EPSON G1-171SZ, G1-221S, G1-171S, G1-221SZ User Manual

Rev.4 EM111R2119F

SCARA ROBOT

G1 series

MANIPULATOR MANUAL

MANIPULATOR MANUAL G1 series Rev.4

SCARA ROBOT

G1 series Manipulator Manual

Rev.4

G1 Rev.4 i

d

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,

or careless use.

2. Malfunctions caused by customers’ unauthorized disasse mbly.

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 an

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 G1 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 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

G1 Rev.4 iii

MANUFACTURER & SUPPLIER

TEL : +81-(0)266-61-1802 FAX : +81-(0)266-61-1846

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 : +1-562-290-5900 FAX : +1-562-290-5999 E-MAIL : info@robots.epson.com

Factory Automation Division

TEL : +49-(0)-2159-538-1391 FAX : +49-(0)-2159-538-3170 E-MAIL : robot.infos@epson.de

Factory Automation Division

TEL : +86-(0)-10-8522-1199 FAX : +86-(0)-10-8522-1120

Taiwan

Factory Automation Division

TEL : +886-(0)-2-8786-6688 FAX : +886-(0)-2-8786-6677

North & South America

Europe

China

EPSON AMERICA, INC.

18300 Central Avenue Carson, CA 90746 USA

EPSON DEUTSCHLAND GmbH

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

EPSON China Co., Ltd

7F, Jinbao Building No. 89 Jinbao Street Dongcheng District, Beijing, China, 100005

EPSON Taiwan Technology & Trading Ltd.

14F, No.7, Song Ren Road, Taipei 110 Taiwan, ROC

iv G1 Rev.4

For Customers in the European Union

The crossed out wheeled bin label that can be found on your product indicates that this product and incorporated batteries should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health please separate this product and its batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner. For more details on available collection facilities please contact your local government office or the retailer where you purchased this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used in the battery.

This information only applies to customers in the European Union, according to DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and accumulators and repealing Directive 91/157/EEC and legislation transposing and implementing it into the various national legal systems. For other countries, please contact your local government to investigate the possibility of recycling your product.

The battery removal/replacement procedure is described in the following manuals: Controller manual / Manipulator manual (Maintenance section)

G1 Rev.4 v

Before Reading This Manual

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

Structure of Control System

The G1 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

Name Structure

RC180 Controller EPSON RC+ 5.0

Software

RC620

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

Control Unit Drive Unit

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+ 6.0

EPSON

RC+

Figures in this Manual

The figures of manipulators indicated in this manual are basically Standard-model Manipulator. Unless special instruction is provided, the specifications of Standard-model, Cleanroom-model, and Protected-model (IP54 / IP65) are the same.

vi G1 Rev.4

Setup & Operation

This volume contains information for setup and operation of the G1 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

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

CAUTION

or physical damage to equipment and facilities exists if the associated instructions are not followed properly.

G1 Rev.4 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 G1 Rev.4

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.

G1 Rev.4 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 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 measurement

Accel setting 100

Speed setting 100

Load [kg] 1

Weight setting 1

Point where the

emergency stop

signal is input

Joint #1

Free running time

Free running angle

Free running distance

Joint #1 + Joint #2 [sec.]

Joint #3 [sec.]

Joint #1 [deg.]

Joint #2 [deg.]

Joint #1 + Joint #2 [deg.]

Joint #3 [mm]

Joint #2

Controller RC180 / RC620

Manipulator

Stop point

G1-171*/ G1-171*Z G1-221*/ G1-221*Z

0.4

0.3

40 50

40 45

80 95

Start point of

operation

Target point

50

6 G1 Rev.4

Setup & Operation 1. Safety

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.

Joint #4........... Rotate the shaft by hand.

Joint #3 brake release button

Joint #2

(rotating)

NOTE

)

Arm #2

Joint #1

(rotating)

Joint #3

(up/down)

Shaft

Joint #4

(rotating)

When the brake release button is pressed in emergency mode, the brake for Joint #3 is

released. Be careful of the shaft while the brake release button is pressed because the

shaft may be lowered by the weight of an end effector.

Arm #1

Base

G1 Rev.4 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:

A

B

C

D

Labels NOTE

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.

Be careful to avoid collision.

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

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

E

Be careful of the hand falling while the brake release button is being pressed.

F

G

8 G1 Rev.4

Setup & Operation 1. Safety

Location of Labels

G1 Rev.4 9

Setup & Operation 2. Specifications

2. Specifications

2.1 Features of G1 series Manipulators

The G1 series Manipulators are high-performance manipulators intended to space saving,

achieve high speed, high DUTY, and high rigidity.

The features of the G1 series Manipulators are as follows:

High Accuracy & High Speed & High Rigidity

Repeating positioning accuracy is ± 0.005 mm Æ Optimum for precision assembling production line

Cycle time under 0.3 seconds (with 175 mm arm)

* When moving 100 mm in horizontally, 25 mm in vertically with load 0.5 kg

Small body yet powerful (Press force: 50N)

Space Saving

Achieves the motion area equivalent to the upper class robot with 225 mm arm

Easy-to-Use

You can easily operate the Light & Compact body

3-Axis Spec

Optimum for screw driving and pressing work using the hand offset

2.2 Model Number

G1-17 1 S Z-UL

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

UL specification

UL : UL compliant

□

: Non UL compliant

Axis

□

: 4-axis spec

Z : 3-axis spec

Environment

S : Standard

C : Cleanroom &ESD

Joint #3 stroke

1 : 100 mm

Arm length

17 : 175 mm

22 : 225 mm

10 G1 Rev.4

2.3 Part Names and Outer Dimensions

Setup & Operation 2. Specifications

2.3.1 4-axis spec Part Names : Standard-model (G1-***S)

Fitting (black) for ø6 mm pneumatic tube

Fitting (black) for ø4 mm pneumatic tube

User connector

(15-pin D-sub connector)

User connector (9-pin D-sub connector)

Joint #3 Brake release switch

Fittings (white) for ø6 mm pneumatic tube

LED

Cable

MT label (only for special order)

NOTE

)

UR label

Shaft

Base

Signal cable

Power cable

Fittings (white)

for ø6 mm pneumatic tube

Face plate (Manipulator serial No.)

User connector (9-pin D-sub connector)

User connector (15-pin D-sub connector)

Fitting (black) for ø4 mm pneumatic tube

Fitting (black) for ø6 mm pneumatic tube

CE label

- The brake release button affects only Joint #3. When the brake release button is pressed in emergency mode, the brake for Joint #3 is released simultaneously.

- When the LED lamp is lighting or the controller power 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 controller power before the maintenance work.

G1 Rev.4 11

Setup & Operation 2. Specifications

Part Dimension : Standard-model (G1-***S)

G1-171S G1-221S

a 75 125 b Max.515 Max.545

(*) indicates the stroke margin by mechanical stop.

Reference through hole

(View from the bottom of the base)

90 or more

Space for cables

1mm

flat cut

Detail of “A”

(Calibration point position of

Joints #3 and #4)

not penetrable

shaft diameter

mechanical stop

diameter

12 G1 Rev.4

Setup & Operation 2. Specifications

Part Names : Cleanroom-model (G1-***C)

Fitting (black) for ø6 mm pneumatic tube

Fitting (black) for ø4 mm pneumatic tube

User connector

(15-pin D-sub connector)

User connector (9-pin D-sub connector)

Joint #3 Brake release switch

Fittings (white) for ø6 mm pneumatic tube

LED

Cable

MT label (only for special order)

NOTE

)

Belows

Shaft

Base

Signal cable

Power cable

Fittings (white)

for ø6 mm pneumatic tube

Face plate (Manipulator serial No.)

User connector (9-pin D-sub connector)

User connector (15-pin D-sub connector)

Exhaust port

Fitting (black) for ø4 mm pneumatic tube

Fitting (black) for ø6 mm pneumatic tube

UR label

CE label

- The brake release button affects only Joint #3. When the brake release button is pressed in emergency mode, the brake for Joint #3 is released simultaneously.

- When the LED lamp is lighting or the controller power 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 controller power before the maintenance work.

G1 Rev.4 13

Setup & Operation 2. Specifications

Part Dimension : Cleanroom-model (G1-***C)

G1-171C G1-221C

a 75 125 b Max.515 Max.545

(*) indicates the stroke margin by mechanical stop.

Reference through hole

(View from the bottom of the base)

1mm flat cut

90 or more

Space for cables

not penetrable

shaft diameter

mechanical stop

diameter

Detail of “A”

(Calibration point position of

Joints #3 and #4)

14

G1 Rev.4

Setup & Operation 2. Specifications

2.3.2 3-axis spec Part Names : Standard-model (G1-***Z)

Fitting (black) for ø6 mm pneumatic tube

Fitting (black) for ø4 mm pneumatic tube

User connector

(15-pin D-sub connector)

User connector (9-pin D-sub connector)

Joint #3 Brake release switch

Fittings (white) for ø6 mm pneumatic tube

LED

Cable

NOTE

)

MT label (only for special order)

UR label

Shaft

Base

Signal cable

Power cable

Fittings (white)

for ø6 mm pneumatic tube

Face plate (Manipulator serial No.)

User connector (9-pin D-sub connector)

User connector (15-pin D-sub connector)

Fitting (black) for ø4 mm pneumatic tube

Fitting (black) for ø6 mm pneumatic tube

CE label

- The brake release button affects only Joint #3. When the brake release button is pressed in emergency mode, the brake for Joint #3 is released simultaneously.

- When the LED lamp is lighting or the controller power 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 controller power before the maintenance work.

G1 Rev.4 15

Setup & Operation 2. Specifications

Part Dimension : Standard-model (G1-***Z)

G1-171Z G1-221Z

a 75 125 b Max.515 Max.545

(*) indicates the stroke margin by mechanical stop.

2-M3

Through hole

(View from the bottom of the base)

Reference through hole

1mm flat cut

(Calibration point position of

90 or more

Space for cables

shaft diameter

Detail of “A”

Joints #3 and #4)

not penetrable

16

G1 Rev.4

Setup & Operation 2. Specifications

Part Names : Cleanroom-model (G1-***CZ)

Fitting (black) for ø6 mm pneumatic tube

Fitting (black) for ø4 mm pneumatic tube

User connector

(15-pin D-sub connector)

User connector (9-pin D-sub connector)

Joint #3 Brake release switch

Fittings (white) for ø6 mm pneumatic tube

LED

Belows

Shaft

Signal cable

Base

Cable

MT label (only for special order)

UR label

CE label

Face plate (Manipulator serial No.)

User connector (9-pin D-sub connector)

User connector (15-pin D-sub connector)

Power cable

Fittings (white)

for ø6 mm pneumatic tube

Exhaust port

Fitting (black) for ø4 mm pneumatic tube

Fitting (black) for ø6 mm pneumatic tube

NOTE

)

- The brake release button affects only Joint #3. When the brake release button is pressed in emergency mode, the brake for Joint #3 is released simultaneously.

- When the LED lamp is lighting or the controller power 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 controller power before the maintenance work.

G1 Rev.4 17

Setup & Operation 2. Specifications

(

Part Dimension : Cleanroom-model (G1-***CZ)

G1-171CZ G1-221CZ

a 75 125 b Max.515 Max.545

(*) indicates the stroke margin by mechanical stop.

Reference through hole

View from the bottom of the base)

1mm flat cut

shaft diameter

Detail of “A”

(Calibration point position of

Joints #3 and #4)

90 or more

Space for cables

not penetrable

18

G1 Rev.4

Setup & Operation 2. Specifications

2.4 Specifications

Item

Mounting type Table Top

Arm length #1, #2

Arm #1, #2 175 mm 225 mm 175 mm 225 mm Arm #1 75 mm 125 mm 75 mm 125 mm

Arm #2 100 mm 100 mm Weight (cables not included) 8 kg 8 kg

Driving method All joints AC servo motor

Max. operating speed

Joints #1, #2 2630 mm/s 3000 mm/s 2630 mm/s 3000 mm/s

Joints #3 (Z) 1200 mm/s 1200 mm/s

*1

Joints #4 (U) 3000 deg/s -

Joints #1, #2 ± 0.005 mm ± 0.008 mm ± 0.005 mm ± 0.008 mm Repeatability

Joints #3 (Z) ± 0.01 mm ± 0.01 mm

Joints #4 (U) ± 0.01 deg. -

Joints #1 ± 125 deg. ± 125 deg

Max. motion range

Joints #2

(Cleanroom model)

Z stroke

± 140 deg.

(± 140 deg.)

(Cleanroom model)

Joints #4 ± 360 deg -

Joints #1 − 1019449 ∼ 6262329 pulse

Max. pulse range (pulse)

Joints #2

(Cleanroom model)

Joints #3

(Cleanroom model)

± 2548623

(± 2548623)

Joints #4 − 393216 ∼ 393216

Joints #1 3.43322E-05 deg/pulse

Resolution

Joints #2 5.49316E-05 deg/pulse

Joints #3 9.15527E-05 mm/pulse

Joints #4 9.15527E-04 deg/pulse Motor power consumption All joints: 50 W

Payload

moment of inertia

Rated 0.5 kg 0.5 kg Maximum 1 kg 1.5 kg Rated 0.0003 kg·m2 - Joint #4 allowable

*2

Maximum 0.004 kg·m

Shaft diameter ø 8 mm Mounting hole 125×88 (4-M6) Joint #3 down force 50 N Installed wire for customer use 24 pin (9 + 15)

Installed pneumatic tube for customer use

Ambient temperature 5 to 40 degree C (with minimum temperature variation)

Environmental requirements

Noise level

Ambient relative humidity 10 to 80 % RH (no condensation)

Vibration level 4.9 m/s

*3

65dB Installation environment Standard / Cleanroom + ESD (ISO Class 3) *4 Applicable Controller RC180, RC620

4-axis spec 3-axis spec

G1-171* G1-221* G1-171* G1-221*

± 152 deg.

(±149 deg.)

± 135 deg.

(±123 deg.)

± 100 (80) mm ± 100 (80) mm

± 2767076

(± 2712463)

± 2457600

(± 2239147)

− 1092267 ∼ 0

(－873813 ∼ 0)

2

-

1 pneumatic tube (ø 4 mm): 0.59 Mpa (6 kgf/cm

2 pneumatic tubes (ø 6 mm): 0.59 Mpa (6 kgf/cm

2

(0.5G) or less

± 135 deg.

(±132 deg.)

± 2457600

(± 2402987)

2

: 86 psi)

2

: 86 psi)

G1 Rev.4 19

Setup & Operation 2. Specifications

Item

Speed Accel *5

Assignable Value ( ) Default values

MTBF 3 years

Safety standard

SpeedS AccelS Fine Weight

4-axis spec 3-axis spec

G1-171* G1-221* G1-171*Z G1-221*Z

1 ∼ (5) ∼ 100

1 ∼ (10) ∼ 120

1 ∼ (50) ∼ 2000

1 ∼ (200) ∼ 25000

0 ∼ (10000) ∼ 65000

0,100 ∼ (0.5,100) ∼ 1,100 0,100 ∼ (0.5,100) ∼ 1.5,100

UL1740 (Third Edition, Dated December 7, 2007)

ANSI/RIA R15.06-1999 NFPA 79 (2007 Edition)

CSA/CAN Z434-03 (February 2003)

CE Marking − Machinery Directive,

Low Voltage Directive, EMC Directive

*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 : In front of the Manipulator, 1000 mm apart from the motion range, 50 mm above

the base-installed surface.

*4: The exhaust system in the Cleanroom-model Manipulator draws air from the base interior and arm cover

interior. A crack or other opening in the base unit can cause loss of negative air pressure in the outer part of the arm, which can cause increased dust emission. Seal firmly the exhaust port and the exhaust tube with vinyl tape. If the exhaust flow is not sufficient, dust particle emission may exceed the specified maximum level.

Cleanliness level : Class ISO 3 (ISO14644-1)

In previous criteria; Clean Class: 10 or its equivalent

Amount of Dust (0.1 µm diameter or larger) in 28317 cm

3

(1cft) sample-air around the center of the motion rang: 10 particles or less.)

Exhaust System : Exhaust port : Inner diameter: ø8 mm

Exhaust tube : Polyurethane tube Outer diameter ø8 mm or Inner diameter ø16mm or larger Recommended exhaust flow rate: approx. 1000 cm

3

/s (Normal)

*5: In general use, Accel setting 100 is the optimum setting that maintains the balance of acceleration and

vibration when positioning. However, you may require an operation with high acceleration to shorten the cycle time by decreasing the vibration at positioning. In this case, set Accel to larger than 100. If you specify a larger Accel value, the frequency of the overload error and over heat may rise during continuous operation. The use of large Accel setting is recommended only for necessary motions.

20

G1 Rev.4

2.5 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

CAUTION

NOTE

)

result in abnormal or no operation of the Manipulator and/or cause safety problems.

If an MT label is attached to the rear of a Manipulator, the Manipulator has custom

specifications. The custom specifications may require a different configuration

procedure; check the custom specifications number described on the MT label 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.

Setup & Operation 2. Specifications

G1 Rev.4 21

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 *1 5 to 40°C (with minimum temperature variation)

Ambient relative humidity 10 to 80% (no condensation)

First transient burst noise 2 kV or less (Power supply wire)

1 kV or les (Signal wire)

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 and oil.

· 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.

*1 The ambient temperature conditions are for the Manipulators only. For the Controller

the Manipulators are connected to, refer to the Controller manual.

22

G1 Rev.4

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.

The base table must not only be able to bear the weight of the Manipulator but also be able

to withstand the dynamic movement of the Manipulator when the Manipulator operates at

maximum acceleration. Ensure that there is enough strength on the base table by

attaching reinforcing materials such as crossbeams.

The torque and reaction force produced by the movement of the Manipulator are as

follows:

Setup & Operation 3. Environments and Installation

Max. Reaction torque on the horizontal plate : 100 Nm

Max. Horizontal reaction force : 200 N

NOTE

Max. Vertical reaction force : 300 N

The threaded holes required for mounting the Manipulator base are M6. 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 15 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 M8 diameter or more.

If you are passing cables through the holes on the base table, see the figures below.

M/C Cables

Do not remove the M/C cables from the Manipulator.

47

Power Cable

Connector

26

[unit : mm]

53

18

Signal Cable

Connector

)

WARNING

G1 Rev.4 23

For environmental conditions regarding space when placing the Controller on the base

table, refer to the Controller manual.

■

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.

Setup & Operation 3. Environments and Installation

3.3 Mounting Dimensions

The maximum space described in figures shows that the radius of the end effector is 30 mm or less. If the radius of the end effector exceeds 30 mm, define the radius as the distance to the outer edge of maximum space. If a camera or electromagnetic valve extends outside of the arm, set the maximum range including the space that they may reach.

g Length of Arm #1 (mm)

h-g Length of Arm #2 (mm)

m Stroke of Joint #3 (mm)

f Motion range a Motion range of Joint #1 (degree) c Motion range of Joint #2 (degree) e Mechanical stop area b Joint #1 angle to hit mechanical stop (degree) d Joint #2 angle to hit mechanical stop (degree) n Joint #3 range to hit lower mechanical stop (mm) p Joint #3 range to hit upper mechanical stop (mm)

j Range from center of axis to back end (mm) k Range from center of axis to back end after moved to mechanical stop (mm) q Joint #2 motion range + angle to hit mechanical stop (degree)

Be sure to allow for the following extra spaces in addition to the space required for mounting the Manipulator, Controller, and peripheral equipment.

space for teaching

space for maintenance and inspection

(Ensure a space to open the rear side cover and the maintenance cover for maintenance.)

24

G1 Rev.4

Setup & Operation 3. Environments and Installation

r

3.3.1 4-axis spec Standard-model (G1-***S)

Center of Joint#3

Maximum space

Motion

ange

Area limited by mechanical stop

G1-171S G1-221S

Base mounting face

(unit: mm, ° = degree)

a b c d e f g h j k m n p

125° 3°

140° 3° 152° 4°

60.4

52.8

64.3

59.6

75 175 143 146.1 143°

100 6

2.5

125 225 171.6 176.9

Cleanroom-model (G1-***C)

Center of Joint#3

Maximum space

Motion

ange

Area limited by mechanical stop

q

154°

Base mounting face

(unit: mm, ° = degree)

G1-171C G1-221C

a b c d e f g h j k m n p

125° 3°

140° 3° 149° 5°

62.6

56.2

64.3

64.8

75 175 143 146.1 143°

125 225 171.6 176.9

80 3

2.5

q

154°

G1 Rev.4 25

Setup & Operation 3. Environments and Installation

r

3.3.2 3-axis spec Standard-model (G1-***SZ)

Center of Joint#3

Maximum space

Motion

ange

Area limited by mechanical stop

G1-171SZ G1-221SZ

Base mounting face

(unit: mm, ° = degree)

a b c d e f g h j k m n p

125° 3° 135°

1.3° 4°

69.2

82.2

70.9

89.2

75 175 143 146.1 136.3°

100 6

2.5

125 225 171.6 176.9

Cleanroom-model (G1-***CZ)

Center of Joint#3

Maximum space

Motion

ange

Area limited by mechanical stop

q

139°

Base mounting face

(uinit mm, ° = degree)

G1-171CZ G1-221CZ

a b c d e f g h j k m n p

125° 3°

123° 3° 132° 7°

82.5

82.2

86.4

94.4

75 175 143 146.1 126°

125 225 171.6 176.9

80 3

2.5

26

q

139°

G1 Rev.4

Setup & Operation 3. Environments and Installation

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

extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

■

Using a cart or similar equipment, transport the Manipulator in the same manner as it was delivered.

■

To carry the Manipulator, secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand. Never hold the duct to carry the Manipulator. There are the possibility such as the damage of cable and duct.

Duct DO NOT hold here for carrying

CAUTION

Hold here for carrying

G1-171S

approx. 8 kg :18 lb.

■

Be careful not to get hands or fingers caught when holding the bottom of the base by hand.

■

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.

G1 Rev.4 27

Setup & Operation 3. Environments and Installation

3.5 Installation

■

Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator when installing or transporting it. Manipulator weight: approx. 8 kg: 18 lb.

The robot system must be installed to avoid interference with buildings,

■

structures, utilities, other machines and equipment that may create a trapping

CAUTION

NOTE

hazard or pinch points.

■

Do not allow unnecessary strain on the arm.

The unnecessary strain on the arm may result in damage to the bearing and/or the arm.

Max. press force: 50N (Arm tip)

Secure the base to the base table.

bolt (4-M6×25) + spring washer + flat washer

Use bolts with specifications conforming to ISO898-1 Property Class: 6.9.

)

3.6 Connecting the Cables

■

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.

■

Be sure to connect the cables properly. Do not allow unnecessary strain on the

WARNING

cables. (Do not put heavy objects on the cables. Do not bend or pull the cables 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 the controller. Ensure that the controller is grounded and the cables are correctly connected. If the ground wire is improperly connected to ground, it may result in the fire or electric shock.

28 G1 Rev.4

Setup & Operation 3. Environments and Installation

3.7 User Wires and Pneumatic Tubes

■

Only authorized or certified personnel should be allowed to perform wiring.

CAUTION

Electrical Wires

Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system.

User electrical wires and pneumatic tubes are contained in the cable unit.

Rated Voltage

Allowable

Current

Wires Nominal Sectional Area Outer Diameter Note

AC/DC30 V 1 A 9+15 0.211 mm2

Maker Standard

9 pin

15 pin

Suitable Connector JAE DE-9PF-N (Solder type)

Clamp Hood JAE DE-C8-J9-F2-1R (Connector setscrew: #4-40 NC) Suitable Connector

JAE DA-15PF-N (Solder type)

Clamp Hood JAE DA-C8-J10-F2-1 (Connector setscrew: #4-40 NC)

Pins with the same number, indicated on the connectors on both ends of the cables, are

connected.

Prepare D-sub connectors for wiring.

ø8.3±0.3 mm

Twist pair

Pneumatic Tubes

Fittings for ø4 mm / ø6 mm (outer diameter) pneumatic tubes are supplied on both ends of

the pneumatic tubes.

Fitting (black) for ø4 mm pneumatic tube

Max. Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter × Inner Diameter

0.59 MPa (6 kgf/cm2 : 86 psi)

Fitting (black) for ø6 mm pneumatic tube

User connector

(15-pin D-sub connector)

User connector (9-pin D-sub connector)

Signal cable

Power cable

Fittings (white)

for ø6 mm pneumatic tube

2

1

Joint #3 Brake release switch

Fittings (white) for ø6 mm pneumatic tube

LED

User connector (9-pin D-sub connector)

User connector (15-pin D-sub connector)

Exhaust port (only Cleanroom-model)

Fitting (black) for ø4 mm pneumatic tube

Fitting (black) for ø6 mm pneumatic tube

ø6 mm × ø4 mm

ø4 mm × ø2.5 mm

G1 Rev.4 29

Setup & Operation 3. Environments and Installation

3.8 Relocation and Storage

3.8.1 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

CAUTION

extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

■

Before relocating the Manipulator, fold the arm and secure it tightly with a wire tie 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, secure the 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. Do not hold the duct joint on the back of the base.

CAUTION

■

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 to +55 degree C. Humidity within 10 to 80 % 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.

Be careful not to get hands, fingers, or feet caught and/or have equipment

■

damaged by a fall of the Manipulator.

Manipulator weight: approx. 8 kg: 18 lb.

30

(1) Turn OFF the power on all devices and unplug the cables.

(2)

Hold the bottom of Arm #1 by hand to unscrew the anchor bolts.

Then, remove the Manipulator from the base table.

G1 Rev.4

b

n

d

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

CAUTION

as the work piece is released when the Emergency Stop switch is pressed. 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.

Setup & Operation 4. Setting of End Effectors

- 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 button

- Joint #3 cannot be moved up/down by hand because the electromagnetic brake is

applied to the joint while power to the robot system is turned OFF. This prevents the

shaft from hitting peripheral equipment in the case that the shaft is lowered

weight of the end effector when the power is disconnected during operation, or whe

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 Controller an

move the joint with the brake release button pressed.

- This button switch is a momentary-type; the brake is released only while the button

switch is being pressed.

Joint #3 brake release button

y the

- Be careful of the shaft while the brake release button is being pressed because the shaft

G1 Rev.4 31

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.

Setup & Operation 4. Setting of End Effectors

4.2 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, “4.2.1Weight Setting” and “4.2.2 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 that the default setting.

CAUTION

4.2.1 Weight Setting

■

The total weight of the end effector and the work piece must not exceed 1 kg (3-axis spec: 1.5 kg). The G1 series Manipulators (4-axis spec) are not designed to work with loads exceeding 1 kg (3-axis spec: 1.5 kg). Always set the Weight parameters according to the load. Setting a value that is 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 G1 series

4-axis spec 0.5 kg 1 kg

3-axis spec 0.5 kg 1.5 kg

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

RC+

Enter a value into the [Load:] text box on the [Inertia] panel ([Tools] - [Robot Manager]).

(You may also execute the Inertia command from the [Command Window].)

Default rating Maximum

32

G1 Rev.4

Setup & Operation 4. Setting of End Effectors

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

= M (L1)2/(L1+L2)2

When you attach the equipment near Arm #2:

When you attach the equipment to the end of Arm #2:

W

: equivalent weight

M

: weight of air valves etc.

L

: length of Arm #1

1

L

: length of Arm #2

2

L

: distance from rotation center of Joint #2 to center of gravity

M

W

M

= M (LM)2/(L2)2

W

M

of camera etc.

Automatic speed setting by Weight

(%)

140

120

100 100 100 100

100

80

60

* The percentage in the graph is

based on the speed at rated

weight (0.5 kg) as 100%.

* 1.5 kg is only for 3-axis spec.

4-axis spec is up to 1.0 kg.

40

(%)

20

0 0.5 1.0 1.5 (kg)

Automatic acceleration/deceleration setting by Weight

140

120

11 0

100

80

70

60

40

20

0 0.5 1.0 1.5 (kg)

Weight setting

* The percentage in the graph is

based on the acceleration

/ deceleration at rated weight

(0.5 kg) as 100%.

* 1.5 k g is o nly for 3-axis spe c.

4-axis spec is up to 1.0 kg.

Weight setting

G1 Rev.4 33

Setup & Operation 4. Setting of End Effectors

t

4.2.2 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”,

2

“inertia”, or “GD

”. 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)

2

wm

must be 0.004 kg

or less. The G1 series Manipulators (4-axis spec) are not

designed to work with a moment of inertia exceeding 0.004 kg

CAUTION

Always set the moment of inertia parameter to the correct moment of inertia. Setting a value that is smaller 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 G1 series Manipulator (4-axis spec) is 0.0003

2

at the default rating and 0.004 kgwm2 at the maximum. When the moment of

kgwm

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

RC+

Enter a value into the [Load inertia:] text box on the [Inertia] panel ([Tools] - [Robo

Manager]). (You may also execute the Inertia command from the [Command Window].)

wm

2

.

(%)

Automatic acceleration/deceleration setting of Joint #4 by Inertia (moment of inertia)

140

120

100

80

60

40

20

10

0 0.001 0.002 0.003 0.004 (kg･m2) Moment of inertia setting

34

G1 Rev.4

CAUTION

Setup & Operation 4. Setting of End Effectors

Eccentric Quantity and the Inertia Setting

■

The eccentric quantity of load (weight of the end effector and work piece) must be 50 mm or less. The G1 series Manipulators are not designed to work with eccentric quantity exceeding 50 mm. Always set the eccentric quantity parameter according to the eccentric quantity. 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 G1 series is 0 mm at the default rating and 50

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.

Rotation center

Position of load’s center of gravity

Eccentric quantity (50 mm or less)

Eccentric Quantity

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

RC+

Enter a value into the [Eccentricity:] text box on the [Inertia] panel ([Tools] - [Robot

Manager]). (You may also execute the Inertia command from the [Command Window].)

Automatic acceleration/deceleration setting by Inertia (eccentric quantity)

120

(%)

100

80

60

100

65

* The percentage in the graph is

based on the acceleration /

deceleration at rated eccentricity

(0 mm) as 100%.

G1 Rev.4

40

30

20

0 10 20 30 40 50 (mm)

* Please contact EPSON for over 50 mm.

20

Eccentricity setting

35

Setup & Operation 4. Setting of End Effectors

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)

Whole moment

of inertia

Moment of inertia

=

of end effector (a)

Moment of inertia

+

of work piece (b)

Work piece (c)

Moment of inertia

+

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

Mass (m)

2

+ h2

b

m+ m

12

× L

2

36

L

h

(b) Moment of inertia of a cylinder

Cylinder’s center of gravity

Rotation center

Mass (m)

b

r

L

2

r

m+ m

2

× L

2

G1 Rev.4

Setup & Operation 4. Setting of End Effectors

(c) Moment of inertia of a sphere

Sphere’s center of gravity

Rotation center

2

5

L

r

Mass (m)

m r

4.3 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 figure 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

80

60

40

100100

* Figures on the graph (%) are

the proportion to the

acceleration/deceleration speed

at the shaft upper limit position.

30

+ m × L2

G1 Rev.4

NOTE

)

20

0 -30 -60 -90 -120 -150 (mm) Shaft height

When moving the Manipulator horizontally while the shaft is being lowered, it may cause

over-shoot at the time of final positioning.

37

Setup & Operation 5. Motion Range

5. Motion Range

■

When setting up the motion range for safety, both the pulse range and

CAUTION

mechanical stops must always be set at the same time.

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 (fix or change is not available)

3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the

Manipulator (for Joints #1 and #2)

Rectangular range setting

Mechanical

stop

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.

Motion range

Pulse range

Mechanical

stop

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

5.1.2 Max. Pulse Range of Joint #2

5.1.3 Max. Pulse Range of Joint #3

5.1.4 Max. Pulse Range of Joint #4.

NOTE

)

EPSON

RC+

38 G1 Rev.4

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.

The pulse range can be set on the [Range] panel shown by selecting [Tools]-[Robot Manager]. (You may also execute the Range command from the [Command Window].)

Setup & Operation 5. Motion Range

5.1.1 Max. Pulse Range of Joint #1

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

B B

A

+X 0 pulse

All models

A Max. Motion Range B Max. Pulse Range

− 1019449 ～ + 6262329

± 125 deg.

5.1.2 Max. Pulse Range of Joint #2

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

G1 Rev.4

4-axis spec G1-171S G1-171C G1-221S G1-221C

A Max. Motion Range B Max. Pulse Range

3-axis spec G1-171SZ G1-171CZ G1-171CZ G1-221CZ

A Max. Motion Range B Max. Pulse Range

A A

B B

±140 deg. ±152 deg. ±149 deg.

± 2548623 ± 2767076 ± 2712463

±135 deg. ±123 deg. ±135 deg. ±132 deg.

± 2457600 ± 2239147 ± 2457600 ± 2402987

39

Setup & Operation 5. Motion Range

±

5.1.3 Max. Pulse Range of Joint #3

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.

Type Joint #3 Stroke Minimum Limit

Standard-model G1-**1S Cleanroom-model G1-**1C

Maximum Limit

:0 pulse

100 mm − 1092267

80 mm

－873813

5.1.4 Max. Pulse Range of Joint #4

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 pulse

Clockwise (

-value)

393216 pulse

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)

(Do not move the upper

limit mechanical stop.)

Mechanical stop of Joint #1

(Adjustable)

40 G1 Rev.4

Setup & Operation 5. Motion Range

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.

Joint #1

C

A

D

B

° = degree )

(

Model A B C D

All

+125° -125° +120° -120°

Joint #2

G1-171*

D

B

Top Bottom

Model A B

4-axis spec

3-axis spec

G1-171CZ

E

C

G1-171S

G1-171C G1-221S

G1-221C G1-171SZ G1-171CZ G1-221SZ G1-221CZ

E

C

B

-

±152

±149

-

*2

-

G1-221*

D

*1

C

A

B

E

C

Top

*1

D E

(

+140° −140° +130° −130° +140° −140° +130° −130° +140° −140° +125° −125° +140° −140° +125° −125° +135° −135° +125° −125° +123° −123° +115° −115° +135° −135° +120° −120° +132° −132° +120° −120°

° = degree )

*1 Standard position of the mechanical stop

G1 Rev.4

*2 Limits the motion range using the bolts in the Arm #2 bottom to prevent the

bellows from contacting the manipulator body.

41

Setup & Operation 5. Motion Range

m

j

(1) Turn OFF the Controller.

(2) Install a hexagon socket head cap bolt into the hole corresponding to the setting angle,

and tighten it.

Joint

(3) Turn ON the Controller.

Hexagon socket head cap

1 2

bolt (fully threaded)

M6×10 M5×10

The number

of bolts

2 2

Recommended

tightening torque

1760 N⋅cm (180kgf⋅cm) 980 N⋅cm (100kgf⋅cm)

(5) Move the arm by hand until it touches the mechanical stops, and make sure that the

(6) Operate the joint changed at low speeds until it reaches the positions of the minimu

(4) Set the pulse range corresponding to the new positions of the mechanical stops.

NOTE

)

EPSON

RC+

EPSON

RC+

Be sure to set the pulse range inside the positions of the mechanical stop range.

Example: Using G1-171S*

The angle of Joint #1 is set from –120 degrees to +120 degrees.

The angle of Joint #2 is set from -130 degrees to +130 degrees.

Execute the following commands from the [Command Window].

>JRANGE 1,-873814,6116694 ' the pulse range of Joint #1

>JRANGE 2,-2366578,2366578 ' the pulse range of Joint #2

>RANGE ' Checks the setting using Range

-873814, 6116694,-2366578,2366578, −1092267 , 0 , −393216, 393216

arm does not hit any peripheral equipment during operation.

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 G1-171S*

The angle of Joint #1 is set from -120 degrees to +120 degrees. The angle of Joint #2 is set from -130 degrees to +130 degrees.

Execute the following commands from the [Command Window].

>MOTOR ON ' Turns ON the motor

>LP ON ' Enters low-power mode

>SPEED 5 ' Sets at low speeds

>PULSE -873814,0,0,0 ' Moves to the min. pulse position of Joint #1

>PULSE 6116694,0,0,0 ' Moves to the max. pulse position of Joint #1

>PULSE 2621440,-2366578,0,0 ' Moves to the min. pulse position of Joint #2

>PULSE 2621440,2366578,0,0 ' 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

oints 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:

2621440) 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.

42 G1 Rev.4

Setup & Operation 5. Motion Range

w

5.2.2 Setting the Mechanical Stop of Joint #3

NOTE

)

(1) Turn ON the Controller and turn OFF the motors using the Motor OFF command.

This method applies only to the Standard-model Manipulator (

For the

stop cannot be changed.

Cleanroom-model (G1-***C*), the motion range set with the Joint #3 mechanical

G1-***S*).

(2) Push up the shaft while pressing the brake release

button.

NOTE

)

(3) Turn OFF the Controller.

(4) Remove the Arm Top Cover.

(5) Loosen the lower limit mechanical stop screw. (2-M3×4 set screws)

NOTE

)

When you press the brake release button, the shaft may lower due to the weight of the end effector. Be sure to hold the shaft by hand while pressing the button.

For details, refer to Maintenance: 3.1 Arm Top Cover.

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.

Brake

release

button

Shaft

(6) The upper end of the shaft defines the

maximum stroke. Move the lower limit

mechanical stop down by the length you

want to limit the stroke.

For example, when the lower limit

mechanical stop is set at “100 mm”

stroke, the lower limit Z coordinate value is “-100”. To change the value to

“-80”, move the lower limit mechanical

stop down “20 mm”. Use calipers to

measure the distance when adjusting the

mechanical stop.

(7) Firmly tighten the lower limit mechanical stop screw (2-M3×4 set screws) not to let it

enter the shaft groove. Recommended tightening torque: 147 N⋅cm (15 kgf⋅cm)

(8) Mount the Arm top cover to the base.

For details, refer to Maintenance: 3.1 Arm Top Cover

(9) Turn ON the Controller.

Measure this distance.

2-M3×4 set scre

G1 Rev.4

43

Setup & Operation 5. Motion Range

k

j

n

(10) Move Joint #3 to its lower limit while pressing the brake release button, and then chec

the lower limit position. Do not lower the mechanical stop too far. Otherwise, the

oint may not reach a target position.

** For the Joint #3 resolution,

(12) Using the Pulse command (Go Pulse command), move Joint #3 to the lower limit

(11) 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) / Resolution (

refer to the section Setup & Operation 2.4 Specifications.

EPSON

RC+

NOTE

)

EPSON

RC+

Execute the following command from the [Command Window]. Enter the

calculated value in X.

>JRANGE 3,X,0 ' Sets the pulse range of Joint #3

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.

If it is difficult to check whether Joint #3 hits a mechanical stop, turn OFF the Controller and lift the arm top cover to check the condition causing the problem from the side.

Execute the following commands from the [Command Window]. Enter the value

calculated in Step (10) 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 eve

when lowering Joint #3.)

mm/pulse)

44 G1 Rev.4

Setup & Operation 5. Motion Range

t

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

RC+

Set the XYLim setting on the [XYZ Limits] panel shown by selecting [Tools]-[Robo

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.

G1 Rev.4

45

Setup & Operation 5. Motion Range

46 G1 Rev.4

Maintenance

This volume contains maintenance procedures with safety precautions for G1 series Manipulators.

48

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 maintenancetraining 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.

Maintenance 1. Safety Maintenance

WARNING

■

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 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.

■

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.

G1 Rev.4 49

Maintenance 1. Safety Maintenance

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 forcibly.) The unnecessary strain on the cables may result in damage to the

CAUTION

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.

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 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.

1 month (250 h) √

2 months (500 h) √

3 months (750 h) √ √

4 months (1000 h) √

5 months (1250 h) √

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)

…

Daily

inspection

Inspect every day

…

Monthly

inspection

√

…

Inspection Point

Quarterly

inspection

…

Biannual

inspection

…

Annual

inspection

…

h = hour

50 G1 Rev.4

2.2 Inspection Point

2.2.1 Inspection While the Power is OFF (Manipulator is not operating)

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

Maintenance 2. General Maintenance

Check looseness or backlash of

bolts/screws.

Tighten them if necessary.

(For the tightening torque, refer to

Maintenance: 2.4 Tightening

Hexagon Socket Head Cap Bolts.)

Check looseness of connectors.

If the connectors are loosen, push it

securely or tighten.

Visually check for external defects.

Clean up if necessary.

Check for bends or improper

location. Repair or place it properly

if necessary.

Check tension of timing belts.

Tighten it if necessary.

Grease conditions Refer to Maintenance: 2.3 Greasing.

End effector mounting bolts √ √ √ √ √

Manipulator mounting bolts √ √ √ √ √

Each arm locking bolts √ √ √ √ √

Bolts/screws around shaft √

Bolts/screws securing motors,

reduction gear units, etc.

External connectors on

Manipulator (on the connector

plates etc.)

Manipulator cable unit √ √ √ √

External appearance of

Manipulator

External cables √ √ √ √

Safeguard etc. √ √ √ √ √

Inside of Arm #2 √ √

√ √ √ √ √

2.2.2 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

lightly to check whether the cables

are disconnected.

Push each arm in MOTOR ON

status to check whether backlash

exists.

Check whether unusual sound or

vibration occurs.

Measure the accuracy repeatedly by

a gauge.

External cables

(including cable unit of the

Manipulator)

Each arm √

Whole √ √ √ √ √

Whole √

√ √

G1 Rev.4 51

Maintenance 2. General Maintenance

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

CAUTION

the Manipulator. Once the parts are damaged, a lot of time and money will be required for the repairs.

Greasing part Greasing Interval Grease

CAUTION

Joint #3 Ball screw spline shaft

Joint #1

Joint #2

* Under normal conditions, the reduction gear units shall be greased only when the motor is

replaced. However, in case of severe working conditions (such as high duty, high speeds,

large payloads, etc.), the reduction gear units must be greased every 10,000 hours.

Reduction gear units In the replacement of motor* SK-2

First time: after 50 km operation

2nd or more: after 100 km operation

AFB

■

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

: 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.

52 G1 Rev.4

Maintenance 2. General Maintenance

a

2.4 Tightening Hexagon Socket Head Cap Bolts

Hexagon socket head cap bolts are used in places where mechanical strength is required.

(A hexagon socket head cap bolt will be called a “bolt” in this manual.) 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.

Tightening Torque

Bolt

Refer below for the set screw.

M3 245 N⋅cm (25 kgf⋅cm)

M4 490 N⋅cm (50 kgf⋅cm) M3 147 N⋅cm (15 kgf⋅cm)

M5 980 N⋅cm (100 kgf⋅cm) M4 245 N⋅cm (25 kgf⋅cm)

M6 1,760 N⋅cm (180 kgf⋅cm)

We recommend that the bolts aligned on a circumference should be fastened in a crisscross

pattern as shown in the figure below.

5

Bolt hole

3

7

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

Controller. After replacing the parts, it is necessary to match these origins.

Set Screw Tightening Torque

1

8

Do not fasten all bolts securely at one time.

Divide the number of times that the bolts are

fastened into two or three and fasten the bolts

securely with a hexagonal wrench. Then, use

4

torque wrench so that the bolts are fastened with

tightening torques shown in the table above.

6

2

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

RC+

Execute the following command from the [Command Window].

>PULSE

PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value]

pls [Joint #4 Pulse value] pls

G1 Rev.4 53

Maintenance 2. General Maintenance

2.6 Layout of Maintenance Parts

2.6.1 4-axis spec

G1-***S : Standard-model

Brake release button switch

Arm top cover

Ball screw spline unit

Joint #4 motor

Joint #3 motor

Zbelt

U belt

Joint #3 brake

Joint #1 reduction gear unit

Joint #1 motor

G1-***C : Cleanroom-model

Cable unit

LED lamp

Joint #2 motor

Joint #2 reduction gear unit

Power cable

Signal cable

Lithium battery and Battery board

Gasket

Bellows

54 G1 Rev.4

Maintenance 2. General Maintenance

2.6.2 3-axis spec

G1-***SZ : Standard-model

Arm top cover

Ball screw spline unit

Joint #3 motor

Zbelt

Joint #3 brake

Joint #1 reduction gear unit

Joint #1 motor

G1-***CZ : Cleanroom-model

Bellows

Cable unit

LED lamp

Joint #2 motor

Joint #2 reduction gear unit

Power cable

Signal cable

Lithium battery and Battery board

Gasket

Bellows

G1 Rev.4 55

Maintenance 3. Covers

3. Covers

All procedures for removing and installing covers in maintenance are described in this

chapter.

■

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.

■

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

WARNING

Maintenance Parts and Tools

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.

■

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.

Maintenance

parts

Tools

Name Quantity Note

Arm Top Cover 1

Arm Top Cover for Cleanroom-model 1

Gasket unit 1 Only for Cleanroom-model

Hexagonal wrench (width across flats: 3 mm) 1 For M4 screw

Cross-point screwdriver 1

For bellows removal

Only for Cleanroom-model

Wiping cloth 1 For wiping adhesive

User plate

Arm top cover

Connector plate

Connector sub plate

56 G1 Rev.4

3.1 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

CAUTION

cover. 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 cover. Be sure to place the cables back to their original locations.

Maintenance 3. Covers

Unscrew the arm top cover mounting bolts, and

then lift the cover.

When bellows are installed to the manipulator,

remove / install the arm top cover and then remove

/ install the upper bellows.

4-M4×12 : Truss

4-M4×8 : Hexagonal

G1 Rev.4 57

Maintenance 3. Covers

3.2 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. 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 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

CAUTION

the cover. 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.

Unscrew the connector plate mounting bolts and

remove the plate.

4-M4×12

58 G1 Rev.4

3.3 Connector Sub Plate

■

Do not remove the connector sub plate forcibly. Removing the connector sub 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 connector sub plate, be careful not to allow the cables to interfere with the plate mounting and do not bend these cables forcibly to push

CAUTION

them into the cover. 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 sub plate. Be sure to place the cables back to their original locations.

Unscrew the connector sub plate mounting bolts and

remove the plate.

Maintenance 3. Covers

3.4 User Plate

(1) Remove the Arm top cover.

(2) Unscrew the user plate mounting bolts and

4-M4×5

For detail, refer to Maintenance 3.1 Arm top

cover.

2-M4×8

remove the plate.

G1 Rev.4 59

Maintenance 4. Cable Unit

4. Cable Unit

■

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.

■

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.

■

WARNING

CAUTION

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.

■

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.

■

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 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.

60 G1 Rev.4

4.1 Replacing Cable Unit

Since the power is supplied to each motor from the lithium battery installed on the battery

board via the battery connector, the position data will not be lost when the Controller is

turned OFF. When the battery connectors are disconnected, the position data will be lost,

and EPSON RC+ will display an error when the Controller is turned ON.

If the error occurs, execute the calibration of all joints and axes. For details of the

calibration, refer to Maintenance 13. Calibration.

Maintenance parts, Tools and Materials

Name Quantity Note

Maintenance 4. Cable Unit

Maintenance

parts

Tools

Cable unit 1

Battery Unit (Lithium battery) 1 R13ZA00600300

Hexagonal wrench (width across flats: 3 mm) 1 For M4 screw

Spanner (width across flats: 5 mm) 1 For D-sub connector removal

Nut screwdriver (width across flats: 5 mm) 1 For D-sub connector removal

Cross-point screwdriver 1

Torque wrench 1

Nippers 1 For cutting wire tie

Alcohol

Proper

quantity

For wiping grease

Wiping cloth 1 For wiping grease

Cable unit

G1 Rev.4 61

Maintenance 4. 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 block diagrams. Improper connection of the connectors may result in improper function of the robot system. For details on the connections, refer to Maintenance: 4.2 Wiring Diagrams.

■

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, and/or contact failure. Damaged cables, disconnection, or

CAUTION

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 cover. Be sure to place the cables back to their original locations.

■

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 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.

62 G1 Rev.4

Maintenance 4. Cable Unit

Cable unit Removal

(3) Turn OFF the Controller and disconnect the power cable and signal cable connectors

(4) Remove the arm top cover.

(5) Connect the spare battery to connector X60C.

(1) Turn ON the Controller and change the motor to OFF status (MOTOR OFF).

(2) Press and hold the brake release button switch to let the shaft down. Be sure to keep

enough space and prevent the end effector hitting any peripheral equipment.

The brake release button switch affects only Joint #3. When the brake release

button switch is pressed, the brake for Joint #3 is released.

Be careful of the shaft falling while the brake release button switch is being pushed

because it may be lowered by the weight of an end effector.

from thee controller.

For details, refer to Maintenance: 3.1 Arm Top Cover.

- Use the battery unit as the spare battery.

- The position data of Joint #2, #3, #4 motor is stored with the battery on base.

Connect the spare battery otherwise the Joint #2, #3, #4 position data will be lost.

(6) Cut off the wire tie binding cables on the arm side.

(7) Remove the 10 connectors and ground wire on the arm side.

Connector: X21, X22, X31, X32, X33, X41, XB10, X221, X231, X241

- Remember the cable layout so that the cables can be reconnected correctly after

replacement.

(8) Remove the screw securing the user plate and remove the user plate from Arm #2.

For details, refer to Maintenance: 3.4 User Plate.

(9) Remove the connectors of the following from the user plate.

D-sub cable, Air tube, Brake release switch

NOTE

)

Be careful not to lose the set screws of D-sub cable because they are so small.

To pull out the air tube, press the ring of fittings. (ø6×2, ø4×2)

- Remember the cable layout so that the cables can be reconnected correctly after

replacement.

(10) Remove the duct fitting from the user plate and pull

out the cables.

Duct fittings

User plate

G1 Rev.4 63

(11) Remove the connector plate.

For details, refer to Maintenance: 3.2 Connector Plate.

Maintenance 4. Cable Unit

r

g

(12) Remove the cables from the connector plate.

Air tube, D-sub cable 6 connectors : X10, X20, X30, X111, X121, X131

NOTE

Be sure to keep the connectors of the battery board connected while replacing the

)

cables. Otherwise, you will lose the position data and must execute the calibration

again.

- Remember the cable layout so that the cables can be reconnected correctly afte

replacement.

(13) Remove the ground wire from the base.

(14) Remove the mounting plate of the cable unit.

(15) Remove the wire tie binding the cables on the base side.

(16) Pull out the connector X62 from the battery board.

(X62: lower of two connectors)

Be sure to keep the connector X61 (upper one) of the

battery board connected. Otherwise, you will lose

the position data of the Joint #1 motor and must

execute the calibration again. Do not remove the

connector X61.

Mounting plate of cable unit

4-M4×12

X62

- Remember the cable layout so that the cables can

be reconnected correctly after replacement.

(17) Remove the duct fittings from the mounting plate of

the cable unit.

Mounting plate of

cable unit

Duct fittin

s

64 G1 Rev.4

g

Cable unit Installation

Pass the cables through the user plate and secure the

(1)

duct fittings.

Be careful of the cable support direction.

Maintenance 4. Cable Unit

Duct fittings

User plate

(2) Mount the air tube, ground wire, and D-sub cable to the user plate.

Pass the cables though the mounting plate of the cable

(3)

unit and secure the duct fittings.

Mounting plate of

cable unit

Duct fittin

s

Connect the connector X62 to the battery board.

(4)

(5) Secure the ground wire to the base.

(6) Re-bundle the wire tie removed in the removal step (16).

(7)

Mount the cable unit to the J1 flange.

Be careful of the cable support direction.

X62

Cable support

(8)

Mount the following to the inner side of connector plate, connector sub plate.

Air tube, ground wire, D-sub cable Joint #1 signal cable connector, power cable connector: X10, X111 4 connectors: X20, X30, X121, X131

(9)

Mount the user plate to Arm #2.

For details, refer to Maintenance: 3.4 User Plate.

(10) Mount the ground wire to Arm #2.

(11)

Connect the following connectors on the arm side.

X21, X22, X31, X32, X33, X41, XB10, X221, X231, X241

(12)

Remove the spare battery connected to X60C.

(13)

Re-bundle the wire tie removed in the removal step (6).

G1 Rev.4 65

Maintenance 4. Cable Unit

(14)

Mount the connector plate to the base.

For details, refer to Maintenance: 3.2 Connector Plate.

(15)

Set the Arm #2 cover without cables caught and secure it.

For details, refer to Maintenance: 3.1 Arm Top Cover.

(16)

If a connector falls out from the battery board, you must execute the calibration for all

axes.

66 G1 Rev.4

r

4.2 Wiring Diagrams

4.2.1 Signal Cable

Maintenance 4. Cable Unit

Cable colo

Pink

Red

Violet

White

Yel low

P R V W Y

Code

Cable color

Black

Brown

Green

Blue

Orange

B

Detail Board Diagram

Code

BR

G L O

G1 Rev.4 67

Maintenance 4. Cable Unit

4.2.2 Power Cable

Cable color

Pink

Red

Violet

White

Yellow

Green

Blue

G L O

Orange

Gray

GR

P R V W Y

Code

Cable color

Black

Brown

B

BR

Code

68 G1 Rev.4

Maintenance 4. Cable Unit

4.2.3 User Cable

Code Cable color Code Cable color

B Black R Red

BR Brown V Violet

G Green W W hite L Blue Y Yellow

G1 Rev.4 69

Maintenance 5. Arm #1

5. Arm #1

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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.

■

To shut off power to the robot system, pull out the power plug from the power

WARNING

CAUTION

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.

■

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.

■

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, brakes, timing belts, 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

Controller.

After replacing the parts, it is necessary to match these origins.

The process of aligning the two origins is called “Calibration”.

Refer to Maintenance: 13. Calibration to perform the calibration.

Joint #1 reduction gear

Joint #1 motor

70 G1 Rev.4

5.1 Replacing Joint #1 Motor

Maintenance parts and Tools

Name Quantity Note

Maintenance 5. Arm #1

Maintenance parts

AC Servo Motor (50 W) 1 R13B000621

Hexagonal wrench (width across flats: 1.5 mm) 1 For M3 set screw

Hexagonal wrench (width across flats: 3 mm) 1 For M4 screw

Tools

Hexagonal wrench (width across flats: 5 mm) 1 For M6 screw

Torque wrench 1

Wiping cloth 1 For wiping grease

Joint #1 motor Removal

(1) Remove Arm #1 from the base.

Put Arm #1 softly on the floor to avoid a shock to the arm.

(2) Remove the connector plate.

For details, refer to Maintenance: 3.4 Connector Plate.

(3) Disconnect the following connectors.

Connectors X111, X10 (Hold the claw to remove.)

Connector X61

(4) Remove the Joint #1 flange with the Joint #1

unit from the base.

The base and Joint #1 flange has been aligned

to the assembly position with the positioning

pin. Be careful not to lose the positioning pin.

4-M6×15

2-M4×45

(5) Loosen the screw of motor flange on the Joint

#1 flange. Remove the Joint #1 unit.

Joint #1 motor unit

4-M4×40

G1 Rev.4 71

Maintenance 5. Arm #1

w

(6) Loosen the screw fixing the motor flange and

reduction gear and remove the motor unit.

There is an O-ring in the assembly position of

motor flange and reduction gear. Be careful

not to lose the O-ring.

Reduction gear

Joint #1 motor

(7) Remove the wave generator from the Joint

#1motor.

There is a brass bushing in one of the set

screws. Be careful not to lose it.

(8) Remove the motor flange from the Joint #1

motor.

4-M4×12

Wave generator

2-M4×6 set scre

Joint #1 motor

Motor flange

Joint #1 motor

2-M4×12

72 G1 Rev.4

Maintenance 5. Arm #1

r

Joint #1 motor Installation

(1) Mount the motor flange on the Joint #1 motor.

Motor flange

Joint #1 moto

2-M4×12

(2) Mount the waveform generator on the Joint #1

motor.

Press the edge of waveform generator lightly to

the edge of spacer on the motor shaft.

Edge of wave generator

Edge of motor

Screw hole

Tighten one of the set screws on the flat face of

the motor shaft until the screw just touches the

surface. Insert a bushing into the other set

Joint #1 motor

screw hole to prevent damage to the motor shaft.

Then, tighten both set screws.

■

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) Insert the O-ring to the groove in the Joint #1 reduction gear unit and assemble the

Joint #1 motor unit.

(4) Mount the Joint #1 flange on the Joint #1 unit.

Make sure that the motor cable faces toward the Joint #1 flange lengthy side.

(5)

Mount the Joint #1 flange to the base.

The assembly position of the Joint #1 flange and the base has been set by the

positioning pin.

(6) Attach the connectors.

Connector: X110, X10, X61

(7) Mount the connector plate.

For details, refer to Maintenance: 3.4 Connector Plate.

(8) Perform the calibration of Joint #1.

For details refer to Maintenance: 14. Calibration.

G1 Rev.4 73

Maintenance 5. Arm #1

5.2 Replacing Joint #1 Reduction Gear Unit

Maintenance Parts and Tools

Name Quantity Note

Maintenance Parts

Tools

Removal

Installation

Reduction Gear Unit 1 R13B010026

Grease

Hexagonal wrench (width across flats: 1.5 mm) 1 For M3 set screw

Hexagonal wrench (width across flats: 3 mm) 1 For M4 screw

Hexagonal wrench (width across flats: 5 mm) 1 For M6 screw

Nippers 1

1

Wiping cloth

1

(1) Follow the steps in Maintenance: 5.1 Replacing Joint #1 Motor, Removal (1) to (8)

and remove the Joint #1 motor unit and waveform generator.

(1) A new reduction gear unit contains the parts shown in the picture.

For wiping grease

(motor flange)

For wiping grease (bolt)

CAUTION

The grease has been applied to the bearing are of waveform generator. Wipe the grease from the mounting surface.

Wave

Reduction gear

■

Never adjust the bolt fixing the reduction gear. If you did, it needs the alignment

generator

O-ring

by the manufacturer.

(2) Follow the steps in Maintenance: 5.1 Replacing Joint #1 Motor, Installation (2) to (8).

74 G1 Rev.4

6. Arm #2

■

WARNING

■

CAUTION

■

Maintenance 6. Arm #2