Instruction/ maintenance manual of the product G3 Series Epson
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SCARA ROBOT G3 series MANIPULA TOR MANUAL Rev .1 EM08ZR1795F.
M A N I P U L A T O R M A N U A L G 3 s e r i e s R e v . 1.
G3 Rev .1 i SCARA ROBOT G3 series Manipulator Manual Rev .1 Copyright © 2008 SEIKO EPSON CORPORA TION. All rights reserved..
ii G3 Rev .1 FOREWORD Thank you for p urchasing our ro bot products. This manual contai ns the information ne cessary for the correct use of the manipulato r . Please carefully read this manual and o ther related m anuals before installing t he robot system.
G3 Rev .1 iii TRADEMARKS Microsoft, W indows, and W indows logo are eit h er registered tradem ar ks or trademarks of Microsoft Corporation in t h e United S tates and/or other countries. Other brand an d product names are tra demarks or register ed trademarks of the respect ive holders.
iv G3 Rev .1 MANUF ACTURER & SUPPLIER SEIKO EPSON CORPORA TION Japan & Others Suwa Minami Plant Factory Automation Systems Dept. 1010 Fujim i, Fujimi-machi, Suwa-gun, Nagano, 399-0295 JAP AN TEL : +81-(0)266-61-1802 F AX : +81-(0)266-61-1846 SUPPLIERS North & South America EPSON AMERICA, INC.
G3 Rev .1 v Before Reading This Manual This section describes what you should know before reading this manual. S tructure of Control System The G3 series Manipulators can be used with the following combinations of Controllers and software. The operating m ethods and descriptions are dif ferent depending on whic h software you are using.
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G3 Rev .1 vii T ABLE OF CONTENTS Before Reading Th is Manual ................................................................................... v Setup & Operation 1. Safety 3 1.1 Conv entions .....................................................
T ABLE OF CONTENTS viii G3 Rev .1 5. Motion Range 46 5.1 Motion Range Setting by Pu lse Range (for A ll Joints) ........................... 47 5.1.1 Max. Pulse R ange of Jo int #1 .................................................... 48 5.1.2 Max. Pulse R ange of Jo int #2 .
Setup & Operation This volume contains informati on for setup and operation of the G3 series Manipulators. Please read this volume thoroughly before setting up and operating the Manipulators.
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Setup & Operation 1. Safety G3 Rev .1 3 1. Safety Installation and transportation of robots and robot ic equipm ent shall be perfor med by qualified person nel and sh ould conf orm to all na tional and local codes. Please read this manual and ot her related manuals b efore installing th e robot system or before connecting cables.
Setup & Operation 1. Safety 1.2 Design and Installation Safety Only trained personnel should design and install the robot system. T rained personnel are defined as those who have taken robot syste.
Setup & Operation 1. Safety 1.3 Operation Safety The following items are safety precaut ions 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 ro bot system.
Setup & Operation 1. Safety 1.4 Emergency S top If the Manipu lator moves a bnormally during opera tion, imm ediately press the Emer gency Stop swit ch. Stops the power supply to the m otor , and the arm stops in the shortest distance with the dynam ic brake and mechanical brake.
Setup & Operation 1. Safety G3 Rev .1 7 1.5 Emergency Movement Without Drive Power When the system is placed in em ergency mode, push the arm or joi n t of the Manipulat or by hand as shown b elow: Arm #1 ............. Push the arm by hand. Arm #2 .
Setup & Operation 1. Safety 1.6 Manipulator Labels The following labels are attac hed near the locations of the Mani pulator where specific dangers exist. Be sure to comply with descriptions and warnings on the labels to opera te and maintain the Manipulator safely .
Setup & Operation 1. Safety G3 Rev .1 9 A B D C Common T able T op Mounting Multiple Mounting C E C A B E Manipulators with bel lows do not have label D.
Setup & Operation 2. S pecifications 10 G3 Rev .1 2. S pecifications 2.1 Features of G3 series Manipulators The G3 series Manipula tors are high-perform ance manipulators pursuing high sp eed, high accuracy , space saving, and high c o st-performance.
Setup & Operation 2. S pecifications G3 Rev .1 11 2.2 Model Number and Model Differences G3- 25 1 S □ -R- UL Fire resistant □ : No fire resistant UL : UL compl iance T ype □ : S tandard R : .
Setup & Operation 2. S pecifications 12 G3 Rev .1 2.3 Part Names and Outer Dimensions 2.3.1 T able T op Mounting S tandard-model G3-***S CE label + − + − + − + − UR label Joint #3 / #4 Bra.
Setup & Operation 2. S pecifications G3 Rev .1 13 sh aft di amet er G3- 251* S G3-30 1* S G3- 35 1* S a 120 17 0 22 0 b Max .545 Ma x.575 Ma x.595 Max.
Setup & Operation 2. S pecifications 14 G3 Rev .1 Cleanroom-model: G3-***C The following figures show the additional parts and sp ec ifications for Cleanroom-model (T able T op m ounting) when compared with the Standard-m odel in appearance.
Setup & Operation 2. S pecifications G3 Rev .1 15 G3- 251* S G3- 301* S G3- 35 1* S a 120 17 0 22 0 b Max .545 Ma x.575 Max .595 sh aft diam et e r Max.
Setup & Operation 2. S pecifications 16 G3 Rev .1 2.3.2 Multiple Mounting S tandard-model: G3-***1SM + − + − + − + − CE label UR label Joint #3 / #4 Brake release switch Joint #1 (rotating) Joint #2 (rotating) Joint #3 (Up/Down) Arm #1 Arm #2 Base Shaft MT label (only for speci al order) Face plate (Manipulator serial No.
Setup & Operation 2. S pecifications G3 Rev .1 17 G3- 30 1SM G3- 351SM a 70 220 b M ax.4 1 0 M ax. 4 50 sh aft diam et er Max. ø1 1 t hr ough h ol e mech anic al st op di amet er Co nica l ho le .
Setup & Operation 2. S pecifications 18 G3 Rev .1 Cleanroom-model: G3-***1CM The following figures show the additional parts and specifications for Clea nroo m-model (Mul tiple Mounti ng) when compared with the Standard-m odel in appearance.
Setup & Operation 2. S pecifications G3 Rev .1 19 G3- 301 CM G3- 35 1 CM a 70 22 0 b M ax.4 1 0 M ax. 4 5 0 sh aft di am et er Max. ø11 t hr ough h ol e mech an ic al st op di am et er Co nica l .
Setup & Operation 2. S pecifications 20 G3 Rev .1 2.4 S pecifications Item G3 series Manipulator Arm #1, #2 250 mm 300 mm 350 mm Arm #1 120 mm 170 mm 220 mm Arm lengt h Arm #2 130 mm 130 mm 130 mm Joints #1, #2 3550 mm/s 3950 mm/s 4350 mm/s Joint #3 1 100 mm/s Max.
Setup & Operation 2. S pecifications G3 Rev .1 21 Item G3 series Manipulator Ambient T emperature 5 to 40 ° C (wit h minimum tem perature variation) Environm ental requirements Ambient relati ve .
Setup & Operation 2. S pecifications 22 G3 Rev .1 2.5 How to Set the Model The Manipula tor model for y our system has been set before shi pment from the fact ory .
Setup & Operation 3. Environments a nd Installation G3 Rev .1 23 3. Environment s and Inst allation 3.1 Environmental Conditions A suitable environment is necess ary for the robo t system to func tion properly and safe ly .
Setup & Operation 3. Environments a nd Installation 24 G3 Rev .1 3.2 Base T able A base table for anchoring the Manipulator is not suppli ed. Please make or obtain the base table for your Ma nipulator . The shape an d size of the b ase table dif fers depending on the use of the robot system .
Setup & Operation 3. Environments a nd Installation G3 Rev .1 25 3.3 Mounting Dimensions The maximum space described in figure s shows th at the radi us of the end effect or is 60 mm or less. If the radius of the end ef fector exceeds 60 m m, define the radius as the distance to the out er edge of maximum spa ce.
Setup & Operation 3. Environments a nd Installation 26 G3 Rev .1 A A B A B B B A T able Top Mounti ng C en t er of J oin t # 3 Max imum s p ace G3-301S/C G3-251S/C S tandard -R -L a Length of Ar m #1 (mm) 120 170 b Length of Arm #2 (mm) 130 84 / 92 104.
Setup & Operation 3. Environments a nd Installation G3 Rev .1 27 A B B A M ultip le M oun ting C en t er of J oin t # 3 Max imum s pac e G3-301SM/CM G3-351SM/CM S tandard S tandard -R -L a Length of Ar m #1 (mm) 170 220 220 220 b Length of Arm #2 (mm) 130 120.
Setup & Operation 3. Environments a nd Installation 3.4 Unp acking and T ransportation THE INST ALLA TION SHALL BE PREFORMED BY QUALIF IED INST ALLA TION PERSONNEL AND SHOULD CON FORM TO ALL NA TIONAL AND LOCAL CODES. W ARNING ■ Only authorized personnel should perfo rm sling work and operate a crane and a forklift.
Setup & Operation 3. Environments a nd Installation G3 Rev .1 29 3.5 Installation Procedure The following sections descr ibe the install ation of th e St andard Mani pulator . 3.5.1 T able T op Mounting 3.5.2 Multiple Mounting For Cleanroom-m odel manipulator , refer to this section; 3.
Setup & Operation 3. Environments a nd Installation 30 G3 Rev .1 3.5.2 Multiple Mounting ■ Install the Multiple Mounting Manipul ator 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 da maged by a fall of the Manipulator .
Setup & Operation 3. Environments a nd Installation 3.5.3 Cleanroom-model (1) Unpack it outside of the clea n room. (2) Secure the Manipulat or to delivery equipm ent such as a pallet wit h bolts so that the Manipulato r does not fall. (3) W ipe off the dust on the Manipulator with a little alco hol or distilled water on a lint-free cloth.
Setup & Operation 3. Environments a nd Installation 32 G3 Rev .1 When the Manipulator is a Cleanro om-model, be aware of the followings. For the Manipula tor of Cleanroom -model, use it with an ex haust system. For details, refer to Setup & O peration: 2.
Setup & Operation 3. Environments a nd Installation 3.7 User Wires and Pneumatic T ubes CAUTION ■ Only authorized or certified personnel should be allowed to perform wiring . Wiring by unauthorized or uncer tified personnel may result in bodily injur y and/or malfunction of the robot system.
Setup & Operation 3. Environments a nd Installation 34 G3 Rev .1 T able T op Mounting Fitting (blac k) for ø4 mm pneumatic tube Fitting (bla ck) for ø6 mm pneumatic tube Fitting (white) for ø6 .
Setup & Operation 3. Environments a nd Installation 3.8 Relocation and S torage 3.8.1 Precautions for Relocation and S torage Observe the following whe n relocating, s toring, and transporting the Manipulators. THE INST ALLA TION SHALL BE PREFORMED BY QUALIF IED INST ALLA TION PERSONNEL AND SHOULD CON FORM TO ALL NA TIONAL AND LOCAL CODES.
Setup & Operation 3. Environments a nd Installation 36 G3 Rev .1 3.8.2 T able T op Mounting CAUTION ■ Install or relocate the T able T op 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 da maged by a fall of the Manipulator .
Setup & Operation 3. Environments a nd Installation G3 Rev .1 37 3.8.3 Multiple Mounting ■ Install or relocate the Multiple Mountin g 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 da maged by a fall of the Manipulator .
Setup & Operation 4. Setting of End Ef fectors 4. Setting of End Effectors 4.1 Attaching an End Ef fector Users are responsible for making t heir own en d effector(s).
Setup & Operation 4. Setting of End Ef fectors 4.2 Attaching Cameras and V alves Arm #2 has thread ed holes as show n in the fi gure below . Use these holes for attaching cameras, valves, a nd other equipm ent.
Setup & Operation 4. Setting of End Ef fectors 4.3 We ight and Inertia Settings T o ensure optimum Manipu lator performance, it is important to m ake sure that the load (weight of the end ef fector and work piece) an d moment of inerti a of the load are within the maximum rating for the Manipulator , and that Joint #4 does not become eccentric.
Setup & Operation 4. Setting of End Ef fectors G3 Rev .1 41 <Example> A “1 kg” camera is attached to th e end of the G3 series a rm (180 mm away from the rot ation center of Joint #2) with a load weight of “1 kg”. M = 1 L 2 = 130 L M = 180 W M = 1 × 180 2 /130 2 = 1.
Setup & Operation 4. Setting of End Ef fectors 4.3.2 Inertia Setting Moment of Inertia and the Inertia Setting The moment of inertia is d efined as “the ratio of t he torque a pplied to a rigid body and its resistance to motion” . This value is ty pically referred to as “ the moment of in ertia”, “inertia”, or “GD 2 ”.
Setup & Operation 4. Setting of End Ef fectors Eccentric Quantity and the Inertia Setting CAUTION ■ The eccentric quantity of load (weight of the end effector and work piece) must be 150 mm or less. The G3 series Manipul ators ar e not designed to work with eccentric quantity exceeding 150 mm.
Setup & Operation 4. Setting of End Ef fectors Calculating the Mo ment of Inertia Refer to the f ollowing ex amples of form ulas to calculate the mom ent of inertia of load (end effect or with work piece). The moment of inertia of the entire load is calculated by the sum of e ach part (a), (b), a nd (c).
Setup & Operation 4. Setting of End Ef fectors G3 Rev .1 45 (c) Moment of inertia of a sphere m r 2 + m × L 2 2 5 Sphere’s center of gravity r Mass (m) Rotation center L 4.
Setup & Operation 5. Motion Range 5. Motion Range CAUTION ■ When setting up the motion range for safety , both the pulse range and mechanical stops must always be set at the same time. The motion range is preset at the factory as explained in Setup & Operation: 5.
Setup & Operation 5. Motion Range G3 Rev .1 47 5.1 Motion Range Setting by Pulse Range (for All Joint s ) Pulses are the basic uni t of Manipulator motion. The motion range of the Manipulator is controlled by the pulse range betwe en the pulse lower limit and upper limit of each joint.
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 t he positive (+) direction on the X-coordi nate axis.
Setup & Operation 5. Motion Range 5.1.2 Max. Pulse Range of Joint #2 The 0 (zero) pulse pos ition of Joint #2 is the position where Arm #2 is in-line with Arm #1. W ith the 0 pulse as a starting po int, the cou nterclockwise pulse va lue is defined as the positive (+) and t he clockwise p u lse value i s defined as the ne gative ( - ).
Setup & Operation 5. Motion Range 50 G3 Rev .1 5.1.3 Max. Pulse Range of Joint #3 The 0 (zero) pulse position of Joint #3 is the p osition where the sh aft is at its upper lim it. The pulse value is always nega tive because Joint #3 al ways moves lower than the 0 puls e position.
Setup & Operation 5. Motion Range 5.2 Motion Range Setting by Mechanical S tops Mechanical stops physically limit the abs olute area that the Manipula tor can move. Both Joints #1 a nd #2 have threaded hole s in the posit ions correspondin g to the angle f or the mechan ical stop se ttings.
Setup & Operation 5. Motion Range 5.2.1 Setting the Mechanical S t ops of Joint s #1 and #2 Both Joints #1 a nd #2 have threaded hole s in the posit ions corresponding to the angle f or the mechan ical stop se ttings. In stall th e bolts in th e holes corresp onding to th e angle tha t you want to set.
Setup & Operation 5. Motion Range G3 Rev .1 53 Ｒ Ｌ Join t #2 Mechanical Sto ps Views from the top of Arm #1 Model Arm a b c d 250 +141 ° - 141 ° +120 ° - 120 ° 300 +142 ° - 142 ° +122 °.
Setup & Operation 5. Motion Range 54 G3 Rev .1 (1) T urn OFF the Controller . (2) Install a he xagon socket head cap bolt int o the hol e correspond ing to t he setting an gle, and tighten i t.
Setup & Operation 5. Motion Range G3 Rev .1 55 5.2.2 Setting the Mechanical S t op of Joint #3 ) NOTE This method app lies only to the S tandard-model Ma nipulator (G3-**1S*) / Multiple Mounting Manipul ator (G3-**1SM). For the Cleanr oom-m odel ( G3-**1C*), the motion range set with the Joint #3 mechanical stop cannot be changed.
Setup & Operation 5. Motion Range 56 G3 Rev .1 (8) Move Joint #3 to its lower lim it while pressing the brake release button, and the n chec k the lower lim i t position. Do not lower the mechanical stop too far . Otherwise, the j oint may not reach a tar get position.
Setup & Operation 5. Motion Range 5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate System of the Manipulator (for Jo ints #1 and #2) Use this method to set the u pper and lower lim its of the X and Y coordinates. This setting is only enforc ed by software.
Setup & Operation 5. Motion Range 58 G3 Rev .1 T able T op Mounting - S trait Arm Ce nt er of Joint#3 Maxim um s pace Motion range Area l im ited by m echan i cal stop Base m ount i ng f ace a b c d e f g h j k q m n p G3-251S 141° 2.3° 84.0 150 9.
Setup & Operation 5. Motion Range T able T op Mounting - Left-Curved Arm Ce nt er of Joint#3 Maxim um space Motion range Ar ea limit ed by m echa nical stop Base m oun ti ng face a b c d e f g h j k m n p q G3-301S-L 1 5 0° 3 . 3° 1 7 0 30 0 2 77 .
Setup & Operation 5. Motion Range 60 G3 Rev .1 T able T op Mounting - Right-Curved Arm Ce nt er of Joint#3 Maxim um s pace Motion range Area lim it ed by m echa nical stop Base m oun ti ng face a b c d e f g h j k m G3-301S-R 12 5° 6° 15 0° 3° 13 5 ° 3 .
Setup & Operation 5. Motion Range G3 Rev .1 61 Multiple Mounting : S trait Arm Ce nt er of Joint#3 Maxim um s pace Motion range Area lim ited by m echa nical stop Base m oun ti ng f ace a b c d e f g h j k q G3-301SM/CM 1 1 5 ° 1 3 5° 1 12 . 0 1 2 0 .
Setup & Operation 5. Motion Range 62 G3 Rev .1 Multiple Mounting : Left-Curved Arm Ce nter of Joint#3 Maxim um spac e Motion range Area lim ited by m echa nical stop Base mounting face a b c d e f g h j k m G3-351SM-L 3 .3 ° 1 6 0° 2. 8° 10 3. 3 12 5.
Setup & Operation 5. Motion Range G3 Rev .1 63 Multiple Mounting : Right-Curved Arm Ce n ter of Joint#3 Maxim um s pace Motion range Area lim ited by m echa nical stop Base m oun ting f ace a b c d e f g h j k m G3-351SM-R 3 .3 ° 1 6 0° 10 3. 3 12 5 .
Setup & Operation 5. Motion Range 64 G3 Rev .1.
Maintenance This volume contains maint enance procedures with safety precautions for G3 se ries Manipulators..
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Maintenance 1. Safety Maintenance 1. Safety Maintenance Please read this chapter , this manual, a nd other relevant m anuals carefully to understand safe maintenance procedures before performing any routine m aintenance. Only authorized personnel who have taken safety training should be allowed to maintain the robot system.
Maintenance 1. Safety Maintenance 68 G3 Rev .1 CAUTION ■ 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 t he cables may result in damage to the cables, disconnection, and/or contact failure.
Maintenance 2. General Maintenance G3 Rev .1 69 2.2 Inspection Point 2.2.1 Inspection While the Power is OFF (Manipulator is not operating) Inspection Point Inspection Place Daily Monthly Quarterly Bi.
Maintenance 2. General Maintenance 2.3 Greasing The ball screw spline and reduction gea r units need greasing regularly . Only use the grease specified in the following table.
Maintenance 2. General Maintenance 2.4 T ightening Hexagon Socket Head Cap Bolts Hexagon socket head cap bolts are used in pla ces where mechanical strength is required. (A hexagon socket head cap bolt will be call ed a “bolt” in this manual.) These bolts are fastened with the tightening torques s hown in the following table.
Maintenance 2. General Maintenance 2.6 Layout of Maintenance Parts 2.6.1 T able T op Mounting G3-**1S : S tandard-model Joint #3 mo to r Lithiu m batte ry & Battery boar d Join t #1 motor Joint #2.
Maintenance 2. General Maintenance 2.6.2 Multiple Mounting G3-**1SM : S tandard-model Po w er c a bl e Cable un i t Joi nt #3 br ake Lithi um ba t ter y & Batt ery board Si gn al c abl e Brake re .
Maintenance 3. Covers 3. Covers All procedures for removing and installing cove rs 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.
Maintenance 3. Covers G3 Rev .1 75 T able T op Mounting Multiple Mounting Arm bottom cover Arm cap Connector plate Connector sub plate Base bottom cover Arm top cover Connector plate Connector sub plate Arm top cover Arm bottom cover Heatsink plate Heatsink plate 3.
Maintenance 3. Covers 76 G3 Rev .1 (3) T urn OFF the Controller . (4) Unscrew the arm top cover mount ing bolts, and then lift the cover . When bellows are installed to the manip ulator , remove the u pper bellows and the n remove the arm top cover . For bellows rem oval, refer to Maintenance 9.
Maintenance 3. Covers G3 Rev .1 77 3.2 Arm Bottom Cover Unscrew the arm bottom cover m ounting bolts, and then pu ll the cover downw ard and remove it. The arm bot tom cover m a y not be remove d fro m the shaft because t h e end ef fector is installed.
Maintenance 3. Covers 3.4 Connector Plate ■ Do not remove the connector plate fo rcibly . Removing the connector plate forcibly may result in damage to the cabl es, disconnection, and/or contact failure.
Maintenance 3. Covers 3.5 Connector Sub Plate ■ Do not remove the connecto r sub plate forcibly . Removing the connector sub plate forcibly may result in damage to the cables, disconnecti on, and/or contact failure.
Maintenance 3. Covers 80 G3 Rev .1 3.7 Heatsink Plate Unscrew the heatsink plate m ounting bolt s to remove th e plate. G3-**1* T able T op Mounting G3-**1*W Multiple Mounting Tru s s : 4-M4 × 8 Heatsink plate T russ: 2-M4 × 8 T russ: 4-M4 × 8 Heatsink plate T russ: 2-M4 × 8 3.
Maintenance 4. Maintenance Parts List G3 Rev .1 81 4. Maintenance Part s List 4.1 Common P arts Part Name Code Note 250 mm R13B020023 300 mm R13B020024 S/C 350 mm R13B020025 300 mm R13B020026 Cable Un.
Maintenance 4. Maintenance Parts List 82 G3 Rev .1 4.2 Parts by Environment Model 4.2.1 S: S tandard-model Part Name Code Note Ball Screw S pline 150 mm R13B010220 Arm Cover R13B0304 21 White Arm Bottom Cover R13B030423 4.
An important point after buying a device Epson G3 Series (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Epson G3 Series yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Epson G3 Series - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Epson G3 Series you will learn all the available features of the product, as well as information on its operation. The information that you get Epson G3 Series will certainly help you make a decision on the purchase.
If you already are a holder of Epson G3 Series, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Epson G3 Series.
However, one of the most important roles played by the user manual is to help in solving problems with Epson G3 Series. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Epson G3 Series along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
