Epson G3 User Manual
Rev.1 EM08ZR1795F
SCARA ROBOT
G3 series
MANIPULATOR MANUAL
MANIPULATOR MANUAL G3 series Rev.1
SCARA ROBOT
G3 series Manipulator Manual
Rev.1
Copyright © 2008 SEIKO EPSON CORPORATION. All rights reserved.
G3 Rev.1 i
d
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the manipulator.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
WARRANTY
The Manipulator and its optional parts are shipped to our customers only after being
subjected to the strictest quality controls, tests, and inspections to certify its compliance
with our high performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1. Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2. Malfunctions caused by customers’ unauthorized disassembly.
3. Damage due to improper adjustments or unauthorized repair attempts.
4. Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1. If the Manipulator or associated equipment is used outside of the usage conditions 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 G3 Rev.1
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
INQUIRIES
Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier office for
your region.
Please prepare the following items before you contact us.
- Your controller model and its serial number
- Your manipulator model and its serial number
- Software and its version in your robot system
- A description of the problem
SERVICE CENTER
G3 Rev.1 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
North & South America
Europe
EPSON AMERICA, INC.
18300 Central Avenue
Carson, CA 90746
USA
EPSON DEUTSCHLAND GmbH
Otto-Hahn-Str.4
D-40670 Meerbusch
Germany
iv G3 Rev.1
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
The G3 series Manipulators can be used with the following combinations of Controllers and
software.
The operating methods and descriptions are different depending on which software you are
using. The following icons are put beside appropriate text as necessary. Use the
descriptions that pertain to the software you are using.
Controller : RC180
Software : EPSON RC+ 5.0 Ver. 5.3 or greater
For details on commands, refer to User’s Guide or “On-line help”.
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to
turn ON/OFF all the hardware components. For the Controller composition, refer to the
table above.
Shape of Motors
The shape of the motors used for the Manipulator that you are using may be different from
the shape of the motors described in this manual because of the specifications.
Setting by Using Software
This manual contains setting procedures by using software. They are marked with the
following icon.
EPSON
RC+
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
and Cleanroom-model are the same.
G3 Rev.1 v
vi G3 Rev.1
TABLE OF CONTENTS
Before Reading This Manual................................................................................... v
Setup & Operation
1. Safety 3
1.1 Conventions.............................................................................................3
1.2 Design and Installation Safety .................................................................4
1.3 Operation Safety......................................................................................5
1.4 Emergency Stop ......................................................................................6
1.5 Emergency Movement Without Drive Power ...........................................7
1.6 Manipulator Labels ..................................................................................8
2. Specifications 10
2.1 Features of G3 series Manipulators.......................................................10
2.2 Model Number and Model Differences ..................................................11
2.3 Part Names and Outer Dimensions .......................................................12
2.3.1 Table Top Mounting....................................................................12
2.3.2 Multiple Mounting.......................................................................16
2.4 Specifications.........................................................................................20
2.5 How to Set the Model ............................................................................22
3. Environments and Installation 23
3.1 Environmental Conditions......................................................................23
3.2 Base Table.............................................................................................24
3.3 Mounting Dimensions ............................................................................25
3.4 Unpacking and Transportation...............................................................28
3.5 Installation Procedure ............................................................................29
3.5.1 Table Top Mounting....................................................................29
3.5.2 Multiple Mounting.......................................................................30
3.5.3 Cleanroom-model ......................................................................31
3.6 Connecting the Cables ..........................................................................31
3.7 User Wires and Pneumatic Tubes .........................................................33
3.8 Relocation and Storage .........................................................................35
3.8.1 Precautions for Relocation and Storage.....................................35
3.8.2 Table Top Mounting....................................................................36
3.8.3 Multiple Mounting.......................................................................37
4. Setting of End Effectors 38
4.1 Attaching an End Effector ......................................................................38
4.2 Attaching Cameras and Valves..............................................................39
4.3 Weight and Inertia Settings....................................................................40
4.3.1 Weight Setting............................................................................40
4.3.2 Inertia Setting.............................................................................42
4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 ...................45
G3 Rev.1 vii
TABLE OF CONTENTS
5. Motion Range 46
5.1 Motion Range Setting by Pulse Range (for All Joints)........................... 47
5.2 Motion Range Setting by Mechanical Stops.......................................... 51
5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate
5.4 Standard Motion Range ........................................................................ 57
Maintenance
1. Safety Maintenance 67
2. General Maintenance 68
2.1 Schedule for Maintenance Inspection ................................................... 68
2.2 Inspection Point..................................................................................... 69
2.3 Greasing ............................................................................................... 70
2.4 Tightening Hexagon Socket Head Cap Bolts ........................................ 71
2.5 Matching Origins ................................................................................... 71
2.6 Layout of Maintenance Parts................................................................. 72
5.1.1 Max. Pulse Range of Joint #1.................................................... 48
5.1.2 Max. Pulse Range of Joint #2.................................................... 49
5.1.3 Max. Pulse Range of Joint #3.................................................... 50
5.1.4 Max. Pulse Range of Joint #4.................................................... 50
5.2.1 Setting the Mechanical Stops of Joints #1 and #2 ..................... 52
5.2.2 Setting the Mechanical Stop of Joint #3..................................... 55
System of the Manipulator (for Joints #1 and #2)................................ 57
2.2.1 Inspection While the Power is OFF
(Manipulator is not operating).................................................... 69
2.2.2 Inspection While the Power is ON
(Manipulator is operating).......................................................... 69
2.6.1 Table Top Mounting ................................................................... 72
2.6.2 Multiple Mounting ...................................................................... 73
3. Covers 74
3.1 Arm Top Cover ...................................................................................... 75
3.2 Arm Bottom Cover................................................................................. 77
3.3 Arm Cap ................................................................................................ 77
3.4 Connector Plate .................................................................................... 78
3.5 Connector Sub Plate ............................................................................. 79
3.6 User Plate ............................................................................................. 79
3.7 Maintenance Plate ................................................................................ 80
3.8 Base Bottom Cover ............................................................................... 80
4. Maintenance Parts List 81
4.1 Common Parts ...................................................................................... 81
4.2 Parts by Environment Model ................................................................. 81
4.2.1 S: Standard-model .................................................................... 82
viii G3 Rev.1
4.2.2 C: Cleanroom-model ................................................................. 82
Setup & Operation
This volume contains information for setup and operation of the
G3 series Manipulators.
Please read this volume thoroughly before setting up and
operating the Manipulators.
1. Safety
Installation and transportation of robots and robotic equipment shall be performed by
qualified personnel and should conform to all national and local codes. Please read this
manual and other related manuals before installing the robot system or before connecting
cables.
Keep this manual handy for easy access at all times.
1.1 Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
WARNING
Setup & Operation 1. Safety
This symbol indicates that a danger of possible serious injury
or death exists if the associated instructions are not followed
properly.
This symbol indicates that a danger of possible serious injury
or death caused by electric shock exists if the associated
instructions are not followed properly.
This symbol indicates that a danger of possible harm to
people or physical damage to equipment and facilities exists if
CAUTION
the associated instructions are not followed properly.
G3 Rev.1 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 G3 Rev.1
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.
G3 Rev.1 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] 3
Weight Setting 3
Point where the
emergency stop
signal is input
Joint #1
Stop point
Joint #2
Start point of
operation
Target point
Controller RC180
Manipulator G3-25*** G3-30*** G3-35***
Free running
time
Free running
angle
Free running
distance
Joint #1 + Joint #2 [sec.] 0.8 1.2 0.6
Joint #3 [sec.] 0.6 0.6 0.6
Joint #1 [deg.] 41 53 57
Joint #2 [deg.] 13 20 20
Joint #1 + Joint #2 [deg.] 54 73 77
Joint #3 G3-**1** [mm] 95 95 95
6 G3 Rev.1
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
switch.
Joint #4........... Rotate the shaft by hand.
Joint #3 and #4
brake release button
Joint #2
(rotating)
−
+
Joint #1
(rotating)
−
+
Arm #1
NOTE
)
Arm #2
Base
+
Joint #3
(up and down)
−
Joint #4
(rotating)
Shaft
+
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.
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.
G3 Rev.1 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:
Labels NOTE
A
B
C
D
Before loosening the base mounting
screws, hold the arm and secure it tightly
with a band to prevent hands or fingers
from being caught in the Manipulator.
Hazardous voltage exists while the
Manipulator is ON. To avoid electric
shock, do not touch any internal electric
parts.
You can catch your hand or fingers
between the shaft and cover when
bringing your hand close to moving parts.
E
8 G3 Rev.1
HOT
Be careful not to burn yourself.
Common
Setup & Operation 1. Safety
C
D
Multiple Mounting
C
Table Top Mounting
NOTE
)
Manipulators with bellows do not have label D.
Because they have no risk of catching your hand or fingers.
E
B
C
A
B
E
A
G3 Rev.1 9
Setup & Operation 2. Specifications
2. Specifications
2.1 Features of G3 series Manipulators
The G3 series Manipulators are high-performance manipulators pursuing high speed, high
accuracy, space saving, and high cost-performance.
The features of the G3 series Manipulators are as follows:
Space productivity
Top level of cycle time and positioning accuracy
Minimized body
10 % downsize of overall height in the rank
Extended motion range
The same size of motion range compared with the other brands’ one up robots
Extended range in Z direction
Obtain the stroke under the body
Succeeded E2C series advantages
Compatibility with the E2 series Manipulators
The installation procedure and mounting dimensions of end effector for the G3 series
are compatible with those for E2 series
* Secure the compatible mounting position with optional parts
Improved productivity
Increase in number of user wires and pneumatic tubes
Enhanced speed of Joint #1, 2, 3, and 4
Improved cycle time
10 G3 Rev.1
2.2 Model Number and Model Differences
G3-25 1 S □-R-UL
Fire resistant
□
: No fire resistant
UL : UL compliance
Type
□
: Standard
R : Right-Curved
L : Left-Curved
Mounting type
□
: Table Top Mounting
M : Multiple Mounting
Environment
S : Standard
C : Cleanroom & ESD (Anti-Static)
Joint #3 stroke
: 150 mm
1
: 120 mm (Cleanroom-model)
Arm length
25 : 250 mm
30 : 300 mm
35 : 350 mm
Setup & Operation 2. Specifications
Environment
Cleanroom-model
This model has additional features that reduce dust emitted by the Manipulator to enable
use in clean room environments.
For details on the specifications, refer to Setup & Operation: 2.4 Specifications.
G3 Rev.1 11
Setup & Operation 2. Specifications
−
−
2.3 Part Names and Outer Dimensions
2.3.1 Table Top Mounting
Standard-model G3-***S
Joint #2
(rotating)
+
Joint #3 / #4
Brake release switch
Arm #2
−
Joint #1
(rotating)
Arm #1
+
NOTE
)
Base
+
Fittings (white)
for ø6 mm
pneumatic tube
Fittings (black)
for ø6 mm
pneumatic tube
Signal cable
Joint #3
(Up/Down)
−
Joint #4
(rotating)
User connector
(15-pin D-sub connector)
Power cable
Shaft
+
Fitting (black)
for ø4 mm
pneumatic tube
MT label (only for special order)
Face plate (Manipulator serial No.)
CE label
UR 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.
12 G3 Rev.1
Setup & Operation 2. Specifications
(
)
(
)
or more
Space f or cables
G3-251*S G3-301*S G3-351*S
(*) indicates the stroke margin
by mechanical stop.
1 mm flat cut
Conical hole
Ø3,90°
Max.ø11 through hole
shaft diameter
mechanical stop diameter
Detail of “A”
Calibration point position of Joints #3 and #4
a 120 170 220
b Max.545 Max.575 Max.595
Reference through hole
View from the bottom of the base
G3 Rev.1 13
Setup & Operation 2. Specifications
Cleanroom-model: G3-***C
The following figures show the additional parts and specifications for Cleanroom-model (Table Top mounting)
when compared with the Standard-model in appearance.
Plate cover
Upper bellows
(For Anti-static)
Exhaust port
Lower bellows
Plate cover
(For Anti-static)
Cover
for Table Top mounting surface
14 G3 Rev.1
Setup & Operation 2. Specifications
(
)
or
more
Space for cables
G3-251*S G3-301*S G3-351*S
(*) indicates the stroke margin by mechanical stop.
1 mm flat cut
Conical hole
Ø3,90°
Max.ø11 through hole
shaft diameter
mechanic al stop diameter
Detail of “A”
a 120 170 220
b Max.545 Max.575 Max.595
Reference through hole
(View from the bottom of the base)
Calibration point position of Joints #3 and #4
G3 Rev.1 15
Setup & Operation 2. Specifications
−
2.3.2 Multiple Mounting
Standard-model: G3-***1SM
−
Joint #3 / #4
Brake release switch
Joint #2
(rotating)
+
Base
Arm #1
+
NOTE
)
Joint #3
(Up/Down)
Fitting (white)
for ø6 mm
pneumatic tube
Fitting (black)
for ø4 mm
pneumatic tube
+
−
−
+
Fitting (black)
pneumatic tube
Arm #2
Shaft
User connector
(15-pin D-sub connector)
for ø6 mm
Joint #1
(rotating)
Power cable
Signal cable
Face plate (Manipulator serial No.)
MT label (only for special order)
UR label
CE label
The brake release button affects only Joints #3. When the brake release button is pressed in
emergency mode, the brake for Joint #3 is released simultaneously.
16 G3 Rev.1
Setup & Operation 2. Specifications
(
)
(
)
(*) indicates the stroke margin by mechanical stop.
1 mm flat cut
or more Space for cables
G3-301SM G3-351SM
a 70 220
b Max.410 Max.450
Conical hole
Ø3,90°
Calibration point position of Joints #3 and #4
Max.ø11 through hole
shaft diameter
mechanical stop diameter
Detail of “A”
Reference through hole
View from the bottom of the base
G3 Rev.1 17
Setup & Operation 2. Specifications
Cleanroom-model: G3-***1CM
The following figures show the additional parts and specifications for Cleanroom-model (Multiple Mounting)
when compared with the Standard-model in appearance.
Upper bellows
Exhaust port
Lower bellows
Plate cover
(For Anti-static)
18 G3 Rev.1
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