EPSON RC700, RC90 User Manual
Rev.5 EM208C4437F
Robot Controller
RC700 / RC90 Option
PG Motion System
Robot Controller RC700 / RC90 Option PG Motion System Rev.5
Robot Controller RC700 / RC90 Option
PG Motion System
Rev.5
Copyright 2012-2020 SEIKO EPSON CORPORATION. All rights reserved.
RC700 / RC90 Option PG Motion System Rev.5 i
FOREWORD
1. Damage or malfunction caused by improper use which is not described in the manual,
or ca
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.
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.
Thank you for purchasing our robot products.
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):
reless use.
Warnings, Cautions, Usage:
ii RC700 / RC90 Option PG Motion System Rev.5
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
TRADEMARK NOTATION IN THIS MANUAL
Microsoft® Windows® 8 Operating system
Microsoft® Windows® 10 Operating system
Throughout this manual, Windows 8, and Windows 10 refer to above respective operating
systems. In some cases, Windows refers generically to Windows 8, and Windows 10.
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
CONTACT INFORMATION
Contact information is described in “SUPPLIERS” in the first pages of the following
manual:
Robot System Safety and Installation Read this manual first
RC700 / RC90 Option PG Motion System Rev.5 iii
Before Reading This Manual
■
Install a separate hardware piece, an emergency stop circuit
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
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
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 and PG board.
■
Use extra caution w
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 extremely hazardous and may cause damage to
robot and/or peripheral equipment.
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.
This symbol indicates that danger of possible serious
WARNING
This symbol indicates that danger of possible harm to
WARNING
injury or death exists if the associated instructions are
not followed properly.
people caused by electric shock exists if the associated
instructions are not followed properly.
CAUTION
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.
for the motor drive
input at the Pulse Generating Board is designed to be
.
installing or wiring the PG board to the
hen setting PG robot parameter values.
iv RC700 / RC90 Option PG Motion System Rev.5
the
Control System Configuration
Controller
Software
RC90 controller firmware
Ver.7.0.2.0
Before Ver.7.0.1
!!!
Ver.7.0.2 or later
OK
NOTE
NOTE
This option is used with the following combinations of Controllers and software.
TYPE A:
RC700 EPSON RC+ 7.0
TYPE B: Robot Controller RC90 with the following label attached.
Label
EPSON RC+ 7.0
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.
Controller Software
RC90 EPSON RC+ 7.0
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
RC700 / RC90 Option PG Motion System Rev.5 v
vi RC700 / RC90 Option PG Motion System Rev.5
Table of Contents
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
RC700 / RC90 Option PG Motion System Rev.5 vii
Table of Contents
3.4 Using PG Robots in EPSON RC+ ..................................................................... 35
4. Calibration Types 38
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
3.4.1 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
5. Troubleshooting 50
6. Maintenance Parts List 54
viii RC700 / RC90 Option PG Motion System Rev.5
1. Getting Started
PG board
100 Pin
50 Pin
× 2
57FE-30500-20N (D8)
(DDK)
57FE-30500-20N (D8)
(DDK)
1 m
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.
1. Getting Started
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:
RC700 / RC90 option PG motion system Rev.5 1
1. Getting Started
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 RC700 / RC90 option PG motion system Rev.5
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
2. Hardware
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
Arm Travel Range [pulse]
Pulse Output Type
Rotating Direction Programmable in the software.
Positioning Method
Calibration
Stop Function
S-curved
Acceleration/Deceleration
Continuous Rotation Selectable in software
Relative Quantity Travel Selectable in software
The program provides 100 steps each for Acceleration and
Deceleration. (The maximum acceleration or maximum
deceleration setting can be changed.)
− 2,147,483,647 to 2,147,483,647 (32 bits)
Selectable in software: Pulse / Direction Output Method or
CW / CCW Pulse Output Method
The DEND (detection-end) signal generated from the servo
drive (when a servo drive is used).
Selectable from the seven (7) calibration types in the
software.
The pulse generation to be stopped at the input of either the
limit or alarm signal.
Selectable in software
RC700 / RC90 option PG motion system Rev.5 3
2. Hardware
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
PG Robot Limitations Refer to the section 3.4 Using PG robots in EPSON RC+
5 V ±5 % 1.0 A (max.)
24 V ±2 V 200 mA (max.)
(from the external power source)
4 RC700 / RC90 option PG motion system Rev.5
2.2 Part Names and Functions
JP1
CN2
134
130
CN1
CN3
X
Y
S3
S2
S1
2.2.1 Component Names & Locations
2. Hardware
Rotary switch : S1
DIP Switch : S2, S3
LED : X, Y
Jumpers : JP1
Connectors : CN1, CN2, CN3
RC700 / RC90 option PG motion system Rev.5 5
2. Hardware
1 2 3 4 1 2 3 4
ON
ON : 0
OFF : 1
DIP switch
S2
DIP switch S3
ON
1 2 3 4 1 2 3 4
ON
ON : 0
OFF : 1
DIP switch S2
DIP switch S3
ON
1 2 3 4 1 2 3 4
ON
ON : 0
DIP switch S2
DIP switch S3
ON
1 2 3 4 1 2 3 4
ON
ON : 0
DIP switch S2
DIP switch S3
ON
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:
The second PG board must be set as shown below:
The third PG board must be set as shown below:
OFF : 1
The fourth PG board must be set as shown below:
OFF : 1
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.
6 RC700 / RC90 option PG motion system Rev.5
2.2.3 Jumper Settings
Do not change the jumper settings. At shipment, it is set as below:
2. Hardware
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 LEDs
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.
RC700 / RC90 option PG motion system Rev.5 7
2. Hardware
+COMMON for CWP
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
Output +COM
+DRSTCOM
CWP
CWP
CCWP
CCWP
DRST Drive reset signal Outputs a signal to reset the drive's deviation counter.
SVON Servo ON signal Outputs the servo ON signal when connecting the PG board to the
Outputs the +5V power source for the CWP and CCWP signals.
and CCWP
+COMMON for DRST Outputs +5V for DRST signal.
Outputs CW pulses
Outputs CCW 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.
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).
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.
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.
8 RC700 / RC90 option PG motion system Rev.5
2. Hardware
clockwise (CW) pulses are generated.
Connect to either a photo or magnetic normally open sensor to detect the
Direction
Input CWLM CW (clockwise) Limit
Signal
Name
CCWLM CCW (counter-
NORG Near-to-Origin signal
ORG Origin signal If the motor encoder Z-Phase signal will not be used, connect either a
Function Description
signal
clockwise) Limit signal
Connect to normally closed CW Limit switch.
This signal is accepted only when
When this signal is detected, the pulse generation will be stopped either
gradually or immediately according to the software setting.
Connect to normally closed CCW Limit switch.
This signal is accepted only when counter-clockwise (CCW) pulses are
generated. When this signal is detected, the pulse generation will be
stopped either gradually or immediately according to the software
setting.
proximity of the target origin. Ensure that the proximity sensor is
always used with an origin sensor (either ORG or Z-Phase).
If a mechanical switch is used, you may need to connect a capacitor in
parallel with the switch (0.1μf 50V recommended).
photo or magnetic normally open sensor to detect the target origin.
Leave the ZORG terminal unconnected. The accuracy of calibration or
positioning can be increased and the calibration time can be shortened
by using the origin sensor with a proximity sensor (NORG).
If a mechanical switch is used, you may need to connect a capacitor in
parallel with the switch (0.1μf 50V recommended).
NOTE
+ZORG
-ZORG
DEND Detection (calibration)
ALM Alarm signal Connect the alarm signal from the drive. Generation of pulses will be
Encoder Phase -Z signal Use this terminal if the motor encoder’s Z-Phase is used as an origin
sensor in which case the ORG terminal must be left disconnected.
Connect to the signal from the drive that indicates that positioning is
end signal
complete. Must be left disconnected if a stepper motor is used.
stopped gradually or immediately when this signal is detected. The
alarm logic and the stop mode are defined in the software.
For DEND input, when a servo motor is used, the position complete signal from the drive must be
connected. After a MOVE command is executed, SPEL waits until the DEND input is activated.
When the DEND input is not activated even after waiting for a time specified by a FINE command,
a message "Error 4004: Event waiting error with the Motion Control Module." appears. In case
of this error, it is necessary to exit controller, stop the SPEL Runtime Drivers, then restart controller.
When it is expected that your servo drive does not have an output equivalent to the positioning
completion signal, or that the DEND input is not activated, the DEND input must be connected to
GND. In this case, SPEL does not check that the servo drive's positioning is completed.
Therefore, after the operation command is executed, use the time delay necessary for positioning
to be complete in your application.
RC700 / RC90 option PG motion system Rev.5 9
2. Hardware
EXTV
ORG, NORG, DEND, ALM
Board
Drive
+24V
External power supply
ON : 2.5mA or over
OFF : 0.8mA or under
6.8kΩ
EXTV
CWLM / CCWLM
6.8kΩ
Board
Sensor
+24V
External power supply
ON : 2.5mA or over
OFF : 0.8mA or under
The CWLIM and CCWLIM limit switches must be
normally closed. The ORG and NORG switches must
be normally open.
+ZORG
-ZORG
220 Ω
26C31
equivalent
Connect to Line driver RS422 Conforming
+5V
+5V
26C32
equivalent
Board
Drive
2.3.2 Input Circuit
ORG(Origin), NORG(Near-to-origin), DEND(Detection-end),
ALM(Alarm)
The DEND terminal must be left disconnected if a stepper motor is used.
The input logic of the Alarm signal can be changed in the software.
CWLM(CW Limit), CCWLM(CCW Limit)
ZORG (Encoder Phase -Z) Signal
This terminal must be connected when an Encoder Z Phase signal is used as the origin signal.
10 RC700 / RC90 option PG motion system Rev.5
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