Epson RC90 User manual

Rev.4 EM145C2707F
ROBOT CONTROLLER
RC90
(EPSON RC+ 7.0)

ROBOT CONTROLLER RC90 (EPSON RC+ 7.0) Rev.4

ROBOT CONTROLLER
RC9 0
(EPSON RC+ 7.0)
Rev.4
Copyright © 2013-2014 SEIKO EPSON CORPORATION. All rights reserved.
RC90 (EPSON RC+ 7.0) Rev.4 i

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.
ii RC90 (EPSON RC+ 7.0) Rev.4

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.
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
RC90 (EPSON RC+ 7.0) Rev.4 iii

MANUFACTURER
Toyoshina Plant
Industrial Solutions Division
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
: [email protected]pson.com
Europe
EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto
-Hahn-Str.4
D
-40670 Meerbusch
Germany
TEL
: [phone]
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
iv RC90 (EPSON RC+ 7.0) Rev.4

Southeast Asia
EPSON Singapore Pte Ltd.
India
Factory Automation System
1 HarbourFrontPlace, #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)
27F DaeSung D
-Polis A, 606,
Seobusaet
-gil, Geumcheon-gu, Seoul, 153-803
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]
RC90 (EPSON RC+ 7.0) Rev.4 v

Before Reading This Manual
Do not connect the followings to the TP/OP port of RC90. 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**
Operator Panel OP1
For RC90, be sure to install the EPSON RC+ 7.0 to the development PC first, then connect
the development PC and RC90 with the USB cable.
If RC90 and the development PC are connected without installing the EPSON RC+ 7.0 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.

NOTE

NOTE

NOTE

NOTE
vi RC90 (EPSON RC+ 7.0) Rev.4

Control System Configuration
This manual explains with the following combinations of Controllers and software.
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.
Manual PDF for this robot system is available from EPSON RC+ 7.0 Ver. 7.0.2
This option is not available for Robot Controller RC90 (EPSON RC+ 5.0) without the label.

NOTE

NOTE
RC90 (EPSON RC+ 7.0) Rev.4 vii

viii RC90 (EPSON RC+ 7.0) Rev.4

Table of Contents
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 .............................................................................................. 13
2.3 LED ....................................................................................................... 15
2.4 Safety Features..................................................................................... 16
3. Installation 18
3.1 Unpacking ............................................................................................. 18
3.2 Environmental Requirements ............................................................... 18
3.2.1 Environment .............................................................................. 18
3.2.2 Installation ................................................................................. 19
3.3 Power Supply........................................................................................ 20
3.3.1 Specifications ............................................................................ 20
3.3.2 AC Power Cable........................................................................ 21
AC Power Cable Connection................................................................ 21
3.3.3 M/C Power Cable ...................................................................... 22
3.4 Cable Connection ................................................................................. 23
3.4.1 Typical Cable Connection ......................................................... 23
3.4.2 Connecting Manipulator to Controller ....................................... 25
LS3 series and RC90 Connection ........................................................ 25
3.5 Noise Countermeasures ....................................................................... 26
RC90 (EPSON RC+ 7.0) Rev.4 ix

Table of Contents
4. Operation Mode (TEACH/AUTO/TEST) 27
4.1 Overview................................................................................................27
4.2 Switch Operation Mode .........................................................................27
4.3 Program Mode (AUTO) .........................................................................28
4.3.1 What is Program Mode (AUTO)?...............................................28
4.3.2 Setup from EPSON RC+ 7.0 .....................................................28
4.4 Auto Mode (AUTO)................................................................................29
4.4.1 What is Auto mode (AUTO)? .....................................................29
4.4.2 Setup from EPSON RC+ 7.0 .....................................................29
4.4.3 Setup from Control Device.........................................................30
5. Development PC Connection Port 31
5.1 About Development PC Connection Port..............................................31
5.2 Precaution..............................................................................................32
5.3 Software Setup and Connection Check ................................................32
5.4 Disconnection of Development PC and Controller................................33
6. Memory Port 34
6.1 What is Controller Status Storage Function?........................................34
6.2 Before Using Controller Status Storage Function .................................34
6.2.1 Precautions ................................................................................34
6.2.2 Adoptable USB Memory ............................................................34
6.3 Controller Status Storage Function .......................................................35
6.3.1 Controller Status Storage with Trigger Button...........................35
6.3.2 Load Data with EPSON RC+ 7.0...............................................35
6.3.3 Transfer with E-mail ...................................................................37
6.4 Details of Data .......................................................................................37
7. LAN (Ethernet Communication) Port 38
7.1 About the LAN (Ethernet Communication) Port....................................38
7.2 IP Address .............................................................................................38
7.3 Changing Controller IP Address............................................................39
7.4 Connection of Development PC and Controller with Ethernet..............40
7.5 Disconnection of Development PC and Controller withEthernet ..........41
xRC90 (EPSON RC+ 7.0) Rev.4

Table of Contents
8. TP Port 42
8.1 What is the TP Port?............................................................................. 42
8.2 Teach Pendant Connection .................................................................. 42
9. EMERGENCY 43
9.1 Safety Door Switch and Latch Release Switch .................................... 43
9.1.1 Safety Door Switch.................................................................... 44
9.1.2 Latch Release Switch................................................................ 44
9.1.3 Checking Latch Release Switch Operation .............................. 45
9.2 Emergency Stop Switch Connection .................................................... 46
9.2.1 Emergency Stop Switch............................................................ 46
9.2.2 Checking Emergency Stop Switch Operation........................... 46
9.2.3 Recovery from Emergency Stop............................................... 46
9.3 Pin Assignments ................................................................................... 47
9.4 Circuit Diagrams ................................................................................... 48
9.4.1 Example 1: External emergency stop switch typical application48
9.4.2 Example 2: External safety relay typical application................. 49
10. Standard RS-232C Port 50
10.1 About the RS-232C Port..................................................................... 50
10.2 Confirmation with EPSON RC+ 7.0.................................................... 50
10.3 RS-232C Software Communication Setup (RS-232C)....................... 51
10.4 Communication Cable (RS-232C) ...................................................... 51
11. I/O Connector 52
11.1 Input Circuit......................................................................................... 52
Typical Input Circuit Application 1......................................................... 52
Typical Input Circuit Application 2......................................................... 53
11.2 Output Circuit ...................................................................................... 54
Typical Output Circuit Application 1: Sink Type ................................... 55
Typical Output Circuit Application 2: Source Type............................... 56
11.3 Pin Assignments ................................................................................. 57
RC90 (EPSON RC+ 7.0) Rev.4 xi

Table of Contents
12. I/O Remote Settings 58
12.1 I/O Signal Description..........................................................................59
12.1.1 Remote Input Signals ..............................................................59
12.1.2 Remote Output Signals............................................................63
12.2 Timing Specifications...........................................................................66
12.2.1 Design Notes for Remote Input Signals ..................................66
12.2.2 Timing Diagram for Operation Execution Sequence...............66
12.2.3 Timing Diagram for Program Execution Sequence.................66
12.2.4 Timing Diagram for Safety Door Input Sequence....................67
12.2.5 Timing Diagram for Emergency Stop Sequence.....................67
13. Option Slots 68
13.1 What are Option Slots? .......................................................................68
13.2 Expansion I/O Board ...........................................................................68
13.2.1 About Expansion I/O Board .....................................................68
13.2.2 Board Configuration (Expansion I/O).......................................68
13.2.3 Confirmation with EPSON RC+ 7.0.........................................69
13.2.4 Input Circuit..............................................................................69
13.2.5 Output Circuit ...........................................................................71
13.2.6 Pin Assignments ......................................................................74
13.3 Fieldbus I/O Board...............................................................................75
13.4 RS-232C Board ...................................................................................76
13.4.1 About the RS-232C Board.......................................................76
13.4.2 Board Setup .............................................................................76
13.4.3 Confirmation with EPSON RC+ 7.0 (RS-232C) ......................77
13.4.4 RS-232C Software Communication Setup (RS-232C)............77
13.4.5 Communication Cable (RS-232C) ...........................................78
Maintenance
1. Safety Precautions on Maintenance 81
1.1 Safety Precautions ................................................................................81
1.2 Lockout / Tagout....................................................................................82
Installing the Lockout Attachment .........................................................82
Padlock Size and Weight.......................................................................83
Safety Precautions.................................................................................83
xii RC90 (EPSON RC+ 7.0) Rev.4

Table of Contents
2. Regular Maintenance Inspection 84
2.1 Schedule for Maintenance Inspection .................................................. 84
2.2 Inspection Point .................................................................................... 85
2.2.1 Inspection While the Controller is Turned OFF......................... 85
2.2.2 Inspection While the Controller is Turned ON .......................... 85
3. Controller Structure 86
3.1 Location of Parts................................................................................... 86
3.2 Diagram of Cable Connections............................................................. 86
4. Backup and Restore 87
4.1 What is the Backup Controller Function? ............................................. 87
4.2 Backup Data Types .............................................................................. 87
4.3 Backup .................................................................................................. 88
4.4 Restore.................................................................................................. 88
5. Firmware Update 91
5.1 Updating Firmware................................................................................ 91
5.2 Firmware Upgrade Procedure .............................................................. 91
5.3 Controller Recovery .............................................................................. 94
5.4 Firmware Initialization Procedure ......................................................... 95
6. Alarm 97
6.1 Alarm Configuration .............................................................................. 97
6.1.1 Robot Battery and Grease Up................................................... 97
6.1.2 Controller Battery ...................................................................... 98
6.2 How to View the Alarm Information......................................................98
6.3 How to Edit the Alarm Information........................................................ 99
6.4 Alarm Notifying Method ........................................................................ 99
6.5 How to Cancel the Alarm.................................................................... 100
6.5.1 Alarm Cancellation Dialog....................................................... 100
6.5.2 Remote Input........................................................................... 100
7. Maintenance Parts Replacement Procedures 101
7.1 Fan Filter............................................................................................. 101
7.2 Fan ...................................................................................................... 102
7.3 Battery................................................................................................. 103
RC90 (EPSON RC+ 7.0) Rev.4 xiii

Table of Contents
7.4 CF (Compact Flash) ............................................................................104
7.5 MDB .....................................................................................................105
7.6 DMB .....................................................................................................107
7.7 DMB Sub Board...................................................................................111
7.8 Option Board........................................................................................112
8. Verifying Robot System Operation 114
9. Troubleshooting 115
9.1 Error Code Table .................................................................................115
9.2 Cannot Connect the Development PC and the Controller using
the USB cable......................................................................................197
9.2.1 Confirmation Using Windows Device Manager.......................198
9.2.2 When recognized under “Other devices” in Windows
Device Manager ......................................................................200
10. Maintenance Parts List 201
xiv RC90 (EPSON RC+ 7.0) Rev.4

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

Safety 1. Safety
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.
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.
RC90 (EPSON RC+ 7.0) Rev.4 3

Safety 3. Safety Precautions
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 n
ormal 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 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
.

Connect input signal wires for Emergency Stop and Safety Door to the
EMERGENCY connector so that the Emergency Stop switch in the Teach
Pendant connected to the TP port always functions. (Refer to the typical
application diagram in Setup & Operation 9.4
Circuit Diagrams.)
4RC90 (EPSON RC+ 7.0) Rev.4