Epson RC180 User manual

Rev.17 EM164C3205F
ROBOT CONTROLLER
RC180

ROBOT CONTROLLER RC180 Rev.17

RC180 Rev.17 i
ROBOT CONTROLLER
RC180
Rev.17
Copyright © 2006-2016 SEIKO EPSON CORPORATION. All rights reserved.

ii RC180 Rev.17
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the robot controller.
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 robot system and its optional parts are shipped to our customers only after being
subjected to the strictest quality controls, tests, and inspections to certify its compliance
with our high performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1.
Damage or malfunction caused by improper use which is not described in the manual,
or
careless use.
2.
Malfunctions caused by customers’ unauthorized disassembly.
3.
Damage due to
improper adjustments or unauthorized repair attempts.
4.
Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1.
If the
robot system
associated equipment is used outside of the usage conditions and
product
specifications described in the manuals, this warranty is void.
2.
If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3.
We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.

RC180 Rev.17 iii
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.
TRADEMARK NOTATION IN THIS MANUAL
Microsoft® Windows® XP Operating system
Microsoft® Windows® Vista Operating system
Microsoft® Windows® 7 Operating system
Microsoft® Windows® 8 Operating system
Throughout this manual, Windows XP, Windows Vista, Windows 7 and Windows 8 refer
to above respective operating systems. In some cases, Windows refers generically to
Windows XP, Windows Vista, Windows 7 and Windows 8.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
MANUFACTURER

iv RC180 Rev.17
Before Reading This Manual
Do not connect the followings to the TP/OP port of RC180. Connecting to the followings
may result in malfunction of the device since the pin assignments are different.
OPTIONAL DEVICE dummy plug
Operation Pendant OP500
Operator Pendant OP500RC
Jog Pad JP500
Teaching Pendant TP-3**
For RC180, be sure to install the EPSON RC+5.0 to the development PC first, then
connect the development PC and RC180 with the USB cable.
If RC180 and the development PC are connected without installing the EPSON RC+5.0 to
the development PC, [Add New Hardware Wizard] appears. If this wizard appears, click
the <Cancel> button.
Concerning the security support for the network connection:
The network connecting function (Ethernet) on our products assumes the use in the local
network such as the factory LAN network. Do not connect to the external network such
as Internet.
In addition, please take security measure such as for the virus from the network connection
by installing the antivirus software.
Security support for the USB memory:
Make sure the USB memory is not infected with virus when connecting to the Controller.
Every data of the Controller is stored to the Compact Flash inside the Controller. When
you execute the commands listed below, data is written to the Compact Flash. Frequent
data writing to the Compact Flash may shorten the Compact Flash life. It is
recommended to use the following commands only when it is necessary.
- Renew the Point files (SavePoints)
- Change the Robot parameters (Base, Local, LocalClr, CalPls, Calib, Hofs,
ArmSet, ArmClr, HomeSet, HomeClr, Hordr, MCOder, Weight, JRange, Range,
XYLim, TLSet, TLClr, Arm, Tool, Inertia, EcpSet, EcpClr, Box, BoxClr, Plane,
PlaneClr)

NOTE

NOTE

NOTE

NOTE

NOTE

Table of Contents
RC180 Rev.17 v
Safety 1. Safety 3
2. Conventions 3
3. Safety Precautions 4
Setup & Operation
1. Specifications 9
1.1 System Example.......................................................................................9
1.2 Standard Specifications..........................................................................10
1.3 Outer Dimensions...................................................................................12
2. Part Names and Functions 13
2.1 Part Names.............................................................................................13
2.2 Functions.................................................................................................14
2.3 LED and Seven-segment LED................................................................17
2.3.1 LED and Seven-segment Display...............................................17
2.3.2 Particular Status Display.............................................................18
2.4 Safety Features.......................................................................................18
3. Installation 21
3.1 Unpacking...............................................................................................21
3.2 Environmental Requirements .................................................................21
3.2.1 Environment................................................................................21
3.2.2 Installation...................................................................................22
3.2.3 Install inside the Cabinet.............................................................24
3.3 Power Supply..........................................................................................25
3.3.1 Specifications..............................................................................25
3.3.2 AC Power Cable.........................................................................26
3.4 Cable Connection ...................................................................................26
3.4.1 Typical Cable Connection...........................................................27
3.4.2 Connecting Manipulator to Controller.........................................30
3.5 Noise Countermeasures.........................................................................32
4. Operation Mode (TEACH/AUTO) 33
4.1 Overview.................................................................................................33
4.2 Switch Operation Mode ..........................................................................33
4.3 Program Mode (AUTO)...........................................................................34
4.3.1 What is Program Mode (AUTO)? ...............................................34

Table of Contents
vi RC180 Rev.17
4.3.2 Setup from EPSON RC+5.0.......................................................34
4.3.3 Setup from Teach Pendant ........................................................34
4.4 Auto Mode (AUTO).................................................................................35
4.4.1 What is Auto mode (AUTO)?......................................................35
4.4.2 Setup from EPSON RC+ 5.0......................................................35
4.4.3 Setup from Control Device .........................................................36
5. Development PC Connection Port 37
5.1 About Development PC Connection Port...............................................37
5.2 Precaution...............................................................................................38
5.3 Software Setup and Connection Check.................................................38
5.4 Disconnection of Development PC and Controller.................................39
6. Memory Port 40
6.1 What is Controller Status Storage Function?.........................................40
6.2 Before Using Controller Status Storage Function..................................40
6.2.1 Precautions.................................................................................40
6.2.2 Adoptable USB Memory.............................................................40
6.3 Controller Status Storage Function........................................................41
6.3.1 Controller Status Storage with Trigger Button ...........................41
6.3.2 Controller Status Storage with Teach Pendant (Option)............41
6.3.3 Load Data with EPSON RC+ 5.0 ...............................................42
6.3.4 Transfer with E-mail....................................................................43
6.4 Details of Data........................................................................................44
7. LAN (Ethernet Communication) Port 45
7.1 About LAN (Ethernet Communication) Port...........................................45
7.2 IP Address..............................................................................................46
7.3 Changing Controller IP Address.............................................................46
7.4 Connection of Development PC and Controller with Ethernet...............48
7.5 Disconnection of Development PC and Controller
with Ethernet...........................................................................................49
8. TP/OP Port 50
8.1 What is TP/OP Port?..............................................................................50
8.2 Teach Pendant Connection....................................................................51
8.3 Operator Panel Connection....................................................................51
9. EMERGENCY 52
9.1 Safety Door Switch and Latch Release Switch......................................53
9.1.1 Safety Door Switch.....................................................................53

Table of Contents
RC180 Rev.17 vii
9.1.2 Latch Release Switch.................................................................54
9.1.3 Checking Latch Release Switch Operation................................54
9.2 Emergency Stop Switch Connection......................................................55
9.2.1 Emergency Stop Switch..............................................................55
9.2.2 Checking Emergency Stop Switch Operation............................55
9.2.3 Recovery from Emergency Stop.................................................55
9.3 Pin Assignments.....................................................................................56
9.4 Circuit Diagrams .....................................................................................57
9.4.1 Example 1:
External emergency stop switch typical application...................57
9.4.2 Example 2:
External safety relay typical application .....................................58
10. I/O Connector 59
10.1 Input Circuit.............................................................................................59
10.2 Output Circuit..........................................................................................61
10.3 Pin Assignment.......................................................................................63
11. I/O Remote Set Up 64
11.1 I/O Signal Description.............................................................................65
11.1.1 Remote Input Signals................................................................65
11.1.2 Remote Output Signals.............................................................68
11.2 Timing Specifications..............................................................................70
11.2.1 Design Notes for Remote Input Signals....................................70
11.2.2 Timing Diagram for Operation Execution Sequence................70
11.2.3 Timing Diagram for Program Execution Sequence..................70
11.2.4 Timing Diagram for Safety Door Input Sequence.....................71
11.2.5 Timing Diagram for Emergency Stop Sequence......................71
12. Option Units 72
12.1 What are Option Units? ..........................................................................72
12.2 Expansion I/O Board...............................................................................72
12.2.1 About Expansion I/O Board ......................................................72
12.2.2 Board Configuration (Expansion I/O)........................................72
12.2.3 Confirmation with EPSON RC+5.0...........................................73
12.2.4 Input Circuit...............................................................................73
12.2.5 Output Circuit ............................................................................75
12.2.6 Pin Assignments .......................................................................77
12.3 Fieldbus I/O Board..................................................................................79
12.3.1 Overview of Fieldbus I/O...........................................................79

Table of Contents
viii RC180 Rev.17
12.3.2 Response Speed of Fieldbus I/O..............................................79
12.3.3 Fieldbus I/O Board Configuration.............................................80
12.3.4 DeviceNet..................................................................................81
12.3.5 PROFIBUS-DP .........................................................................85
12.3.6 CC-Link.....................................................................................89
12.3.7 EtherNetI/P................................................................................99
12.3.8 PROFINET..............................................................................103
12.3.9Operation (DeviceNet, PROFIBUS-DP, EtherNetI/P) ............107
12.4 RS-232C Board ....................................................................................109
12.4.1 About RS-232C Board............................................................109
12.4.2 Board Setup (RS-232C)..........................................................110
12.4.3 Verify with EPSON RC+5.0 (RS-232C)..................................110
12.4.4 RS-232C Software Communication Setup (RS-232C)...........111
12.4.5 Communication Cable (RS-232C)..........................................111
Maintenance 1. Safety Precautions on Maintenance 115
1.1 Safety Precautions................................................................................115
1.2 Lockout / Tagout...................................................................................116
2. Regular Maintenance Inspection 117
2.1 Schedule for Maintenance Inspection..................................................117
2.2 Inspection Point....................................................................................118
2.2.1 Inspection While the Controller is Turned OFF........................118
2.2.2 Inspection While the Controller is Turned ON..........................118
3. Controller Structure 119
3.1 Location of Parts...................................................................................119
3.2 Diagram of Cable Connections ............................................................121
3.3 Connector Pin Assignment...................................................................124
3.3.1 M/C Power Connector..............................................................124
3.3.2 M/C Signal Connector..............................................................125
4. Backup and Restore 126
4.1 What is Backup Controller?..................................................................126
4.2 Backup Data Types..............................................................................126
4.3 Backup..................................................................................................127
4.3.1 Backup from EPSON RC+5.0..................................................127
4.3.2 Backup from the Teach Pendant (Option)................................128

Table of Contents
RC180 Rev.17 ix
4.4 Restore..................................................................................................130
4.4.1 Restore from EPSON RC+5.0..................................................130
4.4.2 Restore from Teach Pendant (Option).....................................132
5. Firmware Update 135
5.1 Updating Firmware................................................................................135
5.2 Firmware Upgrading Procedure ...........................................................135
5.3 Controller Recovery..............................................................................138
5.4 Firmware Initialization Procedure.........................................................139
6. Maintenance Parts Replacement Procedures 141
6.1 Fan and Fan Filter.................................................................................142
6.1.1 Cleaning and Replacing Fan Filter...........................................142
6.1.2 Replacing Fan Unit...................................................................143
6.1.3 Cleaning and Replacing Fan Filter of Option Unit....................145
6.2 Battery...................................................................................................146
6.3 Motor Driver..........................................................................................148
6.3.1 Part Names...............................................................................148
6.3.2 Replacing Motor Driver (Axis from 1 to 4)................................148
6.3.3 Replacing Motor Driver (Axis 5 and 6) .....................................153
6.4 CPU Board Unit ....................................................................................155
6.5 CF (Compact Flash)..............................................................................158
6.6 Fuse......................................................................................................159
6.7 Option Unit............................................................................................161
6.7.1 Remove Option Unit 1 ..............................................................161
6.7.2 Mount Option Unit 1..................................................................162
6.7.3 Remove Option Unit 2 ..............................................................162
6.7.4 Mount Option Unit 2..................................................................164
6.7.5 Remove Option Unit 1, 2..........................................................165
6.7.6 Mount Option Unit 1, 2..............................................................166
6.7.7 Replacing Adding Option Board...............................................167
7. Verifying Manipulator Operation 168
8. Trouble Shooting 169
8.1 Error Code table....................................................................................169
8.2 Cannot Connect the Development PC and the Controller
using the USB cable.............................................................................243
8.2.1 Confirmation Using Windows Device Manager........................243

Table of Contents
xRC180 Rev.17
8.2.2 When recognized under “Other devices”
in Windows Device Manager....................................................246
9. Maintenance Parts List 247
Appendix. Alarm 248

Safety
This section contains information for safety
of the Robot System.

Safety 1. Safety
RC180 Rev.17 3
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 in a handy location for easy access at all
times.
Read the Safety chapter in EPSON RC+ 5.0 User’s Guide and confirm Safety-related
requirements.
2. Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
This symbol indicates that a danger of possible
serious injury or
death exists if the associated instructions are not followed
properly.
WARNING
This symbol indicates that a danger of possible harm to people
caused by electric shock exists if the associated instructions are
not followed properly.
CAUTION
This symbol indicates that a danger of possible harm to people or
physical damage to equipment and facilities
exists if the
associated instructions are not followed properly.

Safety 3. Safety Precautions
4RC180 Rev.17
3. Safety Precautions
Only trained personnel should design and install the robot system.
Trained personnel are defined as those who have taken robot system training class 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.
The following items are safety precautions for qualified design or installation
personnel:
WARNING

Personnel
who design and/or construct the robot system with this product must
read the Safety chapter in 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.

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
problem
s.

The interlock of the Safety Door must be functioning when the
robot system is
operated.
Do not operate th
e system under the condition that the switch cannot
be turned ON/OFF. (I.E. the condition where the switch is disabled)
(Example: Tape is put around the switch to hold it closed.) Operating the robot
system when the switch is not
functioning properly is extremely hazardous and
may
cause serious safety problem
s as the Safety Door input cannot fulfill its
intended function
.

Connect input signal wires for Emergency Stop and Safety Door to the
EMERGENCY connector so that the Emergency Stop switch in the O
perator
Panel or Teach Pendant connected to the TP/OP port always functions. (Refer
to the typical application diagram in Setup & Operation 9.4
Circuit Diagrams.)

Safety 3. Safety Precautions
RC180 Rev.17 5
The following items are safety precautions for qualified design or installation
personnel: (cont.)
WARNING

Do not open the cover(s) of the Control
ler except while maintaining it. Opening
the cover(s) of the Controller is
extremely hazardous
and may result in electric
shock
even when its main power is OFF because of the high voltage charge
inside the Control
ler.

Make sure that the power to the Control
ler is turned OFF
before connecting or
disconnecting any cables.
Connecting or disconnecting
any cables with the
power ON
is extremely hazardous and may result in electric shock and/or
ma
lfunction of the Controller.

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 a contact failure is extremely hazardous and may result in electric shock and/or
improper function of the system.

When
connecting the plug to fit the outlet in your factory, make sure that it is done
by qualified personnel. When connecting the plug,
be sure to connect the earth
wire of the AC power cable colored green/yellow
on the Controller to the earth
terminal of the factory power supply.
The equipment must be grounded properly
at all times to avoid the risk of electric shock.
Always use a power plug and
receptacle
. Never connect the Controller directly to the factory power supply.
(Field wiring)
CAUTION

The serial number of the Manipulator
that should be connected is indicated on the
Connection Check Label
on the Controller. Connect the Controller and the
Manipulator correctly.
Improper connection between the Controller and the
Manipulator may cause improper function of the robot system an
d also safety
problems.

When using remote I/O, always make sure of the following. Using the robot
system under
unsatisfactory
conditions may cause malfunction of the system
and/or safety problems.
-
Assign remote functions to inputs/outputs correctly
and wire correctly when
setting up remote I/O signals.
-
Make sure that the functions correspond to the correct input/output signals
before turning ON the system.
-
When verifying the robot system operation, prepare for failures with initial
settings or wiring. If the Manipulator functions unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to stop
the Manipulator.

Safety 3. Safety Precautions
6RC180 Rev.17
The following items are safety precautions for qualified operator personnel:
WARNING

The interlock of the Safety Door must be functioning when the
robot system is
operated. Do not operate the system under the condition that the switch cannot
be turned ON/OFF. (I.E. the condition where the switch is disabled)
(Example: Tape is put around the switch to hold it closed.) Operating the robot
system when the switch is not
functioning properly is extremely hazardous and
may
cause serious safety problem
s as the Safety Door input cannot fulfill its
intended function
.
WARNING

Do not open the cover(s) of the Control
ler except while maintaining it. Opening
the cover(s) of the Controller is
extremely hazardous
and may result in electric
shock
even when its main power is OFF because of the high voltage charge
inside the Control
ler.

Setup & Operation
This section contains information for setup and operation
of the Robot Controller.