Epson RC700 User manual

Rev.2 EM132C2449F
Robot Controller
RC700 / RC90 Option
PG Motion System

Robot Controller RC700 / RC90 Option PG Motion System Rev.2

RC700 / RC90 Option PG Motion System Rev.2 i
Robot Controller RC700/ RC90 Option
PG Motion System
Rev.2
Copyright 2012-2013 SEIKO EPSON CORPORATION. All rights reserved.

ii RC700/ RC90 Option PG Motion System Rev.2
FOREWORD
Thank you for purchasing this product. This manual is intended for the users who setup
and program the PG Motion System.
Please thoroughly read this and other related manuals prior to and while using this option.
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’ unauth
orized disassembly.
3.
Damage due to improper adjustments or unauthorized repair attempts.
4.
Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1.
If the Manipulator or associated equipment is used outside of the usage conditions 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.

RC700 / RC90 Option PG Motion System Rev.2 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
Throughout this manual, Windows XP, Windows Vista, and Windows 7 refer to above
respective operating systems. In some cases, Windows refers generically to Windows XP,
Windows Vista, and Windows 7.
NOTICE No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
INQUIRIES
Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier office for
your region.
Please prepare the following items before you contact us.
-Your controller model and its serial number
-Your manipulator model and its serial number
-Software and its version in your robot system
-A description of the problem
SERVICE CENTER

iv RC700/ RC90 Option PG Motion System Rev.2
MANUFACTURER
Toyoshina Plant
Factory Automation Systems Dept
.
6925 Toyoshina Tazawa,
Azumino
-shi, Nagano, 399-8285
JAPAN
TEL
: [phone]
FAX
: [phone]
SUPPLIERS
North & South America
EPSON AMERICA, INC.
Factory Automation/Robotics
18300 Central Avenue
Carson, CA 90746
USA
TEL
: +1-562
-
290-5900
FAX
: +1-562
-
290-5999
E-MAIL
: [e-mail]
Europe
EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto
-Hahn-Str.4
D
-40670 Meerbusch
Germany
TEL
: +49
-
(0)-2159
-
538-1391
FAX
: [phone]
E-MAIL
: [e-mail]
China
EPSON China Co., Ltd
Factory Automation Division
7F, Jinbao Building No. 89 Jinbao Street
Dongcheng District, Beijing,
China, 100005
TEL
: [phone]
-
1199
FAX
: +86-(0)-10
-
8522-1120
Taiwan
EPSON Taiwan Technology & Trading Ltd.
Factory Automation Division
14F, No.7, Song Ren Road, Taipei 110
Taiwan, ROC
TEL
: [phone]
-
6688
FAX
: +886-(0)-2
-
8786
-
6677

RC700 / RC90 Option PG Motion System Rev.2 v
Southeast Asia
EPSON Singapore Pte Ltd.
India
Factory Automation System
1 HarbourFrontP
lace, #03-02
HarbourFront Tower one, Singapore
098633
TEL
: +65-(0)-6586
-
5696
FAX
: +65-(0)-6271
-
3182
Korea
EPSON Korea Co, Ltd.
Marketing Team (Robot Business)
11F Milim Tower, 825
-22
Yeoksam
-dong, Gangnam-gu, Seoul, 135-934
Korea
TEL
: [phone]
-
6692
FAX
: +82-(0)-2-558
-
4271
Japan
EPSON SALES JAPAN CORPORATION
Factory Automation Systems Department
Nishi
-Shinjuku Mitsui Bldg.6-24-1
Nishishinjuku
．Shinjuku-ku．Tokyo．160-8324
JAPAN
TEL
: [phone]

vi RC700/ RC90 Option PG Motion System Rev.2
Before Reading This Manual
This section describes what you should know before reading this manual.
Safety Precautions
Installation of robots and robotic equipment should only be performed by qualified
personnel in accordance with national and local codes. Please carefully 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. Please read the Safety chapter in
User’s Guide to understand safety requirements before installing the robot system.
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 danger of possible serious
injury or death exists if the associated instructions are
not followed properly.
WARNING
This symbol indicates that 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.
CAUTION
■
Install a separate hardware piece, an emergency stop circuit
for the motor drive
that your PG board will be driving (apart from the emergency stop that inputs to
the Controller) to securely stop the
robot when an emergency stop occurs. The
emergency stop input at the Pulse Generating Board is designed to be
processed within the software.
■
Carefully read the manual for the motor drive you are using and follow both the
safety and caution principles
.
■
Always turn OFF the power before installing or wiring the PG board to the
Controller. Installing or wiring the PG board while the power is ON may result in
electric shock, abnormal operation of the robot system, and/or malfunction of the
Controller a
nd PG board.
■
Use extra caution when setting PG robot parameter values.
The validity of the data is not completely checked or adjusted. If improper
settings are used, the robot may move unexpectedly. The unexpected
movement of the robot is extremel
y hazardous and may cause damage to the
robot and/or peripheral equipment.

RC700 / RC90 Option PG Motion System Rev.2 vii
Control System Configuration
This option is used with the following combinations of Controllers and software.
TYPE A:
Controller
Software
RC700 EPSON RC+ 7.0
TYPE B: Robot Controller RC90 with the following label attached.
Label
Controller
Software
RC90 EPSON RC+ 7.0
RC90 controller firmware
Ver.7.0.2.0
EPSON RC+ 7.0
Before Ver.7.0.1
!!!
Ver.7.0.2 or later
OK
OK: Compatible All functions of the EPSON RC+ 7.0 and the Controller are
available.
!!!: Compatible Connection is OK. We recommend using EPSON RC+7.0 Ver.
7.0.2 or later.
This option is not available for Robot Controller RC90 (EPSON RC+ 5.0) without the
label.
Manual PDF for TYPE B is available from EPSON RC+ 7.0 Ver. 7.0.2

NOTE

NOTE

viii RC700/ RC90 Option PG Motion System Rev.2

Table of Contents
RC700 / RC90 Option PG Motion System Rev.2 ix
1. Getting Started 1
1.1 Introduction........................................................................................................1
1.2 System Overview...............................................................................................1
1.3 How to Setup and Use the System ....................................................................2
1.3.1 Hardware Setup Overview......................................................................2
1.3.2 Software Setup Overview.......................................................................2
2. Hardware 3
2.1 PG Board Specifications....................................................................................3
2.2 Part Names and Functions.................................................................................5
2.2.1 Component Names & Locations.............................................................5
2.2.2 DIP Switch Settings................................................................................6
2.2.3 Jumper Settings .....................................................................................7
2.2.4 Rotary Switch Settings ...........................................................................7
2.2.5 LEDs.......................................................................................................7
2.2.6 Connectors.............................................................................................7
2.2.7 Installation in the Controller....................................................................7
2.3 Internal Circuitry.................................................................................................8
2.3.1 Signal Functions.....................................................................................8
2.3.2 Input Circuit ..........................................................................................10
2.3.3 Output Circuit .......................................................................................11
2.4 Wiring...............................................................................................................12
2.4.1 Minimizing Noise Interference..............................................................12
2.4.2 Connectors...........................................................................................13
2.4.3 PG Board Connector Pin Outs .............................................................14
2.4.4 PG Terminal Block Pin Outs.................................................................16
2.4.5 Typical Applications..............................................................................18
2.5 Safety Features................................................................................................19
2.5.1 Typical Application of Emergency Stop Circuit.....................................20
3. Software 21
3.1 Creating PG Robots in EPSON RC+ ...............................................................21
3.2 PG Robot Configuration...................................................................................23
3.2.1 PG Robot Parameters Overview ..........................................................23
3.2.2 PG Parameters.....................................................................................24
3.2.3 PG Parameters joint.............................................................................25
3.2.4 Backup and Restore Parameter Data...................................................30
3.3 [Robot Manger] Configuration..........................................................................32

Table of Contents
xRC700/ RC90 Option PG Motion System Rev.2
3.3.1 Overview of [Robot Manager] ..............................................................32
3.3.2 [Range] ................................................................................................33
3.3.3 [Home Config]......................................................................................33
3.3.4 [Mcal Order].........................................................................................34
3.4 Using PG Robots in EPSON RC+ ...................................................................35
3.4.1 PG Cartesian Robots...........................................................................35
3.4.2 PG Joint Robots...................................................................................35
3.4.3 Tuning..................................................................................................35
3.4.4 Motion Commands...............................................................................36
3.4.5 SLock and SFree.................................................................................36
3.4.6 Dry Run................................................................................................36
3.4.7 PG Signal Status Display.....................................................................37
4. Calibration Types 38
5. Troubleshooting 50
6. Maintenance Parts List 54

1. Getting Started
RC700 / RC90 option PG motion system Rev.2 1
1. Getting Started
1.1 Introduction
The PG Motion System option enables you to create robots that use third party drives and
motors. PG robots can coexist with and behave similar to standard robots in the EPSON
RC+ system. Use PG robots to control auxiliary equipment such as XY tables, slides,
rotary axes, etc.
Features include:
One or more PG robots can be used along with standard robots on the same system. (Max.
16 robots in total)
PG robots can be a Cartesian or Joint type.
Both stepper motors and servo motors are supported.
Cartesian type PG robots with 2 or more axes can use Vision Guide.
PG robots are fully integrated into the EPSON RC+ environment and basically operate the
same as standard robots.
Safety features include Emergency Stop, Safeguard, over travel limits, and drive alarm.
Before using the PG Motion System option, read through this entire manual.
1.2 System Overview
The PG Motion System is a Robot Controller RC700 / RC90 option that includes a
software component of EPSON RC+ and one or more Pulse Generator boards. The
customer supplies the drives and motors using third party equipment.
The PG Motion System supports up to 4 PG boards for RC700 and 2 PG boards for RC90.
Each board has four channels, which allows a total of sixteen joints for RC700 and eight
joints for RC90. A PG robot can have from 1 to 4 joints for Cartesian coordinate robot, 1
to 7 joints for the Joint type robot.
Included in this package:
Pulse Generator board (hereinafter referred to as PG board)
PG board label (attached only if the PG board is purchased separately)
PG board connector
(Plug:DX40-100P, Cover:DX-100-CV-1 Hirose Electric Co.,Ltd.)
A PG board cable is available as an optional part. This cable is configured as shown
below:
PG board
100 Pin 50 Pin 2
57FE-30500-20N (D8)
(DDK)
57FE-30500-20N (D8)
(DDK)
1 m

1. Getting Started
2RC700 / RC90 option PG motion system Rev.2
1.3 How to Setup and Use the System
The following sections describe the basic steps on how to setup and use the PG Motion
System.
1.3.1 Hardware Setup Overview
Refer to Chapter 2, Hardware for the following instructions:
(1) Read the entire Hardware chapter and design the PG hardware for your system.
Two examples are provided.
(2) Configure and install one or more PG boards in the Controller.
(3) Wire cables for PG boards and drives.
1.3.2 Software Setup Overview
Refer to Chapter 3, Software for the following instructions:
(1) Create one or more PG robots in the EPSON RC+ system configuration.
(2) Test each PG robot and verify that all safety features are operating properly.
(3) Write SPEL+ software to control PG robots from your EPSON RC+ applications.

2. Hardware
RC700 / RC90 option PG motion system Rev.2 3
2. Hardware
This chapter describes the PG board hardware including the functions, switch settings, and
internal circuits of the PG board.
2.1 PG Board Specifications
Item Description
Board Name H756
Compatible Controller RC700 / RC90
Expansion Capability RC700: 4 boards maximum / RC90: 2 boards maximum
Control Axes 4 axes per board
Target Motor Either servo motors or stepper motors can be used.
Output Pulse Rate 0.1 pps to 6.5 Mpps
Speed Setting 100 steps in the program with the flexible maximum speed setting. The calibration speed can be programmed
separately from the normal operation speeds.
Acceleration Settings The program provides 100 steps each for Acceleration and Deceleration. (The maximum acceleration or maximum
deceleration setting can be changed.)
Arm Travel Range [pulse] 2,147,483,647 to 2,147,483,647 (32 bits)
Pulse Output Type Selectable in software: Pulse / Direction Output Method or
CW / CCW Pulse Output Method
Rotating Direction Programmable in the software.
Positioning Method The DEND (detection-end) signal generated from the
servo drive (when a servo drive is used).
Calibration Selectable from the seven (7) calibration types in the
software.
Stop Function The pulse generation to be stopped at the input of either
the limit or alarm signal.
S-curved
Acceleration/Deceleration Selectable in software
Continuous Rotation Selectable in software
Relative Quantity Travel Selectable in software

2. Hardware
4RC700 / RC90 option PG motion system Rev.2
Item Description
Output Signal Counter reset (DRST)signal
Input Signal - Origin signal (ORG). Normally open.
- Near-to-origin signal (NORG). Normally open.
- CW limit signal (CWLM). Normally closed.
- CCW limit signal (CCWLM). Normally closed.
- Alarm signal (ALM)
- Encoder Phase -Z signal (ZORG)
- Detection-end signal (DEND)
Safety Features The following safety features of Robot Controller RC700 /
RC90 are supported:
- Emergency Stop Input
- Safeguard Input
- Enable SW Input
- Low/High Power Mode
Board Address Set by DIP switches on the board.
I/F Connector on the Board DX10A-100S (Hirose Electric Co.,Ltd.)
Power Supply 5 V ±5 % 1.0 A (max.)
24 V ±2 V 200 mA (max.)
(from the external power source)
PG Robot Limitations Refer to the section 3.4 Using PG robots in EPSON RC+

2. Hardware
RC700 / RC90 option PG motion system Rev.2 5
2.2 Part Names and Functions
2.2.1 Component Names & Locations
JP1
CN2
134
130
CN1
CN3
X
Y
S3
S2S1
Rotary switch : S1
DIP Switch : S2, S3
LED : X, Y
Jumpers : JP1
Connectors : CN1, CN2, CN3

2. Hardware
6RC700 / RC90 option PG motion system Rev.2
2.2.2 DIP Switch Settings
The board number is set by DIP switch (S2, S3) on the PG board.
The first PG board must be set as shown below:
1 2 3 4 1 2 3 4
ON
ON : 0
OFF : 1
DIP switch S2 DIP switch S3
ON
The second PG board must be set as shown below:
1 2 3 4 1 2 3 4
ON
ON : 0
OFF : 1
DIP switch S2 DIP switch S3
ON
The third PG board must be set as shown below:
1 2 3 4 1 2 3 4
ON
ON : 0
OFF : 1
DIP switch S2 DIP switch S3
ON
The fourth PG board must be set as shown below:
1 2 3 4 1 2 3 4
ON
ON : 0
OFF : 1
DIP switch S2 DIP switch S3
ON
If you purchased the PG board alone, apply the provided board number seal to the board
panel before installing to the controller and be sure to keep a written record of the board
number.
If the board has been already installed before shipment, the board number is properly
configured and there is no need of your further configuration.
)
NOTE If you use the PG board for the conveyor tracking, use another address for the PG board of
the PG motion system. For example, if the PG board 1 is used for the conveyor tracking,
then use the PG board 2 for the PG motion system.

2. Hardware
RC700 / RC90 option PG motion system Rev.2 7
2.2.3 Jumper Settings
Do not change the jumper settings. At shipment, it is set as below:
JP1 : with jumpers
2.2.4 Rotary switch Settings
Do not change the Rotary switch S1 settings. At shipment, it is set as below:
S1 : Position of 1
2.2.5 LED s
The LEDs on the board are used to monitor the following signals:
X, Y : Inside status of each axis. Turns ON when ready to receive a command.
2.2.6 Connectors
CN1 : Connection for the external devices
(Refer to the section 2.3 Internal Circuitry for further details.)
CN2 : Unused
CN3 : Connector for internal connection
2.2.7 Installation in the Controller
Turn OFF the Controller.
Remove the open slot panel at the front of the Controller. Install the PG board and
secure it with screws. For details, refer to the instruction sheet attached to the board.
Once the board is installed, refer to the section 3.1 Creating PG Robots in EPSON RC+
for software installation and settings.

2. Hardware
8RC700 / RC90 option PG motion system Rev.2
2.3 Internal Circuitry
2.3.1 Signal Functions
The table below describes the function of each PG board signal.
Direction Signal Name Function Description
+COM +COMMON for CWP
and CCWP
Outputs the +5V power source for the CWP and CCWP signals.
+DRSTCOM +COMMON for DRST Outputs +5V for DRST signal.
CWP
CWP
Outputs CW pulses Generates the pulse train for the CW direction when the Pulse
Output parameter is set to CW/CCW.
Generates the pulse train when the Pulse Output parameter is set to
Pulse / Direction.
CCWP
CCWP
Outputs CCW pulses Generates the pulse train for the CCW direction when the Pulse
Output parameter is set to CW/CCW.
Generates the direction signal when the Pulse Output parameter is
set to Pulse / Direction (clockwise when the CCWP is low).
DRST Drive reset signal Outputs a signal to reset the drive's deviation counter.
If the pulse output is put into a rapid stop, the DRST signal = Low is
output for 10 ms.
Must be disconnected when a stepper motor is used.
Output
SVON Servo ON signal Outputs the servo ON signal when connecting the PG board to the
servo drive. Must be left disconnected when a stepper motor is
used.
The signal is OFF when controller is launched.
It turns OFF automatically when any one of the joints within a
manipulator indicates either a servo error or limit switch related
errors.