EPSON G3-351SM, G3-351SM-R, G3-351SM-L, G3-301S-R, G3-351CM-L User Manual

Rev.5 EM111R2120F

SCARA ROBOT

G3 series

MANIPULATOR MANUAL

MANIPULATOR MANUAL G3 series Rev.5

SCARA ROBOT

G3 series Manipulator Manual

Rev.5

Copyright © 2008-2011 SEIKO EPSON CORPORATION. All rights reserved.

G3 Rev.5 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 G3 Rev.5

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

G3 Rev.5 iii

MANUFACTURER & SUPPLIER

TEL : [phone]
FAX : [phone]

Japan & Others

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

SUPPLIERS

Factory Automation/Robotics

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

Factory Automation Division

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

Factory Automation Division

TEL : [phone]
FAX : [phone]

Taiwan

Factory Automation Division

TEL : [phone]
FAX : [phone]

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 G3 Rev.5

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)

G3 Rev.5 v

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

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
and Cleanroom-model are the same.

vi G3 Rev.5

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....................................................... 13

2.3.1 Table Top Mounting....................................................................13

2.3.2 Multiple Mounting.......................................................................17

2.4 Specifications.........................................................................................21

2.5 How to Set the Model ............................................................................25

TABLE OF CONTENTS

3. Environments and Installation 26

3.1 Environmental Conditions......................................................................26

3.2 Base Table.............................................................................................27

3.3 Mounting Dimensions............................................................................28

3.3.1 Table Top Mounting - Straight Arm .............................................29

3.3.2 Table Top Mounting - Left-Curved Arm.......................................30

3.3.3 Table Top Mounting - Right-Curved Arm ....................................31

3.3.4 Multiple Mounting - Straight Arm................................................32

3.3.5 Multiple Mounting - Left-Curved Arm..........................................33

3.3.6 Multiple Mounting - Right-Curved Arm .......................................34

3.4 Unpacking and Transportation...............................................................35

3.5 Installation .............................................................................................36

3.5.1 Table Top Mounting....................................................................36

3.5.2 Multiple Mounting.......................................................................37

3.5.3 Cleanroom-model ......................................................................38

3.6 Connecting the Cables ..........................................................................39

3.7 User Wires and Pneumatic Tubes.........................................................40

3.8 Relocation and Storage.........................................................................42

3.8.1 Precautions for Relocation and Storage.....................................42

3.8.2 Table Top Mounting....................................................................43

3.8.3 Multiple Mounting.......................................................................44

G3 Rev.5 vii

TABLE OF CONTENTS

4. Setting of End Effectors 45

4.1 Attaching an End Effector......................................................................45

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

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

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3...................53

5. Motion Range 54

5.1 Motion Range Setting by Pulse Range (for All Joints)........................... 54

5.2 Motion Range Setting by Mechanical Stops..........................................58

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

System of the Manipulator (for Joints #1 and #2)............................................64

5.4 Standard Motion Range ........................................................................64

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

4.3.2 Inertia Setting............................................................................49

5.1.1 Max. Pulse Range of Joint #1....................................................55

5.1.2 Max. Pulse Range of Joint #2....................................................56

5.1.3 Max. Pulse Range of Joint #3....................................................57

5.1.4 Max. Pulse Range of Joint #4....................................................57

5.2.1 Setting the Mechanical Stops of Joints #1 and #2..................... 58

5.2.2 Setting the Mechanical Stop of Joint #3.....................................62

Maintenance

1. Safety Maintenance 67

2. General Maintenance 68

2.1 Schedule for Maintenance Inspection ...................................................68

2.2 Inspection Point.....................................................................................69

2.2.1 Inspection While the Power is OFF........................................... 69

2.2.2 Inspection While the Power is ON.............................................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

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 Heatsink Plate....................................................................................... 80

3.8 Base Bottom Cover...............................................................................80

viii G3 Rev.5

TABLE OF CONTENTS

4. Cable Unit 81

4.1 Replacing Cable Unit.............................................................................82

4.2 Wiring Diagrams....................................................................................87

4.2.1 Signal Cable...............................................................................87

4.2.2 Power Cable ..............................................................................88

4.2.3 User Cable.................................................................................89

5. Arm #1 90

5.1 Replacing Joint #1 Motor.......................................................................91

5.2 Replacing Joint #1 Reduction Gear Unit................................................94

6. Arm #2 97

6.1 Replacing Joint #2 Motor.......................................................................98

6.2 Replacing Joint #2 Reduction Gear Unit..............................................102

7. Arm #3 105

7.1 Replacing Joint #3 Motor.....................................................................106

7.2 Replacing the Timing Belt....................................................................110

7.3 Replacing the Brake ............................................................................114

8. Arm #4 116

8.1 Replacing Joint #4 Motor.....................................................................117

8.2 Replacing the Timing Belt....................................................................121

9. Replacing Arm #1 129

10. Bellows 136

11. Ball Screw Spline Unit 138

11.1 Greasing the Ball Screw Spline Unit ..................................................138

11.1.1 Standard-model......................................................................139

11.1.2 Cleanroom-model / Protected-model......................................140

11.2 Replacing the Ball Screw Spline Unit.................................................141

12. Lithium Battery 145

12.1 Replacing the Battery Unit (Lithium Battery)......................................146

12.2 Replacing the Battery Board..............................................................147

13. LED Lamp 149

14. Calibration 150

14.1 About Calibration ...............................................................................150

14.2 Calibration Procedure........................................................................151

14.3 Accurate Calibration of Joint #2.........................................................161

14.4 Calibration Procedure without using Calibration Wizard....................163

G3 Rev.5 ix

TABLE OF CONTENTS

15. Maintenance Parts List 167

15.1 Common Parts ..................................................................................167

15.2 Parts by Environment Model .............................................................168

x G3 Rev.5

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 the

CAUTION

associated instructions are not followed properly.

G3 Rev.5 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.5

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.5 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

Joint #2

Stop point

Start point of
operation

Target point

Controller RC180 / RC620

Manipulator G3-25*** G3-30*** G3-35***

Free running
time

Free running
angle

Free running
distance

Joint #1 + Joint #2 [sec.] 0.5 0.5 0.5

Joint #3 [sec.] 0.5 0.5 0.5

Joint #1 [deg.] 35 35 40

Joint #2 [deg.] 50 50 50

Joint #1 + Joint #2 [deg.] 85 85 90

Joint #3 G3-**1** [mm] 95 95 95

6 G3 Rev.5

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 #2

(rotating)

−

+

Joint #1

(rotating)

NOTE

)

Joint #3brake release button

Arm #2

+

Joint #3

(up and down)

−

Joint #4

(rotating)

+

−

+

Base

Arm #1

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.

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.5 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.

* Manipulators with bellows do not have this
label for no danger of your hand or fingers being
caught.

E

HOT
Be careful not to burn yourself.

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

F

G

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.

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

8 G3 Rev.5

Setup & Operation 1. Safety

Common

H

I

Table Top Mounting

Multiple Mounting

G3 Rev.5 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, compared to E2C

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 E2C series Manipulators

The installation procedure and mounting dimensions of end effector for the G3 series

are compatible with those for E2C 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.5

2.2 Model Number and Model Differences

G3-25 1 S □-R-UL

UL specification

UL : UL compliant

□

: Non UL compliant

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.5 11

Setup & Operation 2. Specifications

Arm

length

250 mm

300 mm

350 mm

Arm type Mounting type Environment

Standard

Standard

Right-Curved

Left-Curved

Standard

Right-Curved

Left-Curved

Table Top Mounting

Table Top Mounting

Multiple Mounting

Table Top Mounting

Table Top Mounting

Table Top Mounting

Multiple Mounting

Table Top Mounting

Multiple Mounting

Table Top Mounting

Multiple Mounting

Joint #3

stroke

Standard 150 G3-251S
Cleanroom 120 G3-251C
Standard 150 G3-301S
Cleanroom 120 G3-301C
Standard 150 G3-301SM
Cleanroom 120 G3-301CM
Standard 150 G3-301S-R
Cleanroom 120 G3-301C-R
Standard 150 G3-301S-L
Cleanroom 120 G3-301C-L
Standard 150 G3-351S
Cleanroom 120 G3-351C
Standard 150 G3-351SM
Cleanroom 120 G3-351CM
Standard 150 G3-351S-R
Cleanroom 120 G3-351C-R
Standard 150 G3-351SM-R
Cleanroom 120 G3-351CM-R
Standard 150 G3-351S-L
Cleanroom 120 G3-351C-L
Standard 150 G3-351SM-L
Cleanroom 120 G3-351CM-L

Model

Number

12 G3 Rev.5

−

−+−

2.3 Part Names and Outer Dimensions

2.3.1 Table Top Mounting

Standard-model G3-**1S

Joint #2

(rotating)

+

Setup & Operation 2. Specifications

Joint #1

(rotating)

Joint #3 Brake release switch

Fittings (white)

for ø6 mm

pneumatic tube

Arm #2

Arm #2

Joint #3

(Up/Down)

−

Shaft

+

Joint #4

(rotating)

User connector
(15-pin D-sub connector)

+

Base

Arm #1

MT label (only for special order)

Face plate (Manipulator serial No.)

Fittings (black)

for ø6 mm

pneumatic tube

Signal cable

Power cable

Fitting (black)

for ø4 mm

pneumatic tube

CE label

UR label

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.

- While the LED lamp is on, the current is being applied to the manipulator. Performing any work

with the power ON is extremely hazardous and it may result in electric shock and/or improper

function of the robot system. Make sure to turn OFF the controller power before the maintenance

work.

G3 Rev.5 13

Setup & Operation 2. Specifications

(

)

(

)

or more
Space for cables

G3-251S G3-301S G3-351S

(*) 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

14 G3 Rev.5

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.

Upper bellows

Setup & Operation 2. Specifications

Plate cover
(For Anti-static)

Exhaust port

Lower bellows

Plate cover
(For Anti-static)

Cover
for Table Top mounting surface

G3 Rev.5 15

Setup & Operation 2. Specifications

(

)

or
more

Space for cables

G3-251C G3-301C G3-351C

(*) 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”

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

16 G3 Rev.5

−

−

2.3.2 Multiple Mounting

Standard-model: G3-**1SM

Joint #3 Brake release switch

LED lamp

−

Setup & Operation 2. Specifications

Joint #2

(rotating)

+

Base

Arm #1

+

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

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.

- While the LED lamp is on, the current is being applied to the manipulator. Performing any work

with the power ON is extremely hazardous and it may result in electric shock and/or improper

function of the robot system. Make sure to turn OFF the controller power before the maintenance

work.

G3 Rev.5 17

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 170 220
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

18 G3 Rev.5

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

Setup & Operation 2. Specifications

Exhaust port

Lower bellows

Plate cover
(For Anti-static)

G3 Rev.5 19

Setup & Operation 2. Specifications

(

)

(

)

1 mm flat cut

Conical hole

Ø3,90°

(*) indicates the stroke
margin by mechanical stop.

or more Space for cables

G3-301CM G3-351CM
a 170 220
b Max.410 Max.450

Max.ø11 through hole

shaft diameter

mechanical stop diameter

Reference through hole

View from the bottom of the base

Detail of “A”

Calibration point position of Joints #3 and #4

20 G3 Rev.5

Setup & Operation 2. Specifications

2.4 Specifications

Item G3 series Manipulator

Arm #1, #2 250 mm 300 mm 350 mm

Arm length

Max. operating
speed *1

Repeatability

Payload (Load)

Joint #4 allowable
moment of inertia *2

Resolution

Hand

Mounting hole

Weight (cables not included)
Driving method All joints AC servo motor

Motor
energy consumption

Option

Installation method

Installation environment
Joint #3 down force 150 N
Installed wire for customer use

Installed pneumatic
tube for customer use

Environmental
requirements

Noise level *4 L
Applicable Controller RC180, RC620

Assignable Value
( ) Default values

MTBF 3 years

Safety standard

Arm #1 120 mm 170 mm 220 mm
Arm #2 130 mm 130 mm 130 mm
Joints #1, #2 3550 mm/s 3950 mm/s 4350 mm/s
Joint #3 1100 mm/s
Joint #4 3000 deg/s
Joints #1, #2 ± 0.008 mm ± 0.01 mm ± 0.01 mm
Joint #3 ± 0.01 mm
Joint #4 ± 0.005 deg
Rated 1 kg
Max. 3 kg
Rated 0.005 kg·m2

2

Max. 0.05 kg·m
Joints #1
Joint #2
Joint #3
Joint #4

0.0000343323 deg/pulse

0.0000549316 deg/pulse

0.0000878906 mm/pulse

0.000240928 deg/pulse
Shaft diameter ø 16 mm
Through hole ø 11mm

Table top mounting 120 × 120 mm (4-M8)

Multiple mounting

Wall mounting : 174 × 70 mm (4-M8)
Ceiling mounting : 120 × 120 mm (4-M8) / custom specification

14 kg : 31 lb.

Joint #1
Joint #2
Joint #3
Joint #4

200 W
150 W
150 W
150 W

- Multiple Mounting

Cleanroom *3 & ESD

15 (15 pin: D-sub) 15 cores
2 pneumatic tubes (ø6 mm) : 0.59 Mpa (6 kgf/cm2 : 86 psi)
1 pneumatic tubes (ø4 mm) : 0.59 Mpa (6 kgf/cm

Ambient Temp. 5 to 40°C (with minimum temperature variation)

Ambient relative
humidity

10 to 80% (no condensation)

= 70 dB (A)

Aeq

SPEED 1 to (5) to100
ACCEL *5 1 to (10) to 120
SPEEDS 1 to (50) to 2000
ACCELS 1 to (200) to 25000
FINE 0 to (10000) to 65000
WEIGHT 0,130 to (1,130) 3,130

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, Low Voltage, EMC Directive

2

: 86 psi)

G3 Rev.5 21

Setup & Operation 2. Specifications

Max. motion range (deg) (mm) / Max. pulse range (pulse)

Standard-model / Table Top Mounting

Item

Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4
Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4

Right hand
Left hand
Right hand
Left hand

± 2566827 ± 2585032

Right hand
Left hand
Right hand
Left hand

Max.
motion range
(deg), (mm)

Max.
pulse range
(pulse)

Straight

Curved

Common

Straight

Curved

Common

Standard-model / Multiple Mounting

Item

Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4
Joint #1
Joint #2

Joint #1

Joint #2

Joint #3

Joint #4

Right hand

Left hand
Right hand
Left hand

Right hand
Left hand
Right hand
Left hand

Max.
motion range
(deg), (mm)

Max.
pulse range
(pulse)

Straight

Curved

Common

Straight

Curved

Common

G3-251S G3-301S-* G3-351S-*

± 140

± 141 ± 142

-

-

-

-

− 125~150 − 110~165

− 150~125 − 165~110

− 135~150 − 120~165

− 150~135 − 165~120

150 mm

± 360

− 1456356~6699236

-

-

-

-

− 1019449~6990507 − 582543~7427414

− 1747627~6262329 − 2184534~5825423

− 2457600~2730667 − 2184534~3003734

− 2730667~2457600 − 3003734~2184534

−1706667~0

± 1494221

G3-301SM G3-351SM-*

± 115 ± 120
± 135 ± 142

-

-

-

-

− 105~130

− 130~105

− 120~160

− 160~120

150 mm

± 360

− 728178~5971058 − 873814~6116694

± 2457600 ± 2585032

-

-

-

-

− 436907~6407965

− 1165085~5679787

− 2184534~2912712

− 2912712~2184534

−1706667~0

± 1494221

22 G3 Rev.5

Cleanroom-model / Table Top Mounting

Item

Item

Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4
Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4

Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4
Joint #1
Joint #2

Joint #1

Joint #2

Joint #3
Joint #4

Right hand
Left hand
Right hand
Left hand

Right hand
Left hand
Right hand
Left hand

Right hand
Left hand
Right hand
Left hand

Right hand

Left hand

Right hand
Left hand

Straight

Max.
motion range
(deg), (mm)

Max.
pulse range
(pulse)

Cleanroom-model / Multiple Mounting

Max.
motion range
(deg), (mm)

Max.
pulse range
(pulse)

Curved

Common

Straight

Curved

Common

Straight

Curved

Common

Straight

Curved

Common

Setup & Operation 2. Specifications

G3-251C G3-301C-* G3-351C-*

± 140

± 137 ± 141 ± 142

-

-

-

-

− 125~150 − 110~165

− 150~125 − 165~110

− 135~145 − 120~160

− 145~135 − 160~120

120 mm

± 360

− 1456356~6699236

± 2494009 ± 2566827 ± 2585032

-

-

-

-

− 1019449~6990507 − 582543~7427414

− 1747627~6262329 − 2184534~5825423

− 2457600~2639645 − 2184534~2912712

− 2639645~2457600 − 2912712~2184534

−1365334~0

± 1494221

G3-301CM G3-351CM-*

± 115 ± 120
± 135 ± 142

-

-

-

-

− 105~130

− 130~105

− 120~150

− 150~120

120 mm

± 360

− 728178~5971058 − 873814~6116694

± 2457600 ± 2585032

-

-

-

-

− 436907~6407965

− 1165085~5679787

− 2184534~2730667

− 2730667~2187534

−1365334~0

± 1494221

G3 Rev.5 23

Setup & Operation 2. Specifications

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

interior together.
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.
Do not remove the maintenance cover on the front of the base.
Seal the exhaust port and the exhaust tube with vinyl tape so that the joint is airtight.
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 diameter : Inner diameter: ø12 mm / Outer diameter: ø16 mm

Exhaust tube : Polyurethane tube

Outer diameter: ø12 mm (Inner diameter:ø8 mm) or
Inner diameter ø16mm or larger
Recommended exhaust flow rate : approx. 1000 cm

3

/s (Normal)

*4: 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.

*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.

24 G3 Rev.5

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

G3 Rev.5 25

Setup & Operation 3. Environments and Installation

3. Environments and Installation

3.1 Environmental Conditions

A suitable environment is necessary for the robot system to function properly and safely.

Be sure to install the robot system in an environment that meets the following conditions:

Item Conditions

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

Ambient relative humidity 10 to 80% (no condensation)

First transient burst noise 2 kV or less

Electrostatic noise 6 kV or less

Environment · Install indoors.

· Keep away from direct sunlight.

· Keep away from dust, oily smoke, salinity, metal

powder or other contaminants.

· Keep away from flammable or corrosive solvents

and gases.

· Keep away from water.

· Keep away from shocks or vibrations.

· Keep away from sources of electric noise.

NOTE

)

WARNING

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.

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

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

Special Environmental Conditions

The surface of the Manipulator has general oil resistance. However, if your
requirements specify that the Manipulator must withstand certain kinds of oil, please
consult your distributor.
Rapid change in temperature and humidity can cause condensation inside the
Manipulator.
If your requirements specify that the Manipulator handles food, please consult your
distributor to check whether the Manipulator gives damage to the food or not.
The Manipulator cannot be used in corrosive environments where acid or alkaline is
used. In a salty environment where the rust is likely to gather, the Manipulator is
susceptible to rust.

■

Use an earth leakage breaker on the AC power cable of the Controller to avoid
the electric shock and circuit breakdown caused by an unexpected water leak.
Prepare the earth leakage brake that pertains the controller you are using. For
details, refer to the controller manual.

26 G3 Rev.5

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 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 : 300 Nm

Max. Horizontal reaction force : 2000 N

Max. Vertical reaction force : 1000 N

The threaded holes required for mounting the Manipulator base are M8. Use mounting
bolts with specifications conforming to ISO898-1 property class: 10.9 or 12.9.
For dimensions, refer to Setup & Operation: 3.3 Mounting Dimensions.

The plate for the Manipulator mounting face should be 20 mm thick or more and made of
steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or
less.

The table must be secured on the floor or wall to prevent it from moving.

The Manipulator must be installed horizontally.

When using a leveler to adjust the height of the base table, use a screw with M16 diameter
or more.

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

M/C Cables

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

47

26

Power Cable

Connector

[unit : mm]

53

18

Signal Cable

Connector

NOTE

)

WARNING

G3 Rev.5 27

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 60
mm or less. If the radius of the end effector exceeds 60 mm, define the radius as the
distance to the outer edge of maximum space.
If a camera or electromagnetic valve extends outside of the arm, set the maximum range
including the space that they may reach.

Be sure to allow for the following extra spaces in addition to the space required for
mounting the Manipulator, 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.)

space for cables

The minimum bend radius of the power cable is 90 mm. When installing the cable, be
sure to maintain sufficient distance from obstacles. In addition, leave enough space for
other cables so that they are not bent forcibly.

Ensure distance to the safeguard from the maximum motion range is more than 100 mm.

28 G3 Rev.5

Setup & Operation 3. Environments and Installation

3.3.1 Table Top Mounting – Straight Arm

Base mounting face

Center of Joint#3

Maximum space

Motion range

Area limited by mechanical stop

G3-251S 141° 2.3° 84.0 150 9.6 6.7
G3-251C 137° 6.3°
G3-301S 142° 3.8° 104.8 150 9.6 6.7
G3-301C 141° 4.8°
G3-351S 142° 3.8° 142.3 150 9.6 6.7
G3-351C

a b c d e f g h j k

140° 2°

142° 3.8°

79.3

96.2

134.2

92.0

107.1

146.6

120 250 221.9 224.5 143.3°

170 300 260.2 263.9

220 350 298.5 303.3

q

145.8°

m n p

120 4.1 10.7

120 4.1 10.7

120 4.1 10.7

g Length of Arm #1 (mm) b Joint #1 angle to hit mechanical stop (degree)

h-g Length of Arm #2 (mm) d Joint #2 angle to hit mechanical stop (degree)

m Stroke of Joint #3 (mm) n Joint #3 range to hit lower mechanical stop (mm)

f Motion range p Joint #3 range to hit upper mechanical stop (mm)

a Motion range of Joint #1 (degree) j Range from center of axis to back end (mm)

c Motion range of Joint #2 (degree) k

Range from center of axis to back end after moved to
mechanical stop (mm)

e Mechanical stop area q Joint #2 motion range + angle to hit mechanical stop (degree)

G3 Rev.5 29

Setup & Operation 3. Environments and Installation

3.3.2 Table Top Mounting – Left-Curved Arm

Center of Joint#3

Motion range

Maximum space

Area limited
by mechanical stop

Base mounting face

G3-301S-L 150° 3.3°
G3-301C-L
G3-351S-L 165° 2.8° 100.3 183.0
G3-351C-L

a b c d e f g h j k

150° 3° 125° 6°

165° 5° 110° 4°

145° 8.3°

160° 7.8°

135° 79.5 86.8 113.2 120.7 170 300 277.2

120° 97.0

107.5 184.2

m

n p q

191.6 220 350 342.5

G3-301S-L 281.4 227.5 241.5
G3-301C-L 288.7 201.8 227.5
G3-351S-L 219.4
G3-351C-L

r s t u v w x y z

6.7 －

153.3° 138.3°

10.7

6.7

167.8° 123.8° 3.8°

10.7

3.8°

346.6 205.2

222.9

150 9.6
120 4.1
150 9.6
120 4.1

n Length of Arm #1 (mm) b, d Joint #1 angle to hit mechanical stop (degree)

p-n Length of Arm #2 (mm) f, z Joint #2 angle to hit mechanical stop (degree)

u Stroke of Joint #3 (mm) v Joint #3 range to hit lower mechanical stop (mm)

m, j Motion range w Joint #3 range to hit upper mechanical stop (mm)

a, c Motion range of Joint #1 (degree) q, s

e, g Motion range of Joint #2 (degree) r, t

Range from center of axis to back end (mm)
Range from center of axis to back end after moved to

mechanical stop (mm)

h, k Mechanical stop area x, y Joint #2 motion range + angle to hit mechanical stop (degree)

30 G3 Rev.5

Setup & Operation 3. Environments and Installation

3.3.3 Table Top Mounting – Right-Curved Arm

Center of Joint#3

Maximum space

Motion range

Area limited
by mechanical stop

Base mounting face

G3-301S-R 150°
G3-301C-R
G3-351S-R 165° 100.3 183.0
G3-351C-R

a b c d e f g h j k

125° 6° 150° 3° 135° 3.3°

110° 4° 165° 5° 120° 3.8°

145°

160°

79.5 86.8 113.2 120.7

97.0

107.5 184.2

m

191.6

G3-301S-R 227.5 241.5 281.4
G3-301C-R
G3-351S-R 219.4
G3-351C-R

n p q r s t u v w x y z

170 300

201.8 227.5

220 350 205.2

222.9

277.2

288.7

342.5 346.6

150 9.6
120 4.1
150 9.6
120 4.1

6.7 －

138.3° 153.3°

10.7

6.7 2.8°

123.8° 167.8°

10.7

8.3°

7.8°

n Length of Arm #1 (mm) b, d Joint #1 angle to hit mechanical stop (degree)

p-n Length of Arm #2 (mm) f, z Joint #2 angle to hit mechanical stop (degree)

u Stroke of Joint #3 (mm) v Joint #3 range to hit lower mechanical stop (mm)
m, j Motion range w Joint #3 range to hit upper mechanical stop (mm)
a, c Motion range of Joint #1 (degree) q, s

e, g Motion range of Joint #2 (degree) r, t

Range from center of axis to back end (mm)
Range from center of axis to back end after moved to

mechanical stop (mm)

h, k Mechanical stop area x, y Joint #2 motion range + angle to hit mechanical stop (degree)

G3 Rev.5 31

Setup & Operation 3. Environments and Installation

3.3.4 Multiple Mounting – Straight Arm

Center of Joint#3

Maximum space

Motion range

Area limited
by mechanical stop

Base mounting face

G3-301SM/CM 115° 135° 112.0 120.7 170 300 201.8 212.4 138.8°
G3-351SM/CM 120°

a b c d e f g h j k

4°

142°

3.8°

134.2 142.3 220 350 240.0 253.0 145.8°

q

G3-301SM

m n p

150 9.6

6.7
G3-301CM 120 4.1 10.7
G3-351SM

150 9.6

6.7
G3-351CM 120 4.1 10.7

g Length of Arm #1 (mm) b Joint #1 angle to hit mechanical stop (degree)

h-g Length of Arm #2 (mm) d Joint #2 angle to hit mechanical stop (degree)

m Stroke of Joint #3 (mm) n Joint #3 range to hit lower mechanical stop (mm)

f Motion range p Joint #3 range to hit upper mechanical stop (mm)

a Motion range of Joint #1 (degree) j Range from center of axis to back end (mm)

c Motion range of Joint #2 (degree) k

Range from center of axis to back end after moved to
mechanical stop (mm)

e Mechanical stop area q Joint #2 motion range + angle to hit mechanical stop (degree)

32 G3 Rev.5

Setup & Operation 3. Environments and Installation

3.3.5 Multiple Mounting – Left-Curved Arm

Center of Joint#3

Maximum space

Motion range

Area limited
by mechanical stop

Base mounting face

G3-351SM-L 3.3°

G3-351CM-L

a b c d e f g h j k

130°

2°

105° 5°

160° 2.8° 107.5
150° 12.8°

120° 103.3

125.6

183.0 191.9

m

G3-351SM-L 280.8
G3-351CM-L

n p q r s t x y z

220 350 271.4

277.2

186.9 205.2 162.8° 123.8° 3.8°

G3-351SM-L
G3-351CM-L

u v w

150 9.6
120 4.1

6.7

10.7

n Length of Arm #1 (mm) b, d Joint #1 angle to hit mechanical stop (degree)

p-n Length of Arm #2 (mm) f, z Joint #2 angle to hit mechanical stop (degree)

u Stroke of Joint #3 (mm) v Joint #3 range to hit lower mechanical stop (mm)
m, j Motion range w Joint #3 range to hit upper mechanical stop (mm)
a, c Motion range of Joint #1 (degree) q, s

e, g Motion range of Joint #2 (degree) r, t

Range from center of axis to back end (mm)
Range from center of axis to back end after moved to

mechanical stop (mm)

h, k Mechanical stop area x, y Joint #2 motion range + angle to hit mechanical stop (degree)

G3 Rev.5 33

Setup & Operation 3. Environments and Installation

3.3.6 Multiple Mounting – Right-Curved Arm

Center of Joint#3

Maximum space

Motion range

Area limited
by mechanical stop

Base mounting face

G3-351SM-R 3.3° 160° 107.5
G3-351CM-R

a b c d e f g h j k

105° 5° 130°

2°

120° 3.8°

150°

103.3

125.6

183.0 191.9

m

G3-351SM-R 280.8 2.8°
G3-351CM-R

N p q r s t x y z

220 350 186.9 205.2 271.4

277.2

123.8° 162.8°

12.8°

G3-351SM-R
G3-351CM-R

u v w

150 9.6
120 4.1

6.7

10.7

n Length of Arm #1 (mm) b, d Joint #1 angle to hit mechanical stop (degree)

p-n Length of Arm #2 (mm) f, z Joint #2 angle to hit mechanical stop (degree)

u Stroke of Joint #3 (mm) v Joint #3 range to hit lower mechanical stop (mm)

m, j Motion range w Joint #3 range to hit upper mechanical stop (mm)

a, c Motion range of Joint #1 (degree) q, s

e, g Motion range of Joint #2 (degree) r, t

Range from center of axis to back end (mm)
Range from center of axis to back end after moved to

mechanical stop (mm)

h, k Mechanical stop area x, y Joint #2 motion range + angle to hit mechanical stop (degree)

34 G3 Rev.5

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.

■

After removing the bolts securing the Manipulator to the delivery equipment, the
Manipulator can fall. Be careful not to get hands or fingers caught.

■

The arm is secured with a wire tie. Leave the wire tie secured until you finish the
installation so as not to get hands or fingers caught.

CAUTION

■

To carry the Manipulator, have two or more people to work on it and 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.
When holding the bottom of the base by hand, be very careful not to get your
hands or fingers caught.

Multiple M ounting

G3-301*M : approx. 14 kg: 31 lb.

Table Top Mounting

G3-251* : approx. 14 kg: 31 lb.
G3-301* : approx. 14 kg: 31 lb.
G3-351* : approx. 14 kg: 31 lb.

■

Stabilize the Manipulator with your hands when hoisting it.

■

When transporting the Manipulator for a long distance, secure it to the delivery

G3-351*M : approx. 14 kg: 31 lb

equipment directly so that the Manipulator never falls.
If necessary, pack the Manipulator in the same style as it was delivered.

G3 Rev.5 35

Setup & Operation 3. Environments and Installation

3.5 Installation Procedure

■

The robot system must be installed to avoid interference with buildings,
structures, utilities, other machines and equipment that may create a trapping
hazard or pinch points.

The following sections describe the installation of the Standard Manipulator.

3.5.1 Table Top Mounting

3.5.2 Multiple Mounting

For Cleanroom-model manipulator, refer to this section;

3.5.3 Cleanroom-model

3.5.1 Table Top Mounting

■

Install the Table Top Mounting Manipulator with two or more people.
The Manipulator weights are as follows. Be careful not to get hands, fingers, or
feet caught and/or have equipment damaged by a fall of the Manipulator.
G3-251* : approx. 14 kg: 31 lb.
G3-301* : approx. 14 kg: 31 lb.
G3-351* : approx. 14 kg: 31 lb.

CAUTION

CAUTION

Standard-model

(1) Secure the base to the base table with

four bolts.

NOTE

)

(2) Using nippers, cut off the wire tie

(3) Remove the bolts securing the wire ties

Use bolts with specifications

conforming to ISO898-1 Property

Class: 10.9 or 12.9.

binding the shaft and arm retaining

bracket on the base.

removed in step (2).

Wire tie

10 mm

4-M8×30

Spring
Washer

Plane
Washer

Screw Hole
(depth 20 mm
or more)

Bolt

:M4×15

Sheet

36 G3 Rev.5

WARNING

Setup & Operation 3. Environments and Installation

3.5.2 Multiple Mounting

■

Install the Multiple Mounting Manipulator with two or more people.
The Manipulator weights are as follows. Be careful not to get hands, fingers, or
feet caught and/or have equipment damaged by a fall of the Manipulator.
G3-301*M : approx. 14 kg: 31 lb.
G3-351*M : approx. 14 kg: 31 lb.

■

When installing the Manipulator to the wall, support the Manipulator, and then
secure the anchor bolts. Removing the support without securing the anchor
bolts properly is extremely hazardous and may result in fall of the Manipulator.

NOTE

)

Design and make the base table for anchoring the Multiple Mounting Manipulators so that

it does not touch any cable connected to the base connector plate and duct.

The recommended installation patterns are as follows:

Side Ceiling

G3 Rev.5 37

Setup & Operation 3. Environments and Installation

Standard-model

(1)

Unpack the manipulator with retaining the

arm posture.

(2) Secure the base to the wall with four bolts.

NOTE

)

Use bolts with specifications conforming

to ISO898-1 Property Class: 10.9 or 12.9.

3.5.3 Cleanroom-model

(1) Unpack it outside of the clean room.

(2) Secure the Manipulator to delivery equipment such as a pallet with bolts so that the

Manipulator does not fall.

(3) Wipe off the dust on the Manipulator with a little alcohol or distilled water on a

lint-free cloth.

(4) Carry the Manipulator in the clean room.

(5) Refer to the installation procedure of each Manipulator model and install the

Manipulator.

Screw Hole
(depth 20 mm or more)

Plane Washer

Spring Washer

4-M8×30

(6) Connect an exhaust tube to the exhaust port.

■

When operating the Manipulator under special environmental conditions (adverse
conditions with dust and oily smoke), do not place the controller in the same

CAUTION

38 G3 Rev.5

condition since the controller does not comply with IP54 / IP65. Doing so may
cause equipment damage to and/or malfunction of the controller.

Setup & Operation 3. Environments and Installation

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

CAUTION

When the Manipulator is a Cleanroom-model, be aware of the followings.

CAUTION

C able Connections

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.

■

When connecting the Manipulator to the Controller, make sure that the serial
numbers on each equipment match. Improper connection between the
Manipulator and Controller may not only cause improper function of the robot
system but also serious safety problems. The connection method varies with the
Controller used. For details on the connection, refer to the Controller manual.
If the G series Manipulator or E2 series Manipulator is connected to the Controller
for the PS series (ProSix), it may result in malfunction of the Manipulator.

For the Manipulator of Cleanroom-model, use it with an exhaust system.

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

■

When operating the Manipulator under special environmental conditions (adverse
conditions with dust and oily smoke), do not place the controller in the same
condition since the controller does not comply with IP54 / IP65. Doing so may
cause equipment damage to and/or malfunction of the controller.

Connect the power connector and signal connector of
the M/C cables to the Controller.

Power Connector

Signal Connector

G3 Rev.5 39

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

Pneumatic Tubes

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 Note

AC/DC30 V 1 A 15 0.211 mm2 Twist pair

Maker Standard

15 pin

Suitable Connector JAE
Clamp Hood JAE

DA-15PF-N (Solder type)

DA-C8-J10-F2-1R (Connector setscrew: #4-40 NC)

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

connected.

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

0.59 MPa (6 kgf/cm2 : 86 psi)

2

1

ø6 mm × ø4 mm

ø4 mm × ø2.5 mm

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

of the pneumatic tubes.

Common Parts

Brake release
button switch

15-pin D-sub connector

Fitting (black) for
ø4 mm pneumatic tube

Fitting (black) for
ø6 mm pneumatic tube

Fitting (white) for
ø6 mm pneumatic tube

40 G3 Rev.5

Setup & Operation 3. Environments and Installation

Table Top Mounting

Multiple Mounting

Fitting (white) for
ø6 mm pneumatic tube

Fitting (black) for
ø6 mm pneumatic tube

Fitting (white) for
ø6 mm pneumatic tube

Fitting (black) for
ø4 mm pneumatic tube

Fitting (black) for
ø6 mm pneumatic tube

Base back side

User connector
(15-pin D-sub connector)

Fitting (black)
for ø4 mm pneumatic tube

User connector
(15-pin D-sub connector)

Base upper side

G3 Rev.5 41

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

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.

CAUTION

■

To carry the Manipulator, have two or more people to work on it and secure the
Manipulator to the delivery equipment or hold the bottom of Arm #1, the bottom of
the main cable fitting, and the bottom of the base by hand. When holding the
bottom of the base by hand, be very careful not to get hands or fingers caught.

■

Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is
extremely hazardous and may result in fall of the Manipulator.

When transporting the Manipulator for a long distance, secure it to the delivery
equipment so that the Manipulator cannot fall.
If necessary, pack the Manipulator in the same way as it was delivered.

When the Manipulator is used for a robot system again after long-term storage,
perform a test run to verify that it works properly, and then operate it thoroughly.

Transport and store the Manipulator in the range of -25°C to +55°C.
Humidity within 10% to 90% is recommended.

When condensation occurs on the Manipulator during transport or storage, turn
ON the power only after the condensation dries.

Do not shock or shake the Manipulator during transport.

42 G3 Rev.5

CAUTION

Setup & Operation 3. Environments and Installation

3.8.2 Table Top Mounting

■

Install or relocate the Table Top Mounting Manipulator with two or more people.
The Manipulator weights are as follows. Be careful not to get hands, fingers, or
feet caught and/or have equipment damaged by a fall of the Manipulator.
G3-251* : approx. 14 kg: 31 lb.
G3-301* : approx. 14 kg: 31 lb.
G3-351* : approx. 14 kg: 31 lb.

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

NOTE

)

Remove the mechanical stops if using them to limit the motion range of Joints #1 and

#2. For details on the motion range, refer to Setup & Operation: 5.2 Motion Range

Setting by Mechanical Stops.

(2) Cover the arm with a sheet so that the arm will not be damaged.

Tie the lower end of the shaft and arm, and the base and arm together with the wire

tie.

Be careful not to tie them too tight. Otherwise, the shaft may bend.

Example of Arm Retaining Posture

Wire tie

Bolt

:M4

×15

Sheet

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

Then, remove the Manipulator from the base table.

G3 Rev.5 43

Setup & Operation 3. Environments and Installation

3.8.3 Multiple Mounting

■

Install or relocate the Multiple Mounting Manipulator with two or more people.
The Manipulator weights are as follows. Be careful not to get hands, fingers, or
feet caught and/or have equipment damaged by a fall of the Manipulator.
G3-301*M : approx. 14 kg: 31 lb.

WARNING

)

G3-351*M : approx. 14 kg: 31 lb.

■

When removing the Manipulator from the wall, support the Manipulator, and then
remove the anchor bolts. Removing the anchor bolts without supporting is
extremely hazardous and may result in fall of the Manipulator.

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

NOTE

Remove the mechanical stops if using them to limit the motion range of Joints #1 and

#2. For details on the motion range, refer to Setup & Operation: 5.2 Motion Range

Setting by Mechanical Stops.

(2) Cover the arm with a sheet so that the arm will not be damaged.

Refer to the figure below and bind the shaft and arm retaining bracket on the base.

Example of Arm

Retaining Posture

Wire tie

Sheet

(3) Hold the bottom of Arm #1 by hand to unscrew the anchor bolts. Then, remove the

Manipulator from the wall.

44 G3 Rev.5

t

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 by the

weight of the end effector when the power is

disconnected during operation, or when the motor is

turned OFF even though the power is turned ON.

To move Joint #3 up/down while attaching an end

effector, turn ON the Controller and press the brake

release button.

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

switch is being pressed.

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

Brake release button

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

G3 Rev.5 45

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

g

g

4.2 Attaching Cameras and Valves

Arm #2 has threaded holes as shown in the figure below. Use these holes for attaching
cameras, valves, and other equipment. [Unit: mm]

Common Dimensions

Table Top Mounting

face

From the base mountin

Multiple Mounting

From the reference hole

face

From the base mountin

46 G3 Rev.5

t

4.3 Weight and Inertia Settings

To ensure optimum Manipulator performance, it is important to make sure that the load

(weight of the end effector and work piece) and moment of inertia of the load are within

the maximum rating for the Manipulator, and that Joint #4 does not become eccentric.

If the load or moment of inertia exceeds the rating or if the load becomes eccentric, follow

the steps below, “4.3.1Weight Setting” and “4.3.2 Inertia Setting” to set parameters.

Setting parameters makes the PTP motion of the Manipulator optimal, reduces vibration to

shorten the operating time, and improves the capacity for larger loads. In addition, it

reduces persistent vibration produced when the moment of inertia of the end effector and

work piece is larger that the default setting.

CAUTION

4.3.1 Weight Setting

■

The total weight of the end effector and the work piece must not exceed 3 kg.
The G3 series Manipulators are not designed to work with loads exceeding 3 kg.
Always set the Weight parameters according to the load. Setting a value that is
smaller than the actual load may cause errors, excessive shock, insufficient
function of the Manipulator, and/or shorten the life cycle of parts/mechanisms.

Setup & Operation 4. Setting of End Effectors

The acceptable weight capacity (end effector and work piece) in G3 series is 1 kg at the

default rating and 3 kg at the maximum. When the load (weight of the end effector and

work piece) exceeds the rating, change the setting of Weight parameter.

After the setting is changed, the maximum acceleration/deceleration speed of the robot

system at PTP motion corresponding to the “Weight Parameter” is set automatically.

Load on the Shaft

The load (weight of the end effector and work piece) on the shaft can be set by Weight

parameter.

EPSON

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].)

Load on the Arm

When you attach a camera or other devices to the arm, calculate the weight as the

equivalent of the shaft. Then, add this to the load and enter the total weight to the Weight

parameter.

Equivalent Weight Formula

When you attach the equipment near Arm #2:

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

W

: equivalent weight

M

M

: weight of camera 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

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

W

M

= M (LM)2/(L2)2

W

M

of camera etc.

G3 Rev.5 47

Setup & Operation 4. Setting of End Effectors

<Example> A “1 kg” camera is attached to the end of the G3 series arm (180 mm away

from the rotation center of Joint #2) with a load weight of “1 kg”.

M = 1

= 130

L

2

= 180

L

M

= 1 × 1802/1302 = 1.917 ⇒ 1.9 (round up)

W

M

W + W

= 1 + 1.9 = 2.9

M

Enter “2.9” for the Wei gh t P ar am e ter.

Automatic speed setting by Weight

(%)

140

120

100

80

Shaft

Weight of
camera
M=1kg

W=1kg

* The percentage in the graph

100

is based on the speed at

rated weight (1 kg) as 100%.

Joint #2

=130 mm

L

2

=180 mm

L

M

(%)

(%)

60

40

20

0 1 1.5 2 2.5 3 (kg)

Automatic acceleration/deceleration setting by Weight

140

110

120

100

80

100

90

80

60

40

20

0 1 1.5 2 2.5 3 (kg)

140

110

120

100

80

60

70

60

40

Weight setting

* The percentage in the graph is

based on the acceleration

/ deceleration at rated weight

(3 kg) as 100%.

G3-25***

Weight setting

* The percentage in the graph is

based on the acceleration

/ deceleration at rated weight

(3 kg) as 100%.

G3-30***

20

0 1 1.5 2 2.5 3 (kg)

Weight setting

48 G3 Rev.5

Setup & Operation 4. Setting of End Effectors

t

(%)

140

120

100

80

60

110

100

90

70

* The percentage in the graph is

based on the acceleration

/ deceleration at rated weight

(3 kg) as 100%.

G3-35***

40

20

CAUTION

EPSON

RC+

0 1 1.5 2 2.5 3 (kg)

Weight setting

4.3.2 Inertia Setting

Moment of Inertia and the Inertia Setting

The moment of inertia is defined as “the ratio of the torque applied to a rigid body and its

resistance to motion”. This value is typically referred to as “the moment of inertia”,

2

“inertia”, or “GD

end effector) attached to the shaft, the moment of inertia of load must be considered.

■

The moment of inertia of the load (weight of the end effector and work piece)
must be 0.05 kgwm
work with a moment of inertia exceeding 0.05 kgwm
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 a G3 series Manipulator is 0.005 kgwm2 at the
default rating and 0.05 kgwm

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.

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].)

”. When the Manipulator operates with additional objects (such as an

2

or less. The G3 series Manipulators are not designed to

2

at the maximum. When the moment of inertia of the load

2

.

G3 Rev.5 49

Setup & Operation 4. Setting of End Effectors

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

(%)

120

100 100

100

80

80

CAUTION

60

50

40

30

(%)

20

0 0.005 0.01 0.02 0.03 0.04 0.05 (kg･m2) Moment of inertia setting

120

100

100

100

80

60

40

80

50

G3-35***

30

20

0 0.005 0.01 0.02 0.03 0.04 0.05 (kg･m2) Moment of inertia setting

Eccentric Quantity and the Inertia Setting

■

The eccentric quantity of load (weight of the end effector and work piece) must be
150 mm or less. The G3 series Manipulators are not designed to work with
eccentric quantity exceeding 150 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 G3 series is 0 mm at the default rating and

150 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 (150 mm or less)

Eccentric Quantity

50 G3 Rev.5

Setup & Operation 4. Setting of End Effectors

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

40

20

100

60

40

* The percentage in the graph is

based on the acceleration /

deceleration at rated eccentricity

(0 mm) as 100%.

20

0 50 100 150 (mm)

Eccentricity setting

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).

Joint #3 shaft

End effector (a)

Moment of inertia

+

of work piece (b)

Work piece (c)

Moment of inertia

+

of work piece (c)

Work piece (b)

Whole moment

of inertia

Moment of inertia

=

of end effector (a)

Rotation center

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.

G3 Rev.5 51

Setup & Operation 4. Setting of End Effectors

(a) Moment of inertia of a rectangular parallelepiped

Rotation center

Rectangular parallelepiped’s center of gravity

Mass (m)

L

h

(b) Moment of inertia of a cylinder

Cylinder’s center of gravity

Rotation center

Mass (m)

(c) Moment of inertia of a sphere

Rotation center

b

r

L

Sphere’s center of gravity

2

+ h2

b

m+ m

12

2

r

m+ m

2

× L

2

× L

2

L

r

Mass (m)

2

2

5

+ m × L2

mr

52

G3 Rev.5

Setup & Operation 4. Setting of End Effectors

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3

When you move the Manipulator in horizontal PTP motion with Joint #3 (Z) at a high

position, the motion time will be faster.

When Joint #3 gets below a certain point, then auto acceleration/deceleration is used to

reduce acceleration/deceleration. (Refer to the 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

100

100

* Figures on the graph (%) are

the proportion to the

acceleration/deceleration speed

at the shaft upper limit position.

30

G3-25***
G3-30***

NOTE

)

20

(%)

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

120

100

80

100

100

* Figures on the graph (%) are

the proportion to the

acceleration/deceleration speed

60

at the shaft upper limit position.

60

G3-35***

40

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.

G3 Rev.5 53

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 (for Joints #1 to #3)

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

Manipulator (for Joints #1 and #2)

Rectangular range setting

Mechanical

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.

54

NOTE

)

EPSON

RC+

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].)

G3 Rev.5

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

Table Top Mounting

A

Max. Motion Range

(deg.)

B

Max. Pulse Range

(pulse)

Multiple Mounting

A

Max. Motion Range

(deg.)

B

Max. Pulse Range

(pulse)

+ A

+ B

− A

+X 0 pulse

− B

Arm Standard -R -L

25
30
35
25

30

35

±140

−1456356 ~ 6699236

−1019449 ~ 6990507 −1747627 ~ 6262329

−582542 ~ 7427413 −2184533 ~ 5825422

− −

−125 ~ 150 −150 ~ 125

−110 ~ 165 −165 ~ 110

− −

Arm Standard -R -L

30

35

30

35

±115

±120

−728178 ~ 5971058

−873813 ~ 6116693 −436907 ~ 6407965 −1165085 ~ 5679787

− −

−105 ~ 130 −130 ~ 105

− −

G3 Rev.5 55

Setup & Operation 5. Motion Range

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 (-).

+ B

0 pulse

+ A

Table Top Mounting (S: Standard-model / C: Cleanroom-model)

Arm

A

Max. Motion

Range

(deg.)

B

Max. Pulse

Range

(pulse)

Table Top Mounting (S:

25

30

35

25

30

35

Standard-model / C: Cleanroom-model)

Standard

±141 / ±137

±142 / ±141

±142

−

2566827 ~ 2566827

/

−2494009 ~ 2494009

−

2585031 ~ 2585031

/

−2494009 ~ 2494009

2585031 ~ 2585031

−

−135 ~ 150 / −135 ~ 145 −150 ~ 135 / −145 ~ 135

−120 ~ 165 / −120 ~ 160 −165 ~ 120 / −160 ~ 120

−2457600 ~ 2730667

/

−2457600 ~ 2639645

−2184533 ~ 3003733

/

−2184533 ~ 2912711

− A

− B

-R -L

− −

− −

−2730667 ~ 2457600

/

−2639645 ~ 2457600

−3003733 ~ 2184533

/

−2912711 ~ 2184533

Max. Motion

Range

(deg.)

Max. Pulse

Range
(pulse)

56

A

B

Arm

30

35

30

35

Standard

±135

±142

2457600 ~ 2457600

−

2585031 ~ 2585031

−

−120 ~ 160 / −120 ~ 150 −160 ~ 120 / −150 ~ 120

−2184533 ~ 2912711

/

−2184533 ~ 2730667

-R -L

− −

− −

−2912711 ~ 2184533

/

−2730667 ~ 2184533

G3 Rev.5

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.

Upper limit: 0 pulse

NOTE

)

Model Joint #3 Stroke Lower Limit Pulse

G3-**1S* 150 mm −1706667
G3-**1C* (Cleanroom-model) 120 mm −1365334

For the

stop cannot be changed.

Cleanroom-model (G3-**1C*), the motion range set with the Joint #3 mechanical

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 ± 1494221 pulse

Clockwise (-value)

G3 Rev.5 57

Setup & Operation 5. Motion Range

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.

Table Top Mounting

Mechanical stop of Joint #3
(Lower limit mechanical stop)

(Do not move the upper

limit mechanical stop.)

Mechanical stop of
Joint #2 (Adjustable)

Mechanical stop of
Joint #1 (Fixed)

Mechanical stop of Joint #2

(Fixed)

Mechanical stop of Joint #1

(Adjustable)

Multiple Mounting

Mechanical stop of Joint #1 (Adjustable)

Mechanical stop of Joint #1 (Fixed)

* The different mechanical stop positions from Table Top mounting are indicated for

Multiple mounting.

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

58

Both Joints #1 and #2 have threaded holes in the positions corresponding to the angle for

the mechanical stop settings. Install the bolts in the holes corresponding to the angle that

you want to set.

Install the bolts for the mechanical stop of Joint #1 (adjustable) to the following position.

Table Top mounting : Arm bottom side

Multiple mounting : Arm top side

G3 Rev.5

Setup & Operation 5. Motion Range

Joint #1 Mechanical Stops

Setting Angle

Pulse Value

Setting Angle

Pulse Value

Setting Angle

Pulse Value

Setting Angle

Pulse Value

R L

Views from the bottom of Arm #1

Model Arm a b c

G3-**1S/C

250

300

350

300

±140°
±140°
±140°

-125°

~ +150° -105°

-110°

-110°

-110°

+110°
+110°
+110°
+130°

G3-**1S/C-R

350

300

~ +165° -90°

-150°

~ +125° -130°

+145°
+105°

-110°

G3-**1S/C-L

350

300

-165°

~ +110° -145°

±115°

-100°

＋90°
+100°

G3-**1SM/CM

350

G3-351SM/CM-R 350

G3-351SM/CM-L 350

±120°

-105°

~ +130° -95°

-130°

~ +105° -120°

-105°

+105°
+120°

+95°

+90° +95° +100° +105° +110° +115° +120°

5242880 5388516 5534151 5679787 5825423 5971058 6116694

+125° +130° +140° +145° +150° +165°

6262329 6407965 6699236 6844872 6990507 7427414

-90° -95° -100° -105° -110° -115 -120°

0

-145636

-125° -130° -140° -145° -150°

-291271 -436907 -582542 -728178 -873813

+165°

-1019449 -1165085 -1456356 -1601991 -1747627 -2184533

(°: degree)

G3 Rev.5 59

Setup & Operation 5. Motion Range

Joint #2 Mechanical Stops

Ｌ

Ｒ

Views from the top of Arm #1

Model Arm a b c d

250

G3-**1S/C

G3-**1S/C-R

G3-**1S/C-L

G3-**1SM/CM

G3-351SM/CM-R 350

G3-351SM/CM-L 350

300

350

300

350

300

350

300

350

+141°
+142°
+142°
+150°
+165°
+135°
+120°
+135°
+142°
+160°
+120°

-141°

-142°

-142°

-135°

-120°

-150°

-165°

-135°

-142°

-120°

-160°

+120°
+120°
+120°
+130°
+145°

+115°

+100°

+115°
+120°
+150°

+110°

-120°

-120°

-120°

-115°

-100°

-130°

-145°

-115°

-120°

-110°

-150°

Setting Angle

Pulse Value

Setting Angle

Pulse Value

Setting Angle

Pulse Value

Setting Angle

Pulse Value

+100° +110° +115° +120° +130° +135°

1820444 2002488 2093511 2184533 2366577 2457600

+141° +142° +145° +150° +160° +165°

2566826 2585031 2639644 2730666 2912711 3003733

-100° -100° -115° -120° -130° -135°

-1820444 -2002488 -2093511 -2184533 -2366577 -2457600

-141° -142°

-2566826 -2585031 -2639644 -2730666 -2912711 -3003733

-145°

-150° -160° -165°

(°: degree)

NOTE

)

In case of Multiple Mounting, it is impossible to limit the operating range completely.

Because it may hit the wall within the setting range of mechanical stops.

60

G3 Rev.5

Setup & Operation 5. Motion Range

(1) Turn OFF the Controller.

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

(3) Turn ON the Controller.

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

NOTE

)

Example: Using G3-251S*

EPSON

RC+

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

and tighten it.

Joint

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

Execute the following commands from the [Command Window].

>JRANGE 1,-582542,5825423 ' the pulse range of Joint #1
>JRANGE 2,-2184533,2184533 ' Sets the pulse range of Joint #2
>RANGE ' Checks the setting using Range

-582542, 5825423,-2184533,2184533,-1706667
,0, -1494221, 1494221

arm does not hit any peripheral equipment during operation.

Hexagon socket head cap

bolt (fully threaded)

1

The angle of Joint #1 is set from –110 degrees to +110 degrees.

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

M8 × 10

The number

of bolts

1 bolt /

one side

Recommended

tightening torque

3720 N⋅cm (380 kgf⋅cm)

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

and maximum pulse range. Make sure that the arm does not hit the mechanical

stops. (Check the position of the mechanical stop and the motion range you set.)

Example: Using G3-251S*

The angle of Joint #1 is set from -110 degrees to +110 degrees.

EPSON

RC+

The Pulse command (Go Pulse command) moves all joints to the specified positions at

Execute the following commands from the [Command Window].

>MOTOR ON ' Turns ON the motor
>CP ON ' Enters low-power mode
>SPEED 5 ' Sets at low speeds
>PULSE -582542,0,0,0 ' Moves to the min. pulse position of Joint #1
>PULSE 5825423,0,0,0 ' Moves to the max. pulse position of Joint #1
>PULSE 2621440,- 2184533,0,0 ' Moves to the min. pulse position of Joint #2
>PULSE 2621440,2184533,0,0 ' Moves to the max. pulse position of Joint #2

the same time. Specify safe positions after considering motion of not only the joints

whose pulse range have been changed, but also other joints.

In this example, Joint #1 is moved to the center of its motion range (pulse value:

2621440) when checking Joint #2.

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

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.

G3 Rev.5 61

Setup & Operation 5. Motion Range

f

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 (G3-**1S*) / Multiple

Mounting Manipulator (G3-**1SM).

For the

stop cannot be changed.

Cleanroom-model (G3-**1C*), the motion range set with the Joint #3 mechanical

(2) Push up the shaft while pressing the brake

release button.

Do not push the shaft up to its upper limit or it

will be difficult for the arm top cover to be

removed. Push the shaft up to a position

where the Joint #3 mechanical stop can be

changed.

NOTE

(3) Turn OFF the Controller.

(4) Loosen the lower limit mechanical stop screw (M3×10).

A mechanical stop is mounted on both the top and bottom of Joint #3. However, only

(5) The upper end of the shaft defines the maximum

When you press the brake release button, the shaft may lower due to the weight of the

)

NOTE

)

end effector. Be sure to hold the shaft by hand while pressing the button.

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 o

Joint #3 is specified using the stop.

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 “150 mm” stroke, the lower limit Z
coordinate value is “-150”. To change the

value to “-130”, move the lower limit

mechanical stop down “20 mm”. Use calipers

to measure the distance when adjusting the

mechanical stop.

Measure
this distance.

Brake release button

Lower limit
mechanical
stop screw

M3×10

Shaft

62

(6) Firmly tighten the lower limit mechanical stop screw (M3×10) not to let it enter the

shaft groove.
Recommended tightening torque: 245 N⋅cm (25 kgf⋅cm)

(7) Turn ON the Controller.

G3 Rev.5

Setup & Operation 5. Motion Range

k

j

m

(8) 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.

(9) Calculate the lower limit pulse value of the pulse range using the formula shown below

and set the value.

The result of the calculation is always negative because the lower limit Z coordinate

value is negative.

** For the Joint #3 resolution,

EPSON

RC+

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

NOTE

If it is difficult to check whether Joint #3 hits a mechanical stop, turn OFF the

)

EPSON

RC+

Lower limit of pulse (pulse)

= lower limit Z coordinate value (mm) / Resolution (

refer to the section Setup & Operation 2.4 Specifications.

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

calculated value in X.

>JRANGE 3,X

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.

Controller and lift the arm top cover to check the condition causing the problem fro

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.

,0 ' Sets the pulse range of Joint #3

.

(In this example, all pulses except those for Joint #3 are “0”.

Substitute these “0s” with the other pulse values specifying a

position where there is no interference even when lowering

Joint #3.)

mm/pulse)

G3 Rev.5 63

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.

64

G3 Rev.5

Maintenance

This volume contains maintenance procedures with safety
precautions for G3 series Manipulators.

66

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

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.

G3 Rev.5 67

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

68 G3 Rev.5

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 √

√ √

G3 Rev.5 69

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

Greasing part Greasing Interval Grease Refer to:

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

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

Reduction gear units In the replacement of motor* SK-1A

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.

First time: after 50 km operation

2nd or more: after 100 km operation

Maintenance: 11.1 Greasing the Ball

AFB

Screw Spline Unit

Maintenance:

5.2 Replacing the Joint #1 Reduction

Gear Unit

6.2 Replacing the Joint #2 Reduction

Gear Unit

■

If grease gets into your eyes, mouth, or on your skin, follow the instructions
below.

If grease gets into your eyes

: Flush them thoroughly with clean water, and then see a doctor

immediately.

If grease gets into your mouth

CAUTION

: If swallowed, do not induce vomiting. See a doctor immediately.

: If grease just gets into your mouth, wash out your mouth with water

thoroughly.

If grease gets on your skin

: Wash the area thoroughly with soap and water.

70 G3 Rev.5

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) M4 245 N⋅cm (25 kgf⋅cm)

M5 980 N⋅cm (100 kgf⋅cm) M5 392 N⋅cm (40 kgf⋅cm)

M6 1,760 N⋅cm (180 kgf⋅cm)

M8 3,720 N⋅cm (380 kgf⋅cm)

M10 7,350 N⋅cm (750 kgf⋅cm)

M12 12,740 N⋅cm (1,300 kgf⋅cm)

Set Screw Tightening Torque

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 4

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

torque wrench so that the bolts are fastened with

tightening torques shown in the table above.

7

2

6

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.

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+

G3 Rev.5 71

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

Maintenance 2. General Maintenance

2.6 Layout of Maintenance Parts

2.6.1 Table Top Mounting

G3-**1S : Standard-model

LED lamp

Ball screw spline unit

Brake release button switch

Cable unit

Arm cover

Joint #4 motor

Z belt

U1 belt

Joint #3

motor

Joint #2 motor

Joint #2 reduction gear unit

U2 belt

Joint #1

reduction

gear unit

Joint #1 motor

G3-**1C : Cleanroom-model (with bellows)

Bellows

Lithium battery &

Battery board

Joint #3

motor

Power cable

Signal cable

Joint #3 brake

(Figure: G3-301S)

Gasket

Gasket

Bellows

Heat release sheet

(Figure: G3-301C)

72 G3 Rev.5

Maintenance 2. General Maintenance

y

2.6.2 Multiple Mounting

G3-**1SM : Standard-model

Ball screw
spline unit

Arm cover

Joint #4

motor

Z belt

U1 belt

LED lamp

U2 belt

Brake release switch

Joint #3
motor

Joint #2

Joint #2
reduction
gear

motor

Cable unit

Power cable

Signal cable

Joint #1
motor

Joint #1
reduction
gear

Lithium batter
Battery board

Joint #3
motor

&

Joint #3 brake

(Figure: G3-301SM）

G3-**1CM : Cleanroom-model (with bellows)

Bellows

Gasket

Gasket

Bellows

Heat release sheet

(Figure: G3-301CM）

G3 Rev.5 73

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

Under cover gasket 1

Silicon adhesive

(for the gasket on the

Connector Plate)

Hexagonal wrench

(width across flats: 3 mm)

Torque wrench 1

Cross-point screwdriver 1

Wiping cloth 1 For wiping adhesive

R13B031226

1

R13B031227

1 For M4 screw

For M4 truss screw

For bellows removal (Only for Cleanroom-model)

Only for Cleanroom-model

Only for Cleanroom-model

74 G3 Rev.5

Maintenance 3. Covers

Table Top Mounting Multiple Mounting

Connector plate

Arm top cover

Arm

bottom cover

Connector
sub plate

Arm cap

Connector

plate

Connector

sub plate

Heatsink plate

Arm top cover

Arm bottom cover

Base bottom cover

Heatsink plate

G3 Rev.5 75

Maintenance 3. Covers

b

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

Arm Top Cover
Removal

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.

(1) Turn ON the Controller.

(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.

NOTE

)

(3) Turn OFF the Controller.

(4) Unscrew the arm top cover mounting bolts, and

NOTE

)

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

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

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

may be lowered by the weight of an end effector.

then lift the cover.

When bellows are installed to the manipulator,

remove the upper bellows and then remove the

arm top cover. For bellows removal, refer to

Maintenance 10. Bellows.

Be careful for user wires and tubes when

removing the cover.

ecause it

4-M4×12

4-M4×8
Truss

Arm top cover

76 G3 Rev.5

d

d

Arm Top Cover
Installation

(1) Set the arm top cover to the arm and secure with

the arm top cover mounting bolts.

After mounting the arm top cover, make sure

that the lower limit mechanical stop does not

touch the cylindrical part of the arm top cover.

Maintenance 3. Covers

Brake release switch

Lower limit

mechanical stop

Arm top cover

Cylindrical part

Shaft

(2) When bellows are installed to the manipulator, install the arm top cover and then

install the upper bellows.

For bellows installation, refer to Maintenance10. Bellows.

3.2 Arm Bottom Cover

Unscrew the arm bottom cover mounting bolts, and then pull the cover downward and

remove it.

NOTE

)

The arm bottom cover may not be removed from the shaft because the end effector is

installed.

If it is necessary to remove the cover completely (for replacement of the ball screw spline

unit etc.), remove the end effector.

If it is not necessary to remove the cover completely, move the shaft to the lower limit, an

lower the arm bottom cover. Then, perform maintenance or inspection.

When bellows are installed to the manipulator, remove or pull down the lower bellows an

then remove the arm bottom cover. For bellows removal, refer to Maintenance 10.

Bellows.

G3-**1S* (Standard-model) G3-**1C* (Cleanroom-model)

3-M4×12

Arm bottom cover

A gasket is installed to G3-**1C* (Cleanroom-model).

G3 Rev.5 77

Gasket

Arm bottom cover

3-M4×12

Maintenance 3. Covers

3.3 Arm Cap

Unscrew the arm cap mounting bolts and remove the cover.

Arm cap is not installed to the Multiple Mounting Manipulators.

G3-**1 Table Top Mounting

M4×8

Flat washer

Arm cap

3.4 Connector Plate

■

Do not remove the connector plate forcibly. Removing the connector plate
forcibly may result in damage to the cables, disconnection, and/or contact failure.
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.

G3-**1* Table Top Mounting G3-**1*M Multiple Mounting

Truss:
4-M4×8

Connector plate

Truss:
4-M4×8

Connector plate

78 G3 Rev.5

Maintenance 3. Covers

3.5 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

G3-**1* Table Top Mounting G3-**1*M Multiple Mounting

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.

Truss:
4-M4×8

3.6 User Plate

Unscrew the user plate mounting bolts and remove the plate.

G3-**1S* Standard-model G3-**1C* Cleanroom-model

Connector sub plate

Truss: 4-M4×8

User plate

3-M4×12

Truss: 4-M4×8

Connector sub plate

Truss: 4-M4×8

Gasket

User plate

3-M4×12

A gasket is installed to G3-**1C* (Cleanroom-model).

G3 Rev.5 79

Maintenance 3. Covers

T

4

×

r

×

3.7 Heatsink Plate

Unscrew the heatsink plate mounting bolts to remove the plate.

G3-**1* Table Top Mounting G3-**1*M Multiple Mounting

Heatsink plate

russ:

-M4×8

Truss:
2-M4×8

Heat release sheet

Be careful of the Heat release sheet at the side of the Motor, and be sure to keep it.

NOTE

)

Be careful when you mount the Heatsink plate without the Heat release sheet, it may cause

the malfunction or break by the heat from the Motor.

3.8 Base Bottom Cover

Unscrew the base bottom cover mounting bolts and remove the cover.

G3-**1C* Cleanroom-model

Heatsink plate

Truss:
4-M4×8

Truss:
2-M4

8

Heat release sheet

NOTE

)

Base bottom cove

Truss: 4-M4 8

A base bottom cover is not installed to G3-**1S* (Standard-model).

80 G3 Rev.5

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.

Maintenance 4. Cable Unit

G3 Rev.5 81

Maintenance 4. Cable Unit

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, refer to Maintenance: 14. Calibration.

Maintenance parts, Tools and Materials

Name Quantity Note

Maintenance

parts

Tools

Material

Cable unit 1

Battery Unit (Lithium battery) 1 R13ZA00600300

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

Hexagonal wrench (width across flats: 4 mm) 1 For M5 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

Torque wrench 1

Nippers 1 For cutting wire tie

Wire tie 9

Each manipulator model

(Refer to Maintenance:

15. Maintenance parts)

Table Top mounting

Cable Unit

(Figure: G3-301S)

82 G3 Rev.5

Maintenance 4. Cable Unit

CAUTION

Multi-Layout mounting

Cable unit

(Figure: G3-301SM)

■

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
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.

G3 Rev.5 83

Maintenance 4. Cable Unit

y

Cable unit
Removal

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

(4) Remove the connector plate.

(5) Remove the connector sub plate.

(6) Connect the spare battery to the spare battery connector (XB11) of Joint #1 signal

(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 simultaneously.

Be careful of the shaft 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: 3.4 Connector Plate.

For details, refer to Maintenance: 3.5 Connector Sub Plate.

cable.

- Use the battery unit as the spare battery.

- The position of Joint #1 motor is stored with the battery on Arm #2/

Connect the spare battery otherwise the Joint #1 position data will be lost.

(7) Disconnect the air tubes, ground wire, D-sub cable, and seven connectors (X10, X20,

X30, X111, X121, X131, XB10) connected to the connector plate and connector sub

plate (inner side).

NOTE

)

(8) Cut off one wire tie binding Base side cables.

(9) Remove the arm top cover.

(10)

(11)

- Be sure to keep the connectors of the battery board connected at cables

replacement. Otherwise, the motor will lose position data and the calibration

must be executed again.

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

replacement.

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

Remove the Battery board.

Loosen the mounting screws for the User plate

and remove the plate from the Arm #2.

At this point, the ground is removed with the

plate.

2-M4×10

Batter

2-M4×12

board

84 G3 Rev.5

×

×

(12) Disconnect 11 connectors on the Arm side.

X21, X22, X31, X32, X33, X41, X42, X61, X221, X231, X241

Maintenance 4. Cable Unit

NOTE

)

(13) Disconnect the D-sub cable, air tubes, and connector of the brake release button

NOTE

)

(14) Remove the mounting screws for the cable unit and remove the unit from the

X61 is connected to the battery board.

Be sure to keep the connectors of the battery board connected at cables replacement.

Otherwise, the Joint #2, #3, and #4 motors will lose position data and the calibration

must be executed again.

switch from the user plate.

Mounting screws for the D-sub cable are very small. Be sure to keep the screws.

Press the ring on the fitting and pull out the air tube. (ø6×2, ø4×2)

Be sure to observe the connection for connecting the disconnected parts after

replacement.

Manipulator.

Table Top Mounting Multiple Mounting

Cable

unit

3-M4

12

4-M4×10

3-M4

Cable

unit

12

3-M4×10

G3 Rev.5 85

Maintenance 4. Cable Unit

Cable unit

(1) Mount the cable unit to the Manipulator.

Installation

(2) Connect the following to inner connector plate and connector sub plate.

(3) Connect Joint #1 Signal cable connector and XB10.

(4) Bundle the wire tie removed in Removal Step (8).

Air tube // Ground wire // D-sub cable

Joint #1 Signal cable connector and Power cable connector

4 connectors (X20, X30, X121, X131)

(5) Mount the user plate to the Arm #2.

At this point, mount the ground together.

(6) Connect the connectors:

X21, X22, X31, X32, X33, X41, X61,X221, X231, X241

(7) Mount the battery board to the Arm #2.

(8) Remove the spare battery from XB11.

(9) Mount the connector plate to the base.

For the details, refer to Maintenance: 3.4 Connector Plate.

(10)Mount the connector sub plate to the base.

For details, refer to Maintenance: 3.5 Connector Sub Plate.

(11) Set and secure the Arm #2 cover without the cables being stuck.

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

(12)When the connector falls off from the battery board, execute the calibration of all axes.

For details, refer to Maintenance: 14 Calibration.

86 G3 Rev.5

4.2 Wiring Diagrams

4.2.1 Signal Cable

Maintenance 4. Cable Unit

Mounting plate

Cable color

Pink

Red

P R V W Y

Code

Cable color

Black

Brown

B

BR

Code

Detail Board Diagram

Violet

White

Green

Blue

G L O

Yellow

Orange

G3 Rev.5 87

Maintenance 4. Cable Unit

4.2.2 Power Cable

Cable color

Pink

Red

Violet

White

Yellow

Blue

L

Light green

LG

Orange

O

P R V W Y

Code

Cable color

Black

Brown

B

BR

Code

Green

G

88 G3 Rev.5