Epson G20, G10 User Manual

G10 / G20 series

Rev.2 EM082R1662F

SCARA ROBOT

MANIPULATOR MANUAL

MANIPULATOR MANUAL G10 / G20 series Rev.2

SCARA ROBOT

G10 / G20 series Manipulator Manual

Rev.2

Copyright © 2007-2008 SEIKO EPSON CORPORATION. All rights reserved.

G10 / G20 Rev.2 i

FOREWORD

Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the manipu lat o r.
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,

2. Malfunctions caused by customers’ unauthorized disasse mbly.

3. Damage due to improper adjustments or unauthorized repair attempts.

or careless use.

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 G10 / G20 Rev.2

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 wit ho ut no tice.
Please notify us if you should fi nd any errors in thi s manual or if you have any comments
regarding its contents.

INQUIRIES

Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier office for
your region.

Please prepare the following items before you contact us.

- Your controller model and its serial number

- Your manipulator model and its serial number

- Software and its version in your robot system

- A description of the problem

SERVICE CENTER

G10 / G20 Rev.2 iii

MANUFACTURER & SUPPLIER

TEL : [phone]
FAX : [phone]

Japan & Others

SEIKO EPSON CORPORATION
Suwa Minami Plant
Factory Automation Systems Dept.
1010 Fujimi, Fujimi-machi,
Suwa-gun, Nagano, 399-0295
JAPAN

SUPPLIERS

Factory Automation/Robotics

TEL : [phone]
FAX : [phone]
E-MAIL : [e-mail]

Factory Automation Division

TEL : [phone]
FAX : [phone]
E-MAIL : [e-mail]

North & South America

Europe

EPSON AMERICA, INC.

18300 Central Avenue
Carson, CA 90746
USA

EPSON DEUTSCHLAND GmbH

Otto-Hahn-Str.4
D-40670 Meerbusch
Germany

iv G10 / G20 Rev.2

Before Reading This Manual

This section describes what you should know before reading this manual.

Structure of Control System

The G10 / G20 series Manipulators can be used with the following combinations of
Controllers and software.

The operating methods and descriptions are different depending on which software you are
using. The following icons are put beside appropriate text as necessary. Use the
descriptions that pertain to the software you are using.

Controller : RC180
Software : EPSON RC+ 5.0 Ver. 5.2 or later

For details on commands, refer to User’s Guide or “On-line help”.

Turning ON/OFF Controller

When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to
turn ON/OFF all the hardware components. For the Controller composition, refer to the
table above.

Shape of Motors

The shape of the motors used for the Manipulator that you are using may be different from
the shape of the motors described in this manual because of the specifications.

Setting by Using Software

This manual contains setting procedures by using software. They are marked with the
following icon.

EPSON

RC+

G10 / G20 Rev.2 v

vi G10 / G20 Rev.2

TABLE OF CONTENTS

Before Reading This Manual............................................................................v

Setup & Operation

1. Safety 3

1.1 Conventions.............................................................................................3

1.2 Design and Installation Safety .................................................................4

1.3 Operation Safety......................................................................................5

1.4 Emergency Stop......................................................................................6

1.5 Emergency Movement Without Drive Power ...........................................7

1.6 Manipulator Labels ..................................................................................8

2. Specifications 10

2.1 Features of G10 series and G20 series Manipulators............................10

2.2 Model Number and Model Differences ..................................................11

2.3 Part Names and Outer Dimensions....................................................... 12

2.3.1 Table Top Mounting....................................................................12

2.3.2 Wall Mounting............................................................................ 16

2.3.3 Ceiling Mounting ........................................................................20

2.4 Specifications.........................................................................................24

2.5 How to Set the Model ............................................................................26

3. Environments and Installation 27

3.1 Environmental Conditions......................................................................27

3.2 Base Table.............................................................................................28

3.3 Mounting Dimensions............................................................................29

3.4 Unpacking and Transportation...............................................................31

3.4.1 Precautions for Transportation................................................... 31

3.4.2 Transportation............................................................................32

3.5 Installation Procedure............................................................................33

3.5.1 Table Top Mounting....................................................................33

3.5.2 Wall Mounting............................................................................ 34

3.5.3 Ceiling Mounting ........................................................................35

3.5.4 Cleanroom-model ......................................................................36

3.6 Connecting the Cables ..........................................................................37

3.7 User Wires and Pneumatic Tubes.........................................................38

3.8 Relocation and Storage.........................................................................40

3.8.1 Precautions for Relocation and Storage.....................................40

3.8.2 Table Top Mounting....................................................................41

3.8.3 Wall Mounting............................................................................ 42

3.8.4 Ceiling Mounting ........................................................................43

G10 / G20 Rev.2 vii

TABLE OF CONTENTS

4. Setting of End Effectors 44

4.1 Attaching an End Effector......................................................................44

4.2 Attaching Cameras and Valves ............................................................. 46

4.3 Weight and Inertia Settings...................................................................47

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3...................56

5. Motion Range 57

5.1 Motion Range Setting by Pulse Range (for All Joints)........................... 58

5.2 Motion Range Setting by Mechanical Stops..........................................61

5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate

5.4 Standard Motion Range ........................................................................ 68

6. Maintenance Parts List 71

4.3.1 Weight Setting...........................................................................47

4.3.2 Inertia Setting............................................................................51

5.1.1 Max. Pulse Range of Joint #1.................................................... 58

5.1.2 Max. Pulse Range of Joint #2.................................................... 59

5.1.3 Max. Pulse Range of Joint #3.................................................... 60

5.1.4 Max. Pulse Range of Joint #4.................................................... 60

5.2.1 Setting the Mechanical Stops of Joints #1 and #2..................... 62

5.2.2 Setting the Mechanical Stop of Joint #3.....................................65

System of the Manipulator (for Joints #1 and #2).................................67

viii G10 / G20 Rev.2

Setup & Operation

This volume contains information for setup and operation of the
G10 / G20 series Manipulators.

Please read this volume thoroughly before setting up and
operating the Manipulators.

1. Safety

Installation and transportation of robots and robotic equipment shall be performed by
qualified personnel and should conform to all national and local codes. Please read this
manual and other related manuals before installing the robot system or before connecting
cables.
Keep this manual handy for easy access at all times.

1.1 Conventions

Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.

WARNING

WARNING

Setup & Operation 1. Safety

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

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

This symbol indicates that a danger of possible harm to
people or physical damage to equipment and facilities

CAUTION

exists if the associated instructions are not followed
properly.

G10 / G20 Rev.2 3

Setup & Operation 1. Safety

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 Manipulator and the Controller must be used within the environmental
conditions described in their respective manuals. This product has been
designed and manufactured strictly for use in a normal indoor environment.
Using the product in an environment that exceeds the specified environmental
conditions may not only shorten the life cycle of the product but may also cause
serious safety problems.

■

The robot system must be used within the installation requirements described in
the manuals. Using the robot system outside of the installation requirements
may not only shorten the life cycle of the product but also cause serious safety
problems.

Further precautions for installation are mentioned in the chapter Setup &
Operation: 3. Environments and Installation. Please read this chapter carefully to
understand safe installation procedures before installing the robots and robotic
equipment.

4 G10 / G20 Rev.2

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

■

Please carefully read the Safety-related Requirements in the Safety chapter of
the EPSON RC+ User’s Guide before operating the robot system. Operating
the robot system without understanding the safety requirements is extremely
hazardous and may result in serious bodily injury and/or 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.

■

WARNING

Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
The motion of the Manipulator is always in restricted (low speeds and low power)
status to secure the safety of an operator. However, operating the robot system
while someone is inside the safeguarded area is extremely hazardous and may
result in serious safety problems in case that the Manipulator moves
unexpectedly.

Setup & Operation 1. Safety

WARNING

CAUTION

■

Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally while the robot system is operated.

■

To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.

■

Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.

■

Do not insert or pull out the motor connectors while the power to the robot system
is turned ON. Inserting or pulling out the motor connectors with the power ON is
extremely hazardous and may result in serious bodily injury as the Manipulator
may move abnormally , and also may result in electric shock and/or malfunction of
the robot system.

■

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.

G10 / G20 Rev.2 5

Setup & Operation 1. Safety

1.4 Emergency Stop

If the Manipulator moves abnormally during operation, immediately press the Emergency
Stop switch. Stops the power supply to the motor, and the arm stops in the shortest
distance with the dynamic brake and mechanical brake.

However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator
is running normally. Otherwise, the Manipulator may hit the peripheral equipment since
the operating trajectory while the robot system stops is different from that in normal
operation.
To place the system in emergency mode during normal operation, press the Emergency
Stop switch when the Manipulator is not moving.
Refer to the Controller manual for instructions on how to wire the Emergency Stop switch
circuit.

Free running distance in emergency

The operating Manipulator cannot stop immediately aft er 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 Measure ment

G10 G20
Accel Setting 100 100

Speed Setting 100 100
Load [kg] 10 20
Weight Setting 10 20

Point w here the
emergency stop
signal is input

Joint #1

Stop point

Joint #2

Controller RC180
Manipulator G10-85*** G20-A0***

Joint #1 + Joint #2 [sec.] 0.7 1.3 Free running

time
Free running

angle
Free running

distance

Joint #3 [sec.] 0.5 0.8
Joint #1 [deg.] 70 110
Joint #2 [deg.] 50 50
Joint #1 + Joint #2 [deg.] 120 160
Joint #3 G10/G20-**1**[mm]
G10/G20-**4**

Contact us for details of G10-65*** or G20-85***.

80

160

Start point of
operation

Target point

90

170

6 G10 / G20 Rev.2

A

A

−

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 electromagnetic

brake applied to the joint has been released. Move the joint up/down
while pressing the brake release button switch.

Joint #4 The shaft cannot be rotated by hand until the electromagnetic brake

applied to the shaft has been released.
Move the shaft while pressing the brake release button switch.

Setup & Operation 1. Safety

Joint #3 and #4

brake release button

rm #2

Joint #3

(up and down)

Joint #2

(rotating)

−

+

+

Shaft

−

+

Joint #1

(rotating)

−

+

rm #1

Base

Joint #4

(rotating)

NOTE

)

The brake release button affects both Joints #3 and #4. When the brake release button
is pressed in emergency mode, the brakes for both Joints #3 and #4 are released
simultaneously.

Be careful of the shaft falling and rotating while the brake release button is pressed
because the shaft may be lowered by the weight of an end effector.

G10 / G20 Rev.2 7

Setup & Operation 1. Safety

1.6 Manipulator Labels

The following labels are attached near the locations of the Manipulator 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 labels. Use meticulous care when handling those
parts or units to which the following labels are attached as well as the nearby areas:

Location of Labels Labels NOTE

A

B

C

D

Before loosening the base mounting screws, hold
the arm and secure it tightly with a band to prevent
hands or fingers from being caught in the
Manipulator.

Hazardous voltage exists while the Manipulator is
ON. To avoid electric shock, do not touch any
internal electric parts.

You can catch your hand or fingers between the
shaft and cover when bringing your hand close to
moving parts.

Only authorized personnel should perform sling
work and operate a crane. When these

E

operations are performed by unauthorized
personnel, it is extremely hazardous and may
result in serious bodily injury and/or severe
equipment damage to the robot system.

NOTE

Manipulators with bellows do not have label D for no danger of your hand or fingers

)

being caught.

8 G10 / G20 Rev.2

Setup & Operation 1. Safety

A

Table Top Mounting: G10/G20-****

C

D

Wall Mounting: G10/G20-****W

C

A

D

B

Ceiling Mounting: G10/G20-****R

A

E

B

C

D

C

C

B

G10 / G20 Rev.2 9

Setup & Operation 2. Specifications

2. Specifications

2.1 Features of G10 series and G20 series Manipulators

The G10 series and G20 series Manipulators are high-performance manipulators intended
to achieve high speed, high accuracy, space saving, and high cost-performance.

The G10 series Manipulators are optimized for high speed assembly and alignment
procedure using multiple-hand.
The G20 series Manipulators are optimized for heavy payload transfer and alignment
packing procedure. The 1000 mm long arm model of the G20 series enables wide range
motion.

The features of the G10 series and G20 series Manipulators are as follows:

Compatibility with E2H Manipulators (our existing models)

The installation procedure and mounting dimensions of the end effector are compatible
with those for the E2H Manipulators (our existing models).

Space Saving

Compactness achieved by using a ductless design.
Reduce the system height by the new short stroke (Z: 180 mm) lineup.

Motion Range Extended

The motion range has been extended by 20% compared to E2 series.

Improved Productivity

The numbers of user wires and pneumatic tubes have been increased.
The speed of Joints #1, 2, 3, and 4 has been enhanced.
Cycle time has been improved.

Increased Load Capacity

The load capacity has been increased to handle greater work load.

G10: Max. 10 kg
G20: Max. 20 kg

Increased Inertia

The available end effector capacity has been enlarged to enable larger multiple-hand
that holds multi-kind and different types of work piece.
Allowable moment of inertia has been enlarged according to the load.

G10: Max. 0.25 kgm
G20: Max. 0.45 kgm

V arious Types Available

Long stroke (Z: 420 mm)
Short stroke (Z: 180 mm)

2
2

10 G10 / G20 Rev.2

2.2 Model Number and Model Differences

G10-85 4 S □

Type

□

: Table Top mounting

W : Wall mounting

R : Ceiling mounting

Environment

S : Standard
C : Cleanroom
D : Protected : IP 54 (with bellow option)
P : Protected : IP 65

Joint #3 stroke

: 180 mm (G10/G20***S*)

1

: 150 mm (G10/G20***C*)
: 420 mm (G10/G20***S*)

4

: 390 mm (G10/G20***C*)

Arm Length

65 : 650 mm (G10 series only)
85 : 850 mm

Environment

A0 : 1000 mm (G20 series only)

Series

G10 : G10 series
G20 : G20 series

Setup & Operation 2. Specifications

Cleanroom-model

Cleanroom-model Manipulator includes additional features that reduce dust emitted by
the Manipulator to enable use in clean room environments.

Protected-model (IP54 / IP65)

Contact us for detail information regarding the protected-model.

For details on the specifications, refer to Setup & Operation: 2.4 Specifications.

G10 / G20 Rev.2 11

Setup & Operation 2. Specifications

−

−

2.3 Part Names and Outer Dimensions

2.3.1 Table Top Mounting

Standard-model : G10/G20-***S

Joint #2

Joint #3 and #4

brake release button

Arm #2

(rotating)

+

Joint #2

(rotating)

+

Arm #1

Base

+

Joint #3

(up and down)

−

−

+

Joint #4

(rotating)

Signature label

(Serial No. of Manipulator)

User connector
(9-pin D-sub connector)

Signal cable
Fitting (white)
for ø 6 mm pneumatic tube

Fitting (white)
for ø 4 mm pneumatic tube

Shaft

MT label
(only for custom specification)

CE label

User connector
(15-pin D-sub connector)

Power cable

Fitting (black)
for ø 6 mm pneumatic tube

Fitting (black)
for ø 4 mm pneumatic tube

NOTE

)

The brake release button affects both Joints #3 and #4. When the brake release button is pressed in
emergency mode, the brakes for both Joints #3 and #4 are released simultaneously.

12 G10 / G20 Rev.2

Setup & Operation 2. Specifications

G10-65*S G10/G20-85*S G20-A0*S

a 250 450 600

G10/G20-**1S G10/G20-**4S
b 180 420
c 813.5 1053.5
d213.5 -26.5

(Mount ey eb olt

at shipment)

(*) indicates the stroke margin by mechanical stop.

1 mm flat cut

Conical hole ø4,90°

Max.ø18 through hole
ø25 h7 shaft diameter
ø39.5 mechanical stop diameter

Detail of “A”

(Calibration point position of Joints #3 and #4)

Reference through hole

(View from the bottom of the base)

90 or more
Space for cables

Root both side chamfer C0.5

G10 / G20 Rev.2 13

Setup & Operation 2. Specifications

Cleanroom-model G10/G20-***C

The following figure shows the additional parts and specifications for the Table Top mounting
Cleanroom-model when compared with the Standard-model in appearance.

Upper bellows

Lower bellows

Plate cover
(For static electricity
countermeasure)

Plate cover
(For static electricity
countermeasure)

Cover
for Table T op mounti ng surface

14

Exhaust port

G10 / G20 Rev.2

Setup & Operation 2. Specifications

(

)

(Mount eyebolt

at shipment)

G10-65*C G10/G20-85*C G20-A0*C

a 250 450 600

G10/G20-**1C G10/G20-**4C

b 150 390
c 870.5 1129.5
d 205.5 -34.5

(*) indicates the stroke margin by mechanical stop.

1 mm flat cut

Conical hole

ø4,90°

Max.ø18 through hole
ø25 h7 shaft diameter
ø39.5 mechanical stop diameter

Detail of “A”

Calibration point position of Joints #3 and #4

Root both side chamfer C0.5

Reference through hole

(View from the bottom of the base)

90 or more
Space for cables

G10 / G20 Rev.2 15