conditions that the safeguard is open or the
operation mode is “TEACH”.
Closed : The latch release switch releases the latched conditions.
NOTE When the latched TEACH mode is released while the safeguard is open, the status of
 Manipulator power is operation-prohibited because the safeguard is open at that time.

To execute a Manipulator operation, close the safeguard again, and then close the latch
release input.
70 T3 Rev.4
11.1.3 Checking Latch Release Switch Operation

After connecting the safeguard switch and latch release switch to the EMERGENCY
connector, be sure to check the switch operation for safety by following the procedures
described below before operating the Manipulator.
(1) Turn ON the Controller while the safeguard is open in order to boot the controller
software.
(2) Make sure that “Safety” is displayed on the main window status bar.
(3) Close the safeguard, and turn ON the switch connecting to the latch release input.
Make sure that the “Safety” is dimmed on the status bar.
The information that the safeguard is open can be latched by software based on the latch
release input condition.
Open : The latch release switch latches the condition that the safeguard is open.
To cancel the condition, close the safeguard, and then close the safeguard latch
release input.
Closed : The latch release switch does not latch the condition that the safeguard is open.
NOTE The latch release input also functions to acknowledge the change of to TEACH mode.
 In order to change the latched condition of TEACH mode, turn the mode selector key
switch on the Teach Pendant to “Auto”. Then, close the latch release input.
11.2 Emergency Stop Switch Connection
11.2.1 Emergency Stop Switch

If it is desired to add an external Emergency Stop switch(es) in addition to the Emergency
Stop on the Teach Pendant and Operator Panel, be sure to connect such Emergency Stop
switch(es) to the Emergency Stop input terminal on the EMERGENCY connector.
The Emergency Stop switch connected must comply with the following and related safety
standard (IEC60947-5-5, etc.):
- It must be a push button switch that is “normally closed”.
- A button that does not automatically return or resume.
- The button must be mushroom-shaped and red.
- The button must have a double contact that is “normally closed”.
NOTE The signal from the Emergency Stop switch is designed to use two redundant circuits.
 If the signals at the two circuits differ by two seconds or more, the system recognizes it as
a critical error. Therefore, make sure that the Emergency Stop switch has double contacts
and that each circuit connects to the specified pins on the EMERGENCY connector at the
Controller. Refer to the Setup & Operation 11.4 Circuit Diagrams.
T3 Rev.4 71
11.2.2 Checking Emergency Stop Switch Operation

Once the Emergency Stop switch is connected to the EMERGENCY connector, continue
the following procedure to make sure that the switch functions properly. For the safety
of the operator, the Manipulator must not be powered ON until the following test is
completed.
(1) Turn ON the Manipulator to boot the controller software while pressing the
Emergency Stop switch.
(2) Make sure that E-STOP LED of the Manipulator is lighting.
(3) Make sure that “E.Stop” is displayed on the status bar on the main window.
(4) Release the Emergency Stop Switch.
(5) Execute the RESET command.
(6) Make sure that E-STOP LED is turned OFF and that “E-Stop” is dimmed on the main
window status bar.
11.2.3 Recovery from Emergency Stop

To recover from the emergency stop condition, follow the procedure of safety check as
required by the system.
After safety check, the operations below are required to recover from the emergency stop
condition.
- Release the Emergency Stop Switch
- Execute the RESET command
72 T3 Rev.4
11.3 Pin Assignments

The EMERGENCY connector pin assignments are as follows: (D-Sub 25 pin male)
Pin No. Signal Function Pin No. Signal Function

1 ESW11 Emergency Stop switch contact (1) *3 14 ESW21 Emergency Stop switch contact (2) *3
2 ESW12 Emergency Stop switch contact (1) *3 15 ESW22 Emergency Stop switch contact (2) *3
3 ESTOP1+ Emergency Stop circuit 1 (+) *4
16 ESTOP2+ Emergency Stop circuit 2 (+) *4
*4 *4
4 ESTOP1- Emergency Stop circuit 1 (-) 17 ESTOP2- Emergency Stop circuit 2 (-)
5 Not Used *1
18 SDLATCH1 Safeguard Latch Release
6 Not Used *1
19 SDLATCH2 Safeguard Latch Release
7 SD11 Safeguard input (1) *2 20 SD21 Safeguard input (2) *2
8 SD12 Safeguard input (1) *2 21 SD22 Safeguard input (2) *2
9 24V +24V output 22 24V +24V output
10 24V +24V output 23 24V +24V output
11 24VGND +24V GND output 24 24VGND +24V GND output
12 24VGND +24V GND output 25 24VGND +24V GND output
13 Not Used *1
*1 Do not connect anything to these pins.

*2 A critical error occurs if the input values from the Safeguard 1 and Safeguard 2 are
different for two or more seconds. They must be connected to the same switch with
two sets of contacts.
*3 A critical error occurs if the input values from the Emergency Stop switch contact 1
and Emergency Stop switch contact 2 are different for two or more seconds. They
must be connected the same switch with two sets of contacts.
*4 Do not apply reverse voltage to the Emergency Stop circuit.
Emergency Stop switch output rated load +30 V 0.3 A or under 1-2, 14-15 pin
Emergency Stop rated input voltage range +24 V ±10%
3-4, 16-17 pin
Emergency Stop rated input current 37.5 mA ±10% /+24 V input
Safeguard rated input voltage range +24 V ±10%
7-8, 20-21 pin
Safeguard rated input current 10 mA/+24 V input
Latch Release rated input voltage range +24 V ±10%
18-19 pin
Latch Release rated input current 10 mA/+24 V input
NOTE

The total electrical resistance of the Emergency Stop switches and their circuit should be 1
Ω or less.
■ The 24 V output is for emergency stop. Do not use it for other purposes.
Doing so may result in system malfunction.
■ Do not apply reverse voltage to the Emergency Stop circuit. Doing so may
CAUTION result in system malfunction.
T3 Rev.4 73
11.4 Circuit Diagrams

11.4.1 Example 1: External emergency stop switch typical application
Manipulator
External Emergency
Stop switches
+24V
9
Emergency 10
Stop switch of
22
an Operation
Unit (TP) 23
1
2
14
15
ESTOP1+ 3
+5V
ESTOP2+ 16
Main Circuit
Control
Be careful of
the direction
of voltage
application
+ −
+
Motor Driver
ESTOP1−
AC Input 4
ESTOP2− 17
Emergency 11
Stop detection
12
24
25 External
+24V
7
Safety Door input 1
8
20
Safety Door input 2
21
18
Latch release input

19
External +24V
NOTE:+24V GND Latch release input Close :Latch off GND
Open :Latch on
+ 5V GND
74 T3 Rev.4
11.4.2 Example 2: External safety relay typical application

Manipulator External +24V
Fuse
+24V
09
Emergency
Stop switch of 10
an Operation 22
Unit (TP) 23
External
1
+24V
2 GND
14
15
External
3 +24V
+5V 16
External safety relay

Main Circuit (The above diagram
Control is simplified for
representation.)
* For the protection of the
emergency stop circuit,
the fuse’s capacity
should be as follows:
Motor Driver + + - - Meets the capacity of
the external safety
relay
- 0.4A or less
AC Input 4
17
Emergency 11
Stop detection
12 External
+24V GND
24
External
25 +24V
Safety Door input 1

8
20
Safety Door input 2
21
18
Latch Release input

19
External
NOTE:+24V GND Latch release input Close :Latch off +24V
+ 5V GND Open :Latch on GND
T3 Rev.4 75
Setup & Operation 12. Standard I/O Connector
12. Standard I/O Connector

 Be careful not to exceed rated current range or rated current which are defined
in manual.
CAUTION If exceeding rated current, the Manipulator may now operate at worst.
Standard I/O Connector is a connector mounted on back side of the Manipulator for
connecting your input/output equipment to the system.
Connector name Pins Bit number
I/O (Input) Connector 18 0-17
I/O (Output) Connector 12 0-11
For cable wiring, refer to the Setup & Operation 3.7.2 Noise Countermeasures in order to
prevent noise.
Remote function is initially assigned to both input and output from 0 to 7. For further
details, refer to Setup & Operation 14. I/O Remote Settings.
Also, for details of hand I/O, refer to the Setup & Operation 13.Hand I/O Connector
12.1 Input Circuit

Input Voltage Range : +12 to 24 V ±10%
ON Voltage : +10.8 V (min.)
OFF Voltage : +5 V (max.)
Input Current : 10 mA (TYP) at +24 V input
Two types of wiring are available for use with the two-way photo coupler in the input
circuit.
76 T3 Rev.4
12.1.1 Typical Input Circuit Application

Standard I/O (Input) Connector
GND +DC
5 Input No.0 to 7 common
1 Input No.0
(Same) 15 Input No.1
2 Input No.2
(Same)
16 Input No.3
(Same)
3 Input No.4
(Same)
17 Input No.5
(Same)
4 Input No.6
(Same)
18 Input No.7
(Same)
(Same) 6 Input No.8
20 Input No.9
(Same)
Omit
12.1.2 Typical Input Circuit Application 2

Standard I/O (Input) Connector
GND +DC
1 Input No.0
2 Input No.2
(Same)
16 Input No.3
(Same)
3 Input No.4
(Same)
17 Input No.5
(Same)
4 Input No.6
(Same)
18 Input No.7
(Same)
(Same) 6 Input No.8
Omit
T3 Rev.4 77
12.1.3 Pin Assignments of Input Circuit

Pin No. Signal Name Pin No. Signal Name
1 Input No. 0 (Start) 15 Input No. 1 (SelProg1)
2 Input No. 2 (SelProg2) 16 Input No. 3 (SelProg4)
3 Input No. 4 (Stop) 17 Input No. 5 (Pause)
4 Input No. 6 (Continue) 18 Input No. 7 (Reset)
5 Input common No. 0 to 7 19 Input common No. 8 to 15
6 Input No. 8 20 Input No. 9
11 Not Used 25 Not Used
14 Input common No. 16 to 17 28 Not Used
Remote function inside ( ) in the table above is initially assigned to input from 0 to 7.
For further details, refer to Setup & Operation 14. I/O Remote Settings.
Connector Connector model
DMC 0,5/14-G1-2,54 P20THR R72 (Board side)
I/O (Input) Connector DFMC 0,5/14-ST-2,54 (Cable side)
(PHOENIX CONTACT)
* I/O connector is included with shipment.
I/O (Input) Connector pin assignment

14 1
28 15
12.2 Output Circuit

Rated Output Voltage : +12 V to +24 V ±10%
Maximum Output Current : TYP 100 mA/1 output
Output device : PhotoMOS relay
ON resistance : Less than 0.7 Ω
The following two wirings are available since non-polar PhotoMOS relay is used for
output circuit.
 Be sure to wire the output circuit properly because it has no protection circuitry
for short-circuit and reverse-connection. Improper wiring may cause
malfunction of the parts on the board and then improper function of the robot
CAUTION
system.
78 T3 Rev.4
12.2.1 Typical Output Circuit Application 1

Standard I/O (Output) Connector
GND +DC
1 Output No.0
L
Load
10 Output No.1
L
(Same)
2 Output No.2
(Same)
11 Output No.3
(Same)
3 Output No.4
(Same)
12 Output No.5
(Same)
4 Output No.6
(Same)
13 Output No.7
(Same) 5 Output No.0 to 7 Common (GND)
6 Output No.8
(Same)
15 Output No.9
(Same)
Omit
14 Output No.8 to 11 Common (GND)

Standard I/O (Output) Connector
GND +DC
1 Output No.0
L
Load
10 Output No.1
L
(Same)
2 Output No.2
(Same)
11 Output No.3
(Same)
3 Output No.4
(Same)
12 Output No.5
(Same)
4 Output No.6
(Same)
13 Output No.7
(Same) 5 Output No.0 to 7 Common(+DC)
6 Output No.8
(Same)
15 Output No.9
(Same)
Omit
14 Output No.8 to11 Common(+DC)
T3 Rev.4 79
12.2.3 Pin Assignments of Output Circuit

1 Output No. 0 (Ready) 10 Output No.1 (Running)
2 Output No.2 (Paused) 11 Output No.3 (Error)
3 Output No.4 (EstopOn) 12 Output No.5 (SafeguardOn)
4 Output No.6 (SError) 13 Output No.7 (Warning)
5 Output common No. 0 to 7 14 Output common No. 8 to 11
6 Output No. 8 15 Output No. 9
7 Output No.10 16 Output No.11
Remote function inside ( ) in the table above is initially assigned to output from 0 to 7.
For further details, refer to Setup & Operation 14. I/O Remote Settings.
Connector Connector model
DMC 0,5/9-G1-2,54 P20THR R44 (Board side)
I/O (Output) Connector DFMC 0,5/ 9-ST-2,54 (Cable side)
(PHOENIX CONTACT)
I/O (Output) Connector pin assignment

9 1
18 10
80 T3 Rev.4
12.3 I/O Cable Product Procedure

The following describes I/O cable product procedure for connecting user’s input/output
devices.
12.3.1 I/O Cable Connecting Method

(1) Prepare for I/O connector and cable which are included with shipment.
Adaption cable:
Electric wire capacity: 0.14 ~0.5mm2
Wire type: single wire, stranded wire, stranded wire with rod terminal.
(2) Push the edge of cable into wire insertion slot.
For single wire and stranded wire,
peel off the covering of the cable.
NOTE
 - If using a twisted wire or finer single wire, insert it while pushing orange colored
open button.
- Orange push pins are easy to come off. Be careful during operation.
- There is a cable check hole above the open button. You can check cables using
tester.
12.3.2 How to Fix the I/O Cable

You can fix the I/O cables using cable clamp on the back of the manipulator.
Cable clamp
NOTE
 Fixing cables with I/O cable clamp, wiring of I/O cables is difficult to disconnect.
T3 Rev.4 81
Setup & Operation 13. Hand I/O Connector
13. Hand I/O Connector

 Be careful not to exceed rated current range or rated current which are defined
in manual.
CAUTION If exceeding rated current, the Manipulator may now operate at worst.
Hand I/O connector is a connector for connecting your input/output equipment to the
system. It is mounted on upper of Arm #2.
Connector name Polarity Pins Bit number
Input 6 18-23
Hand I/O connector
Output 4 12-15
For cable wiring, refer to the Setup & Operation 3.7.2 Noise Countermeasures in order to
prevent noise.
Also, for details of standard I/O mounted on back side of the manipulator, refer to the
Setup & Operation 12 Standard. I/O Connector.
13.1 Power Supply Specifications

Hand I/O connector has a power supply which user can use. Enable to use this power
supply to operate external devices.
Be careful not to exceed allowable current when using power supply.
Voltage: 24V ±5%
Allowable current: 500mA
82 T3 Rev.4
13.2 Input Circuit

Input Voltage Range : +12 to 24 V ±10%
ON Voltage : +10.8 V (min.)
OFF Voltage : +5 V (max.)
Input Current : 10 mA (TYP) at +24 V input
Two types of wiring are available for use with the two-way photo coupler in the input
circuit.
Hand I/O connector
GND +DC
1 Input No.18

Hand I/O connector
GND +DC
1 Input No.18
T3 Rev.4 83
13.3 Output Circuit

Rated Output Voltage : +12 V to +24 V ±10%
Maximum Output Current : TYP 100 mA/1 output
Output device : PhotoMOS relay
On resistance : Less than 0.7 Ω
The following two wirings are available since non-polar PhotoMOS relay is used for
output circuit.
 Be sure to wire the output circuit properly because it has no protection circuitry
for short-circuit and reverse-connection. Improper wiring may cause
malfunction of the parts on the board and then improper function of the robot
CAUTION
system.

Hand I/O connector
GND +DC
6 Output No.12
Load
14 Output No.13
(Same)
7 Output No.14
(Same)
15 Output No.15
(Same) 8 Output No.12 to 15 Common (GND)

Hand I/O connector
GND +DC
6 Output No.12
Load
14 Output No.13
(Same)
7 Output No.14
(Same) 15 Output No.15

(Same) 8 Output No.12 to 15 Common(GND)
84 T3 Rev.4
13.4 Pin Assignments

The following is pin assignments of Hand I/O connector (D-sub 15 pin male).

1 Input No.18 9 Input No.19
Input common
4 12 Not Used
No.18 to 23
5 +24V 13 GND
Output common
8 No.12 to 15
Connector Standard
Hand I/O connector D-Sub 15 pin female (manipulator side)

D-Sub 15 pin male (cable side)
13.5 How to Control Hand I/O

T3 series has I/O (Input: 6 bit, Output: 4 bit) for hand control I/O.
Input bit port: 18, 19, 20, 21, 22, 23
Output bit port: 12, 13, 14, 15
How to operate
Hand I/O is only supported for bit port operation commands. Byte or word commands
are not supported.
Available commands
Command Function
Sw Input bit port I/O.
SetSw Set an input of virtual I/O.
On Turn ON the output bit.
Off Turn OFF the output bit.
Restriction 1: Remote I/O

Hand I/O cannot be set in Remote I/O.
Restriction 2: Input/Output by byte port or word port

There are restrictions to operate input/output of standard I/O by byte or word port since
hand I/O is included in byte port and word port.
Input: Always “0” is read for bit of hand I/O.
Output: Execute error occurs when specifying “1” for bit of hand I/O.
T3 Rev.4 85
Input example:
When operating byte input by following conditions
Input hand I/O23: ON
Input standard I/O bit: 16=OFF, 17=ON
In(2)---> 0ｘ02 (0000 0010B)
Output example:
When operating byte output by following conditions
Output standard I/O bit port 11＝ON,10~8=OFF
Out 1,'H08
Error output example:

When operating byte output by following conditions
Output standard I/O bit port 11＝ON,10~8=OFF
Out 1,'H18 <--- Error since hand I/O bit is ON
Byte port Word port

Port Description Port Description
Input 2 “0” is read for upper 6 bits 1 “0” is read for upper 6 bits
0000 00xx 0000 00xx xxxx xxxx
Output 1 Always specify “0” for upper 4 bits. 0 Always specify “0” for upper 4 bits.
0000 xxxx 0000 xxxx xxxx xxxx
86 T3 Rev.4
Setup & Operation 14. I/O Remote Settings
14. I/O Remote Settings

This section describes the functions and timings of input and output signals.
The remote functions may be assigned to your standard I/O board(s), or fieldbus I/O
board(s) to enhance robot system control - either from an operational unit of your choice
or a sequencer.
Remote function is initially assigned to both input and output from 0 to 7.
To accept external remote inputs, assign the remote function and the control device is
remote. For further details, refer to the section, Remote Control Software Configuration
in EPSON RC+ 7.0 User’s Guide - Remote Control.
The user defines the I/O number that a remote function is assigned to using software
configuration. For further details, refer to the section, Remote Control Software
Configuration in EPSON RC+ 7.0 User’s Guide - Remote Control.
For details about I/O cable connection, refer to sections on Setup & Operation 12:
Standard I/O Connector, 13. Hand I/O Connector and 17. Fieldbus I/O.
For details about communication with external equipment, refer to EPSON RC+ 7.0
User’s Guide -12. Remote Control.
 When using remote I/O, always make sure of the following. Using the robot
system under unsatisfactory conditions may cause malfunction of the system
and/or safety problems.
- Assign remote functions to inputs/outputs correctly and wire correctly when
setting up remote I/O signals.
- Make sure that the functions correspond to the correct input/output signals
CAUTION before turning ON the system.
When verifying the robot system operation, prepare for failures with initial
settings or wiring. If the Manipulator functions unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to stop
the Manipulator.
Remote function is available when virtual I/O is enabled.

NOTE

When you set up a remote I/O signal, please either keep a written record of the settings or
store the data in a file for later reference.
When you set up a fieldbus I/O signal to the remote function, response depends on the
baud rate of the fieldbus. For details of fieldbus response, refer to Robot Controller
RC700 / RC90 Option Fieldbus I/O.
Hand I/O connecter cannot be set in remote signal.
T3 Rev.4 87
14.1 I/O Signal Description

Remote function is initially assigned to both input and output from 0 to 7.
To change the function assignment from the initial setting, use EPSON RC+ 7.0.
To use all signals, you will need to add Fieldbus I/O module.
14.1.1 Remote Input Signals

Remote inputs are used to control the Manipulators and start programs. Certain
conditions must be met before inputs are enabled, as shown in the table below.
To accept external remote inputs, assign the remote function and set remote to the control
device. When external remote input is available, “AutoMode output” turns ON.
Except “SelProg”, the signals execute each function when the signal starts in input
acceptance condition. The function executes automatically. Therefore, no special
programming is needed.
NOTE When an error occurs, you must execute a “Reset” to clear the error condition before any
 other remote input commands can be executed. Use the “Error output” and “Reset input”
to monitor the error status and clear error conditions from the remote device.
Input Acceptance
Name Initial Description
Condition (*1)
Ready output ON
Error output OFF
Execute function selected at SelProg. EStopOn output OFF
Start 0
(*2) SafeguardOn output OFF
Pause input OFF
Stop input OFF
SelProg1 1
SelProg2 2
SelProg4 3 Specify the executing Main function
SelProg8 Not Set number. (*2)
SelProg16 Not Set
SelProg32 Not Set
Stop 4 All tasks and commands are stopped.
Pause 5 All tasks are paused. (*3) Running output ON
Paused output ON
Continue 6 Continue the paused task. Pause input OFF
Stop input OFF
Reset 7 Reset emergency stop and error. (*4) Ready output ON
Shutdown Not set Terminates the system
Operates as the forced low power function. Any time
The manipulator is operated in the low This input is acceptable
power mode. even AutoMode output is
ForcePowerLow Power High control from the command is OFF.
Not Set not accepted.
(*6)
Executes the following according to the
manipulator preferences.
Stops or temporarily stops all the tasks and
commands. (*12)
Changes the output condition of MotorsOn,
SelRobot Not Set
AtHome, PowerHigh, and MCalReqd.(*9)
88 T3 Rev.4
Input Acceptance
Condition (*1)
SelRobot1
SelRobot2
Specify the number of manipulator which
SelRobot4 Not set
SelRobot8 executes a command. (*5)
SelRobot16
Ready output ON
EStopOn output OFF
SetMotorsOn Not set Turn ON manipulator motors. (*5) (*6) SafeguardOn output OFF
SetMotorOff input OFF
SetMotorsOff Not set Turn OFF manipulator motors. Ready output ON
Ready output ON
Set the manipulator power mode to High EStopOn output OFF
SetPowerHigh Not set
(*5) SafeguardOn output OFF
SetPowerLow input OFF
Set the manipulator power mode to Low. Ready output ON
SetPowerLow Not set
(*5)
Ready output ON
Error output OFF
EStopOn output OFF
Home Move the manipulator Arm to the home SafeguardOn output OFF
Not set
position defined by the user. MotorsOn output ON
Pause input OFF
Stop input OFF
Ready output ON
Error output OFF
EStopOn output OFF
MCal Not set Execute MCal (*5) (*7) SafeguardOn output OFF
MotorsOn output ON
Pause input OFF
Stop input OFF
Paused output ON
Error output OFF
EStopOn output OFF
After the safeguard is closed, recover to the
Recover Not set SafeguardOn output OFF
position where the safeguard is open. RecoverReqd output ON
Pause input OFF
Stop input OFF
ResetAlarm Not Set Cancel the alarm (*11)
SelAlarm1
SelAlarm2
Not Set Specify the alarm number to cancel (*10)
SelAlarm4
SelAlarm8
Input signal for alive monitoring of the
manipulator. Same signal as the input
will be output to ALIVE output. The
ALIVE Not Set master equipment can perform alive
monitoring of the manipulator by switching
the input periodically and checking the
output signal.
(*1) “AutoMode output” ON is omitted from the table. This is an input acceptance condition for all
functions.
T3 Rev.4 89
(*2) “Start input” executes Function specified by the following six bits: SelProg 1, 2, 4, 8, 16, and 32.
Function name SelProg1 SelProg2 SelProg4 SelProg8 SelProg16 SelProg32
Main 0 0 0 0 0 0
Main1 1 0 0 0 0 0
Main2 0 1 0 0 0 0
Main3 1 1 0 0 0 0
..
.
Main60 0 0 1 1 1 1
Main61 1 0 1 1 1 1
Main62 0 1 1 1 1 1
Main63 1 1 1 1 1 1
0=OFF, 1=ON
(*3) “NoPause task” and “NoEmgAbort task” do not pause.
For details, refer to EPSON RC+ 7.0 Online Help or Pause in SPEL+ Language Reference.
(*4) Turns OFF the I/O output and initializes the manipulator parameter.
For details, refer to EPSON RC+ 7.0 Online Help or Reset in SPEL+ Language Reference.
(*5) T series is invalid.
(*6) Initializes the manipulator parameter.
For details, refer to EPSON RC+ 7.0 Online Help or Motor in SPEL+ Language Reference.
(*7) For details, refer to EPSON RC+ 7.0 Online Help or MCal in SPEL+ Language Reference.
(*8) This is for experienced users only. Make sure that you fully understand the input specification before
using.
CmdRunning output and CmdError output will not change for this input.
“NoEmgAbort task” will not stop by this input.
When the input changes from ON to OFF, all tasks and commands will stop.
(*9) This function changes the output condition of MotorsOn, AtHome, PowerHigh, and MCalReqd.
By setting this signal with the condition selected using SelRobot1 - SelRobot16, you can switch the output
condition.
Once you select the condition, it will be kept until you change it or turn off / restart the Controller. All
manipulators are selected as default.
90 T3 Rev.4
(*10) The values specified by “SelAlarm1, 2, 4, and 8” correspond to the alarm numbers.
Alarm # Target SelAlarm1 SelAlarm2 SelAlarm4 SelAlarm8
1 Controller battery 1 0 0 0
2 - 0 1 0 0
3 Manipulator grease 1 1 0 0
4 - 0 0 1 0
5 - 1 0 1 0
6 - 0 1 1 0
7 - 1 1 1 0
8 - 0 0 0 1
9 - 1 0 0 1
0=OFF, 1=ON
The following parts are subject to grease up.
Ball screw spline unit on the Joint # 3
(*11) The specified alarm can be canceled by selecting the conditions using SelAlarm1-SelAlarm8 and setting
this signal.
(*12) Operation of all tasks and commands, power mode of the manipulator, and PowerHigh command by the
setting of the manipulator preferences.
Preferences (1): “Motor power low when ForcePowerLow signal OFF”

Preferences (2): “ForcePowerLow signal change pauses all tasks”
For details of the manipulator preferences, refer to EPSON RC+ 7.0 User’s Guide
[Setup]-[System Configuration]-[Controller]-[Preferences] in 5.12.2 [System
Configuration] Command (Setup Menu).
All tasks and
Preferences (1) Preferences (2) ForcePowerLow commands Power mode PowerHigh
0 0 1→0 Stop Low only Accept
0 0 0→1 Stop Low only Not accept
0 1 1→0 Continue High/Low Accept
0 1 0→1 Temp. stop Low only Not accept
1 0 1→0 Stop Low only Not accept
1 0 0→1 Stop Low only Accept
1 1 1→0 Temp. stop Low only Not accept
1 1 0→1 Continue High/Low Accept
T3 Rev.4 91
14.1.2 Remote Output Signals

Remote output is a function to output a status of the Manipulator or operation mode.
Remote outputs provide the assigned function using with any control device The outputs
execute automatically. Therefore, no special programming is needed.
Turns ON when the manipulator startup completes and no
Ready 0
task is running.
Turns ON when task is running.
Running 1
However, turns OFF when “Paused output” is OFF.
Paused 2 Turns ON when pause task exists.
Turns ON when an error occurs.
Error 3
Use “Reset input” to recover from the error.
EStopOn 4 Turns ON at Emergency Stop.
SafeguardOn 5 Turns ON when the safeguard is open.
Turns ON when critical error occurs.
SError 6 When a critical error occurs, “Reset input” does not
function. Reboot the controller to recover.
Turns ON when warning occurs.
The task runs as normal with the warning. However, be
Warning 7
sure to eliminate the cause of the warning as soon as
possible.
MotorsOn Not set Turns ON when the manipulator motor is ON. (*5)
Turns ON when the manipulator is in the home position.
AtHome Not set (*5)
Turns ON when the manipulator’s power mode is High.
PowerHigh Not set (*5)
Turns ON when the manipulator hasn’t executed MCal.
MCalReqd Not set (*5)
Turns ON when at least one manipulator is waiting for
RecoverReqd Not set Recover after the safeguard is closed.
Turns ON when at least one manipulator is executing
RecoverInCycle Not set Recover.
CmdRunning Not set Turns ON when an input command is executing.
CmdError Not set Turns ON when an input command cannot be accepted.
CurrProg1
CurrProg2
CurrProg4 Indicates the running or the last main function number
CurrProg8 Not set (*1)
CurrProg16
CurrProg32
AutoMode Not set Turns ON in remote input acceptable status. (*2)
TeachMode Not set Turns ON in TEACH mode.
ErrorCode1
..
. Not set Indicates the error number.
ErrorCode8192
InsideBox1
.. Turns ON when the manipulator is in the approach check
. Not set area. (*3)
InsideBox15
92 T3 Rev.4

InsidePlane1
.. Turns ON when the manipulator is in the approach check
. Not set plane. (*4)
InsidePlane15
Alarm Not set Turns ON when any of the alarms is occurring. (*9)
Turns ON when a battery alarm of the manipulator is
Alarm1 Not set occurring.
Turns ON when a battery alarm of the manipulator
Alarm2 Not set connected to CU is occurring.
Turns ON when a grease alarm of the manipulator
Alarm3 Not set connected to CU is occurring. (*10)
Alarm4 Not set connected to DU1 is occurring.
Alarm5 Not set connected to DU1 is occurring. (*10)
Outputs current X coordinate in the World coordinate
PositionX Not set system (*6) (*7)
Outputs current Y coordinate in the World coordinate
PositionY Not set system (*6) (*7)
Outputs current Z coordinate in the World coordinate system
PositionZ Not set (*6) (*7)
Outputs current U coordinate in the World coordinate
PositionU Not set system (*6) (*7)
Outputs current V coordinate in the World coordinate
PositionV Not set system (*6) (*7)
Outputs current W coordinate in the World coordinate
PositionW Not set system (*6) (*7)
Torque1 Not set Outputs the current torque value of Joint #1 (*6) (*7)
CPU Not set Outputs the CPU load factor of the user program (*8)
Outputs how many times emergency stops have been
ESTOP Not set executed.
Output signal for alive monitoring of the manipulator.
The signal input by ALIVE input will be output. The
ALIVE Not set master equipment can perform alive monitoring of the
manipulator by switching the input periodically and
checking the output signal.
T3 Rev.4 93
(*1) Outputs the current or the last function number of CurrProg1, 2, 4, 8, 16, or 32.
Function name CurrProg1 CurrProg2 CurrProg4 CurrProg8 CurrProg16 CurrProg32
Main 0 0 0 0 0 0
Main1 1 0 0 0 0 0
Main2 0 1 0 0 0 0
Main3 1 1 0 0 0 0
..
.
Main60 0 0 1 1 1 1
Main61 1 0 1 1 1 1
Main62 0 1 1 1 1 1
Main63 1 1 1 1 1 1
0=OFF, 1=ON
(*2) Remote function is available in the following conditions.
- The setting is Auto mode and the control device is remote.
- The setting is Program mode and Remote I/O is enabled.
(*3) For details, refer to EPSON RC+ 7.0 Online Help or Box in SPEL+ Language Reference.
(*4) For details, refer to EPSON RC+ 7.0 Online Help or Plane in SPEL+ Language Reference.
(*5) Manipulator status is output as follows, according to the condition selected in SelRobot.
Wait at least 40 ms before inputting the signal after changing the condition in SelRobot.
(SelRobot1- SelRobot16) condition when inputting SelRobot

Name
0: All robots are selected 1 - 16: Particular robot number is selected
Turns ON when at least one Turns ON when the motor of the selected
MotorsOn
manipulator motor is ON. manipulator is ON.
Turns ON when all manipulators are in Turns ON when the selected manipulator is in
AtHome
the home position. the home position.
Turns ON when at least one Turns ON when the selected manipulator’s
PowerHigh
manipulator’s power mode is High. power mode is High.
Turns ON when at least one Turns ON when the selected manipulator
MCalReqd
manipulator hasn’t executed MCal. hasn’t executed MCal.
(*6) T series is invalid.
(*7) Outputs information in Real format.
(*8) Outputs the total load factor of the user created tasks. For details on the CPU load factor, refer to the
task manager.
(*9) The signal turns on when the alarm occurs in the manipulator alarm information.
(*10) The following parts are subject to grease up.
94 T3 Rev.4
14.2 Timing Specifications
14.2.1 Precautions for Remote Input Signals

The following charts indicate the timing sequences for the primary operations of the
Controller.
The indicated time lapses (time durations) should be referred to only as reference values
since the actual timing values vary depending on the number of tasks running, as well as
CPU speed of the Manipulator. Check carefully and refer to the following charts for the
timing interrelation when you enter an input signal.
During system design, make sure that you actuate only one remote input operation at a
time, otherwise an error will occur.
The pulse width of an input signal must be 25 or more milliseconds to be detected.
[Unit: ms]
14.2.2 Timing Diagram for Operation Execution Sequence
MotorsOn 940
Output 1250
AtHome
Output Depending on
HOME motion
SetMotorsOn
Input
SetMotorsOff
Input
Home
Input
14.2.3 Timing Diagram for Program Execution Sequence

Ready 34
410
Output
CurrProg1 34
Output
34 110 34
Running
Output 410
* Paused 110 34
Output
SelProg1
Input
Start
Input
Pause
Input
Continue
Input
Stop
Input
* The duration varies depending on the Quick Pause (QP) setting and the program’s
operating status at the time of Pause input
T3 Rev.4 95
14.2.4 Timing Diagram for Safety Door Input Sequence

Running 1066 17
Output
Paused 1066 17
Output
SafeguardOn 12 9
Output
MotorsOn 600
940
Output
Safety Input
Latch Input
Continue
Input
14.2.5 Timing Diagram for Emergency Stop Sequence

Running
Output 65
12
MotorsOn
Output
EStopOn 10
Output
Emergency Input 10
Reset
Input
96 T3 Rev.4
Setup & Operation 15. SD Card Slots
15. SD Card Slots

 Do not use any SD card other than accessories.
If using other SD card, system may not operate properly.
 SD card is only available for robot system.

CAUTION SD card is written only for robot system. Unable to use for reading/writing data.
If you write data on SD card, robot system may not operate properly.
SD card slot
(Option slot: inside)
SD card slot is a slot for inserting SD card.

Firmware to operate the manipulator is written on SD card.
For replacement method, refer to Maintenance: 14.3 Replacement of SD card.
T3 Rev.4 97
Setup & Operation 16. RESET Switch
16. RESET Switch
RESET Switch
RESET switch has following function.
Manipulator reboot
Push the RESET switch for three seconds when booting the manipulator.
Manipulator reboots.
Shape of RESET switch is difficult to push. Push with sharp edged object as shown in
the figure below when pushing the RESET switch.
98 T3 Rev.4
Setup & Operation 17. Fieldbus I/O
17. Fieldbus I/O

Fieldbus I/O of the T series supports the following model.
DeviceNet * CC-Link
PROFIBUS-DP * PROFINET *
EtherNet/IP * EtherCAT * *: After July 2017
For details, refer to the following manual.
Robot Controller RC700 / RC90 Option Fieldbus I/O
extremely hazardous and may result in electric shock and/or malfunction of the
robot system.
WARNING NOT connect it directly to a factory power source.
■ Be sure to perform installing procedure with turning OFF the robot system and
related equipment and disconnect the power plug. Performing any replacement
procedure with the power ON is extremely hazardous and may result in electric
shock and/or malfunction of the robot system.
 Check the tabs of the fieldbus I/O module are securely hooked on the board
when installing fieldbus I/O module. If tabs do not be hooked securely,
CAUTION connecter or fieldbus I/O module may get damages.
T3 Rev.4 99
Setup & Operation 17. Fieldbus I/O
Fieldbus I/O (1) Turn OFF the Manipulator.

Module
(2) Remove the option slot cover on the back side of
Installation
the Manipulator.
Sems bolt: 2-M3×6
(3) Inset the fieldbus I/O module to the option slot.
 Check the tabs of the fieldbus I/O module are securely hooked on the board
when installing fieldbus I/O module. If tabs do not be hooked securely,
CAUTION connecter or fieldbus I/O module may get damages.
(4) Tighten screws by using special tool until fieldbus

I/O module is fixed completely.
Image of installation
Front Back
Fieldbus I/O (1) Unscrew the screws by using special tool until fieldbus I/O module is loosened.
Module
(2) Remove the fieldbus I/O module.
Removal
You can remove the module by pulling loosened screws toward.
(3) Mount the option slot cover.
100 T3 Rev.4
Maintenance
This volume contains maintenance procedures with safety
precautions for T series Manipulators.
Maintenance 1. Safety Maintenance
1. Safety Maintenance
Please read this chapter, this manual, and other relevant manuals carefully to understand
safe maintenance procedures before performing any routine maintenance.
Only authorized personnel who have taken safety training should be allowed to
maintain the robot system.
Safety training is the program for industrial robot operators that follows the laws
and regulations of each nation.
The personnel who have taken safety training acquire knowledge of industrial
robots (operations, teaching, etc.), knowledge of inspections, and knowledge of
related rules/regulations.
The personnel who have completed the robot system-training and maintenance-
training classes held by the manufacturer, dealer, or locally-incorporated
company are allowed to maintain the robot system.
■ Do not remove any parts that are not covered in this manual. Follow the
maintenance procedure strictly as described in this manual. Improper removal
of parts or improper maintenance may not only cause improper function of the
robot system but also serious safety problems.
■ Keep away from the Manipulator while the power is ON if you have not taken the
training courses. Do not enter the operating area while the power is ON.
Entering the operating area with the power ON is extremely hazardous and may
cause serious safety problems as the Manipulator may move even it seems to be
stopped.
■ When you check the operation of the Manipulator after replacing parts, be sure to
WARNING
check it while you are outside of the safeguarded area. Checking the operation
of the Manipulator while you are inside of the safeguarded area may cause
serious safety problems as the Manipulator may move unexpectedly.
■ Before operating the robot system, make sure that both the Emergency Stop
switches and safeguard switch function properly. Operating the robot system
when the switches do not function properly is extremely hazardous and may
result in serious bodily injury and/or serious damage to the robot system as the
switches cannot fulfill their intended functions in an emergency.
■ Before performing any replacement procedure, turn OFF the robot system and
WARNING related equipment, and then pull out the power plug from the power source.
system.
T3 Rev.4 103
Maintenance 2. General Maintenance
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
WARNING
or contact failure is extremely hazardous and may result in electric shock and/or
improper function of the robot system.
■ Manipulator may be warmed up due to motor heat or similar causes. Do not

touch the Manipulator until temperature falls. Also, make sure the temperature
of the Manipulator falls and you do not feel hot when you touch it. Then perform
CAUTION teaching or maintenance.
2. General Maintenance
This chapter describes maintenance inspections and procedures. Performing maintenance
inspections and procedures properly is essential for preventing trouble and ensuring safety.
Be sure to perform the maintenance inspections in accordance with the schedule.
2.1 Maintenance Inspection

2.1.1 Schedule for Maintenance Inspection
Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and
annual. The inspection points are added every stage.
If the Manipulator is operated for 250 hours or longer per month, the inspection points
must be added every 250 hours, 750 hours, 1500 hours, and 3000 hours operation.
Inspection Point
Daily Monthly Quarterly Biannual Annual Overhaul
inspection inspection inspection inspection inspection (replacement)
1 month (250 h) √
2 months (500 h) √
3 months (750 h) √ √
4 months (1000 h) √
5 months (1250 h) √
Inspect every day
6 months (1500 h) √ √ √
7 months (1750 h) √
8 months (2000 h) √
9 months (2250 h) √ √
10 months (2500 h) √
11 months (2750 h) √
12 months (3000 h) √ √ √ √
13 months (3250 h) √
…
20000 h √
h = hour
104 T3 Rev.4
2.1.2 Inspection Point

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

bolts, screws. Manipulator mounting bolts √ √ √ √ √
Tighten them if necessary. Each arm locking bolts √ √ √ √ √
(For the tightening torque, refer to Bolts, screws around shaft √
Maintenance: 2.4 Tightening Bolts, screws securing motors,
√
Hexagon Socket Head Cap Bolts.) reduction gear units, etc.
External connectors on
Check looseness of connectors.
Manipulator (on the connector √ √ √ √ √
If the connectors are loosen, push it
plates etc.)
securely or tighten.
Manipulator cable unit √ √ √ √
External appearance of
Visually check for external defects. √ √ √ √ √
Manipulator
Clean up if necessary.
External cables √ √ √ √
Check for bends or improper
location. Repair or place it properly Safeguard etc. √ √ √ √ √
if necessary.
Check tension of timing belts.
Inside of Arm #2 √ √
Tighten it if necessary.
Grease conditions Refer to Maintenance: 2.3 Greasing.
Lithium Battery Refer to Maintenance: 14 Lithium Battery, SD Card, Boards, and Filter.
Inspection While the Power is ON (Manipulator is operating)

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual
Check motion range Each joint √
Move the cables back and forth External cables
lightly to check whether the cables (including cable unit of the √ √
are disconnected. Manipulator)
Push each arm in MOTOR ON
status to check whether backlash Each arm √
exists.
Check whether unusual sound or
Whole √ √ √ √ √
vibration occurs.
Measure the accuracy repeatedly by
a dial gauge when positional gap Whole √
occurs.
Turn ON and OFF the brake release
switch and check the sound of the
Brake √ √ √ √ √
electromagnetic brake. If there is
no sound, replace the brake.
T3 Rev.4 105
2.2 Overhaul (Parts Replacement)

■ Overhaul timing is based on an assumption that all joints are operated for equal
distance. If a particular joint has a high duty or high load, it is recommended to
overhaul all joints (as many as possible) before exceeding 20,000 operation
CAUTION hours with the joint as a basis.
The parts for the manipulator joints may cause accuracy decline or malfunction due to
deterioration of the manipulator resulting from long term use. In order to use the
manipulator for a long term, it is recommended to overhaul the parts (parts replacement).
The time between overhauls is 20,000 operation hours of the Manipulator as a rough
indication.
However, it may vary depending on usage condition and degree of the load (such as when
operated with the maximum motion speed and maximum acceleration / deceleration in
continuous operation) applied on the Manipulator.
NOTE For the EPSON RC+ 7.0 the recommended replacement time for the parts subject to
 maintenance (motors, reduction gear units, and timing belts) can be checked in the
[Maintenance] dialog box.
Refer to the Maintenance: 4. Alarm.
Note:
The recommended replacement time for the maintenance parts is when it reaches the L10
life (time until 10% failure probability). In the [Maintenance] dialog box, the L10 life is
displayed as 100%.
106 T3 Rev.4
The manipulator operation hours can be checked in [Controller Status Viewer] dialog
-[Motor On Hours].
(1) Select EPSON RC+ menu-[Tools]-[Controller] to open the [Controller Tools]
dialog.
(2) Click the <View Controller Status> button to open the [Browse For Folder] dialog.
(3) Select the folder where the information is stored.
(4) Click <OK> to view the [Controller Status Viewer] dialog.
(5) Select [Robot] from the tree menu on the left side.
For the parts subject to overhaul, refer to Maintenance: 18. Maintenance Parts List.
For details of replacement of each part, refer to the Maintenance section.
Please contact the distributor of your region for further information.
T3 Rev.4 107
2.3 Greasing
The ball screw spline and reduction gear units need greasing regularly. Only use the
grease specified in the following table.
■ Keep enough grease in the Manipulator. Operating the Manipulator with
insufficient grease will damage sliding parts and/or result in insufficient function of
the Manipulator. Once the parts are damaged, a lot of time and money will be
CAUTION
required for the repairs.
■ If grease gets into your eyes, mouth, or on your skin, follow the instructions
below.
If grease gets into your eyes
: Flush them thoroughly with clean water, and then see a doctor
immediately.
If grease gets into your mouth
CAUTION : If swallowed, do not induce vomiting. See a doctor immediately.
: If grease just gets into your mouth, wash out your mouth with water
thoroughly.
If grease gets on your skin
: Wash the area thoroughly with soap and water.
Greasing part Greasing Interval Grease Refer to Maintenance:

Joint #1 9. Joint #1
Reduction gear units Overhaul timing SK-2
Joint #2 10. Joint #2
At 100 km of operation
Joint #3 Ball screw spline unit AFB 13. Greasing the Ball Screw Spline Unit
(50 km for first greasing)
Joint #1, 2 reduction gear units

As a rough indication, perform greasing at the same timing as overhaul.
However, it may vary depending on usage condition and degree of the load (such as when
operated with the maximum motion speed and maximum acceleration / deceleration in
continuous operation) applied on the Manipulator.
Joint #3 Ball screw spline unit
The recommended greasing interval is at 100 km of operation. However, greasing timing
also can be checked from the grease condition. Perform greasing if the grease is
discolored or becomes dry.
Normal grease Discolored grease
Perform greasing at 50 km of operation for the first time of greasing.
NOTE For the EPSON RC+ 7.0 the recommended replacement time for the grease on the ball
 screw spline unit can be checked in the [Maintenance] dialog box.
Refer to the Maintenance 4. Alarm
108 T3 Rev.4
2.4 Tightening Hexagon Socket Head Cap Bolts

Hexagon socket head cap bolts (herein after referred to as bolt) are used in places where
mechanical strength is required. These bolts are fastened with the tightening torques
shown in the following table.
When it is necessary to refasten these bolts in some procedures in this manual (except
special cases as noted), use a torque wrench so that the bolts are fastened with the
appropriate tightening torques as shown below.
Bolt Tightening Torque Refer below for the set screw.
M3 2.0 ± 0.1 N⋅m (21 ± 1 kgf⋅cm) Set Screw Tightening Torque
M4 4.0 ± 0.2 N⋅m (41 ± 2 kgf⋅cm) M4 2.4 ± 0.1 N⋅m (26 ± 1 kgf⋅cm)
M5 8.0 ± 0.4 N⋅m (82 ± 4 kgf⋅cm) M5 4.0 ± 0.2 N⋅m (41 ± 2 kgf⋅cm)
M6 13.0 ± 0.6 N⋅m (133 ± 6 kgf⋅cm)
M8 32.0 ± 1.6 N⋅m (326 ± 16 kgf⋅cm)
M10 58.0 ± 2.9 N⋅m (590 ± 30 kgf⋅cm)
M12 100.0 ± 5.0 N⋅m (1,020 ± 51 kgf⋅cm)
The bolts aligned on a circumference should be fastened in a crisscross pattern as shown in

the figure below.
1 Do not fasten all bolts securely at one time.
5 8 Divide the number of times that the bolts are
Bolt hole fastened into two or three and fasten the bolts
3 4
securely with a hexagonal wrench. Then, use a
torque wrench so that the bolts are fastened with
tightening torques shown in the table above.
7 6
2
2.5 Matching Origins

After parts have been replaced (motors, reduction gear units, a brake, timing belts, a ball
screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
exists between the origin stored in each motor and its corresponding origin stored in the
Robot system.
Because of that, it is necessary to perform calibration (encoder rest and calibration) to
match these origins.
For calibration, the pulse values for a specific position must be recorded in advance.
Before replacing parts, select easy point (pose) data from the registered point data to check
the accuracy. Then, follow the steps below to display the pulse values and record them.
EPSON Execute the following command from the [Command Window].
RC+ >PULSE
PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value]
pls [Joint #4 Pulse value] pls
T3 Rev.4 109
2.6 Layout of Maintenance Parts
Cable Unit
Brake Release Switch LED Lamp
Air Filter
Joint #4 Motor
Joint #3 Power Supply Board
Motor
Ball Screw
Spline Unit
Joint #1
Reduction Gear Unit
Arm CPU/DPB Unit

Top Cover
Z belt Joint #2
Arm Motor
Joint #3 SD Card
Bottom Cover Joint #2
Brake Reduction Gear
U belt Unit
Lithium Battery
Joint #1 Motor
110 T3 Rev.4
Maintenance 3. Manipulator Structure
3. Manipulator Structure
T3 Rev.4 111
Maintenance 4. Alarm
4. Alarm
When the lithium batteries run out, an alarm warning of voltage reduction occurs.
However, the alarm does not guarantee the battery lives until replacement, and it is
necessary to replace the batteries immediately. If you run out the batteries, the
manipulator parameters will be lost and recalibration of the manipulator will be
required.
In addition, the parts for the manipulator joints may cause accuracy decline or
malfunction due to deterioration of the parts resulting from long term use. If the
manipulator breaks down due to deterioration of the parts, it will take significant time
and cost for repair.
The following sections describe the alarm function which announces the following
maintenance timings in order to perform maintenance well ahead of time before the
warning error.
- Battery replacement
- Grease up
- Replacement of the timing belt
- Replacement of the motor
- Replacement of the reduction gear unit
- Replacement of the ball screw spline unit
112 T3 Rev.4
4.1 Maintenance
The recommended replacement time can be configured for the batteries, grease, timing
belts, motors, reduction gear units, and ball screw spline units.
■ Make sure that the date and time on the Manipulator are set correctly.
Maintenance cannot be performed properly with improper date and time setting.
■ If the CPU/DPB board or SD card is replaced, the maintenance information may
CAUTION be lost. When you replaced these parts, confirm the date and time of the
Manipulator and the maintenance information.
NOTE
 Settings of the maintenance vary depending on installation methods to update from the
firmware.
Initial installation : Maintenance is enabled.
Upgrade : Maintenance inherits the previous data.
(Disables as default)
For details for enabling or disabling the maintenance, refer to the EPSON RC+ 7.0 User’s
Guide 5.12.2 [System Configuration] Command (Setup Menu) - [Setup]-[System
Configuration]-[Controller]-[Preferences] Page.
4.1.1 Manipulator Maintenance Information

If enabled, the maintenance information for the battery, timing belts, motors, reduction
gear units, ball screw spline unit, and grease up will be configured automatically when the
robot is configured or changed.
The following parts are subject to grease up:
When the manipulator is deleted from the configuration, the maintenance information will
also be automatically deleted.
For details on the manipulator configuration, refer to the EPSON RC+ 7.0 User’s Guide
10.1 Setting the Robot Model.
■ Changing of the manipulator should be done carefully. The alarm setting will
be reset when the manipulator is changed.
CAUTION
4.1.2 Manipulator Maintenance Information

If the maintenance is enabled, the battery is automatically configured at the first
connection.
T3 Rev.4 113
4.2 Maintenance Information

4.2.1 How to View the Maintenance Information
The configured maintenance information can be checked in the EPSON RC+.
(1) Select the EPSON RC+ 7.0 menu-[Tools]-[Maintenance] to display the [Controller
Tools] dialog box.
(2) To check the controller maintenance information, click the <Maintenance> button
and display the [Maintenance] dialog box.
(3) Select “General” or specify the axis from the tree to display information of the target
parts.
NOTE The recommended replacement time for the battery is calculated based on the battery
 capacity and the Manipulator ON time. The battery may run out if it passes the
recommended replacement time.
114 T3 Rev.4
NOTE The recommended replacement time for the grease is calculated based on the elapsed days
 since date of grease up. The replacement time may be shorter or longer depending on
usage condition, such the load applied on the robot.
NOTE The recommended replacement time for the parts (timing belts, motors, reduction gear
 units, and ball screw spline unit) is when it reaches the L10 life (time until 10% failure
probability). In the dialog window, the L10 life is displayed as 100%.
4.2.2 How to Edit the Maintenance Information

The configured maintenance information can be edited in the EPSON RC+.
(1) Select the EPSON RC+ 7.0 menu-[Tools]-[Maintenance] to display the [Controller
Tools] dialog box.
(2) To edit the maintenance information, display the [Maintenance] dialog box.
(3) Select “General” or specify the axis from the tree to display information of the target
parts.
(4) Select the alarm to be changed and click the <Change> button.
(5) Display the [Change Alarm] dialog box and enter any of the following.
Purchase or replacement date of the battery

Date of grease up
Purchase or replacement date of the timing belt
Purchase or replacement date of the motor
Purchase or replacement date of the reduction gear unit
Purchase or replacement date of the ball screw spline unit
(6) Click the <OK> button and change the specified alarm information.
NOTE The offset can be set for the consumption rate of already installed parts.
 Follow the steps below to calculate a rough offset setting value.
1. Measure the usable months for the past operation by HealthRBAnalysis.
2. Confirm the past Motor ON time in the controller status viewer.
3. Calculate a rough offset value with the following formula.
Motor On time
Offset=100×
24×30.4375× Usable months
For details, refer to the EPSON RC+ 7.0 SPEL+ Language Reference.
T3 Rev.4 115
4.2.3 Alarm Notifying Method

The Manipulator status becomes warning and displays warning message if any parts
required to perform replacement or grease up.
SPEL+ Language Reference SPEL+ Error Message
The alarm notifying method can be configured by the output bit of the Remote I/O.
The Remote I/O can be configured in the EPSON RC+ 7.0- [Setup] - [System
Configuration] - [Controller] - [Remote Control].
For details, refer to EPSON RC+ 7.0 User’s Guide 12.1 Remote I/O.
NOTE
 The controller enters the warning state if an alarm occurs.
4.2.4 How to Cancel the Alarm

An alarm occurs when the consumption rate of the parts reaches 100%.
NOTE
The alarm cannot be canceled by executing the Reset command or restarting the controller.
 The alarm can be canceled by the following method.
Operation from [Maintenance] dialog box of the EPSON RC+ 7.0
HealthCtrlReset Command
HealthRBReset Command
Refer to Maintenance 4.2.2 How to Edit the Maintenance Information to change the alarm
information in the same steps.
116 T3 Rev.4
Maintenance 5. Backup and Restore
5. Backup and Restore

5.1 What is the Backup Controller Function
The Manipulator configuration set by EPSON RC+ 7.0 can be stored with the “Backup
Controller” function.
The Manipulator settings can be restored easily using the data previously stored with
“Backup Controller” after a configuration mistake or Manipulator problem.
Be sure to execute “Backup Controller” before changing the Manipulator setup, before
maintenance, or after teaching.
For some problems, backup may not be available before maintenance has to be performed.
Be sure to backup the data after making changes, before problems occur.
NOTE “Controller Status Storage” is one of the T series functions. It saves the Controller setup
 data same as “Backup Controller.”
There data can be used as the backup data at restoring.
The methods for “Controller Status Storage” are as follows:
A : “Controller status storage to USB memory”
For details, refer to Setup & Operation 8. Memory Port.
B : “Export Controller Status function” in EPSON RC+ 7.0.
For details, refer to EPSON RC+ 7.0 User’s Guide 5.9.9 Import Command (Project
Menu).
5.2 Backup Data Types

The table below shows the files created with “Backup Controller”.
File Name Overview

Information file for File including information for restoring
Backup.txt
restore the Manipulator.
Manipulator Stores information such as ToolSet.
CurrentMnp01.PRM
parameters
InitFileSrc.txt Initial configuration Stores various Manipulator parameters.
Manipulator Stores connected Manipulator
MCSys01.MCD
configuration information.
Project related All the project files transferred to the
All the files related Controller. Includes program files when
to Project EPSON RC+ 7.0 is configured to transfer
source code to the Controller.
Global Preserve Saves values of Global Preserve
GlobalPreserves.dat
variables variables.
WorkQue Saves information of Queues information
WorkQueues.dat
information of the WorkQue.
T3 Rev.4 117
5.3 Backup
Backup the Manipulator status from the EPSON RC+ 7.0.
(1) Select EPSON RC+ 7.0 menu-[Tools]-[Controller] to display the [Controller Tools]
dialog.
(2) Click the <Backup Controller…> button to display the [Browse For Folder] dialog.
(3) Specify the folder to save the backup data. Create a new folder if desired.
(4) Click the <OK> button. A folder is created in the specified folder containing the
backup data with a name in the following format.
B_T_ serial number_ date status was saved
→ Example: B_T_12345_2016-04-03_092941
■ Do not edit the backup files. Otherwise, operation of the robot system after data
restoration to the Manipulator is not assured.
CAUTION
118 T3 Rev.4
5.4 Restore
Restore the Manipulator status from the EPSON RC+ 7.0.
■ Make sure that the data used for restore was saved previously for same
Manipulator.
■ Do not edit the backup files. Otherwise, operation of the robot system after
CAUTION
data restoration to the Manipulator is not assured.
(1) Select the EPSON RC+ 7.0 menu-[Tools]-[Controller] to display the [Controller Tools]
dialog.
(2) Click the <Restore Controller…> button to display the [Browse For Folder] dialog.
(3) Specify the folder that contains the backup data. Backup data folders are named
using the following format:
B_T_ serial number_ date status was saved
→ Example: B_T_12345_2016-04-03_092941
NOTE Controller status backup to USB memory function can also be specified for restore.
 Specify the following folder.
T3 Rev.4 119
(4) Click the <OK> button to display the dialog to select the restore data.
Robot name, serial #, calibration

This checkbox allows you to restore the robot (Manipulator) name, Manipulator
serial number, Hofs data, and CalPls data. Make sure that the correct Hofs data
is restored. If the wrong Hofs data is restored, the Manipulator may move to
wrong positions.
The default setting is unchecked.
Robot maintenance configuration
This checkbox allows you to restore the robot alarm related files.
For details, refer to Maintenance 4. Alarm.
This is not checked by the default setting.
Project
This checkbox allows you to restore the files related to projects.
The default is unchecked.
When a project is restored, the values of Global Preserve variables are loaded.
For details about Global Preserve variable backup, refer to EPSON RC+ 7.0
User’s Guide 5.10.10 Display Variables Command (Run Menu).
Vision hardware configuration
This checkbox allows you to restore the vision hardware configuration.
For details, refer to EPSON RC+ 7.0 option Vision Guide 7.0.
Security configuration
This checkbox allows you to restore the security configuration.
For details, refer to EPSON RC+ 7.0 User’s Guide 15. Security.
(5) Click the <OK> button to restore the system information.
NOTE Restore the system configuration saved using Backup Controller only for the same system.
 When different system information is restored, the following warning message appears.
Click the <No> button (do not restore data) except for special situations such a
manipulator replacement.
120 T3 Rev.4
Maintenance 6. Firmware Update
6. Firmware Update
This chapter describes the firmware upgrade procedure and data file initialization when
firmware or manipulator configuration errors cause Manipulator startup or operation
failure.
6.1 Updating Firmware

Firmware (software stored in non-volatile memory) and data files necessary to control the
Manipulator are preinstalled in the Manipulator. Controller configuration set from
EPSON RC+ 7.0 is always saved in the Manipulator.
Firmware is supplied by CD-ROM as needed. Please contact us for information.
You must use a PC running EPSON RC+ 7.0 connected to a Manipulator with USB to
update the Manipulator firmware. Firmware cannot be updated with an Ethernet
connection.
6.2 Firmware Upgrade Procedure

The firmware upgrade procedure is described as follows:
(1) Connect the development PC and the Manipulator with a USB cable (the firmware
cannot be changed with an Ethernet connection).
(2) Turn ON the Manipulator. (Do not start the development software EPSON RC+ 7.0
until the firmware upgrade is completed.)
(3) Insert the “firmware CD-ROM” in the development PC CD-ROM drive
(4) Execute “CtrlsetupT.exe”. The following dialog appears.
(5) Select the <Upgrade> option button and click the <Next> button.
T3 Rev.4 121
(6) Make sure that the development PC is connected to the Manipulator with a USB cable
and Click the <Next> button.
(7) Check the current firmware version and the new firmware version and click the
<Install> button.
(8) The firmware upgrade starts. It takes several minutes to complete.

NOTE Do not unplug the USB cable during transfer or turn OFF the Manipulator or the
 development PC.
(9) Continuous data file transfer starts.
122 T3 Rev.4
(10) The following dialog appears when transfer has completed. Click the <Next> button
to reboot the Manipulator.
(11) The following dialog appears after the Controller reboot. Click the <Finish> button.
The firmware upgrade is complete.
T3 Rev.4 123
6.3 Manipulator Recovery

If the Manipulator becomes inoperable, use the procedures described in this section to
recover.
NOTE Controller Backup is recommended for easy recovery of the Controller operation. For
 details of Controller Backup, refer to Maintenance 5. Backup and Restore.
124 T3 Rev.4
6.4 Firmware Initialization Procedure

The firmware initialization procedures are described in this section.
(1) Connect the development PC to the Manipulator with a USB cable (the firmware
cannot be changed with an Ethernet connection).
(2) Turn ON the Manipulator. Do not start the development software EPSON RC+ 7.0
until firmware initialization is complete.
(3) Insert the “Firmware CD-ROM” in the development PC CD-ROM drive.
(4) Execute “Ctrlsetup.exe”.
(5) Select the <Initialize> option button and click the <Next> button.
(6) Make sure that the development PC is connected to the Controller with a USB cable
and Click the <Next> button.
(7) Check the version information and click the <Install> button.
T3 Rev.4 125
(8) Firmware and data file transfer starts. It takes several minutes to complete.
NOTE
Do not unplug the USB cable during transfer or turn OFF the Manipulator or the PC
 for development.
(9) The following dialog appears when transfer is completed. Click the <Next> button
to reboot the Manipulator.
(10) The following dialog appears after the Manipulator reboot. Click the <Finish>
button.
The firmware upgrade is completed.
Start EPSON RC+ 7.0 and restore the Controller settings.

For details of restoring the operating system, refer to Maintenance 5. Backup and Restore.
126 T3 Rev.4
Maintenance 7. Covers
7. Covers
All procedures for removing and installing covers in maintenance are described in this
chapter.
the robot system.
■ Before performing any replacement procedure, turn OFF the Robot system and
system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
foreign substances exist in them is extremely hazardous and may result in electric
shock and/or malfunction of the robot system.
User Plate
Arm Top Cover

Power Unit Cover
Connector Plate
Arm
Bottom Cover
Base Side Cover
Power Cable Cover
T3 Rev.4 127
7.1 Arm Top Cover

■ Do not remove the arm top cover forcibly. Removing the cover forcibly may
result in damage to the cables, disconnection, and/or contact failure. Damaged
cables, disconnection, or contact failure is extremely hazardous and may result in
electric shock and/or improper function of the robot system.
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the
cover. Unnecessary strain on cables may result in damage to the cables,
CAUTION
disconnection, and/or contact failure. Damaged cables, disconnection, or
contact failure is extremely hazardous and may result in electric shock and/or
When routing the cables, observe the cable locations after removing the cover.
Be sure to place the cables back to their original locations.
Arm Top Cover Unscrew the Arm Top Cover mounting bolts, and 6-M4×8
Removal then lift the cover. 2-M4×12 Sems
Sems
NOTE Be careful for user wires and tubes when
 removing the cover.
Arm Top Cover
Arm Top Cover Put the arm top cover to the arm and secure with the Arm Top Cover mounting bolts.
Installation After securing the Arm Top Cover, make sure that the lower limit mechanical stop is not
touching the cylindrical part of the Arm Top Cover.
128 T3 Rev.4
7.2 Arm Bottom Cover

Unscrew the Arm Bottom Cover mounting bolts
and then remove the cover. Arm Bottom Cover
NOTE Be careful of the end effector. When the end

 effector is installed, the Arm Bottom Cover may
not be removed from the shaft
When you replace the ball screw spline unit,
you need to remove the end effector to remove 3-M4×12 Sems
the Arm Bottom Cover completely.
When you can work (maintenance, inspection)
without removing the cover completely, move
the shaft to the lower limit and lower the Arm
Bottom Cover.
7.3 Power Cable Cover

Unscrew the Power Cable Cover mounting bolts
and then remove the Power Cable Cover.
Power Cable
2-M4×8
Cover
Sems
T3 Rev.4 129
7.4 Connector Plate

■ Do not remove the connector plate forcibly. Removing the connector plate
forcibly may result in damage to the cables, disconnection, and/or contact failure.
■ When installing the connector plate, be careful not to allow the cables to interfere
with the plate mounting and do not bend these cables forcibly to push them into
the cover.
CAUTION Unnecessary strain on cables may result in damage to the cables, disconnection,
and/or contact failure. Damaged cables, disconnection, or contact failure is
extremely hazardous and may result in electric shock and/or improper function of
the robot system.
When routing the cables, observe the cable locations after removing the
connector plate. Be sure to place the cables back to their original locations.
Connector (1) Remove the Power Cable Cover.

Plate Refer to Maintenance: 7.3 Power Cable Cover.
Removal
(2) Remove Power cable clamp and then
remove Power cable connector.
NOTE When removing the Power cable
 connector, pull it out with pushing
latches on both side of the connector. 2-M4×6 Truss
(3) Unscrew the Connector Plate mounting
4-M4×10
bolts and then remove the Connector
Connector Plate
Plate.
NOTE M4×8 Sems
 Some fixed bolts are the same as Power

unit cover fixing bolts.
（For Clamp
Fixing）
Connector (1) Put the Connector Plate to the base and secure using the mounting bolts.
Plate
(2) Connect power cable connector and install power cable clamp.
Installation
(3) Mount the power cable cover.
Refer to Maintenance: 7.3 Power Cable Cover.
NOTE
 When mounting the Connector Plate, be careful of the following.
Prevent the air tube from bending sharply inside the

manipulator. Also, do not block the air flow.
If there is a kink in the air tube, air flow is blocked while
the manipulator is operating and may cause a trouble.
130 T3 Rev.4
7.5 Power Unit Cover

Unscrew the Power Unit Cover mounting
bolts, and then remove the Power Unit 9-M4×6
Cover. Truss
NOTE Some fixed bolts are the same as Connector

 plate fixing bolts.
Power Unit
Cover
7.6 Base Side Cover

■ Do not remove the base side cover forcibly. Removing the base side cover
forcibly may result in damage to the cables, disconnection, and/or contact failure.
■ When installing the base side cover, be careful not to allow the cables to interfere
with the plate mounting and do not bend these cables forcibly to push them into
the cover.
the robot system.
Unscrew the Base Side Cover mounting

bolts, and then remove the Base Side Cover.
4-M3×6
Base Side Cover
T3 Rev.4 131
7.7 User Plate

■ Do not remove the user plate forcibly. Removing the user plate forcibly may result
in damage to the cables, disconnection, and/or contact failure. Damaged
cables, disconnection, or contact failure is extremely hazardous and may result in
electric shock and/or improper function of the robot system.
■ When installing the user plate, be careful not to allow the cables to interfere with
the plate mounting and do not bend these cables forcibly to push them into the
cover.
the robot system.
User (1) Remove the Arm Top Cover.

Plate Refer to Maintenance: 7.1 Arm Top Cover.
Removal
(2) Unscrew the User Plate mounting bolts and
remove the plate.
2-M4×10
User (1) Put the User Plate to the arm and secure using the mounting bolts.
Plate
(2) Mount the Arm Top Cover.
Installation
Refer to Maintenance: 7.1 Arm Top Cover.
132 T3 Rev.4
Maintenance 8. Cable
8. Cable
■ Do not insert or pull out the each connector while the power to the robot system is
turned ON. Inserting or pulling out the motor connectors with the power ON is
the robot system.
■ Before performing any replacement procedure, turn OFF the robot system and
system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
foreign substances exist in them is extremely hazardous and may result in
electric shock and/or malfunction of the robot system.
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
CAUTION or contact failure is extremely hazardous and may result in electric shock and/or
8.1 Replacing Cable Unit

Name Quantity Note
Maintenance
part Cable unit 1 2182565
width across flats: 2 mm 1 For M3 button volt

Hexagonal
width across flats: 2.5 mm 1 For M3 screw
wrench
width across flats: 3 mm 1 For M4 screw
Spanner width across flats: 5 mm 1 For hand I/O connector removal
Tools
Nut screwdriver width across flats: 5 mm 1 For hand I/O connector removal
Torque wrench 1
Cross-point screwdriver (No. 2) 1 For cross-recessed screw
Nippers 1 For cutting wire tie
Material Wire tie -
T3 Rev.4 133
Cable Unit
■ If the connectors have been disconnected during the replacement of the cable
unit, be sure to reconnect the connectors to their proper positions. Refer to the
wiring diagrams.
Improper connection of the connectors may result in improper function of the robot
system.
For details on the connections, refer to Maintenance: 3. Manipulator Structure.
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the cover.
Unnecessary strain on cables may result in damage to the cables, disconnection,
CAUTION the robot system.
When routing the cables, observe the cable locations after removing the cover.
Be sure to place the cables back to their original locations.
cables, disconnection, and/or contact failure. Damaged cables, disconnection, or
contact failure is extremely hazardous and may result in electric shock and/or
NOTE A brake is mounted on the Joint #3 motor to prevent the shaft from lowering down due to
 the weight of the end effector while the power to the Manipulator is OFF or while the
motor is in OFF status (MOTOR OFF).
Move the shaft down to its lower limit before the replacement procedure following the
removal steps.
134 T3 Rev.4
Cable Unit (1) Turn ON the Manipulator and change the motor to OFF status (MOTOR OFF).
Removal
(2) Press and hold the brake release switch to let the shaft down. Be sure to keep
enough space and prevent the end effector hitting any peripheral equipment.
The brake release switch affects only Joint #3. When the brake release switch is
pressed, the Joint #3 brake is released.
Be careful of the shaft while the brake release switch is being pressed because the
shaft may be lowered by the weight of an end effector.
(3) Turn OFF the manipulator.
(4) Remove the Power Unit Cover.
For details, refer to Maintenance: 7.5 Power Unit Cover.
(5) Remove the ground wire that secured on the case side cable fixing plate.
(6) Cut off the two wire ties binding the cables in the Base side.
(7) Remove the base side cover.
For details, refer to Maintenance: 7.6 Base Side Cover.
(8) Remove the connector of AMP board. A

B
A: Power cable connector

B: Signal cable connector
C: Motor connector C
(9) Remove the Connector Plate.

For details, refer to Maintenance: 7.4 Connector Plate.
(10) Remove the following parts that connected to the Connector Plate.
Air tube
TP connector
(11) Unscrew the CPU/DPB board mounting screw.

Hexagon socket head cap button: 5-M3×5
Remove the CPU/DPB board from base.

NOTE Heat release sheet is attached on back of the CPU/DPB CPU/DPB
 boards. Be careful not to brake or lose it.

Board
T3 Rev.4 135
(12) Remove CPU/DPB board connector. E B D

B
A: Power connector (IN/OUT ×1 for each)
B: Power cable connector (×2)
C: Signal cable connector
D: Hand I/O connector
E: LED connector
NOTE Remember the cable layout for reconnecting the cables
 correctly after replacement.
C
A-OUT A-IN
(13) Remove the Arm Top Cover.
For details, refer to Maintenance: 7.1 Arm Top Cover.
(14) Remove the User Plate.
For details, refer to Maintenance: 7.7 User Plate.
(15) Remove the motor unit connectors of Joint 2, 3, and 4.

A: Power cable connector B-OUT
B: Signal cable connector (IN/OUT ×1 for each)
A
B-IN
(16) Disconnect the Hand I/O cable and air tube from the User Plate.
NOTE
 Mounting screws for the Hand I/O cable are very small. Be sure to keep the screws.
Press the ring on the fittings to pull out the air tube. (ø6×2, ø4×1)
Remember the cable layout for reconnecting the disconnected parts after replacement.
(17) Remove the ground wire that secured on the user plate.
(18) Cut off the wire tie binding the cables in the Arm side.
(19) Remove the nut that secures the cable duct fittings to the User Plate and pull out the
cables from the User Plate.
(20) Remove the nut that secures the cable duct fittings to the Base.
Base side Arm #2 side
Nut Nut
136 T3 Rev.4
Cable Unit (1) Pass the new cables through the Base, cable fixing plate, and nut, and turn the fittings
Installation to secure the cables.
(2) Pass the cables in the User Plate side through the User Plate and nut and turn the
fittings to secure the cables.
(3) Connect the following parts to User Plate.

Air tube
Hand I/O cable
(4) Connect the ground wire on the Arm side to the User Plate.
(5) Mount the User Plate.

(6) Connect the motor unit connectors of Joint 2, 3, and 4.

B: Signal cable connector (IN/OUT ×1 for each)
A
B-IN
(7) Bind the cables with a wire tie as removed in the removal step (18).
(8) Connect the ground wire on the Base side to the cable fixing plate on the Base side.
(9) Connect CPU/DPB board connector. E B D

B
E: LED connector
C
A-OUT A-IN
(10) Mount CPU/DPB board on the base.

Tightening torque: 0.45 ± 0.1 N·m
NOTE Attach the heat release sheet on back of the CPU/DPB CPU/DPB
 boards when mounting. Board
(11) Connect the following parts that connected to the Connector Plate.
Air tube
TP connector
T3 Rev.4 137
(12) Connect AMP board connector. A

B

C
C: Motor connector
(13) Mount Base Side Cover.

(14) Bind the cables with a wire tie as removed in the removal step (6).
(15) Place and secure the Arm Top Cover without the cables being stuck.
(16) Mount Power Unit Cover.

(17) Mount Connector Plate.

138 T3 Rev.4
8.2 Insert or Pull out of Power Cable

Name Quantity Note
Tools Cross-point screwdriver (No. 2) 1 For cross-recessed screw
Power Cable
Power Cable (1) Turn OFF the Manipulator.

Removal
(2) Remove the Power Cable Cover.
For details, refer to Maintenance: 7.3 Power Cable Cover.
(3) Remove Power cable clamp and then remove Power cable connector.
NOTE When removing the Power cable connector, pull it out with pushing latches on both
 side of the connector.
Power Cable (1) Connect the Power cable connector and mount Power cable clamp.
Installation
(2) Mount Power cable cover.
For details, refer to Maintenance: 7.3 Power Cable Cover.
T3 Rev.4 139
Maintenance 9. Joint #1
9. Joint #1
the robot system.
system.
■ Be careful not to apply excessive shock to the motor shaft when replacing the
motors. The shock may shorten the life cycle of the motors and encoder and/or
damage them.
CAUTION ■ Never disassemble the motor and encoder. A disassembled motor and encoder
will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, a brake, timing belts, ball
Robot system.
Refer to Maintenance 16. Calibration to execute the calibration.
Joint #1 reduction
gear unit
Joint #1 motor
140 T3 Rev.4
9.1 Replacing Joint #1 Motor

Name Quantity Note
Motor 200W 1 2182560

Between reduction gear unit
and Arm #1 1 1213266
Maintenance
parts O-ring Between reduction gear unit
and Flange 1 1653819
Between motor and Flange 1 1709549
1 For M4 set screw
width across flats: 2 mm For M3 button volt
Hexagonal
wrench width across flats: 2.5 mm 1 For M3 set screw
Tools width across flats: 3 mm 1 For M4 screw
Torque wrench 1
Wiping cloth 1 For wiping grease
Grease Grease (SK-2) - -
Joint #1 motor (1) Turn OFF the Manipulator.

Removal
(3) Remove the Base Side Cover.
(4) Remove the connector of amplifier board.

A B
C: Motor connector C
(5) Remove the amplifier board.

Sems screw: 3-M3×6
NOTE Amplifier
 Heat release sheet is attached on the back side of the Board

amplifier board. Be careful not to lose or break it.
3-M3×6
Sems
(6) Remove the connector plate.

Air tube
TP connector
T3 Rev.4 141
(8) Unscrew CPU/DPB board mounting screws,

Remove CPU/DPB board from a base.

NOTE Heat release sheet is attached on the back of CPU/DPB
 CPU/DPB board. Be careful not to break or lose

it.
Board
(9) Remove the CPU/DPB board connector. E B D

B
E: LED connector
NOTE
Remember the cable layout for reconnecting the
 cables correctly after replacement.
C
A-OUT A-IN
(10) Remove the connector of the Joint #1 motor unit.

Signal cable connector (IN/OUT ×1 for each)
IN OUT
(11) Remove the Power board cover.

Truss screw: 2-M4×6
142 T3 Rev.4
(12) Unscrew the Power unit mounting screws.

3-M4×10
Remove Power unit from the base.
(13) Remove the Arm #1 mounting bolt in the Joint #1

A
side and remove the arm.
B
A: 8-M3×30
B: 4-M3×15
There is an O-ring (between the reduction gear unit

O-ring
and Arm #1) between the Joint #1 unit and the arm.
Be sure to keep the O-ring Reduction Gear Unit
(14) Remove the screws mounting the Joint #1 flange

on the Base.
8-M4×15
Remove the Joint #1 motor unit from the base.

NOTE
 When removing the Joint #1 motor unit, pull it up

slowly to avoid hitting the base.
(15) Loosen the motor mounting screws on the Joint #1

motor flange and remove the motor unit.
4-M4×15+small washer
O-ring
There is an O-ring (between the motor and flange)

between the motor and Joint #1 motor flange. Be
sure to keep the O-ring
Joint #1
motor unit
(16) Remove the waveform generator from the Joint #1 Waveform Generator
motor.
A: Brass Bushing
There is a brass bushing in one of the set screw B: Set Screw
holes. Be sure to keep the bushing.
A: Brass Bushing M4
B: Set Screw 2-M4×6
Joint #1 Motor
T3 Rev.4 143
Joint #1 motor (1) Apply grease (SK-2) to the between the Waveform Generator
Installation waveform generator and motor. Mount the
A: Brass Bushing
waveform generator on the Joint #1 motor.
B: Set Screw
Grease volume 4 g
Be sure to align the end face of the waveform
generator to the end face of the motor shaft.
Joint #1 Motor
Tighten one of the set screws vertically on the
flat face of the motor shaft. Insert a bushing A: Brass Bushing M4
into the other set screw hole to prevent damage B: Set Screw 2-M4×6
to the motor shaft.
■ See the figure above for the orientation of the waveform generator. Be sure to
install the waveform generator properly. Improper installation of the waveform
generator will result in improper function of the Manipulator.
CAUTION
(2) Set an O-ring (between the motor and flange) on

the motor mounting surface and assemble the
motor with the Joint #1 flange.
4-M4×15+ small washer O-ring
Replace O-ring to new one if there is swelling,
scratch, or wear.
To insert the motor, turn it slowly from side to
side by hand and push in. Flange notch Joint #1
NOTE Motor Unit
Be careful about flange notch and motor position
 when mounting the flange.
(3) Mount the Joint #1 unit on the Base.

Secure the Joint #1 motor cables facing toward the back of the Base.
(4) Set the O-ring removed in the removal step (10) into the O-ring (between reduction
gear unit and Arm #1) groove of the arm.
Replace O-ring to new one if there is swelling, scratch, or wear.
(5) Mount the arm to the Joint #1 unit.

Loosely fasten all bolts in a crisscross pattern so A
that the bolts will be fastened evenly. B
A: 8-M3×30
B: 4-M3×15
Then, using a torque wrench, tighten each bolt O-ring

securely in a crisscross pattern at the torque
Reduction Gear Unit
specified in the table below.
144 T3 Rev.4
(6) Mount Power unit to base.
(7) Mount a cover of power board.
(8) Connect the connector of Joint #1 motor unit.

Signal cable connector (IN/OUT ×1 for each)
(9) Connect CPU/DPB board connector. E B D

B
E: LED connector
C
A-OUT A-IN
(10) Mount CPU/DPB board to base.

Tightening torque: 0.45±0.1 N·m
NOTE Attach the heat release sheet on the back side of the CPU/DPB
 CPU/DPB boards when mounting.

Board
Air tube
TP connector
T3 Rev.4 145
(12) Mount the amplifier board.

NOTE
Attach the heat release sheet on the back side of the amplifier board when mounting.
 (13) Connect amplifier board connector.
Power cable connector
Signal cable connector
Motor connector
(14) Mount base side cover.
(15) Mount the Power Unit Cover.
(16) Mount the Connector Plate.
(17) Execute the calibration for the Joint #1.
For details, refer to Maintenance: 16. Calibration.
146 T3 Rev.4
9.2 Replacing Joint #1 Reduction Gear Unit

A reduction gear unit consists of the following three parts. When replacing the reduction
gear unit, be sure to always replace the waveform generator, flexspline, and circular spline
all together as one set.
Waveform generator, Flexspline, Circular spline
For details of the reduction gear unit, refer to Maintenance 18. Maintenance Parts List.
Name Quantity Note

Maintenance
Part Reduction Gear Unit 1 1718303
width across flats: 2 mm 1 For M4 set screw

Hexagonal wrench width across flats: 2.5 mm 1 For M3 screw
Torque wrench 1
Tools
Nippers 1
Spatula 1 For apply grease
1 For wiping grease (Flange)
Wiping cloth
1 For wiping grease (Bolt)
About 20 mm in length
Screw (M4) 2 For flexspline removal
Grease Grease (SK-2) - -
Joint #1 (1) Remove the Joint #1 motor unit.

Reduction
Gear Unit For details, refer to Maintenance:
Removal 9.1 Replacing Joint #1 Motor “Removal procedure”.
(2) Remove the reduction gear unit from the Joint #1

flange.
10-M3×20 Flange
Reduction
Gear Unit
T3 Rev.4 147
Joint #1 (1) A new reduction gear unit contains the Flexspline and
Reduction Cross roller bearing unit
parts shown in the picture on the right
Gear Unit
when it is unpacked. O-ring
Installation
The gear grooves of the flexspline,
circular spline, and the bearings of the
waveform generator have been greased.
Wipe off excess grease from the mounting
surface.
Circular spline
Waveform generator
■ Never adjust (loosen or tighten) the mounting bolts between the flexspline and
cross roller bearing unit. If the mounting bolts are adjusted, the flexspline and
CAUTION cross roller bearing unit must be aligned by the maker of the reduction gear unit.
(2) Fit the O-rings (between the reduction Convex side

gear unit and flange) into the grooves on
both sides of the new circular spline.
Grooves
Make sure that the rings do not come out
of the grooves.
The other side
(3) Face the convex side of the circular spline

down, and then fit it into the flexspline.
(4) Match the screw holes on the inner ring of

the cross roller bearing unit and the
through holes of the circular spline.
148 T3 Rev.4
(5) Secure the reduction gear flange to the circular

spline.
Flange
10-M3×20
Loosely fasten all bolts in a crisscross pattern so

Reduction
that the bolts will be fastened evenly. Then, Gear Unit
using a torque wrench, tighten each bolt securely
in a crisscross pattern at the torque specified in
the table below.
Item Bolt type Bolts Tightening torque

Joint #1 reduction
gear unit M3×20 10 2.4±0.1N⋅m
NOTE
 Be careful not to apply too much force since it may damage the parts.
(6) Apply grease (SK-2) inside the flexspline.
Grease volume 13 g
(7) Mount the Joint #1 motor.
For details, refer to Maintenance:
9.1 Replacing Joint #1 Motor “Installation procedure”.
T3 Rev.4 149
10. Joint #2
the robot system.
system.
damage them.
Robot system.
Refer to Maintenance: 16. Calibration to execute the calibration.
Joint #2
Motor
Joint #2
Reduction Gear Unit
150 T3 Rev.4

Name Quantity Note
Motor 100W(J2/J3) 1 2182562
Between reduction gear
Maintenance 1 1213266
unit and Arm #1
Parts O-ring
1 1653819
unit and Arm #2
Hexagonal wrench
Torque wrench 1
Wiping cloth 1 For wiping grease
Material Wire tie -
Grease Grease SK-2 -
removal steps.
Joint #2 Motor (1) Turn ON the Manipulator.

Removal
(2) Push down the shaft to its lower limit while pressing the brake release switch. Be
sure to keep enough space and prevent the end effector hitting any peripheral
equipment.
(6) Remove the Motor unit connector of Joint #2.

B: Signal cable connector (IN/OUT ×1 for each) A
B-IN
T3 Rev.4 151
(7) Unscrew the Motor unit mounting screws.

3-4×10
Remove the Joint #2 motor unit from the Arm #2.

To pull out the motor smoothly, move the Arm #2
slowly by hand while pulling the motor.
Joint #2
Arm 2
Motor Unit
(8) Remove the waveform generator from the Joint #2 Waveform Generator
motor. Brass Bushing
Set Screw
2-M4×6 Set screw
M4 Brass Bushing Joint #2
Motor
NOTE There is a brass bushing in one of the set screw
 holes. Be sure to keep the bushing.
(9) Remove the motor flange from the Joint #2 motor.

Motor
2-M4×55+M4 Small washer Flange
Joint #2
Washer will be necessary again when mounting Motor
motor flange. Be sure to keep the washer.
152 T3 Rev.4
Joint #2 Motor (1) Mount the motor flange on the Joint #2 motor.
Installation Motor
2-M4×55+M4 Small washer
Flange
NOTE
Be careful about position of flange and motor Joint #2
 when mounting flange. Motor
(2) Mount the waveform generator on the Joint #2 Waveform Generator

motor. Brass Bushing
Set Screw
2-M4×6 Set screw
M4 Brass Bushing Joint #2
Motor
Be sure to align the end face of the waveform
generator to the end face of the motor shaft.
Tighten one of the set screws vertically on the flat
face of the motor shaft. Insert a bushing into the
other set screw hole to prevent damage to the motor
shaft.
■ See the figures above for the orientation of the waveform generator. Be sure to
install the waveform generator properly. Improper installation of the waveform
CAUTION generator will result in improper function of the Manipulator.
(3) Apply grease between the waveform generator and motor flange.
Grease volume 4 g (SK-2)
(4) Mount the Joint #2 motor unit on the Arm #2.

3-4×10
To insert the motor, slowly move the Arm #2 by

hand and push in.
Joint #2
Arm #2
Motor Unit
(5) Mount a connector of Joint #2 motor unit.

B: Signal cable connector (IN/OUT ×1 for each) A
B-IN

T3 Rev.4 153
(8) Execute the calibration for Joint #2.

For details refer to Maintenance: 16. Calibration.
154 T3 Rev.4
10.2 Replacing Joint #2 Reduction Gear Unit

A reduction gear unit consists of the following three parts. When replacing the reduction
gear unit, be sure to always replace the waveform generator, flexspline, and circular spline
all together as one set.
Waveform generator, Flexspline, Circular spline
For details of the reduction gear unit, refer to Maintenance 18. Maintenance parts list
Name Quantity Note

Maintenance
parts Reduction Gear Unit 1 1718304

Hexagonal
wrench width across flats: 2.5 mm 1 For M3 screw
Torque wrench 1
Tools
Spatula 1 For apply grease
1 For wiping grease (Flange)
Wiping cloth
1 For wiping grease (Bolt)
Screw (M3) Length about 20 mm 2 For removing the flexspline
Material
Wire tie -
Grease Grease SK-2 -
removal steps.
Joint #2 (1) Remove the waveform generator from the Joint #2 motor.
Reduction
Gear Unit
10.1 Replacing Joint #2 Motor “Removal Procedure”.
Removal
(2) Remove the Arm #2 by removing the
screws mounting the Arm #2 on the
reduction gear unit A
A: 10-M3×18
B: 8-M3×30+M3 small washer Reduction
Gear Unit
C: 4-M3×15+M3 small washer
Arm #2 O ring
Remove the Arm #2
(3) Remove the reduction gear unit from the

Arm #1 by removing the screws that
mounts the reduction gear unit on the B C Arm #1
Arm #1.
There is an O-ring between the Arm #1
and the reduction gear unit. Be sure to
keep the O-ring.
T3 Rev.4 155
Joint #2 (1) A new reduction gear unit contains the Flexspline and
Reduction Cross roller bearing unit
parts shown in the picture on the right
Gear Unit
Installation when it is unpacked. O-ring
The gear grooves of the flexspline,

circular spline, and the bearings of the
waveform generator have been greased.
Wipe off excess grease from the
mounting surface.
Circular spline
Waveform generator
■ Never adjust (loosen or tighten) the mounting bolts between the flexspline and
cross roller bearing unit. If the mounting bolts are adjusted, the flexspline and
CAUTION cross roller bearing unit must be aligned by the maker of the reduction gear unit.
(2) Fit the O-rings into the grooves on both Convex side
sides of the new circular spline.
Make sure that the rings do not come out

Grooves
of the grooves.
The other side
(3) Face the convex side of the circular spline

down, and then fit it into the flexspline.
(4) Match the screw holes on the inner ring

of the cross roller bearing unit and the
through holes of the circular spline.
156 T3 Rev.4
(5) Set the O-ring removed in the removal

step (6) into the O-ring (between the
Arm #1 and the reduction gear unit) A
groove of the Arm #1 and install the
flexspline on the Arm #1. Reduction
A: 10-M3×18 Gear Unit
B: 8-M3×30+8-M3 small washer Arm #2 O-ring
C: 4-M3×15+4-M3 small washer
B C Arm #1
Loosely secure all bolts in a crisscross pattern so that the bolts will be secured evenly.
Then, using a torque wrench, tighten each bolt securely in a crisscross pattern at the
torque specified in the table below.
Item Bolt type Tightening torque
Joint #2
M3 2.4±0.1N⋅m
reduction gear unit
NOTE
 Be careful not to apply too much force since it may damage the parts
(6) Apply grease between the motor flange and waveform generator and next inside the
flexspline.
Between the motor flange and waveform generator

Grease volume: 4 g (SK-2)
Inside the flexspline
Grease volume: 11 g (SK-2)
(7) Set the attached O-ring into the O-ring groove of the circular spline.
Secure the Arm #2 on the circular spline.
(8) Mount and Joint #2 motor.
10.1 Replacing Joint #2 Motor “Installation procedure”.
T3 Rev.4 157
11. Joint #3
the robot system.
■ Before performing any replacement, turn OFF the Controller and related
equipment, and then pull out the power plug from the power source.
Performing any replacement with the power ON is extremely hazardous and may
result in electric shock and/or malfunction of the robot system.
damage them.
After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
Robot system.
Joint #3
Motor
Joint #3 Brake
Z Belt
158 T3 Rev.4

Name Quantity Note
Maintenance
parts Motor 100W(J2/J3) 1 2182562
width across flats: 1.5 mm 1 For M3 set screw
Hexagonal wrench width across flats: 2.5 mm 1 For M5 set screw
Torque wrench 1
Nippers 1 For cutting wire tie
1 Z: Belt tension
Force gauge 69 N (7.0 ± 0.5 kgf⋅cm)
Suitable cord (Length about 800 mm) 1 For belt tension
Material Wire tie -
motor is in OFF status (MOTOR OFF)
removal steps.
Joint #3 motor (1) Turn ON the Manipulator.

Removal
equipment.
Be careful of the shaft while the brake release switch is being pressed because the shaft
may be lowered by the weight of an end effector.
(5) Cut off the wire tie binding the cables.

T3 Rev.4 159
(7) Remove the Joint #3 motor unit connectors.

A: Power cable connector B-OUT B-IN
B: Signal cable connector A
(IN/OUT×1 for each)
C: Brake cable connector
(8) Unscrew the Joint #3 motor unit mounting M3×12

bolts and remove slotted hole washer. +M3 Washer
2-M4×15+M4 Washer Joint #3
M3×12+M3 Washer Motor Unit
NOTE Slotted hole washer will be necessary again 2-M4×15
 when mounting Z belt. Be sure to keep

the slotted hole washer.
+M4 Washer
(9) Unscrew the Joint #3 motor brake mounting

bolts. Joint #3
3-M3×12 Motor Unit
Remove the Joint #3 motor unit and

solenoid brake.
NOTE Pulley carries the belt. Tilts Joint #3
 motor little and pull it up with avoiding the
belt. Then remove the motor.
3-M3×12
(10) Remove the Motor plate from the Joint #3

motor. Joint #3
2-M4×55
2-M4×55+M4 Small washer +M4 Small washer Motor
Washer will be necessary again when

mounting the Motor plate. Be sure to keep
the washer.
(11) Loosen the screws of the pulley and brake

Joint #3
hub and remove them from the Joint #3 Motor
motor.
M5×8
M5×8 Set screw
Set screw
M5×8 Set screw +M5 Busing
M3×3 M5×8
M3×3 Set screw Set screw Set screw
+ M5 Bushing
Brake Hub M3×3
Pulley Set screw
There is a brass bushing in one of the set +M3 Bushing
screw holes. Be sure to keep the bushing.
160 T3 Rev.4
Joint #3 motor (1) Mount the pulley and brake hub to the Joint Joint #3
Motor
Installation #3 motor.
M5×8 Set screw M5×8

Set screw
M3×3 M5×8
M3×3 Set screw Set screw Set screw
+ M5 Bushing
M3×3
Brake Hub Set screw
NOTE Fix the pulley leaving 5.5 mm space from Pulley

+M3 Bushing
the motor.
Make sure to leave 5.5 mm between the
motor and the pulley.
Insert the brake hub all the way seated in
the pulley and secure it.
5.5
Tighten one of the set screws vertically on the flat face of the motor shaft.
Insert a bushing into the other set screw hole to prevent damage to the motor shaft.
(2) Mount the Joint #3 motor on the Motor

plate. 2-M4×55
+ M4 Small Joint #3
2-M4×55+M4 Small washer
Washer Motor
NOTE Be careful about the position of Motor
 plate and motor when mounting Motor
plate.
(3) Pass the pulley through the Z belt and fit the Joint #3
brake disk to the hub. Motor Unit
NOTE When passing the belt, make sure that the

 belt does not out of the pulley.
Mount the Joint #3 motor brake.
3-M3×12
3-M3×12
Secure the motor cables facing to front of

the Arm.
(4) Loosely secure the Joint #3 motor unit to Arm #2.

NOTE Check that the motor unit can be moved by hand, and it will not tilt when pulled.
 If the unit is secured too loose or too tight, the belt will not have the proper tension.
T3 Rev.4 161
(5) Apply the proper tension to the Z belt, and M3×12

secure the Joint #3 motor unit. +M3 Washer
Joint #3
Pass a suitable cord or string around the Motor Unit
plate hole of the Joint #3 motor unit. 2-M4×15
Then, pull the cord using a force gauge or +M4 Washer
similar tool to apply the specified tension
shown in the figure on the right.
Z belt tension:
34.5 N (3.5 ± 0.5 kgf) Z Belt
Axial force (When pulling):

69 N (7.0 ± 0.5 kgf)
Force Gauge
NOTE To check belt tension with the tension meter, refer to the following.
 Maintenance: 11.4 Checking the Timing Belt Tension (Z Belt).
(6) Connect the Joint #3 motor unit connectors.

A: Power cable connector B-OUT B-IN
B: Signal cable connector (IN/OUT) A
C: Brake cable connector

(8) Bind the brake cables with a wire tie in their original positions as before removed in the
removal step (5).
(10) Execute the calibration of Joints #3, #4.
For details, refer to Maintenance: 16. Calibration
162 T3 Rev.4
11.2 Replacing the Timing Belt

Name Quantity Note
Maintenance
part Z belt width: 9 mm 1 1554773
Hexagonal wrench
Torque wrench 1
Z: Belt tension
Force gauge 1
69 N (7.0 ± 0.5 kgf)
Material Wire tie -
removal steps.
Z belt (1) Remove the Joint #3 motor unit and solenoid brake.
Removal
(2) Remove the screws for the spline plate. 3-M4×12 Spline Plate
3-M4×12
Holding the spline plate upward, pull out the Z

belt.
Shaft Z Belt
Z belt (1) Pass a new Z belt through the shaft.

Installation
(2) Lower the spline plate with the Z belt placed around the spline plate pulley.
Secure the spline plate with 3 screws.
Loosely secure the spline plate on the Arm #2 and move the shaft up and down
several times before firmly secure the spline plate.
(3) Mount Joint #3 motor unit and solenoid brake.
11.1 Replacing Joint #3 Motor “Installation Procedure”.
T3 Rev.4 163
11.3 Replacing the Brake

Name Quantity Note
Maintenance
part Solenoid brake unit 1 2182694
width across flats: 2 mm 1 For M2.5 set screw
Hexagonal wrench
Tools Torque wrench 1
Z: Belt tension
Force gauge 1
69 N (7.0 ± 0.5 kgf)
Material Wire tie -
removal steps.
Joint #3 brake (1) Remove the Joint #3 motor unit and solenoid brake.
Removal
(2) Remove the brake form the brake support. 3-M2.5×12
3-M2.5×12
Brake
Joint #3 brake (1) Mount the brake support on the brake.

Installation
3-M2.5×12
(2) Mount Joint #3 motor unit and solenoid brake.

11.1 Replacing Joint #3 Motor “Installation Procedure”.
164 T3 Rev.4
11.4 Checking the Timing Belt Tension (Z Belt)

Name Quantity Note
For details of usage and measurement methods of the tension
Tool Sonic tension meter 1
meter, refer to the instruction manual of the tension meter.
Joint #3 (1) Enter appropriate setting values to the sonic tension meter.
Belt tension Unit mass M Width W Span S
Model Belt
check [g/ (1 mm width ×1 m length)] [mm] [mm]
T3 Z belt 1.9 9 127
(2) Strum the belt and measure tension.
NOTE Measurement failure may occur if the microphone

 touches the belt during measurement.
T3 Rev.4 165
12. Joint #4
the robot system.
■ Before performing any replacement, turn OFF the Controller and related
equipment, and then pull out the power plug from the power source.
damage them.
■ Do not mount Joint #4 motor unit on the other joints Marking

since specification is different from that of Joint #2
or #3 motor units. Marking is applied on the motor
case of Joint #4 motor unit.
CAUTION
■ Never disassemble the motor and encoder. A disassembled motor and encoder
Robot system.
Joint #4 Motor
U belt
166 T3 Rev.4

Name Quantity Note
Maintenance
part
Motor 100W(J4) 1 2182669
Hexagonal wrench
Torque wrench 1
U: Belt tension
Force gauge 1
69N (7.0 ± 0.5 kgf)
■ The belt must be installed with proper tension; otherwise the following problems
may occur.
If falling below the lower limit : Jumping of the belt gears (position gap)
CAUTION If exceeding the upper limit : Abnormal noise or vibration (oscillation),
decline in the life of driving parts
removal steps.
Joint #4 motor (1) Turn ON the Manipulator.

Removal
equipment.
may be lowered by the weight of an end effector.

T3 Rev.4 167
(6) Remove the Joint 4 motor unit connectors.

B
B: Signal cable connector (Only IN)
A
(7) Remove the Joint #4 motor unit from the

Arm #2.
Joint #4
Remove the bolts securing the Joint #4 Motor Unit
motor on the motor plate and pull out the 3-M4×20
motor. +M4 Washer
3-M4x20+M4 washer
Pulley carries the belt. Tilts Joint #4 motor little and pull it up with avoiding the belt
when removing the motor.Slotted hole washer will be necessary again when mounting
the U belt. Be sure to keep the slotted hole washer.
(8) Remove the pulley and bearing from the

Joint 4 motor.
2-M4×8
M4×8 set screw Set Screw
M4×8 set screw +M4 busing
There is a brass bushing in one of the set Bearing

screw holes. Be sure to keep the bushing. Pulley M4 Busing
(9) Remove the motor plate from the Joint #4

2-M4×55
motor. +M4 Small
Washer
Washer will be necessary again when
mounting the motor plate. Be sure to
Motor Plate
keep the washer.
168 T3 Rev.4
Joint #4 motor (1) Loosely secure the Joint #4 motor unit to

2-M4×55
Installation Motor Plate. +M4 Small
Washer
NOTE Be careful about position of the motor plate
 and motor.
Motor Plate
Check that the motor unit can be moved by
hand, and it will not tilt when pulled.
(2) Mount the pulley and bearing to the Joint

#4 motor.
2-M4×8
Tighten one of the set screws vertically on Set screw
the flat face of the motor shaft.
Insert a bushing into the other set screw
Bearing
hole to prevent damage to the motor shaft.
Pulley M4 Busing
Then, tighten both set screws.
NOTE Make sure that the bearing is inserted
 completely when mounting the pulley. If

the end faces of the motor plate and bearing
Bearing
+ Pulley
When Tightening
Set Screw
Payload: 2.9±0.1kg
fit, bearing is inserted completely.
Also, give a pressure to bearing when
tightening.
pressure: 2.9±0.1kg
(3) Secure the motor plate on the Joint #4 motor.

(4) Place the pulley around the U belt and loosely secure to Arm #2.
NOTE Make sure the motor unit can be moved by hand, and it will not tilt when pulled. If
 the unit is secured too loose or too tight, the belt will not have the proper tension.
Make sure the gear grooves of the belt are fit into those of the pulleys completely.
T3 Rev.4 169
(5) Apply the proper tension to the U belt and Joint #4

secure the Joint #4 motor unit. Motor Unit
3-M4x20+M4 washer
Pass a suitable cord or string around the

plate hole of the Joint #4 motor unit near its 3-M4×20
+M4 Washer
mounting plate.
Then, pull the cord using a force gauge or
similar tool to apply the specified tension
shown in the figure.
U belt tension:
Force Gauge
34.5 N (3.5 ± 0.5 kgf)
Axial force (When pulling):
69 N (7.0 ± 0.5 kgf) U belt
NOTE
To check belt tension with the tension meter, refer to the following.
 Maintenance: 8.4 Checking the Timing Belt Tension (U Belt).
(6) Connect the Joint #4 motor unit

connectors. B

B: Signal cable connector A

(9) Execute the calibration of Joint #3 and #4.
For details on the calibration method, refer to Maintenance: 16. Calibration.
170 T3 Rev.4
12.2 Replacing the Timing Belt

Name Quantity Note
Maintenance
part
U belt width 17 mm 1 1709608
Hexagonal width across flats: 2.5 mm 1 For M3 screw

wrench width across flats: 3 mm 1 For M4 screw
Torque wrench 1
U: Belt tension
Force gauge 1
69N (7.0 ± 0.5 kgf)
■ The belt must be installed with proper tension; otherwise the following problems
may occur.
If falling below the lower limit : Jumping of the belt gears (position gap)
CAUTION If exceeding the upper limit : Abnormal noise or vibration (oscillation),
decline in the life of driving parts
removal steps.
U belt (1) Remove the Joint 4 motor unit.

Removal
12.1 Replacing Joint 4 Motor “Removal Procedure”.
(2) Loosen the Joint #3 motor unit mounting

bolts. M3×12
+M3 Washer
2-M4×15+M4 washer
M3×12+M3 washer Joint #3
Motor Unit
2-M4×15
+M4 Washer
(3) Remove the spline plate mounting screw. 3-M4×12 Spline Plate
3-M4×12
Hold up the spline plate, and then pull out

the Z belt and U belt to the upper side.
U Belt
Shaft Z Belt
T3 Rev.4 171
U belt (1) Hold up the spline plate and set the U belt 3-M4×12 Spline Plate
Installation around the U2 pulley.
3-M4×12
Make sure the gear grooves of the belt are fit

into those of the pulleys completely. U Belt
Shaft Z Belt
(2) Hold up the spline plate and set the Z belt around the Z2 pulley.
Make sure the gear grooves of the belt are fit into those of the pulleys completely.
(3) Loosely secure the spline plate on the Arm #2 and move the shaft up and down
several times before firmly secure the spline plate.
(4) Mount the Joint 4 motor unit.
12.1 Replacing the Joint 4 Motor “Installation Procedure”.
(5) Apply the proper tension to the Z belt and secure the Joint #3 motor unit.
11.1 Replacing the Joint 3 Motor “Installation Procedure”.
(6) Execute the calibration for Joint #3 and #4.
For details on the calibration method, refer to Maintenance: 16. Calibration.
172 T3 Rev.4
12.3 Checking the Timing Belt Tension (U Belt)

Name Quantity Note
For details of usage and measurement methods of the tension
Tool Sonic tension meter 1
meter, refer to the instruction manual of the tension meter.
Joint #4 (1) Enter appropriate setting values to the sonic tension meter.
Belt tension Unit mass M Width W Span S
Model Belt
check [g/ (1 mm width ×1 m length)] [mm] [mm]
T3 U belt 1.3 17 127
(2) Strum the U belt and measure tension.
NOTE Measurement failure may occur if the microphone

 touches the belt during measurement.
T3 Rev.4 173
Maintenance 13. Ball Screw Spline Unit
13. Ball Screw Spline Unit

the robot system.
■ Before performing any replacement procedure, turn OFF the Controller and
system.
NOTE After parts have been replaced (motors, reduction gear units, brakes, timing belts, ball
 screw spline unit, etc.), the Manipulator cannot operate properly because a mismatch
Robot system.
Refer to Maintenance: 16. Calibration to perform the calibration.
174 T3 Rev.4
13.1 Greasing the Ball Screw Spline Unit

Name Quantity Note
Proper
Grease For Ball Screw Spline Unit (AFB grease) quantity
Tools Wiping cloth 1 For wiping grease (Spline shaft)
NOTE The brake release switch affects only Joint #3. When the brake release switch is pressed,
 the Joint #3 brake is released.
may be lowered by the weight of the end effector
Cover the surrounding area such as the end effector and peripheral equipment in case the
grease drips.
(1) Turn ON the Manipulator. Stop motor excitation. (MOTOR OFF)。
(2) Move the arm to a position where Joint #3 can be moved in full stroke.
(3) Move the shaft to its upper limit manually while

pressing the brake release switch.
(5) Wipe off the old grease from the upper part of the
shaft, and then apply new grease to it.
When applying the new grease to the upper part of
the shaft, directly fill the grooves on it by hand.
Wipe off excess grease from the shaft.

(7) Move the shaft to its lower limit by hand while pressing the brake release switch.
(8) Wipe off the old grease from the lower part of the shaft, and then apply new grease to
it.
When applying the new grease to the lower part of the shaft, directly fill the grooves
on it by hand. Wipe off excess grease from the shaft.
(9) Move the shaft up and down several times while pressing the brake release switch to
smooth out the grease on the shaft. Wipe off excess grease from the shaft.
When wiping off the excess grease from the upper part of shaft, turn OFF the
Manipulator and remove the Arm Top Cover.
T3 Rev.4 175
13.2 Replacing the Ball Screw Spline Unit

However, brake does not work while the replacement operation. Move the shaft down to
its lower limit before operating the replacement following the removal procedure (1) to
(3).
Name Quantity Note

Maintenance
part Ball Screw Spline Unit (150st) 1 1718877
Proper
Grease For Ball Screw Spline Unit (AFB grease) quantity
Hexagonal wrench (width across flats: 3 mm) 1 For M4 screw
Torque wrench 1
Tools Z, U: Belt tension:
Force gauge 1
69N (7.0 ± 0.5 kgf)
Wiping cloth 1 For wiping grease (Spline shaft)
Material Wire tie -
176 T3 Rev.4
Ball Screw (1) Turn ON the Manipulator.

Spline Unit
Removal
equipment.
(4) Detach the wires/tubes from the end effector, and remove the end effector.
(5) Remove the Arm Top Cover and Arm Bottom Cover.
For details, refer to Maintenance: 7. Covers.
(6) Remove three screws mounting the spline 3-M4×12

plate.
3-M4×12
(7) Remove four screws mounting the spline nut.

4-M4×10
4-M4×10
(8) Pull out the following toward the Arm #2 upper side.
Ball screw spline unit Z belt U belt
T3 Rev.4 177
Ball Screw (1) Insert a new ball screw spline unit in the Arm #2.
Spline Unit
Installation (2) Secure the spline nut from the bottom side
of the Arm #2.
4-M4×10
4-M4×10
(3) Mount the following.

U belt / Z belt
12.2 Replacing the Timing Belt “U Belt Installation Procedure”.
(4) Mount the Arm Top Cover and Arm Bottom Cover.
For details, refer to Maintenance: 7. Covers.
(5) Grease the shaft.

For details, refer to Maintenance 13.1: Greasing the Ball Screw Spline Unit.
(6) Mount the end effector, cables, and tubes.
(7) Perform the calibration of Joints #3, #4.

For details, refer to Maintenance: 16. Calibration.
178 T3 Rev.4
Maintenance 14. Lithium Battery, SD Card, Boards, and Filter.
14. Lithium Battery, SD Card, Boards, and Filter.

the robot system.
system.
■ Use meticulous care when handling the lithium battery. Improper handling of the
lithium battery as mentioned below is extremely hazardous, may result in heat
generation, leakage, explosion, or inflammation, and may cause serious safety
problems.
<Improper Handling>
- Battery Charge - Deformation by Pressure
- Disassembly - Short-circuit (Polarity; Positive/Negative)
- Incorrect Installation - Heating (85°C or more)
WARNING - Exposing to Fire - Soldering the terminal of the lithium battery directly
- Forced Discharge
■ When disposing of the battery, consult with the professional disposal services or
comply with the local regulation.
Spent battery or not, make sure the battery terminal is insulated. If the terminal
contacts with the other metals, it may short and result in heat generation,
leakage, explosion, or inflammation.
The life span of the lithium battery varies depending on the energizing hours and
installation environment of the Manipulator. It is about 7 years as a rough guide (when
the Manipulator is connected to power for 8 hours a day).
When the Manipulator is not connected to power, the battery consumption will
significantly increase compared to when the Manipulator is energized. If warnings of
voltage reduction occur, replace the lithium battery even if it has not reached the above
product life.
NOTE For the EPSON RC+ 7.0, the recommended replacement time for the battery can be
 checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
For details, refer to Maintenance: 4. Alarm.
T3 Rev.4 179
The battery may run out if it passes the recommended replacement time.
If no warnings of voltage reduction occur, the calibration for all joints is not necessary.
You need to perform calibration if the position moves from the originals after replaced the
battery.
Always use the lithium battery and battery board designated by us.
Refer to Maintenance: 18. Maintenance Parts List.
Be careful of the battery polarity to connect it correctly.
180 T3 Rev.4
14.1 Replacing the CPU/DPB Boards

■ Make sure that orange colored charge confirmation LED on the DPB turns off
when eject the CPU or DPB. If operating without tuning off the LED, electric
shock or other serious problems for safety may occur.
WARNING
Charge Confirmation LED
Name Quantity Note

Maintenance 2182747
CPU/DPB boards 1
part CPU/DPB SET FOR T SERIES
Tools
Cross-point screwdriver 1
CPU/DPB Boards (1) Turn OFF the Manipulator.

Replace
(2) Remove the connector plate.
For details, refer to Maintenance 7.4 Connecter Plate
Air tube
TP connector
(4) Remove the CPU/DPB board mounting screws.
Hexagon socket head cap button: 5-M3x5
Remove the CPU/DPB boards from the base.

CPU/DPB
Board
(5) Remove the CPU/DPB board connector. E B D

B
A: Power connector (IN/OUT×1 for each)
E: LED connector
NOTE Remember the cable layout for reconnecting after
 replacement.
C
A-OUT A-IN
T3 Rev.4 181
(6) Remove the heat release sheet attached on the CPU

board.
NOTE Heat release sheet will be used again. Be sure to
 keep the sheet.

Heat
Be careful not to break the sheet. Release
Sheet
(7) Attach the heat release sheet on the face of new

CPU/DPB board connectors do not come out.
Be careful not to attach the sheet on the wrong face.
(8) Connect the CPU/DPB board connectors. E B D

B
A: Power connector (IN/OUT×1 for each)
E: LED connector
C
A-OUT A-IN
(9) Mount CPU/DPB board on a base.
182 T3 Rev.4
14.2 Replacing the Lithium Battery

Name Quantity Note
Maintenance
Lithium Battery 1 2113554
part
Tools
Cross-point screwdriver 1
NOTE Replace the battery within 30 minutes after turning OFF.
 If more than 30 minutes pass after removing the battery, voltage of the capacitor lower and
time may be reset.
Battery unit (1) Turn OFF the Manipulator.

(lithium battery)
(2) Remove the Connector Plate.
Removal
Air tube
TP connector
(4) Unscrew the CPU/DPB board mounting screws.
Remove the CPU/DPB board form the base.

CPU/DPB
Board
(5) Remove the battery connector and connect the new

one.
(6) Mount the CPU/DPB board to the base.

Air tube
TP connector
(8) Mount the Connector Plate.
T3 Rev.4 183
14.3 Replacing the SD Card

Name Quantity Note
Maintenance 2182748
SD card 1
part SD CARD FOR T SERIES
Tool Hexagonal wrench width across flats: 2.5 mm 1 For M3 screw
NOTE Remove the SD card after removing the fieldbus I/O module if fieldbus I/O module is
 inserted to the option slot. Also, install fieldbus I/O module after installing the SD
card.
For more details about fieldbus I/O module, refer to the following.
Setup & Operation 17: Fieldbus I/O.
SD Card (1) Turn OFF the Manipulator.

Removal
(2) Remove the power plug.
(3) Remove the optional slot cover on the back face of the Manipulator.
Sems bolt: 2-M3×6
Optional Slot Cover
(4) Push the SD card which is inserted near the option slot to eject.
SD Card (1) Push the SD card and inset to the SD card slot near the optional slot.
Installation
(2) Mount the optional slot cover by screws.
Sems bolt: 2-M3×6
184 T3 Rev.4
14.4 Replacing the Power Board
14.4.1 Replacing the Power Board Filter

Name Quantity Note
Tool Cross-point screwdriver (No. 2) 1 For truss screw
Power Board (1) Turn OFF the Manipulator.

Filter
Removal
(3) Remove the filter covet of the Power

Unit Cover. 2-M4×8 Sems
Sems bolt: 2-M4×8
Remove the filter.

Filter
(4) Set a new or clean filter to the Power
Filter Cover
Unit Cover and mount on the filter
Power Unit Cover
cover.
(5) Mount on the Power Unit Cover.

T3 Rev.4 185
14.4.2 Replacing the Power Board

Name Quantity Note
Maintenance
part
Power Board 1 2182749
Tool Cross-point screwdriver (No. 2) 1 For truss screw
Power Board (1) Turn OFF the Manipulator.

Removal
(3) Remove the Power Board Cover.
(4) Remove the connectors of the Power board.

Power connector (IN/OUT ×1 for each)
IN
OUT
(5) Remove the Power Board.
Bind-head small screw:4-M3×10
(6) Mount new Power Board.
Bind-head small screw:4-M3×10
(7) Connect the Power Board Connector.

Power connector (IN/OUT ×1 for each)
(8) Mount the Power Board Protect Cover.
(9) Mount the Power Unit Cover.

186 T3 Rev.4
Maintenance 15. LED Lamp Unit
15. LED Lamp Unit

the robot system.
■ Before performing any replacement procedure, turn OFF the Controller and
Name Quantity Note

Maintenance
part LED Lamp Unit 1 2182673
Tools
Nippers 1
Material Wire tie 1
T3 Rev.4 187
Maintenance 15. LED Lamp Unit
LED Lamp Unit (1) Turn OFF the Manipulator.

Replace (2) Remove the Power Unit Cover.
(3) Remove the LED Board Connector.

A
A: LED - .LED Board Connector.
(4) Disconnect the X1 and X2 terminals from the

LED. Lens
Lens Holder
(5) Turn the lens counterclockwise to remove.
Ring
Then, turn the lens holder counterclockwise to
LED
remove. X2
Terminal X1 Terminal
(6) Remove the LED and ring from the Power Unit.
(7) Connect the X1 and X2 terminals to the new

LED.
Each terminal must be connected to the same
terminal number on the LED.
(8) Put the User Plate between the ring and lens
holder, and then secure the LED to the cover.
(9) Mount the lens.
(10) Connect the LED board connector.

LED - .LED Board Connector.
188 T3 Rev.4
Maintenance 16. Calibration
16. Calibration
16.1 About Calibration
screw spline unit, etc.), the Manipulator cannot execute the positioning properly because a
mismatch exists between the origin stored in each motor and its corresponding origin
stored in the Robot system.
match these origins. Note that calibration is not the same as teaching*.
*: “Teaching” means to teach the Manipulator coordinate points (including poses)
anywhere in the operating area of the Manipulator.
■ To ensure safety, a safeguard must be installed for the robot system.

For details on the safeguard, refer to EPSON RC+ User’s Guide: 2.4 Installation
and Design Precautions.
■ Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
WARNING 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 area is extremely hazardous and may
result in serious safety problems in case that the Manipulator moves
unexpectedly.
Command Input
Calibration procedures include the process to input commands. Select EPSON RC+
menu-[Tools]-[Command Window] to use the command window.
The information above is omitted in the calibration procedure.
Jog Motion
The process to set the jog motion is included in the [Jog & Teach] page of the Robot
Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog &
Teach] tab to use the [Jog & Teach] page.
The page above is indicated as [Jog & Teach] in the calibration procedure.
T3 Rev.4 189
16.2 Calibration Procedure

EPSON RC+ has a wizard for calibration.
This section indicates the calibration using the calibration wizard of EPSON RC+.
The same calibration procedure is used for each joint.
The follow the steps below are calibration using Joint #1. Follow the steps below to
calibrate other joints.
When coordinates for the Manipulator working point require calculation, it is important
for Joint #2 to be calibrated accurately. Execute the procedure in “Calibration Using
Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to
Maintenance: 16.3 Accurate Calibration of Joint #2.
When calibrating Joint #4, you must calibrate Joint #3 and #4 at the same time. You
cannot calibrate Joint #4 alone because of the structure of the Manipulator.
NOTE If Err9716 or 5016 (Power supply failure of the absolute encoder. Replace the battery.
 Check the robot internal wiring) occurs, apply the procedure of Maintenance: 16.4
Calibration Procedure without using Calibration Wizard - 3. Encoder Initialization and
then, start the calibration wizard.
The reference point (a point to check the accuracy) needs to be specified for calibration.
(1) Start the calibration wizard.

i. Select EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the
[System Configuration] dialog.
ii. Select [Robot]-[Robot**]-[Calibration] to display [Robot**: Calibration].
iii. Select the joint and click the <Calibrate…> button.
190 T3 Rev.4
(2) Confirm the warning message and click the <Yes> button.
(3) Move the joint to calibrate manually to approximate zero position, as shown in the
dialog. After moving the joint click the <Next> button.
T3 Rev.4 191
0 pulse position of Joint #1:

position aligned with X-axis in
Robot coordinate system
+
0 pulse
−
0 pulse position of Joint #2: 0 pulse

position where Arms #1 and #2 + −
are in a straight line
(Regardless of the Joint #1
direction.)

upper limit position in motion
range

position where the flat surface
+
(or groove in the up/down
mechanical stop) on the shaft 0 pulse
faces toward the tip of Arm #2
−
Groove
Flat surface
192 T3 Rev.4
(4) Click the <Yes> button to reset the encoder.
(5) Restart the Controller (Manipulator).
* This window will disappear when the Controller starts up.

(6) Select the reference point to use for calibration, and click the <Next> button.
Select a point from the

current points to use for
checking the accuracy.
(7) Click the <Jog…> button to display the [Jog & Teach] dialog.
T3 Rev.4 193
(8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for
rough calibration. Then click the <OK> button.
Before operating the robot, open the [Control Panel] and click on the <Motor ON>
button.
NOTE Move the end effector from the zero pulse position to the approximate reference point
 where rough calibration will be executed at by the jog motion. Position gap may
occur if the end effector is not moved by the jog motion.
(9) Click the <Next> button.
194 T3 Rev.4
(10) The manipulator moves to the reference point. Click the <Execute> button.
Input JUMP P0:z(0).

↑
Point selected in step (6)
(11) Confirm the message and click the <Yes> button.
(12) After the manipulator moves to the reference point, click the <Next> button.
T3 Rev.4 195
(13) Jog to the accurate reference position.
(14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for
rough calibration. Then click the <OK> button.
* Position Joint #2 only and move Joint #3 to around 0 pulse.
196 T3 Rev.4
(15) Click the <Next> button.
(16) Execute the procedure in “Calibration Using Right / Left Arm Orientations” to
accurately calibrate Joint #2.
Go on to the step (17) for the other joints calibration.
i. Move to another point that has different pose (from righty to lefty) using Jump
command. Click the <Yes> button.
ii. Jog to the accurate reference position.
T3 Rev.4 197
iii. Jog to the accurate reference position and adjust the position. Click the <OK>
button.
iv. Click the <Next> button.
198 T3 Rev.4
(17) Calibration is complete. Click the <Finish> button.
(18) Move the manipulator to other points and check if it can move without problems.
Teach points where appropriate.
T3 Rev.4 199
16.3 Accurate Calibration of Joint #2

for Joint #2 to be calibrated accurately.
NOTE If the accuracy of Joint #2 is not obtained through the steps in the section Maintenance:
 16.2 Calibration Procedure, follow the steps below “Calibration Using Right / Left Arm
Orientations” to accurately calibrate Joint #2.
The reference point is the center of the ball The center of the shaft
screw spline shaft during this calibration.
When there is a misalignment between the There is a misalignment
center of the end effector and the center of the between the center of
the end effector and the
ball screw spline shaft, remove the end effector center of the shaft.
and execute the calibration of the shaft.
Make a calibration jig as shown in the right The center

of the shaft
figure and attach it on the end of the shaft to
make the center of the shaft clear.
Decide a target point and mark a cross (×) on it
so that you can easily verify the center of the Calibration jig at the
shaft after switching the arm pose between right end of the shaft
(Example)
and left.
Target point
After removing the end effector and executing the calibration, install the end effector and
move the Manipulator to the teaching point to verify whether there is a positional gap. If
there is a positional gap, fine-tune the installation position of the end effector and teach the
point again.
Coordinates for the working point requires calculation in the following cases:
· Teaching the working point by entering the coordinate values (MDI teaching)
· Switching the arm orientation between right and left at a given point
· Using the Pallet command
· Executing CP control (such as liner or circular interpolation)
· Using the Local command
· Pose data specified with relative coordinates <Example: P1+X(100) >
· Vision Guide camera calibrations
200 T3 Rev.4
Calibration Using Right / Left Arm Orientations

(1) Check the point data for calibration
Use a point you can easily verify the accuracy within the work envelop of both right
and left arm. Then, check the number of points you want to use.
(2) Open the Tools menu | Robot Manager | Control Panel and click the MOTOR ON.
(3) Click the <Free All> button to free all joints from servo control. Now, you can move
arms by hands.
(4) Move the arms to the position of point data for calibration in rightly arm orientation.
(5) From the current position, teach any point data number unused.
This point is now called P1.
Specify the point number “1” and click the <Teach> button in the [Jog & Teach].
(6) Click the Lock All in the [Control Panel] to lock all joints under servo control.
(7) Switch to the lefty arm orientation. Then, move the arm to the same point.
>Jump P1/L:Z(0) ' Change the arm orientation from righty to lefty
Z is the maximum position
* If there is interference on the way from right to lefty, click the Free All in the
[Control Panel] and change the arm orientation to lefty by hands. Then, go to the
step (6), (7).
(8) The joints are slightly out of position.
Adjust the gap with the −Z in the Jogging group in the [Jog & Teach]. Then, teach
another point data number unused. This point is now called P2.
Specify point number “P2” and click the <Teach> button in [Jog & Teach].
(9) Input the new Hofs value.
> Hofs Hofs (1), Hofs (2) + (Ppls(P1,2) + Ppls(P2,2)) /
2, Hofs(3), Hofs(4)
(10) From the current lefty arm orientation (the position in the step (8)), teach the point
data number used in the step (8). This point is called P2.
Specify point number “P2” and click the <Teach> button in [Jog & Teach].
(11) Switch to the righty arm orientation. Then, make sure the manipulator move to the
correct position.
>Jump P2/R ' Change the arm orientation from lefty to righty
* If there is any interference on the way from lefty to righty, click the Free All in the
[Control Panel] and change the arm orientation to righty by hands. Then, go to
the step (6), (11).
(12) Move the manipulator to other point data and make sure it moves to the correct
position. Teach some more points if required.
* Delete the two points taught for the Joint #2 calibration.
T3 Rev.4 201
16.4 Reference: Calibration Procedure Without Using Calibration Wizard

NOTE This section indicates the calibration without using the calibration wizard of EPSON RC+.
 For details of calibration using the calibration wizard, refer to Maintenance: 16.2
Calibration Procedure.
for Joint #2 to be calibrated accurately. Execute the procedure in “Calibration Using
Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to
Maintenance: 16.3 Accurate Calibration of Joint #2.
You cannot calibrate Joint #4 alone because of the structure of the Manipulator. When
calibrating Joint #4, you must calibrate Joint #3 and #4 at the same time.
NOTE The reference point (a point to identify the position of the Manipulator) needs to be
 specified for calibration.
Follow steps 1 to 6 described below in order to calibrate the origin.
1. Basic Pose Confirmation
(1)-1 After the part replacement, execute the calibration using the point data
currently registered.
Confirm the point data number (P*) to reconstruct the correct manipulator
position.
* Point data before the parts replacement (motor, reduction gear, belt, etc.) is
necessary for the calibration.
2. Part Replacement
(2)-1 Replace parts as dictated by this manual.

* Be careful not to injure yourself or damage parts during part replacement.
3. Encoder Initialization
(3)-1 Turn ON the Manipulator when all joints are in the motion range.
202 T3 Rev.4
(3)-2 Manually move the joint that needs origin alignment to its approximate 0
pulse position.

position aligned with X-axis in
Robot coordinate system
+
0 pulse
−
0 pulse position of Joint #2: 0 pulse

position where Arms #1 and
+ −
#2 are in a straight line
(Regardless of the Joint #1
direction.)

upper limit position in
motion range

position where the flat surface
(or groove in the up/down
mechanical stop) on the shaft +
faces toward the tip of Arm #2
0 pulse
Groove
Flat surface
T3 Rev.4 203
(3)-3 Connect EPSON RC+ to the Manipulator.
Select a Manipulator to be calibrated. Input as below in the [Command

Window] and execute it.
(This example uses “robot 1”.)
> robot 1
(3)-4 Execute the absolute encoder initialization command.
Input one of the following commands to [Command Window] according to the

joint being calibrated.
Joint #1: >EncReset 1

Joint #4: >EncReset 3, 4
(3)-5 Reboot the Controller (Manipulator).
Select EPSON RC+ menu-[Tools]-[Controller] and click the <Reset

Controller> button.
* This window will be disappeared when the Controller starts up.
4. Rough Calibration
(4)-1 Execute the following command from the menu-[Tools]-[Command Window].
>calpls 0,0,0,0
* Manipulator does not move.
(4)-2 Execute one of the following commands according to the joint you want to
calibrate from the menu-[Tool]-[Command Window].
Joint #1 >calib 1
Joint #2 >calib 2
Joint #3 >calib 3
Joint #4 >calib 3, 4
5. Calibration (Accurate Positioning)
(5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools]-[Robot
Manager]-[Control Panel].
(5)-2 Click the <Free All> button to free all joints from servo control. Now, you
can move arms by hands.
204 T3 Rev.4
(5)-3 Move the Manipulator by hand to a rough position/posture of the calibration

point data.
(5)-4 Create the data from the calibration point data.
Enter and execute the following command in [Command Window].

(In this example, P1 is used as the calibration point data.)
> Calpls Ppls(P1,1), Ppls(P1,2), Ppls(P1,3), Ppls(P1,4)
(5)-5 Move the joint to the specified point using a motion command.
For example, when the specified point data is “P1”,

execute “Jump P1:Z(0)” from [Jog & Teach].
* The joint NOT being calibrated moves to the original position.
(5)-6 Accurately align the joint* being calibrated to the specified point using jog
commands.
* You must move Joint #3 and #4 to the position when calibrating Joint #4.
Select the jog mode [Joint] from [Jog & Teach] to execute the jog motion.
(5)-7 Execute the calibration.
Enter and execute one of the following commands in [Command Window]

according to the joint being calibrated.
Joint #1: >Calib 1

Joint #2: >Calib 2
Joint #3: >Calib 3
Joint #4: >Calib 3, 4
6. Accuracy Testing
(6)-1 Move the Manipulator to another point to confirm that it moves to the same
position.
If it does not move to the same position, re-calibrate using another point.
You must set the point again if reproducibility cannot be assured through
calibration.
T3 Rev.4 205
Maintenance 17. Restrictions
17. Restrictions
For T3 series manipulator, there are commands with restrictions or may cause an error if
executing. However, error does not occur when building a program.
Also, some functions have restrictions.
17.1 Commands Cannot Use

The following commands/ functions are not available.
AbortMotion Aborts a motion command and puts the running task in error status.
Toff Turns off execution line display on the LCD.
Ton Specifies a task which shows an execution line on the LCD.
ShutDown Shuts down EPSON RC+ and optionally shuts down or restarts
Windows.
WindowsStatus Returns the Windows startup status.
17.2 Commands Cause Motion Error If Specifying RS-232C

If specifying RS-232C, the following commands/ functions cause motion error.
Input # Allows string or numeric data to be received from a file,
communications port, or database and stored in one or more variables.
Print # Outputs data to the specified file, communications port, database, or
device.
Line Input # Reads data of one line from a file, communication port, database, or the
device.
Lof Checks whether the specified RS-232 or TCP/IP port has any lines of
data in its buffer.
Print # Outputs data to the specified file, communications port, database, or
device.
Line Input # Reads data of one line from a file, communication port, database,
or the device.
Read Reads characters from a file or communications port.
ReadBin Reads binary data from a file or communications port.
Write Writes characters to a file or communication port without end of line
terminator.
WriteBin Writes binary data to a file or communications port.
206 T3 Rev.4
17.3 Commands Cause Error
17.3.1 6-axis Robot Command

If executing the 6-axis robot command, motion error occurs.
17.3.2 Conveyor Tracking Commands

If executing conveyor tracking commands/functions, motion error occurs.
Cnv_AbortTrack Aborts tracking motion to a conveyor queue point.
Cnv_Accel Function Returns acceleration and deceleration for the conveyor
Cnv_Accel Sets acceleration and deceleration for the conveyor
Cnv_Downstream Function Returns the downstream limit for the specified conveyor.
Cnv_Downstream Sets the downstream limit for the specified conveyor.
Cnv_Fine Function Returns the current Cnv_Fine setting.
Cnv_Fine Sets the value of Cnv_Fine for one conveyor.
Cnv_Flag Function Returns the tracking state of the robot
Cnv_Mode Function Returns the setting mode value of the conveyor
Cnv_Mode Sets the setting mode value of the conveyor
Cnv_Name$ Function Returns the name of the specified conveyor.
Cnv_Number Function Returns the number of a conveyor specified by name.
Cnv_OffsetAngle Sets the offset value for the conveyor queue data.
Cnv_OffsetAngle Function Returns the offset value of the conveyor queue data.
Cnv_Point Function Returns a robot point in the specified conveyor's
coordinate system derived from sensor coordinates.
Cnv_PosErr Function Returns deviation in current tracking position compared to
tracking target.
Cnv_Pulse Function Returns the current position of a conveyor in pulses.
Cnv_QueAdd Adds a robot point to a conveyor queue.
Cnv_QueGet Function Returns a point from the specified conveyor's queue.
Cnv_QueLen Function Returns the number of items in the specified conveyor's
queue.
Cnv_QueList Displays a list of items in the specified conveyor's queue.
Cnv_QueMove Moves data from upstream conveyor queue to downstream
conveyor queue.
Cnv_QueReject Sets and displays the queue reject distance for a conveyor.
Cnv_QueReject Function Returns the current part reject distance for a conveyor.
Cnv_QueRemove Removes items from a conveyor queue.
Cnv_QueUserData Sets and displays user data associated with a queue entry.
Cnv_QueUserData Function Returns the user data value associated with an item in a
conveyor queue.
Cnv_RobotConveyor Function Returns the conveyor being tracked by a robot.
Cnv_Speed Function Returns the current speed of a conveyor.
Cnv_Trigger Latches current conveyor position for the next
Cnv_QueAdd statement.
Cnv_Upstream Function Returns the upstream limit for the specified conveyor.
Cnv_Upstream Sets the upstream limit for the specified conveyor.
T3 Rev.4 207
17.3.3 PG Commands
If executing PG commands, motion error occurs.
PG_FastStop Stops the PG axes immediately.
PG_LSpeed Sets the pulse speed of the time when the PG axis starts
accelerating and finishes decelerating.
PG_Scan Starts the continuous spinning motion of the PG robot axes.
PG_SlowStop Stops slowly the PG axis spinning continuously.
17.3.4 R-I/O Commands

If executing R-I/O commands/functions, motion error occurs.
LatchEnable Enable/Disable the latch function for the robot position by the
R-I/O input.
LatchState Function Returns the latch state of robot position using the R-I/O.
LatchPos Function Returns the robot position latched using the R-I/O input signal.
SetLatch Sets the latch function of the robot position using the R-I/O
input.
17.3.5 Force Sensing Commands

If executing force sensing commands/functions, motion error occurs.
Force_Calibrate Sets zero offsets for all axes for the current force sensor.
Force_ClearTrigger Clears all trigger conditions for the current force sensor.
Force_GetForces Returns the forces and torques for all force sensor axes in an
array.
Force_GetForce Function
Returns the force for a specified axis.
Force_Sensor Sets the current force sensor for the current task.
Force_Sensor Function Returns the current force sensor for the current task.
Force_SetTrigger Sets the force trigger for the Till command.
17.3.6 Others (FineDist)

Unable to use command: FineDist
Robot determines the position by set value of Fine even if using FineDist.
Fine Specifies and displays the positioning error limits.
(Unit: pulse)
FineDist Specifies and displays the positioning error limits (Unit: mm)
17.3.7 Others (HealthCalcPeriod)

Unable to use command: HealthCalcPeriod
A period of parts consumption commands information to calculate “remaining months” is
one day and unable to change.
HealthCalcPeriod Set the calculation period of parts consumption commands.
HealthCalcPeriod Function Returns the calculation period of parts consumption
commands.
208 T3 Rev.4
17.4 Restrictions of Functions

Some of the following functions are not available.
17.4.1 TP3
You cannot use build of the program. An error occurs to finish the program if executing
it. Other functions are available.
17.4.2 Loop Processing

If the created robot control program is consisted of the multi-tasking and also there are
some task with infinite loop, the system may become unstable and the connection with
EPSON RC+ is disconnected.
Do not perform any processing such as infinite loop or any other similar processing.
Execute wait command or similar command in the loop processing and avoid occupying
the CPU if performing calculation which required loop or waiting for I/O signals.
There is no problem if executing commands with Wait in the loop such as Wait command,
robot operating command, Print command, and NetWait command.
NOTE: About infinite loop
Infinite loop is when commands are created only with command without Wait in
the loop such as operation instruction, assignment command, and I/O check
command.
Example 1: Turns ON output port “2” when Input port “0” turned ON
Example of program that may cause errors
Do
If Sw(0) = On Then
On(2)
Exit Do
EndIf
Loop
Correction example
Wait Sw(0) = On
On(2)
T3 Rev.4 209
Example 2: When performing the large amount of calculation with a loop structure.
Example of program that may cause errors
For i = 0 To 10000
For j = 0 To 10000
a = a + 1
Next
Next
Correction example
For i = 0 To 10000
For j = 0 To 10000
a = a + 1
Next
Wait 0.01 ' Execute Wait to avoid occupying the CPU
Next
17.4.3 Camera Searching by CV1/CV2

You may not be able to use Camera searching by T3 Manipulator if CV1/CV2 is used and
the following two conditions are fulfilled.
- When connecting PC and T3 series Manipulator by USB connection
- When the configuration of default gateway of T3 series Manipulator is
None, or “0.0.0.0”.
Type IP address for CV1/ CV2 manually when you cannot use Camera researching.
For more details of Camera researching, refer to the following.
Vision Guide 7.0 Hardware & Setup
Setup: 2.3.2 CV1/CV2 Camera Configuration
17.4.4 Restore the Data of Backup Controller Function

Backup controller function that acquired by virtual controller cannot be restored to T3
series Manipulator.
NOTE : Backup controller function that acquired by actual equipment can be restored to
T3 series Manipulator.
210 T3 Rev.4
Maintenance 18. Maintenance Parts List
18. Maintenance Parts List

Reference: Overhaul
Part Name Code Note *3
Maintenance
Cable Duct Unit 2182565 8.1
Joint #1 2182560 200 W 9.1 ○
Motor Unit Joint #2,3 2182562 100 W(J2/3) 10.1, 11.1 ○
Joint #4 2182669 100 W(J4) 12.1 ○
Reduction Gear Joint #1 1718303 9.2 ○
Unit *1 Joint #2 1718304 10.2 ○
1213266 unit and Arm #1
Joint #1 Between reduction gear 9.2
1653819 unit and Flange
O-Ring 1709549 Between motor and Flange
Joint #2 10.2
Joint #3 1554773 Z 11.2 ○
Timing Belt
Joint #4 1709608 U 12.2 ○
Solenoid Brake Unit 2182694 Z-axis 11.3 ○
Brake Release Switch 2167711 Harness for LS -
Ball Screw Spline (150st) 1718877 13.2 ○
Lithium Battery 2113554 14.1
CPU/DPB SET FOR T
CPU/DPB Board 2182747 SERIES_ASP 14.2
Power Board 2182749 14.3.2
LED Lamp Unit 2182673 15
Ball Screw Spline: AFB For purchasing grease, 13
Grease *2 - please contact the supplier
Reduction Gear Unit: SK-2 in your region. 9.2, 10.2
Arm Cover 1718126 Arm Top Cover (White) 7.1
Under Cover 1625284 Arm Bottom Cover (White) 7.2
SD CARD FOR T
SD Card 2182748 SERIES_ASP 14.2
Air Filter 1713720 AIR_FILTER_GR 14.3.1

RC700A TP bypass
TP Plug 2171258 Plug_ASP -
T3 Rev.4 211
Maintenance 18. Maintenance Parts List
*1 Reduction Gear Unit

A reduction gear unit consists of the following three parts. When replacing the reduction gear unit, be sure
to always replace the waveform generator, flexspline, and circular spline all together as one set.
Waveform generator Waveform generator

This waveform generator consists of an ellipsoidal cam with ball
bearings on its outer circumference.
The inner ring of bearings is secured to the cam, while the outer
ring is capable of flexible deformation through the ball bearings.
Flexspline
A thin, elastic, cup-shaped metal body with gear teeth around the
outer circumference of the opening.
Circular spline Flexspline
Circular spline
A rigid, ring-shaped body with gear teeth on the inner
circumference.
The circular spline has two more teeth than the flexspline does.
Splines are greased. Be careful not to let grease adhere to clothes.
*2 Regarding purchase of grease

Due to the chemicals regulations of individual countries (the UN GHS), we are requesting our customers to
purchase the grease required for maintenance from the manufacturers listed in the table below as of April
2015. Regarding purchase of the grease, please contact the following manufacturers. If there is anything
unclear, please contact our suppliers.
Product name Manufacturer URL

THK AFB-LF Grease THK CO., LTD. http://www.thk.com/
Harmonic Grease SK-1A
Harmonic Drive Systems Inc. http://www.harmonicdrive.net/
Harmonic Grease SK-2
*3 Overhaul
As a rough indication, perform the overhaul (parts replacement) before reaching 20,000 operation hours of
the Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog-[Motor On
Hours].
For details, refer to Maintenance 2.2 Overhaul (Parts Replacement).
212 T3 Rev.4
Appendix A: Open Source Software License for T series

(1) The T series product includes open source software programs listed in Section (6) according to
the license terms of each open source software program.
(2) We provide the source code of the Open Source Programs (each is defined in Section (6)) until
five (5) years after the discontinuation of same model of this option product. If you desire to
receive the source code above, please contact the "SUPPLIER" in the first pages of the Robot
System Safety and Installation manual. You shall comply with the license terms of each open
source software program.
(3) The open source software programs are WITHOUT ANY WARRANTY; without even the
implied warranty of MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
See the license agreements of each open source software program for more details, which are
described on Section (7).
(4) OpenSSL toolkit
The T series product includes software developed by the OpenSSL project for use in the
OpenSSL Toolkit (http://www.openssl.org/).
This product includes cryptographic software written by Eric Young (eay@cryptsoft.com).
(5) The license terms of each open source software program are described on Section (7).
(6) The list of open source software programs which the T series product includes are as follows.
bash dash libc-bin libc6
libcomerr2 libdevmapper 1.02.1 libgcc1 libstdc++6
libudev1 login Logrotate makedev
mount mountall net-tools netbase
rsyslog ssh sudo tzdata
ubuntu-minimal udev Linux Xenomai
T3 Rev.4 213
(7) For the each open source license, please refer to the URLs as follows.
bash http://tiswww.case.edu/php/chet/bash/bashtop.html
dash http://packages.ubuntu.com/ja/precise/dash
libc-bin http://www.eglibc.org/home
libc6 http://www.eglibc.org/home
libcomerr2 http://packages.ubuntu.com/ja/precise/libcomerr2
libdevmapper1.02.1 ftp://sources.redhat.com/pub/lvm2/
libgcc1 ftp://gcc.gnu.org/pub/gcc/releases/
libstdc++6 ftp://gcc.gnu.org/pub/gcc/releases/
libudev0 http://packages.ubuntu.com/ja/precise/libudev0
login http://packages.ubuntu.com/ja/precise/login
logrotate https://fedorahosted.org/logrotate/
makedev ftp.redhat.com
mount ftp://ftp.us.kernel.org/pub/linux/utils/util-linux-ng/
mountall http://packages.ubuntu.com/ja/precise/mountall
net-tools https://developer.berlios.de/projects/net-tools/
netbase http://packages.ubuntu.com/ja/precise/netbase
rsyslog http://www.rsyslog.com
ssh http://www.openssh.com/ftp.html
sudo http://www.sudo.ws/
tzdata http://www.iana.org/time-zones
ubuntu-minimal http://packages.ubuntu.com/ja/precise/ubuntu-minimal
udev http://packages.ubuntu.com/ja/precise/udev
Linux http://www.kernel.org/
Xenomai http://www.xenomai.org/
214 T3 Rev.4

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SCARA ROBOT

T series Manipulator Manual

Copyright  2017 SEIKO EPSON CORPORATION. All rights reserved.

1. Damage or malfunction caused by improper use which is not described in the

manual, or careless use.

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.

cannot warn the user of all possible hazards.

This information only applies to customers in the European Union, according to

The battery removal/replacement procedure is described in the following manuals:

Structure of Robot System

Setting by Using Software

Setup & Operation

3. Environments and Installation 21

4. Setting of End Effectors 35

6. Operation Mode & LED 51

7. Development PC Connection Port 56

9. LAN (Ethernet Communication) Port 64

12. Standard I/O Connector 76

13. Hand I/O Connector 82

14. I/O Remote Settings 87

15. SD Card Slots 97

16. RESET Switch 98

17. Fieldbus I/O 99

1. Safety Maintenance 103

2. General Maintenance 104

3. Manipulator Structure 111

6. Firmware Update 121

7.6 Base Side Cover ..............................................................................131

10. Joint #2 150

11. Joint #3 158

12. Joint #4 166

13. Ball Screw Spline Unit 174

14. Lithium Battery, SD Card, Boards, and Filter. 179

15. LED Lamp Unit 187

16. Calibration 189

18. Maintenance Parts List 211

This symbol indicates that a danger of possible serious injury or

This symbol indicates that a danger of possible serious injury or

This symbol indicates that a danger of possible harm to people

1.2 Design and Installation Safety

1.2.1 Strength of the Ball Screw Spline

[Allowable bending moment]

Example: If 100 N load is applied

1.3 Operation Safety

■ Joint #1, #2, and #4:

■ Oscillation (resonance) may occur continuously in low speed Manipulator motion

■ Oscillation (resonance) may occur continuously in low speed Manipulator motion

■ Manipulator may be warmed up due to motor heat or similar causes. Do not

1.4 Emergency Stop

Before using the Emergency Stop switch, be aware of the following.

For details of the Safeguard system, refer to the following manuals.

To check brake problems, refer to the following manuals.

Free running distance in emergency

Point where the

Joint #2 Stop point

1.5 Emergency Movement Without Drive Power

1.6 ACCELS Setting for CP Motions