EPSON RC90, RC90-B Users guide

Download

Rev.26 EM208C4443F

ROBOT CONTROLLER

RC90 / RC90-B

(EPSON RC+ 7.0)

ROBOT CONTROLLER RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

ROBOT CONTROLLER

RC90 / RC90-B

(EPSON RC+ 7.0)

Rev.26

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 i

FOREWORD

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

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 al

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 contact the supplier of your region for

warranty period information.)

However, customers will be charged for repairs in the following cases (even if they occur

during the warranty period):

disasters such as earthquake, flood, etc.

Warnings, Cautions, Usage:

l possible hazards.

ii RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

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

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 iii

Before Reading This Manual

NOTE

Do not connect the followings to the TP/OP port of RC90 / RC90-B. 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 / RC90-B, be sure to install the EPSON RC+ 7.0 to the development PC first,

then connect the development PC and RC90 / RC90-B with the USB cable.

If RC90 / RC90-B 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.

iv RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Label

Controller

Software

RC90 controller firmware

Ver.7.0.2.0 or later

Before Ver.7.0.1

!!!

Ver.7.0.2 or later

RC90-B controller firmware

Ver.7.4.2.0 or later

Before Ver.7.4.1

!!!

Ver.7.4.2 or later

NOTE

Control System Configuration

This manual explains with the following combinations of Controllers and software.

Robot Controller RC90 with the following label attached:

RC90

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.

Robot Controller RC90-B:

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. 7.4.2 or later.

There is no label on RC90-B.

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.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 v

vi RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

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

3.3.3 M/C Power Cable .......................................................................22

3.4 Cable Connection ..................................................................................23

3.4.1 Typical Cable Connection ..........................................................24

3.4.2 Connecting Manipulator to Controller ........................................26

3.5 Noise Countermeasures ........................................................................28

4. Operation Mode (TEACH/AUTO/TEST) 29

4.1 Overview ................................................................................................29

4.2 Switch Operation Mode .........................................................................29

4.3 Program Mode (AUTO) ..........................................................................30

4.3.1 What is Program Mode (AUTO)? ...............................................30

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 vii

Table of Contents

4.3.2 Setup from EPSON RC+ 7.0 ..................................................... 30

4.4 Auto Mode (AUTO) ................................................................................ 31

4.4.1 What is Auto mode (AUTO)? ..................................................... 31

4.4.2 Setup from EPSON RC+ 7.0 ..................................................... 31

4.4.3 Setup from Control Device ......................................................... 32

5. Development PC Connection Port 33

5.1 About Development PC Connection Port .............................................. 33

5.2 Precaution .............................................................................................. 34

5.3 Software Setup and Connection Check ................................................ 34

5.4 Disconnection of Development PC and Controller ................................ 35

6. Memory Port 36

6.1 What is Controller Status Storage Function? ........................................ 36

6.2 Before Using Controller Status Storage Function ................................. 36

6.2.1 Precautions ................................................................................ 36

6.2.2 Adoptable USB Memory ............................................................ 36

6.3 Controller Status Storage Function ....................................................... 37

6.3.1 Controller Status Storage with Trigger Button ........................... 37

6.3.2 Load Data with EPSON RC+ 7.0 ............................................... 37

6.3.3 Transfer with E-mail ................................................................... 39

6.4 Details of Data ....................................................................................... 39

7. LAN (Ethernet Communication) Port 40

7.1 About the LAN (Ethernet Communication) Port .................................... 40

7.2 IP Address ............................................................................................. 40

7.3 Changing Controller IP Address ............................................................ 41

7.4 Connection of Development PC and Controller with Ethernet .............. 42

7.5 Disconnection of Development PC and Controller with Ethernet ......... 43

8. TP Port 44

8.1 What is the TP Port? ............................................................................. 44

8.2 Teach Pendant Connection ................................................................... 44

9. EMERGENCY 45

9.1 Safety Door Switch and Latch Release Switch ..................................... 45

9.1.1 Safety Door Switch .................................................................... 46

9.1.2 Latch Release Switch ................................................................ 46

9.1.3 Checking Latch Release Switch Operation ............................... 47

viii RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Table of Contents

9.2 Emergency Stop Switch Connection .....................................................48

9.2.1 Emergency Stop Switch .............................................................48

9.2.2 Checking Emergency Stop Switch Operation ............................48

9.2.3 Recovery from Emergency Stop ................................................48

9.3 Pin Assignments ....................................................................................49

9.4 Circuit Diagrams ....................................................................................50

9.4.1 Example 1: External emergency stop switch typical application50

9.4.2 Example 2: External safety relay typical application..................51

10. Standard RS-232C Port 52

10.1 About the RS-232C Port ......................................................................52

10.2 Confirmation with EPSON RC+ 7.0 (RS-232C) ..................................52

10.3 RS-232C Software Communication Setup (RS-232C) .......................53

10.4 Communication Cable (RS-232C) .......................................................53

11. I/O Connector 54

11.1 RC90 (I/O Connector) ..........................................................................55

11.1.1 Input Circuit (RC90) .................................................................55

11.1.2 Output Circuit (RC90)...............................................................57

11.2 RC90-B (I/O Connector) ......................................................................60

11.2.1 Input Circuit (RC90-B) ..............................................................60

11.2.2 Output Circuit (RC90-B) ...........................................................62

11.3 Pin Assignments ..................................................................................64

12. I/O Remote Settings 65

12.1 I/O Signal Description ..........................................................................66

12.1.1 Remote Input Signals ...............................................................66

12.1.2 Remote Output Signals ............................................................70

12.2 Timing Specifications ...........................................................................73

12.2.1 Design Notes for Remote Input Signals...................................73

12.2.2 Timing Diagram for Operation Execution Sequence ...............73

12.2.3 Timing Diagram for Program Execution Sequence .................73

12.2.4 Timing Diagram for Safety Door Input Sequence ....................74

12.2.5 Timing Diagram for Emergency Stop Sequence .....................74

13. Option Slots 75

13.1 About Option Slots ...............................................................................75

13.2 Expansion I/O Board ............................................................................75

13.2.1 About Expansion I/O Board .....................................................75

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 ix

Table of Contents

13.2.2 Board Configuration (Expansion I/O)....................................... 75

13.2.3 Confirmation with EPSON RC+ 7.0 ......................................... 76

13.2.4 Input Circuit .............................................................................. 76

13.2.5 Output Circuit ........................................................................... 78

13.2.6 Pin Assignments ...................................................................... 81

13.3 Fieldbus I/O Board ............................................................................... 82

13.4 RS-232C Board ................................................................................... 82

13.4.1 RS-232C Board ........................................................................ 82

13.4.2 Board Setup (RS-232C) ........................................................... 82

13.4.3 Confirmation with EPSON RC+ 7.0 (RS-232C) ...................... 83

13.4.4 RS-232C Software Communication Setup (RS-232C) ............ 83

13.4.5 Communication Cable (RS-232C) ........................................... 84

13.5 Analog I/O Board ................................................................................. 85

13.5.1 About Analog I/O Board ........................................................... 85

13.5.2 Board Configuration (Analog I/O Board) ................................. 86

13.5.3 Confirmation with EPSON RC+ (Analog I/O Board) ................ 89

13.5.4 Input Circuit (Analog I/O Board) .............................................. 90

13.5.5 Output Circuit (Analog I/O Board) ............................................ 90

13.5.6 Pin Assignments (Analog I/O Board) ....................................... 91

13.6 EUROMAP67 Board ............................................................................ 92

13.6.1 Notes on the EUROMAP67 Board .......................................... 93

13.6.2 Board Settings (EUROMAP67 Board) ..................................... 95

13.6.3 Installation (EUROMAP67 Board) ........................................... 95

13.6.4 Confirming with EPSON RC+ 7.0 (EUROMAP67 Board) ....... 97

13.6.5 Sample Project (EUROMAP67 Board) .................................... 97

13.6.6 Circuit Overview (EUROMAP67 Board) .................................. 98

13.6.7 Input Circuit (EUROMAP67 Board) ......................................... 99

13.6.8 Output Circuit (EUROMAP67 Board) ...................................... 99

13.6.9 Emergency Stop, Safeguard (EUROMAP67 Board) ............. 100

13.6.10 I/O Pin Assignments (EUROMAP67 Board) ........................ 101

13.6.11 Emergency stop connecter Pin Assignments

(EUROMAP67 Board) ......................................................... 102

x RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Maintenance

Table of Contents

1. Safety Precautions on Maintenance 107

1.1 Safety Precautions .............................................................................. 107

1.2 Lockout / Tagout ................................................................................. 108

2. Regular Maintenance Inspection 110

3. Controller Structure 111

3.1 Location of Parts ................................................................................. 111

3.1.1 RC90 (for LS3, LS6) ................................................................ 111

3.1.2 RC90 (for LS20) ...................................................................... 111

3.1.3 RC90-B (for LS3-B, LS6-B) ..................................................... 112

3.1.4 RC90-B (for LS10-B, LS20-B) ................................................. 112

3.2 Diagram of Cable Connections ........................................................... 113

3.2.1 RC90 (for LS3, LS6), RC90-B( for LS3-B, LS6-B) .................. 113

3.2.2 RC90 (for LS20), RC90-B (for LS10-B, LS20-B) .................... 114

4. Backup and Restore 115

4.1 What is the Backup Controller Function? ........................................... 115

4.2 Backup Data Types ............................................................................ 115

4.3 Backup ................................................................................................ 116

4.4 Restore ............................................................................................... 117

5. Firmware Update 120

5.1 Updating Firmware ............................................................................. 120

5.2 Firmware Upgrade Procedure ............................................................ 120

5.3 Controller Recovery ............................................................................ 123

5.4 Firmware Initialization Procedure ....................................................... 124

5.5 Adding Confirmation Steps by Strengthening Security of EtherNet

Connection .......................................................................................... 126

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 xi

Table of Contents

6. Alarm 130

6.1 Before Controller Firmware Ver.7.1.8.x ............................................... 131

6.1.1 Alarm Configuration ................................................................. 131

6.1.2 How to View the Alarm Information ......................................... 132

6.1.3 How to Edit the Alarm Information ........................................... 133

6.1.4 Alarm Notifying Method ........................................................... 133

6.1.5 How to Cancel the Alarm ......................................................... 134

6.2 Controller Firmware Ver.7.2.0.x or later .............................................. 135

6.2.1 Maintenance Information ......................................................... 135

6.2.2 How to View the Maintenance Information .............................. 136

6.2.3 How to Edit the Maintenance Information ............................... 138

6.2.4 Alarm Notifying Method ........................................................... 139

6.2.5 How to Cancel the Alarm ......................................................... 139

7. Maintenance Parts Replacement Procedures 140

7.1 Fan Filter .............................................................................................. 141

7.2 Fan ....................................................................................................... 142

7.3 Battery ................................................................................................. 143

7.4 CF (Compact Flash) ............................................................................ 145

7.5 MDB ..................................................................................................... 146

7.6 DMB ..................................................................................................... 148

7.7 DMB Sub Board ................................................................................... 152

7.8 DPB...................................................................................................... 153

7.9 Option Board........................................................................................ 155

8. Verifying Robot System Operation 157

9. Troubleshooting 158

9.1 Error Code Table ................................................................................. 158

9.2 Cannot Connect the Development PC and the Controller using the USB

cable .................................................................................................... 291

9.2.1 Confirmation Using Windows Device Manager ....................... 292

9.2.2 When recognized under “Other devices”

in Windows Device Manager ................................................... 294

10. Maintenance Parts List 295

xii RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Safety

This section contains information for safety of the Robot System.

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

Safety 1. Safety

This symbol indicates that a danger of possible serious injury or death

exists if the associated instructions are not followed properly.

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 / RC90-B (EPSON RC+ 7.0) Rev.26 3

Safety 3. Safety Precautions

Personnel read the Safety chapter in User before designing and/or constructing the robot system. Designing and/or constructing the robot system withou 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 environmen conditions may not only shorten the life cycle of the serious safety problems.

The the manuals. may problem

The interlock of the Safety Door must be functioning when the operated. 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 s may

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

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



who design and/or construct the robot system with this product must

’s Guide to understand the safety requirements

t understanding the safety requirements is

t that exceeds the specified environmental

product but may also cause

robot system must be used within the installation requirements described in

Using the robot system outside of the installation requirements

not only shorten the life cycle of the product but also cause serious safety

robot system is

Do not operate the system under the condition that the switch cannot

witch is not functioning properly is extremely hazardous and

cause serious safety problem



Circuit Diagrams.)

4 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Do not open the cover(s) of the Controller 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 t the Controller.

Make sure that the power to the Controller 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 malfunction 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 termin 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)

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 problems.

When using remote I/O, always make sure of the following. Using the robot system under

conditions may cause malfunction of the system

and/or safety problems.

- When verifying the robot system operation, prepare for failures with initial

WARNING

Safety 3. Safety Precautions

The following items are safety precautions for qualified design or installation personnel: (cont.)



he high voltage charge inside



CAUTION



al of the factory power supply. The equipment must be grounded properly



cause improper function of the robot system and also safety



unsatisfactory

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.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 5

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

is extremely hazardous and

may

s as the Safety Door input cannot fulfill its

intended function

Do not open the cover(s) of the Control the cover(s) of the Controller is

and may result in electric shock the Control

The following items are safety precautions for qualified operator personnel:

WARNING



robot system is

Do not operate the system under the condition that the switch cannot

functioning properly

cause serious safety problem

ler except while maintaining it. Opening

extremely hazardous

even when its main power is OFF because of the high voltage charge inside

ler.

6 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation

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

Setup & Operation 1. Specifications

*1 EPSON RC+ 7.0 supports the following OS

ndows 8.1 Pro

(EPSON RC+7.0 Ver.7.1.0

or later

)

Windows 10 Pro

(EPSON RC+7.0 Ver.7.2.0 or later)

Operation panel

Motion Controller

RC90 / RC90-B

Expansion I/O Board

Fieldbus

PROFIBUS-DP DeviceNet CC-Link EtherNet/IP PROFINET EtherCAT

RS-232C Board

Windows *1

EPSON RC+ 7.0

Software

Option

USB 2.0

Ethernet

TP2

(Option)

Standard I/O Remote I/O Ethernet RS-232C

Requires preparation by users

LS / LS-B series

PLC (Sequencer)

Option

Standard

PG Board

TP1

(Option)

AnalogI/O Board

EUROMAP67 Board

1. Specifications

1.1 System Example

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 9

Setup & Operation 1. Specifications

Item

Specification

Model

Robot Controller RC90 / RC90-B

Controllable axes

4 AC servo motors

Programming

software

Up to 4 joints simultaneous control Software AC servo control

PTP motion : Programmable in the range of

to be manually entered.)

PTP motion : Programmable in the range of

to be manually entered.)

Maximum Object Size : 4 MB

of array variables.)

Including 8 inputs,

allowed

RS-232C port

1 port

1.2 Standard Specifications

CPU 32 bits Micro Processor

Robot manipulator control

Positioning control

Memory capacity

Teaching method

language and Robot control

Joint Control

Speed Control

Acceleration/ deceleration control

PTP (Point-To-Point control) CP (Continuous Path control)

Point data area : 1000 points (per file) Backup variable area : Max. 100 KB (Includes the memory area for

Remote Direct MDI (Manual Data Input)

EPSON RC+ 7.0 (multi-tasking robot language) Ver.7.0.2 or later is recommended.

1 to 100%

CP motion : Programmable (Actual value

1 to 100%; Automatic

CP motion : Programmable (Actual value

the management table.) Approx. 1000 variables (Depends on the size

External input/output signals (standard)

Communication interface (standard)

10 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Standard I/O

Ethernet 1 channel

Input : 24 Output : 16

8 outputs with remote function assigned Assignment change

Setup & Operation 1. Specifications

Item

Specification

Addition of 2 boards allowed

EtherCAT

1 board from the left Controllable joints

4 joints/board

Addition of 2 board allowed

SKU1

Output: 1ch

Addition of 2 board from the left

Output: 2ch Input: 2ch

Input : 15 Output : 16

Addition of 1 board allowed

Rated Ambient

Options (Max. 2 slots)

Safety features

Expansion I/O

Input : 24 per board Output : 16 per board

Addition of 2 boards allowed

RS-232C : 2ch per board

Communication interface

Fieldbus I/O : 1ch per board

PROFIBUS-DP, DeviceNet, CC-Link, EtherNet/IP, PROFINET,

Addition of

allowed

Analog I/O

SKU2

allowed

EUROMAP67

- Emergency stop switch

- Safety door input

- Low power mode

- Dynamic brake

- Motor overload detection

- Irregular motor torque (out-of-control Manipulator) detection

- Motor speed error detection

- Positioning overflow - servo error - detection

- Speed overflow - servo error - detection

- CPU irregularity detection

- Memory check-sum error detection

- Overheat detection at the Motor Driver Module

- Relay welding detection

- Over-voltage detection

- AC power supply voltage reduction detection

- Temperature error detection

- Fan error detection

Power Source

Maximum Rated Capacity 2.5 kVA (Depending on the Manipulator model)

Insulation Resistance 100 MΩ or more

Temperature

Rated Relative Humidity 20% to 80% (with no condensation)

Weight *1 7.5 kg or 10 kg (Depending on the Manipulator model)

Degree of protection IP20

*1 Weight of the unit is indicated on the Controller itself.

Make sure to check the weight before units transfer or relocation and prevent throwing out your back

at holding the unit.

Also, make sure to keep your hands, fingers, and feet safe from being caught or serious injury.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 11

200 VAC to 240 VAC Single phase 50/60 Hz

5 to 40

°C

Setup & Operation 1. Specifications

1.3 Outer Dimensions

[Unit : mm]

12 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 2. Part Names and Functions

(3)

(18)

(11) (12) (13) (14) (15) (16) (6)

(4)

(1)

(10) (9)

(8)

(19)

(17)

(5)

(Left side)

(2)

(7)

The details of the Manipulator to be connected are recorded on

label indicates the

Manipulator model and Manipulator serial number.

MANIPULATOR

00002

LS3-401S

NOTE

2. Part Names and Functions

2.1 Part Names

Illustration is RC90. Part names and functions of RC90 and RC90-B are the same.

2.2 Functions

(1) POWER switch

(2) AC IN

(3) LED

(4) Fan Filter

(5) Signature label

(6) Controller Number label

(7) Connection Check label

Turns ON or OFF the Controller.

The terminal block for 200VAC power input. For details, refer to Setup & Operation 3.3.2 AC Power Cable.

The LED indicates current operation mode (ERROR, E-STOP, TEACH, AUTO, or

PROGRAM mode). For details, refer to Setup & Operation 2.3 LED.

A protective filter is installed in front of the fan to filter out dust.

Check the condition of the filter regularly and clean it when necessary. A dirty filter may result in malfunction of the robot system due to temperature rise of the Controller.

The serial number of the Controller and other information are shown.

The serial number of the Controller is indicated.

the label as shown in the right. The

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 13

Setup & Operation 2. Part Names and Functions

NOTE

(8) M/C POWER connector

A connector for the Manipulator power source. Connect the dedicated power cable attached to the Manipulator.

(9) M/C SIGNAL connector

This connector is used for signals such as the manipulator’s motor position detector, etc. Connect the Manipulator’s dedicated signal cable.

(10) EMERGENCY connector

This connector is used for input/output from/to Emergency Stop and Safety Door switches. For details, refer to the Setup & Operation 9. EMERGENCY.

(11) TP port

Connects Teach Pendant TP1 (Option), TP2 (Option) and TP bypass plug. For details, refer to Setup & Operation 8. TP Port.

Do not connect the following to the TP port of RC90 / RC90-B. 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

(12) Development PC connection port

This port connects the Controller and the Development PC using a USB cable.

Do not connect other devices except the Development PC.

For details, refer to Setup & Operation 5. Development PC Connection Port.

(13) Memory port

This port connects the common USB memory for Controller status storage function.

Do not connect other USB devices except the USB memory. For details, refer to Setup & Operation 6. Memory Port.

(14) Trigger Switch

This switch is for Controller status storage function using the USB memory. For details, refer to Setup & Operation 6. Memory Port.

(15) LAN (Ethernet communication) port

This port connects the Controller and the Development PC using an Ethernet cable. 100BASE-TX / 10BASE-T communication are available. For details, refer to Setup & Operation 7. LAN (Ethernet communication) Port.

(16) I/O connector

This connector is used for input/output device. There are 24 inputs and 16 outputs. For details, refer to Setup & Operation 11. I/O Connector.

(17) Standard RS-232C port

This port is used for the RS-232C communication with external devices.

For details, refer to

Setup & Operation 10. Standard RS-232C Port.

14 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Controller status

LED display

Execute Controller status

USB memory

TEACH, AUTO, PROGRAM turn ON

ERROR turns OFF even if an error occurs.

2.3 LED

Setup & Operation 2. Part Names and Functions

(18) Option slot

Option boards such as expansion I/O board, Fieldbus I/O board, RS-232C board, PG

board, Analog I/O board can be installed. Two slots are available.

For details, refer to Setup & Operation 13.Option Slots.

(19) Cable Clamp

This can be used to secure the M/C Power Cable and the AC Power cable.

(20) Battery (Mounted inside the controller)

This is a lithium battery for data backup.

Five LEDs are located on the front panel of the Controller.

LEDs (ERROR, E-S TO P, TEACH, AUTO, PROGRAM) turn ON according to the controller status (error, Emergency Stop, TEACH mode, Auto mode, Program mode).

From turning ON the Controller to completing startup

Three LEDs (TEACH, AUTO, PROGRAM) blink.

After Controller Startup

storage function to the

Complete Controller status storage to USB memory

Failure of Controller status storage to USB memory

Error ERROR turns ON.

Warning ERROR blinks.

Emergency Stop E-STOP turns ON.

TEACH mode TEACH blinks.

Auto mode (AUTO mode) AUTO blinks.

Program mode (AUTO mode) PROGRAM blinks.

Recovery mode ERROR, TEACH, PROGRAM turn ON.

TEACH, AUTO, PROGRAM blink.

(for 2 seconds).

ERROR, TEACH, AUTO, PROGRAM turn ON (for 2 seconds).

AC power supply drop TEACH, AUTO turn ON.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 15

Test mode TEACH turns ON.

Setup & Operation 2. Part Names and Functions

2.4 Safety Features

The robot control system supports safety features described below. However, it is recommended to strictly follow the proper usage of the robot system by thoroughly reading the attached manuals before using the system. Failure to read and understand the proper usage of the safety functions is highly dangerous.

Among the following safety features, the Emergency Stop Switch and Safety Door Input are particularly important. Make sure that these and other features function properly before operating the robot system.

For details, refer to the Setup & Operation 9. EMERGENCY.

Emergency Stop Switch

The EMERGENCY connector on the Controller has expansion Emergency Stop input terminals used for connecting the Emergency Stop switches. Pressing any Emergency Stop switch can shut off the motor power immediately and the robot system will enter the Emergency Stop condition.

Safety Door Input

In order to activate this feature, make sure that the Safety Door Input switch is connected to the EMERGENCY connector at the Controller.

When the safety door is opened, normally the Manipulator immediately stops the current operation, and the status of Manipulator power is operation-prohibited until the safety door is closed and the latched condition is released. In order to execute the Manipulator operation while the safety door is open, you must change the mode selector key switch on the Teach Pendant to the “Teach” mode. Manipulator operation is available only when the enable switch is on. In this case, the Manipulator is operated in low power status.

Low Power Mode

The motor power is reduced in this mode. Executing a power status change instruction will change to the restricted (low power) status regardless of conditions of the safety door or operation mode. The restricted (low power) status ensures the safety of the operator and reduces the possibility of peripheral equipment destruction or damage caused by careless operation.

Dynamic Brake

The dynamic brake circuit includes relays that short the motor armatures. The dynamic brake circuit is activated when there is an Emergency Stop input or when any of the following errors is detected: encoder cable disconnection, motor overload, irregular motor torque, motor speed error, servo error (positioning or speed overflow), irregular CPU, memory check-sum error and overheat condition inside the Motor Driver Module.

Motor Overload Detection

The dynamic brake circuit is activated when the system detects that the load on the motor has exceeded its capacity.

Irregular Motor Torque (out-of-control manipulator) Detection

The dynamic brake circuit is activated when irregularity with motor torque (motor output) is detected (in which case the Manipulator is out of control).

16 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 2. Part Names and Functions

Motor Speed Error Detection

The dynamic brake circuit is activated when the system detects that the motor is running at incorrect speed.

Positioning Overflow –Servo Error- Detection

The dynamic brake circuit is activated when the system detects that the difference between the Manipulator’s actual position and commanded position exceeds the margin of error allowed.

Speed Overflow –Servo Error- Detection

The dynamic brake circuit is activated when the Manipulator’s actual speed is detected to mark an overflow (the actual speed is outside the nominal range) error.

CPU Irregularity Detection

Irregularity of CPU that controls the motor is detected by the watchdog timer. The system CPU and the motor controlling CPU inside the Controller are also designed to constantly check each other for any discrepancies. If a discrepancy is detected, the dynamic brake circuit is activated.

Memory Check-sum Error Detection

The dynamic brake circuit is activated when a memory check-sum error is detected.

Overheat Detection at the Motor Driver Module

The dynamic brake circuit is activated when the temperature of the power device inside the Motor Driver module is above the nominal limit.

Relay Deposition Detection

The dynamic brake circuit is activated when relay deposition, junction error, or open fault is detected.

Over-Voltage Detection

The dynamic brake circuit is activated when the voltage of the Controller is above the normal limit.

AC Power Supply Voltage Drop Detection

The dynamic brake circuit is activated when the drop of the power supply voltage is detected.

Temperature Anomaly Detection

The temperature anomaly is detected.

Fan Malfunction Detection

Malfunction of the fan rotation speed is detected.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 17

Setup & Operation 3. Installation

The Manipulator and the Controller must be used within the environmental conditions described in their manuals. This product has been designed and manufactured strictly for use in a normal indoor environment in the environment that exc of the

Item

Condition

Use a base table that is at least 100 mm off the floor.

3. Installation

3.1 Unpacking

TP/OP Bypass Plug 1 unit

EMERGENCY Port Connector 1 set I/O Connector 1 set Rack-Mount Plate 1 set

3.2 Environmental Requirements

■

WARNING

eeds the conditions may not only shorten the life cycle

product but also cause serious safety problems.

. Using the product

3.2.1 Environment

In order to optimize the robot system’s performance for safety, the Controller must be placed in an environment that satisfies the following conditions:

- The Controller is not designed for clean-room specification. If it must be installed in a clean room, be sure to install it in a proper enclosure with adequate ventilation and cooling.

- Install Controller in a location that allows easy connection / disconnection of cables.

Ambient temperature

Ambient relative humidity 20% to 80% (with no condensation)

Fast transient burst noise 2 kV or less (Power supply wire)

Electrostatic noise 4 kV or less

Base table

5 to 40 °C (with minimal variation)

1 kV or less (Signal wire)

Placing the Controller directly on the floor could allow dust penetration leading to malfunction.

If the Controller must be used in an environment that does not fulfill the conditions mentioned above, take adequate countermeasures. For example, the Controller may be enclosed in a cabinet with adequate ventilation and cooling.

- Install indoors only.

- Place in a well-ventilated area.

- Keep away from direct sunlight and radiation heat.

- Keep away from dust, oily mist, oil, salinity, metal powder or other contaminants.

- Keep away from water.

- Keep away from shocks or vibrations.

- Keep away from sources of electronic noise

- Keep away from strong electric or magnetic fields.

18 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 3. Installation

* The rubber foot needs to be replaced.

* Rack-mount plate is required.

133.35 mm

463 mm

50 mm

100 mm Excluding the installation side such as base table

Air flow of the Controller Fan

100 mm

200 mm

NOTE

3.2.2 Installation

Install the controller on a flat surface such as wall, floor, and controller box in the direction shown from (A) to (C).

(A) Flat Mounting

(B) Upright Mounting (C) Rack Mounting

For installing the Controller to the Controller box or the base table, process screw holes as follows.

Ensure the draft around the in/out and prevent the other equipment, walls and install the Controller by keeping the distance as follows for maintenance.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 19

- Hot air with higher temperature than the ambient temperature (about 10 °C) comes out from the Controller. Make sure that heat sensitive devices are not placed near the outlet.

- Arrange the cables in front of the Controller so that you can pull the Controller forward.

Setup & Operation 3. Installation

Phase

Single phase

For approximate power consumption of each model, refer to

LS3 : 1.0 kVA

LS6 : 1.1 kVA

LS20 : 2.4 kVA

LS3-B: 1.0 kVA

LS6-B : 1.1 kVA

LS20-B : 2.4 kVA

LS10-B : 1.8 kVA

3.3 Power Supply

3.3.1 Specifications

Ensure that the available power meets following specifications.

Item Specification

Voltage 200 to 240 VAC

Frequency 50/60 Hz

Momentary Power Interrupt

Rated Capacity Max. 2.5 kVA

Input voltage should be with in ±10 % of the rated voltage.

10 ms or less

Actual power consumption depends on the model, motion, and load of the Manipulator.

the following values

Peak Current When power is turned ON : approximately 70 A (2 ms.)

Leakage Current Max. 10 mA

Ground Resistance

Install an earth leakage circuit breaker or a circuit breaker in the AC power cable line at 15 A or less rated electric current. Both should be a two-pole disconnect type. If you install an earth leakage circuit breaker, make sure to use an inverter type that does not operate by induction of a 10 kHz or more leakage current. If you install a circuit breaker, please select one that will handle the above mentioned “peak current”.

The power receptacle shall be installed near the equipment and shall be easily accessible.

Refer to the Manipulator manual for rated capacity of the Manipulator motor.

When motor is ON : approximately 50 A (2 ms.)

100 Ω or less

20 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 3. Installation

Make sure that

B terminal of the factory power supply. at all times to avoid the risk of electric shock.

Always use a power plug

for power connecting cable.

Never connect the Controller directly to the factory power supply.

Select the plug

which conform safety standards for

nations.

Ground wire

Green / Yellow

3.3.2 AC Power Cable

■

e sure to connect the earth wire (green/yellow) of the AC power cable to the earth

WARNING

■

AC power wire (2 cables)

Cable length 3 m

Terminal M4 round solderless terminal

operations are done by a qualified personal.

The equipment must be grounded properly

or a disconnecting device

Item Specification

Black, Black or Black, White

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 21

Setup & Operation 3. Installation

(1)

Mount the M/C Power Cable as shown

e picture and

form the cables.

(2)

Set the M/C Power Cable in the clamp for the M/C Power

Cable.

(3)

Mount the cover for the M/C Power

(4)

Secure the cover with the screw.

3.3.3 M/C Power Cable

in th

Connector.

22 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Make sure that the power to the Control disconnected

Connecting or disconnecting result in electric shock and malfunction of the Controller.

Be sure to connect the cables properly. Do not 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, d contact failure is extremely hazardous and may result in electric shock and/or improper function of the system.

Before connecting the connector, make sure

the pins are not bent. Connecting with of the robot system.

3.4 Cable Connection

Setup & Operation 3. Installation

■

WARNING

■

CAUTION

■

ler is turned OFF and the power plug is

before connecting or disconnecting any cables.

any cables with the power ON is extremely hazardous and may

allow unnecessary strain on the

isconnection, or

that

the pins bent may damage the connector and result in malfunction

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 23

Setup & Operation 3. Installation

Manipulator

(6) USB Memory

PC for Development

Input/Output Device

Connect by (5) or (7)

Controller

(1) AC Power Terminal Block

(2) M/C Power Connector

(3) M/C Signal Connector

(4) EMERGENCY Connector

(5) Development PC Connection Port

200VAC-240VAC

(7) LAN (Ethernet Communication)

(8) I/O Connector

(9) TP Connector

(10) Standard RS-232C Connector

Emergency Stop Safety Door, etc.

Teach

Pendant

Option

FieldBus I/O Expansion I/O RS-232C PG board Analog I/O EUROMAP67

Detachable connector

Cable attached at shipping

Cable prepared by users

(1)

AC Power terminal block

(2)

M/C Power cable

(3)

M/C Signal cable

(4)

EMERGENCY

3.4.1 Typical Cable Connection

*1: Only LS-B series is detachable.

Terminal block for 200VAC power input to the Controller.

The cable with 20-pin connector on the Controller side.

Connect the Manipulator and the M/C POWER connector on the Controller

Insert the connectors until you hear a “click”.

The cable with 36-pin connector on the Controller side.

Connect the Manipulator and the M/C SIGNAL connector on the Controller.

The EMERGENCY connector has inputs to connect the Emergency Stop switch

and the Safety Door switch. For safety reasons, connect proper switches for these

input devices.

For details, refer to the Setup & Operation 9. EMERGENCY.

24 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 3. Installation

(5)

PC for development

(6)

USB memory

(7)

LAN (EtherNet Communication)

(8)

I/O connector

(9)

TP cable

(10)

Standard RS-232C port

Connect the PC for development.

For details, refer to the Setup & Operation 5. Development PC Port.

Connect the USB memory.

For details, refer to the Setup & Operation 6. Memory Port.

Connect the EtherNet cable.

For details, refer to the Setup & Operation 7. LAN (Ethernet Communication) Port.

This connector is used for input/output devices of the user.

When there are input/output devices, use this connector.

There are I/O cable (option) and terminal block (option) for the I/O connector.

For details, refer to the Setup & Operation 11. I/O Connector.

Connect the option Teach Pendant.

For details, refer to the Setup & Operation 8.TP Port.

This port is used for the RS-232C communication with external devices.

For details, refer to Setup & Operation 10. Standard RS-232C Port.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 25

Setup & Operation 3. Installation

Make sure that the power to the Control

turned OFF before connecting or

disconnecting any cables.

any cables with the power ON of

Be sure to connect the cables 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. contact failure is extremely hazardous and may result in electric shock and/or improper function of the system.

on the Controller. Connect the Controller and the

Improper connection between the Controller and the

When connecting the Manipulator to the Controller, make sure that the serial numbers on each equipment match. Improper connection between the Manipulator and Controller may not only cause improper function of the robot

3.4.2 Connecting Manipulator to Controller

Connect the Manipulator to the Controller by using the Power cable and the Signal cable.

■

is extremely hazardous and may result in electric shock and malfunction

the Controller.

■

WARNING

■ The serial number of the Manipulator that should be connected is indicated on the Connection Check Label Manipulator correctly. Manipulator may cause not only improper function of the robot system but also safety problems.

CAUTION

■

system but also serious safety problems. The connection method varies with the Controller used. For details on the connection, refer to the Controller manual.

ler is

Connecting or disconnecting

properly. Do not allow unnecessary strain on the

Damaged cables, disconnection, or

26 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 3. Installation

LS3 series Manipulator (Figure: LS3-401S)

RC90 Controller

M/C Power Cable

M/C Signal Cable

NOTE

The configuration data for the Manipulator and Manipulator model are stored in the Controller. Therefore the Controller should be connected to the Manipulator whose serial number is specified in the Connection Check label attached on the front of the Controller.

The Manipulator’s serial number is indicated on the signature label of the Manipulator.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 27

Setup & Operation 3. Installation

preferable example is shown in the right figure.

AC Line duct

DC line duct

As far as possible

3.5 Noise Countermeasures

To minimize electrical noise conditions, the following items must be observed in the system’s cable wiring:

To minimize electrical noise condition, be sure of followings for wiring.

- The earth wire of the power supply should be grounded. (Ground resistance: 100 Ω or

less) It is important to ground the frame of Controller not only for prevention from

electric shock, but also for reducing the influence of electric noise around the Controller.

Therefore, be sure to connect the earth wire (yellow/green) of the Controller’s power

cable to the ground terminal of the factory power supply. For details about the plug

and AC power cable, refer to the Setup & Operation 3.3 Power Supply.

- Do not tap power from a power line that connects to any equipment which may cause

noise.

- When you tap power for the Controller and the single-phase AC motor from the same

power line, change the phase of one or the other. Ensure that they will not be the same

phase.

- Use a twisted pair motor power line.

- Do not run AC power lines and DC power lines in

the same wiring duct, and separate them as far as

possible. For example, separate the AC motor

power line and the Controller power line as far as

possible from the sensor or valve I/O lines; and do

not bundle both sets of wiring with the same cable

tie. If more than one duct/cable must cross each

other, they should cross perpendicularly. The

- Wire as short as possible to the I/O connector and EMERGENCY connector. Use a

shielded cable and clamp the shield to the attached connector interior. Make sure to

keep away from the peripheral noise source as far as possible.

- Make sure that the induction elements used to connect to the Controller’s I/O (such as

relays and solenoid valves) are noise suppression parts. If an induction element without

protection against noise is used, make sure to connect a noise suppression part such as a

diode located at the induction element in parallel with it. In selecting noise suppression

parts, make sure that they can handle the voltage and current incurred by the induction

load.

- To start and change revolutions of the conveyer’s (or the like’s) AC motor (ex: an

induction motor or three-phase induction motor) regularly or abruptly, make sure to

install a spark suppressor between the wires. The spark suppressor is more effective

when placed closer to the motor.

- As they are easily influenced by noise, keep cable such as USB, Ethernet, RS-232C, or

fieldbus away from peripheral noise sources.

28 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 4. Operation Mode (TEACH/AUTO/TEST)

In this mode the Robot operates in Low power status.

This mode enables automatic operation (program execution) of the

This mode cannot operate the Robots or run programs with the Safety Door open.

This is a low speed program verification function (T1: manual

task, multi-manipulator / single-manipulator at low speed.

The operating Robot stops by Quick Pause.

and turn on the latch

release input signal for AUTO mode.

mode.

[Test Mode] in [Jog & Teach] dialog of TEACH mode.

The mode will be changed to TEST

4. Operation Mode (TEACH/AUTO/TEST)

4.1 Overview

The Robot system has three operation modes.

TEACH mode This mode enables point data teaching and checking close to the Robot

using the Teach Pendant.

AUTO mode

Robot system for the manufacturing operation, and also programming,

debug, adjustment, and maintenance of the Robot system.

TEST mode

4.2 Switch Operation Mode

Change the operation mode using the mode selector key switch on the Teach Pendant.

TEACH mode Turn the mode selector key switch to “Teach” for TEACH mode.

AUTO mode Turn the mode selector key switch to “Auto”

TEST mode Turn the mode selector key switch to “Teach” for “TEACH”

This mode enables program verification while the Enable Switch is

held down and the safeguard is open.

deceleration mode) which is defined in Safety Standards.

This mode can operate the specified Function with multi-task / single-

Switching to TEACH mode pauses the program if it was running.

Push <F1> key-

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 29

Setup & Operation 4. Operation Mode (TEACH/AUTO/TEST)

(2)

(5)

(3)

(4)

4.3 Program Mode (AUTO)

4.3.1 What is Program Mode (AUTO)?

Program mode is for programming, debug, adjustment, and maintenance of the Robot system.

Follow the procedures below to switch to the Program mode.

4.3.2 Setup from EPSON RC+ 7.0

Switch the mode to Program mode from the EPSON RC+ 7.0.

(1) Select EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the [System

Configuration] dialog.

(2) Select [Startup].

(3) Select [Start mode]-<Program> button.

(4) Click the <Apply> button.

(5) Click the <Close> button.

30 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

(2)

(5)

(3)

(4)

NOTE

4.4 Auto Mode (AUTO)

4.4.1 What is Auto mode (AUTO)?

Auto mode (AUTO) is for automatic operation of the Robot system.

Procedures for switching to the Auto mode (AUTO) are the followings.

A : Set the start mode of the EPSON RC+ 7.0 to “Auto” and start the EPSON RC+ 7.0.

(Refer to Setup & Operation 4.4.2 Setup from EPSON RC+ 7.0.)

B : Offline the EPSON RC+ 7.0.

Execute and stop the program from the control device specified by the EPSON RC+ 7.0. (Refer to Setup & Operation 4.4.3 Setup Control Device.)

4.4.2 Setup from EPSON RC+ 7.0

Switch the mode to Auto mode (AUTO) from the EPSON RC+ 7.0.

(1) Select EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the [System

Configuration] dialog.

Setup & Operation 4. Operation Mode (TEACH/AUTO/TEST)

(2) Select [Startup].

(3) Select [Start Mode]-<Auto> button.

(4) Click the <Apply> button.

(5) Click the <Close> button.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 31

Setup & Operation 4. Operation Mode (TEACH/AUTO/TEST)

(2)

(5)

(3)

(4)

4.4.3 Setup from Control Device

Set the control device from EPSON RC+ 7.0.

(1) Select EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the [System

Configuration] dialog.

(2) Select [Controller]-[Configuration].

(3) Select [Control Device] to select the control device from the following two types.

- PC

- Remote (I/O)

(4) Click the <Apply> button.

(5) Click the <Close> button.

32 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 5. Development PC Connection Port

Development PC connection Port

NOTE

5. Development PC Connection Port

Development PC connection USB port (USB B series connector)

For other details of development PC and Controller connection, refer to EPSON RC+ 7.0

User’s Guide 5.12.1 PC to Controller Communications Command.

For RC90/RC90-B, be sure to install the EPSON RC+ 7.0 to the development PC first, then

connect the development PC and RC90/RC90-B with the USB cable.

If RC90/RC90-B 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.

5.1 About Development PC Connection Port

The development PC connection port supports the following USB types.

- USB2.0 HighSpeed/FullSpeed (Speed auto selection, or FullSpeed mode)

- USB1.1 FullSpeed

Interface Standard : USB specification Ver.2.0 compliant

Connect the Controller and development PC by a USB cable to develop the robot system or

set the Controller configuration with the EPSON RC+ 7.0 software installed in the

development PC.

Development PC connection port supports hot plug feature. Cables insert and remove from the development PC and the Controller is available when the power is ON. However, stop occurs when USB cable is removed from the Controller or the development PC during connection.

(USB Ver.1.1 upward compatible)

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 33

Setup & Operation 5. Development PC Connection Port

5.2 Precaution

When connecting the development PC and the Controller, make sure of the following:

- Connect the development PC and the Controller with a 5 m or less USB cable.

Do not use the USB hub or extension cable.

- Make sure that no other devices except the development PC are used for development

PC connection port.

- Use a PC and USB cable that supports USB2.0 HighSpeed mode to operate in USB2.0

HighSpeed mode.

- Do not pull or bend the cable strongly.

- Do not allow unnecessary strain on the cable.

- When the development PC and the Controller are connected, do not insert or remove

other USB devices from the development PC. Connection with the Controller may be

lost.

5.3 Software Setup and Connection Check

Connection of the development PC and the Controller is indicated.

(1) Make sure that software EPSON RC+ 7.0 (Ver.7.0.2 or later is recommended) is

installed to the Controller connected to the development PC.

(Install the software when it is not installed.

Installation or EPSON RC+ 7.0 User’s Guide.

Refer to Robot System Safety and

(2) Connect the development PC and the Controller using a USB cable.

(3) Turn ON the Controller.

(4) Start EPSON RC+ 7.0.

(5) Select the EPSON RC+ 7.0 menu-[Setup]-[PC to Controller Communications] to

display the [PC to Controller Communications] dialog.

(6) Select “No.1 USB” and click the <Connect> button.

34 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 5. Development PC Connection Port

NOTE

(7) After the development PC and the Controller connection has completed, “Connected”

is displayed at [Connection status]. Make sure that “Connected” is displayed and

click the <Close> button to close the [PC to Controller Communications] dialog.

The connection between the development PC and the Controller is completed. Now the

robot system can be used from EPSON RC+ 7.0.

5.4 Disconnection of Development PC and Controller

Disconnection of the development PC and the Controller communication.

(1) Select the EPSON RC+ 7.0 menu-[Setup]-[PC to Controller Communications] to

display the [PC to Controller Communications] dialog.

(2) Click the <Disconnect> button.

Communication between the Controller and the development PC is disconnected and

the USB cable can be removed.

If the USB cable is removed when the Controller and the development PC are connected,

the Robot will stop. Be sure to click the <Disconnect> button in the [PC to Controller

Communications] dialog before USB cable is removed.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 35

Setup & Operation 6. Memory Port

■

Controller status storage function is available at any time and in any Controller status after starting the Controller. However, operations form the console including stop and pause are not while executing this function. Also, EPSON function when operating the robot.

6. Memory Port

Connect a commercial USB memory to the Controller memory port to use the Controller

status storage function to the USB memory.

6.1 What is Controller Status Storage Function?

This function saves various kinds of Controller data with one push to the USB memory.

Data saved in USB memory is loaded to EPSON RC+ 7.0 to get the status of the Controller

and the program simply and accurately.

The saved data can also be used for restoring the Controller.

6.2 Before Using Controller Status Storage Function

6.2.1 Precautions

CAUTION

this function influences the robot cycle time and the communication with

RC+ 7.0. Other than only when it is necessary, do not execute this

available

- Make sure that the USB port is used only for USB memory even though the port on the

Controller is a universal USB port.

- Insert the USB memory directly into the Controller memory port. Connection with

cables or hubs between the Controller and the USB memory is not assured.

- Make sure that the USB memory is inserted or removed slowly.

- Do not edit the saved files with an editor. Operation of the robot system after data

restoration to the Controller is not assured.

6.2.2 Adoptable USB Memory

Use USB memory that meets following conditions.

- USB2.0 supported

- Without security function

USB memory with password input function cannot be used.

- No installation of a driver or software is necessary for Windows 8, or Windows 10.

(For supported operating systems for the EPSON RC+ 7.0, refer to Setup & Operation

1.1 System Example.)

36 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

6.3 Controller Status Storage Function

■

NOTE

6.3.1 Controller Status Storage with Trigger Button

CAUTION

influences the robot cycle time and the communication with

RC+ 7.0. Other than only when it is necessary, do not execute this

Use this procedure to save the status of the Controller to USB memory.

(1) Insert the USB memory into the memory port.

(2) Wait approximately 10 seconds for USB memory recognition.

(3) Press the trigger button on the Controller.

When the data transfer starts, the LED of

Wait until the LED status changes.

(The data transfer time varies according to the data size such as of the projects.)

Setup & Operation 6. Memory Port

available

TEACH, AUTO, and PROGRAM starts blinking.

(4) When the controller status storage is completed successfully, the LED of TEACH, AUTO,

and PROGRAM are turned ON for two seconds. Note that the LED of ERROR turns OFF

even in the error status.

If it ends in failure, the LED of ERROR, TEACH, AUTO, and PROGRAM are turned ON

for two seconds.

(5) Remove the USB memory from the Controller.

- USB memory with LED is recommended to check the status changes in procedure (2).

- When storage is executed during Motor ON status, it may fail to store the status.

Use another USB memory or execute the storage during Motor OFF status.

6.3.2 Load Data with EPSON RC+ 7.0

The following shows the procedure to read the data stored in the USB memory by EPSON

RC+ 7.0 and display the Controller status.

(1) Insert the USB memory into the PC with EPSON RC+ 7.0.

(2) Make sure that the following folder is indicated in the USB memory.

B_controller model_serial number_data status was saved

→ Example RC90 : B_RC90_12345_2013-10-29_092951

→ Example RC90-B : B_RC90-B_12345_2013-10-29_092951

(3) Copy the folder confirmed in procedure (2) to the “\EpsonRC70\Backup” folder.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 37

Setup & Operation 6. Memory Port

(4) Select the EPSON RC+ 7.0 menu-[Tools]-[Controller] to display the [Controller Tools]

dialog.

(5) Click the <View Controller Status…> button.

(6) [Browse For Folder] dialog appears. Select the folder copied in procedure (3) and click

the <OK> button.

(7) [Controller Status Viewer] dialog appears to confirm the Controller status.

For details, refer to View Controller Status in EPSON RC+ 7.0 User’s Guide 5.11.8

Controller Command (Tools Menu).

38 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

6.3.3 Transfer with E-mail

File Name

Outline

for restore

parameter

CurrentStatus.txt

Save status

Saves program and I/O status.

ErrorHistory.csv

Error history

InitFileSrc.txt

Initial setting

Saves various settings of the Controller.

MCSys01.MCD

Robot setting

Saves information of connected robot.

information

Prg file is not included.

variables

information

VXDWORK.bin

When [Include project files when status exported] check box

the project file is stored. Includes program files.

NOTE

Follow this procedure to transfer the data by e-mail that was saved to the USB memory.

(1) Insert the USB memory to a PC that supports sending of e-mail.

(2) Make sure that the USB memory has following folders.

B_controller model_serial number_data status was saved

→ Example RC90 : B_RC90_12345_2013-10-29_092951

→ Example RC90-B : B_RC90-B_12345_2013-10-29_092951

(3) Send all the folders by e-mail.

- Delete files that do not relate to the project before transfer.

- This function is used to send the data to the system director and EPSON from the end

users for problem analysis.

6.4 Details of Data

The following data files are created by the Controller status storage function.

Setup & Operation 6. Memory Port

Backup.txt Information file

CurrentMnp01.PRM Robot

SrcmcStat.txt Hardware

File with information for Controller restore.

Saves information such as ToolSet.

Saves installation information of hardware.

ProjectName.obj OBJ file Result of project build.

GlobalPreserves.dat *1 Global Preserve

WorkQueues.dat WorkQue

MCSRAM.bin

MCSYSTEMIO.bin

MCTABLE.bin

MDATA.bin

Inner

information

of Robot

operation

Saves values of Global Preserve variables.

Saves information of Queues information of the WorkQue.

SERVOSRAM.bin

All files related to

Project

project except

ProjectName.obj *2

*1 When the Controller firmware version is Ver.1.0.*.*, GlobalPreserves.dat is not stored.

*2 Storage of “All files related to project except ProjectName.obj” can be specified by a setting.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 39

is checked in EPSON RC+ 7.0 menu-[Setup]-

[System Configuration]-[Controller]-[Preference],

Setup & Operation 7. LAN (Ethernet Communication) Port

Private Address List

NOTE

7. LAN (Ethernet Communication) Port

- Refer to EPSON RC+ 7.0 User’s Guide 5.12.1 [PC to Controller Communications]

Command (Setup Menu)

connection.

- For Ethernet (TCP/IP) communication with robot application software, refer to EPSON

RC+ 7.0 Online Help or User’s Guide 14. TCP/IP Communications.

7.1 About the LAN (Ethernet Communication) Port

Ethernet communication port supports 100BASE-TX / 10 BASE-T.

This port is used for two different purposes.

Connection with development PC

LAN (Ethernet communication) port is used for connection of the Controller and the

development PC.

Equivalent operation is available to connect between the Controller and the development

PC with the development PC connection port.

(Refer to Setup & Operation 5. Development PC Connection Port)

for other details for the development PC and Controller

Connection with other Controller or PC

7.2 IP Address

From the following firmware version password authentication is required when connecting

Controllers and PCs to a global accessible network.

F/W : Ver.7.4.8.x

Our robot system is provided on the assumption that customers use it in the closed local area

networks. We considered the setting of the global IP address is access to the Internet and

changed the specification to perform password authentication in order to secure the

connections.

Password authentication is not performed in case of USB connections.

Be sure to use the following private IP addresses.

The LAN (Ethernet communication) port can be used as an Ethernet (TCP/IP)

communication port to communicate between multiple controllers from robot application

software.

10.0.0.1 to 10.255.255.254

172.16.0.1 to 172.31.255.254

192.168.0.1 to 192.168.255.254

The following is the configuration of the controller at delivery.

IP Address : 192.168.0.1 IP Mask : 255.255.255.0 IP Gateway : 0.0.0.0

40 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 7. LAN (Ethernet Communication) Port

NOTE

7.3 Changing Controller IP Address

In this section, the procedure to change the Controller IP address when connecting

Controller development PC connection port and the development PC by the USB cable is

indicated.

(1) For connection between the development PC and the Controller, refer to Setup &

Operation

(2) Select the EPSON RC+ 7.0 menu-[Setup]-[Controller] to display the following dialog.

5. Development PC Connection Port.

(3) Select [Controller]-[Configuration].

(4) Enter the proper IP address and subnet mask and click the <Apply> button.

(5) Click the <Close> button. The Controller reboots automatically.

IP address configuration is completed and the Controller reboot dialog disappears.

When the Controller and the development PC are connected via the Ethernet, the Controller

IP address can also be changed. However, Controller and the development PC do not

connect automatically after rebooting the Controller at Ethernet connection.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 41

Setup & Operation 7. LAN (Ethernet Communication) Port

7.4 Connection of Development PC and Controller with Ethernet

Connection between the development PC and the Controller is shown below.

(1) Connect the development PC and the Controller using the Ethernet cable.

(2) Turn on the Controller.

(3) Start EPSON RC+ 7.0.

(4) Display the [PC to Controller Communication] dialog from [Setup] in EPSON RC+ 7.0

menu.

(5) Click the <Add> button.

(6) Connection “No.2” is added. Set the following and click the <Apply> button.

Name : Valid value to identify the controller to connect

IP Address : IP address for Controller to connect

(7) [Name] and [IP Address] specified in procedure (6) is displayed.

42 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 7. LAN (Ethernet Communication) Port

NOTE

(8) Make sure that “No.2” is selected, and click the <Connect> button.

(9) After the development PC and Controller connection is completed, “Connected” is

displayed in the [Connection status:]. Make sure that “Connected” is displayed and

click the <Close> button to close the [PC to Controller Communications] dialog.

Connection between the development PC and the Controller is complete. Now the robot

system can be used via an Ethernet connection from EPSON RC+ 7.0.

7.5 Disconnection of Development PC and Controller with Ethernet

Disconnection of the development PC and the Controller is shown below.

(1) Display [PC-Controller Connection] dialog from [Setup] in EPSON RC+ 7.0 menu.

(2) Click the <Disconnect> button.

Communication between the Controller and the development PC is disconnected and

the Ethernet cable can be removed.

If the Ethernet cable is removed when the Controller and the development PC is connected,

Emergency Stop occurs and the Robot stops. Be sure to click the <Disconnect> button in

the [PC to Controller Communications] dialog before the Ethernet cable is removed.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 43

Setup & Operation 8. TP Port

NOTE

8. TP Port

8.1 What is the TP Port?

The TP port connects the Teach Pendant to the Controller. You can connect the Teach

Pendant.

When nothing is connected to the TP port, Emergency Stop status occurs in the Controller.

When the Teach Pendant is not connected, connect the TP bypass plug.

Do not connect the following devices to the TP port of RC90/RC90-B. Connecting these

devices 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

8.2 Teach Pendant Connection

A cable for connection to the RC90/RC90-B Controller is attached to the Teach Pendant.

Connect this cable connector to the TP port.

Communication is set automatically. Enable the Teach Pendant by one of the following

procedures.

- Insert the Teach Pendant connector to the Controller and turn ON the Controller.

- Insert the Teach Pendant connector while the Controller is turned ON.

- Teach Pendant connection and disconnection from the Controller are allowed when the

Controller power is ON.

- When the Teach Pendant connector is removed from the Controller with the mode

selector key switch of the Teach Pendant in the “Teach” position, the operation mode

will remain in the TEACH mode. The operation mode cannot be switched to AUTO

mode. Be sure to remove the Teach Pendant after switching the operation mode to

“Auto” mode.

For details, refer to manual

Robot Contoroller RC700/RC90 Option Teach Pendant TP1.

Robot Contoroller RC700/RC90 Option Teach Pendant TP2.

44 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

9. EMERGENCY

■

Before connecting the connector, make sure that the pins are not bent. Connecting with of

EMERGENCY Connector

Connector

Standard

NOTE

The details of safety requirements for this section are described in EPSON RC+ 7.0 2. Safety. Please refer to them to keep the robot system safe.

Connect a safeguard switch or Emergency Stop switch to the Controller EMERGENCY connector for safety. When nothing is connected to the EMERGENCY connector, the robot system does not operate normally.

Setup & Operation 9. EMERGENCY

the pins bent may damage the connector and result in malfunction

WARNING

the robot system.

9.1 Safety Door Switch and Latch Release Switch

The EMERGENCY connector has input terminals for the Safety Door switch and the

Emergency Stop switch. Be sure to use these input terminals to keep the system safe.

EMERGENCY connector

(Controller side)

* The E-STOP BOX, EMERGENCY connector cable, terminal block, and EMERGENCY

connector kit are offered as options.

D-sub 25 male pin

Screwlock #4 - 40

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 45

Setup & Operation 9. EMERGENCY

■

The interlock of the Safety Door must be functioning when the operated. be turned ON/OFF (e.g. The tape is put around the switch.). Operating the robot system when the s cause function

NOTE

9.1.1 Safety Door Switch

Do not operate the system under the condition that the switch cannot

robot system is

WARNING

witch is not functioning properly is extremely hazardous and may

serious safety problems as the Safety Door input cannot fulfill its intended

In order to maintain a safe working zone, a safeguard must be erected around the

Manipulator. The safeguard must have an interlock switch at the entrance to the working

zone. The Safety Door that is described in this manual is one of the safeguards and an

interlock of the Safety Door is called a Safety Door switch. Connect the Safety Door

switch to the Safety Door input terminal on the EMERGENCY connector.

The Safety Door switch has safety features such as temporary hold-up of the program or the

operation-prohibited status that are activated whenever the Safety Door is opened.

Observe the followings in designing the Safety Door switch and the Safety Door.

- For the Safety Door switch, select a switch that opens as the Safety Door opens, and not

by the spring of the switch itself.

- The signal from the Safety Door (Safety Door input) is designed to input to two

redundant signals. If the signals at the two inputs differ by two seconds or more, the

system recognizes it to be a critical error. Therefore, make sure that the Safety Door

switch has two separate redundant circuits and that each connects to the specified pins

at the EMERGENCY connector on the Controller.

- The Safety Door must be designed and installed so that it does not close accidentally.

9.1.2 Latch Release Switch

The controller software latches these conditions:

- The safety door is open.

- The operation mode is set to “TEACH”.

The EMERGENCY connector has an input terminal for a latch release switch that cancels

the latched conditions.

Open : The latch release switch latches conditions that the safety door is open or the

operation mode is “TEACH”.

Closed : The latch release switch releases the latched conditions.

When the latched TEACH mode is released while the safety door is open, the status of

Manipulator power is operation-prohibited because the safety door is open at that time.

To execute a Manipulator operation, close the safety door again, and then close the latch

release input.

46 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

9.1.3 Checking Latch Release Switch Operation

NOTE

After connecting the safety door switch and latch release switch to the EMERGENCY

connector, be sure to check the switch operation for safety by following the procedures

described below before operating the Manipulator.

(1) Turn ON the Controller while the safety door is open in order to boot the controller

software.

(2) Make sure that “Safety” is displayed on the main window status bar.

(3) Close the safety door, and turn ON the switch connecting to the latch release input.

Make sure that the “Safety” is dimmed on the status bar.

The information that the safety door is open can be latched by software based on the latch

release input condition. To cancel the condition, close the safety door, and then close the

safety door latch release input.

Open : The latch release switch latches the condition that the safety door is open.

Closed : The latch release switch does not latch the condition that the safety door is open.

The latch release input also functions to acknowledge the change of to TEACH mode.

In order to change the latched condition of TEACH mode, turn the mode selector key switch

on the Teach Pendant to “Auto”. Then, close the latch release input.

Setup & Operation 9. EMERGENCY

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 47

Setup & Operation 9. EMERGENCY

NOTE

9.2 Emergency Stop Switch Connection

9.2.1 Emergency Stop Switch

If it is desired to add an external Emergency Stop switch(es) in addition to the Emergency

Stop on the Teach Pendant and Operator Panel, be sure to connect such Emergency Stop

switch(es) to the Emergency Stop input terminal on the EMERGENCY connector.

The Emergency Stop switch connected must comply with the following:

- It must be a push button switch that is “normally closed”.

- A button that does not automatically return or resume.

- The button must be mushroom-shaped and red.

- The button must have a double contact that is “normally closed”.

The signal from the Emergency Stop switch is designed to use two redundant circuits.

If the signals at the two circuits differ by two seconds or more, the system recognizes it as

a critical error. Therefore, make sure that the Emergency Stop switch has double

contacts and that each circuit connects to the specified pins on the EMERGENCY

connector at the Controller. Refer to the Setup & Operation 9.4 Circuit Diagrams.

9.2.2 Checking Emergency Stop Switch Operation

Once the Emergency Stop switch is connected to the EMERGENCY connector, continue

the following procedure to make sure that the switch functions properly. For the safety

of the operator, the Manipulator must not be powered ON until the following test is

completed.

(1) Turn ON the Controller to boot the controller software while pressing the Emergency

Stop switch.

(2) Make sure that E-STOP LED of the controller is lighting.

(3) Make sure that “EStop” is displayed on the status bar on the main window.

(4) Release the Emergency Stop Switch.

(5) Execute the RESET command.

(6) Make sure that E-STOP LED is turned OFF and that “EStop” is dimmed on the main

window status bar.

9.2.3 Recovery from Emergency Stop

To recover from the emergency stop condition, follow the procedure of safety check as

required by the system.

After safety check, the operations below are required to recover from the emergency stop

condition.

- Release the Emergency Stop Switch

- Execute the RESET command

48 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 9. EMERGENCY

Emergency Stop switch output rated load

+30 V 0.3 A or under

1-2, 14-15 pin

■

The 24 V output is for emergency stop. Do not use it for other purposes. Doing so may result in system malfunction.

■

Do not apply reverse voltage to the Emergency Stop circuit. Doing so may result in system malfunction.

NOTE

9.3 Pin Assignments

The EMERGENCY connector pin assignments are as follows:

Pin No. Signal Function Pin No. Signal Function

1 ESW11 Emergency Stop switch contact (1) *3 14 ESW21 Emergency Stop switch contact (2) *3

2 ESW12 Emergency Stop switch contact (1) *3 15 ESW22 Emergency Stop switch contact (2) *3

3 ESTOP1+ Emergency Stop circuit 1 (+) *4 16 ESTOP2+ Emergency Stop circuit 2 (+) *4

ESTOP1−

5 Not Used *1 18 SDLATCH1 Safety Door Latch Release

6 Not Used *1 19 SDLATCH2 Safety Door Latch Release

7 SD11 Safety Door input (1) *2 20 SD21 Safety Door input (2) *2

8 SD12 Safety Door input (1) *2 21 SD22 Safety Door input (2) *2

9 24V +24V output 22 24V +24V output

10 24V +24V output 23 24V +24V output

11 24VGND +24V GND output 24 24VGND +24V GND output

12 24VGND +24V GND output 25 24VGND +24V GND output

13 Not Used

Emergency Stop circuit 1 (

) *4

ESTOP2−

Emergency Stop circuit 2 (-) *4

*1 Do not connect anything to these pins.

*2 A critical error occurs if the input values from the Safety Door 1 and Safety Door 2 are

different for two or more seconds. They must be connected to the same switch with

two sets of contacts.

*3 A critical error occurs if the input values from the Emergency Stop switch contact 1

and Emergency Stop switch contact 2 are different for two or more seconds. They

must be connected the same switch with two sets of contacts.

*4 Do not apply reverse voltage to the Emergency Stop circuit.

Emergency Stop rated input voltage range Emergency Stop rated input current

Safety Door rated input voltage range Safety Door rated input current

Latch Release rated input voltage range Latch Release rated input current

The total electrical resistance of the Emergency Stop switches and their circuit should be

1 Ω or less.

+24 V ±10%

37.5 mA ±10% /+24 V input

+24 V ±10% 10 mA/+24 V input

3-4, 16-17 pin

7-8, 20-21 pin

18-19 pin

CAUTION

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 49

+24V

+5V

Safety Door input 1

External +24V

Safety Door input 2

Latch release input

Latch release input Close :Latch off

Open :Latch on

Main Circuit

Control

AC Input

Emergency Stop switch of an Operation Unit (TP)

External +24V GND

External Emergency

Stop switches

Motor Driver

−

Controller

Emergency

Stop detection

NOTE:+24V GND

+ 5V GND

ESTOP1+

ESTOP2+

ESTOP1−

ESTOP2−

Be careful of the direction of voltage application

Setup & Operation 9. EMERGENCY

9.4 Circuit Diagrams

9.4.1 Example 1: External emergency stop switch typical application

50 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 9. EMERGENCY

+24V

+5V

Safety Door input 1

External

+24V

Safety Door input 2

Latch Release input

Latch release input Close :Latch off

Open :Latch on

AC Input

Emergency

Stop switch of

an Operation

Unit (TP)

External +24V GND

External +24V

Motor Drive

−

Controller

NOTE:+24V GND

+ 5V GND

External +24V GND

External +24V

Fuse

External

+24V GND

* For the protection of the

emergency stop circuit, the fuse’s capacity should be as follows:

- Meets the capacity of the external safety relay

- 0.4A or less

External safety relay

(The above diagram

is simplified for representation.)

Emergency

Stop detection

Main Circuit

Control

9.4.2 Example 2: External safety relay typical application

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 51

Setup & Operation 10. Standard RS-232C Port

Port No.

Supported hardware

Standard RS-232C connector

First expansion RS-232C board CH1

First expansion RS-232C board CH2

Second expansion RS-232C board CH1

10. Standard RS-232C Port

10.1 About the RS-232C Port

A standard RS-232C port is available with the Controller.

Mount the RS-232C board(s) in the option slot to communicate with external equipment

with two or more RS-232C ports.

For the details of the expansion port, refer to Setup & Operation 13.4 RS-232C Board.

Port numbers are assigned as follows.

#5 Second expansion RS-232C board CH2

10.2 Confirmation with EPSON RC+ 7.0 (RS-232C)

When an RS-232C board is mounted in as option unit, the Controller software automatically

identifies the RS-232C board. Therefore, no software configuration is needed. Correct

identification can be confirmed from EPSON RC+ 7.0.

(1) Select the EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the

[System Configuration] dialog.

(2) Select the [RS232]-[CU].

52 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 10. Standard RS-232C Port

Item

Specification

Baud Rates

110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200

Data bit length

7, 8

Stop bit length

1, 2

Parity

Odd, even, NA

Terminator

CR, LF, CRLF

Connector

Standard

Pin No

Signal

Function

Signal Direction

DCD

Data carrier detect

Input 2 RXD

Receive data

Input 3 TXD

Send data

Output 4 DTR

Terminal ready

Output 5 GND

Signal ground

- 6 DSR

Data set ready

Input 7 RTS

Request to send

Output 8 CTS

Clear to send

Input 9 RI

Ring indicator

Input

NOTE

10.3 RS-232C Software Communication Setup (RS-232C)

Available communication settings are as follows.

Refer to EPSON RC+ 7.0 Online Help or Users Guide – 13. RS-232C Communications for

RS-232C communication from the Robot application.

10.4 Communication Cable (RS-232C)

Prepare a communication cable as described in this section.

Use twisted pair cable for shielded wire.

Clamp the shield to the hood for noise prevention.

Pin assign of the RS-232C connector is as follows.

RS-232C Connector

(Controller side)

D-sub 9 male pin

Screwlock #4 - 40

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 53

Setup & Operation 11. I/O Connector

Pins

Bit number

Input

0 to 23

Output

0 to 15

11. I/O Connector

The I/O connector is for connecting your input/output equipment to the system.

Specification of I/O connector differs between RC90 and RC90-B.

RC90 : The output circuit has two types: Sink type and Source type. The either type

has been configured in the controller before shipment.

RC90-B : Non-polar PhotoMOS relay is used. Two types of connection are available.

Refer to Setup & Operation 13.2. Expansion I/O board.

For cable wiring, refer to the Setup & Operation 3.5 Noise Countermeasures in order to

prevent noise.

Remote function is initially assigned to both input and output from 0 to 7. For further

details, refer to Setup & Operation 11. I/O Remote Settings.

54 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

I/O-1

(Same)

Omit

GND +DC

34 Input No.16～23 common

Omit

26 Input No.15

42 Input No.23

35 Input No.16

36 Input No.17

1 Input No.0 to 7 common

2 Input No.0

3 Input No.1

4 Input No.2

5 Input No.3

6 Input No.4

7 Input No.5

8 Input No.6

9 Input No.7

18 Input No.8 to 15 common 19 Input No.8

20 Input No.9

(Same)

11.1 RC90 (I/O Connector)

11.1.1 Input Circuit (RC90)

Input Voltage Range : +12 to 24 V ±10%

ON Voltage : +10.8 V (min.)

OFF Voltage : +5 V (max.)

Input Current : 10 mA (TYP) at +24 V input

Two types of wiring are available for use with the two-way photo coupler in the input circuit.

Typical Input Circuit Application 1 (RC90)

Setup & Operation 11. I/O Connector

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 55

Setup & Operation 11. I/O Connector

I/O-1

(Same

)

Omit

GND +DC

34 Input No.16～23 common

Omit

26 Input No.15

42 Input No.23

35 Input No.16

36 Input No.17

1 Input No.0 to 7 common

2 Input No.0

3 Input No.1

4 Input No.2

5 Input No.3

6 Input No.4

7 Input No.5

8 Input No.6

9 Input No.7

18 Input No.8 to 15 common 19 Input No.8

Input No.9

(Same)

(Same

)

(Same)

(Same

)

(Same)

Typical Input Circuit Application 2 (RC90)

56 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

■

The output circuit has two types: Sink type and Source type. The either type has been configured in the controller before the shipment. Before routing the cables, make connection d If you route the cables with wrong output type, the parts on the board will be broken and the robot system won

■

Use the wiring diagram of correctly. Improper wiring may cause Manipulator

■

Be for of the parts on the board and then

CAUTION

Setup & Operation 11. I/O Connector

11.1.2 Output Circuit (RC90)

Rated Output Voltage : +12 V to +24 V ±10%

Maximum Output Current : TYP 100 mA/1 output

Output Driver : Photo coupler

sure that the I/O output type of your controller conforms to the external

evices.

’t operate normally.

move unusually.

sure to wire the output circuit properly because it has no protection circuitry

short-circuit and reverse-connection. Improper wiring may cause malfunction

2: Source Type for CE conformance. Be sure to wire

safety problems as it may make the

improper function of the robot system.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 57

Setup & Operation 11. I/O Connector

10 Output No.0

12 Output No.2

11 Output No.1

13 Output No.3

29 Output No.8

17 Output No.0 to 7 Common (GND)

30 Output No.9

GND +DC

Omit

～

14 Output No.4

15 Output No.5

27 Output No.6

28 Output No.7

(Same)

Typical Output Circuit Application 1: Sink Type (NPN) (RC90)

58 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

■

Be for of the parts on the board and then

17 Output No.0 to 7 Common

11 Output No.1

10 Output No.0

12 Output No.2

13 Output No.3

GND +DC

33 Output No.8 to 15 Common

Omit

～

29 Output No.8

14 Output No.4

15 Output No.5

27 Output No.6

30 Output No.9

(Same)

28 Output No.7

CAUTION

Setup & Operation 11. I/O Connector

Typical Output Circuit Application 2: Source Type (PNP) (RC90)

sure to wire the output circuit properly because it has no protection circuitry

short-circuit and reverse-connection. Improper wiring may cause malfunction

improper function of the robot system.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 59

Setup & Operation 11. I/O Connector

I/O-1

(Same)

Omit

GND +DC

34 Input No.16～23 common

Omit

26 Input No.15

42 Input No.23

35 Input No.16

36 Input No.17

1 Input No.0 to 7 common

2 Input No.0

Input No.1

4 Input No.2

Input No.3

6 Input No.4

7 Input No.5

8 Input No.6

9 Input No.7

18 Input No.8 to 15 common 19 Input No.8

20 Input No.9

(Same)

11.2 RC90-B (I/O Connector)

11.2.1 Input Circuit (RC90-B)

Input Voltage Range : + 12∼24 V±10%

ON Voltage : + 10.8 V(MIN.) OFF Voltage : + 5 V(MAX.) Input Current : 3mA TYP／+ 24 V input

Two types of wiring are available for use with the two-way photo coupler in the input circuit.

Typical Input Circuit Application 1 (RC90-B)

60 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 11. I/O Connector

I/O-1

(Same)

Omit

GND +DC

34 Input No.16～23 common

Omit

26 Input No.15

42 Input No.23

35 Input No.16

36 Input No.17

1 Input No.0 to 7 common

2 Input No.0

3 Input No.1

4 Input No.2

5 Input No.3

6 Input No.4

7 Input No.5

8 Input No.6

9 Input No.7

18 Input No.8 to 15 common 19 Input No.8

20 Input No.9

(Same)

Typical Input Circuit Application 2 (RC90-B)

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 61

Setup & Operation 11. I/O Connector

10 Output No.0

I/O-1

Omit

+DC

29 Output No.8

30 Output No.9

11 Output No.1

Output

No.2

13 Output No.3

14 Output No.4

15 Output No.5

27 Output No.6

28 Output No.7

17 Output No.0 to 7 Common (GND)

Load

GND

Output

No.8 to 15 Common (GND)

(Same)

11.2.2 Output Circuit (RC90-B)

Rated Output Voltage : +12V∼24V±10%

Maximum Output Current : TYP 100mA/1 output

Output Driver : PhotoMOS relay

On-resistance (average) :0.13Ω or less

Two types of wiring are available for use with the non-polar PhotoMOS relay in the output

circuit.

Typical Output Circuit Application 1: Sink Type (NPN) (RC90-B)

62 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 11. I/O Connector

10 Output No.0

I/O-1

Omit

+DC

29 Output No.8

30 Output No.9

11 Output No.1

12 Output No.2

13 Output No.3

14 Output No.4

15 Output No.5

27 Output No.6

28 Output No.7

17 Output No.0 to 7 Common (+DC)

Load

GND

33 Output No.8 to 15 Common (+DC)

(Same)

Typical Output Circuit Application 2: Source Type (PNP) (RC90-B)

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 63

Setup & Operation 11. I/O Connector

Pin No.

11.3 Pin Assignments

Signal Name

1 Input common No. 0 to 7 18 Input common No. 8 to 15 34 Input common No. 16 to 23

2 Input No. 0 (Start) 19 Input No. 8 35 Input No. 16

3 Input No. 1 (SelProg1) 20 Input No. 9 36 Input No. 17

4 Input No. 2 (SelProg2) 21 Input No. 10 37 Input No. 18

5 Input No. 3 (SelProg4) 22 Input No. 11 38 Input No. 19

6 Input No. 4 (Stop) 23 Input No. 12 39 Input No. 20

7 Input No. 5 (Pause) 24 Input No. 13 40 Input No. 21

8 Input No. 6 (Continue) 25 Input No. 14 41 Input No. 22

9 Input No. 7 (Reset) 26 Input No. 15 42 Input No. 23

10 Output No. 0 (Ready) 27 Output No. 6 (SError) 43 Output No.11

11 Output No. 1 (Running) 28 Output No. 7 (Warning) 44 Output No.12

12 Output No. 2 (Paused) 29 Output No. 8 45 Output No.13

13 Output No. 3 (Error) 30 Output No. 9 46 Output No.14

14 Output No. 4 (EstopOn) 31 Output No.10 47 Output No.15

15 Output No. 5 (SafeguardOn) 32 Not Used 48 Not Used

16 Not Used 33 Output common No. 8 to 15 49 Not Used

17 Output common No. 0 to 7 50 Not Used

Signal Name

Remote function inside ( ) in the table above is initially assigned to both input and output from 0 to 7. For

further details, refer to 12. I/O Remote Settings.

Connector Standard

I/O Connector (Controller side)

D-sub 50 male pin Screwlock #4 - 40

* The I/O connector, I/O cable, and terminal block are offered as options.

* I/O connector is included with shipment.

64 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

When using remote I/O, always make sure of the following. Using the robot system under and/or safety problems.

NOTE

12. I/O Remote Settings

This section describes the functions and timings of input and output signals.

The remote functions may be assigned to your standard I/O board(s), expansion I/O board(s),

or fieldbus I/O board(s) to enhance robot system control - either from an operational unit of

your choice or a sequencer.

Remote function is initially assigned to both input and output from 0 to 7.

To accept external remote inputs, assign the remote function and the control device is remote.

For further details, refer to the section, Remote Control Software Configuration in EPSON

RC+ 7.0 User’s Guide - Remote Control.

The user defines the I/O number that a remote function is assigned to using software

configuration. For further details, refer to the section, Remote Control Software

Configuration in EPSON RC+ 7.0 User’s Guide - Remote Control.

For details about I/O cable connection, refer to sections on Setup & Operation 11. I/O

Connector and 13.2. Expansion I/O Board and 13.3 Fieldbus I/O Board.

For details about communication with external equipment, refer to EPSON RC+ 7.0 U s e r ’s

Guide -12. Remote Control.

Setup & Operation 12. I/O Remote Settings

■

- Assign remote functions to inputs/outputs correctly and wire correctly when setting up remote I/O signals.

CAUTION

- 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.

Remote function is available when virtual I/O is enabled.

When you set up a remote I/O signal, please either keep a written record of the settings or

store the data in a file for later reference.

When you set up a fieldbus I/O signal to the remote function, response depends on the baud

rate of the fieldbus. For details of fieldbus response, refer to Robot Controller RC700 /

RC90 Option Fieldbus I/O.

unsatisfactory conditions may cause malfunction of the system

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 65

Setup & Operation 12. I/O Remote Settings

Ready output ON

Stop input OFF

Running output ON

Paused output ON

Stop input OFF

Ready output ON Shutdown

Not set

Terminates the system

Operates as the forced low power

Power High control from the

Executes the following according to

tasks and commands. (*12)

Any time

NOTE

12.1 I/O Signal Description

Remote function is initially assigned to both input and output from 0 to 7.

To change the function assignment from the initial setting, use EPSON RC+ 7.0.

To use all signals, you will need to add Expansion I/O or Fieldbus I/O board(s).

12.1.1 Remote Input Signals

Remote inputs are used to control the Manipulators and start programs. Certain conditions

must be met before inputs are enabled, as shown in the table below.

To accept external remote inputs, assign the remote function and set remote to the control

device. When external remote input is available, “AutoMode output” turns ON.

Except “SelProg”, the signals execute each function when the signal starts in input

acceptance condition. The function executes automatically. Therefore, no special

programming is needed.

When an error occurs, you must execute a “Reset” to clear the error condition before any

other remote input commands can be executed. Use the “Error output” and “Reset input”

to monitor the error status and clear error conditions from the remote device.

Name Initial Description

Input Acceptance Condition (*1)

Start 0

SelProg1 SelProg2 SelProg4 SelProg8 SelProg16 SelProg32

1 2 3

Not Set Not Set Not Set

Stop 4 All tasks and commands are stopped.

Pause 5 All tasks are paused. (*3)

Continue 6

Reset 7

ForcePowerLow

(*6)

Not Set

Execute function selected at SelProg. (*2)

Specify the executing Main function number. (*2)

Continue the paused task.

Reset emergency stop and error. (*4)

function. The robot is operated in the low power mode.

command is not accepted.

Error output OFF EStopOn output OFF SafeguardOn output OFF Pause input OFF

Pause input OFF

This input is acceptable even

AutoMode output is OFF.

66 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

the controller preferences. Stops or temporarily stops all the

Setup & Operation 12. I/O Remote Settings

Changes the output condition of

MCalReqd. (*9)

SelRobot1

SelRobot16

robot which

Ready output ON

SetMotorOff input OFF

Ready output ON

SetPowerLow input OFF

Ready output ON

Move the Robot Arm to the home

Ready output ON

Stop input OFF

Ready output ON

Stop input OFF

Paused output ON

Stop input OFF

ResetAlarm

Not Set

Cancel the alarm (*11)

SelAlarm1

SelAlarm8

Input signal for alive monitoring of the

master equipment can perform alive monitoring of the controller by switching the input periodically and checking the output signal.

Name Initial

Description

Input Acceptance Condition (*1)

SelRobot

SelRobot2 SelRobot4 SelRobot8

SetMotorsOn

SetMotorsOff

SetPowerHigh

SetPowerLow

Home

Not Set

Not set

MotorsOn, AtHome, PowerHigh, and

Specify the number of executes a command. (*5)

Turn ON robot motors. (*5)

Turn OFF robot motors.

Not set Set the robot power mode to High (*5)

Not set Set the robot power mode to Low. (*5)

Not set

position defined by the user.

EStopOn output OFF SafeguardOn output OFF

Error output OFF EStopOn output OFF SafeguardOn output OFF MotorsOn output ON Pause input OFF

MCal

Recover

SelAlarm2 SelAlarm4

Not set Execute MCal (*5) (*7)

Not set

Not Set

ALIVE Not Set

After the safeguard is closed, recover

to the position where the safeguard is

open.

Specify the alarm number to cancel (*10)

controller. Same signal as the input will be output to ALIVE output. The

Error output OFF EStopOn output OFF SafeguardOn output OFF MotorsOn output ON Pause input OFF

Error output OFF EStopOn output OFF SafeguardOn output OFF RecoverReqd output ON Pause input OFF

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 67

Setup & Operation 12. I/O Remote Settings

Function name

SelProg1

SelProg2

SelProg4

SelProg8

SelProg16

SelProg32

Main

0 0 0 0 0 0 Main1

1 0 0 0 0 0 Main2

0 1 0 0 0 0 Main3

1 1 0 0 0

. . .

Main60

0 0 1 1 1 1 Main61

1 0 1 1 1 1 Main62

0 1 1 1 1 1 Main63

1 1 1 1 1

Robot number

SelRobot1

SelRobot2

SelRobot4

SelRobot8

SelRobot16

0 (All)

0 0 0 0 0

1 1 0 0 0 0 2 0 1 0 0

3 1 1 0 0

. . .

13 1 0 1 1

14 0 1 1 1 0 15 1 1 1 1

16 0 0 0 0

(*1) “AutoMode output” ON is omitted from the table. This is an input acceptance condition for all functions.

“Start input” executes Function specified by the following six bits: SelProg 1, 2, 4, 8, 16, and 32.

(*2)

0=OFF, 1=ON

(*3) “NoPause task” and “NoEmgAbort task” do not pause.

For details, refer to EPSON RC+ 7.0 Online Help or Pause in SPEL

Language Reference.

(*4) Turns OFF the I/O output and initializes the robot parameter.

For details, refer to EPSON RC+ 7.0 Online Help or Reset in SPEL

Language Reference.

(*5) The values specified by “SelRobot1, 2, 4, 8, and 16” correspond to the robot numbers.

0=OFF, 1=ON

(*6) Initializes the robot parameter.

For details, refer to EPSON RC+ 7.0 Online Help or Motor in SPEL

(*7) For details, refer to EPSON RC+ 7.0 Online Help or MCal in SPEL

Language Reference.

(*8) This is for experienced users only. Make sure that you fully understand the input specification before

using. CmdRunning output and CmdError output will not change for this input. “NoEmgAbort task” will not stop by this input. When the input changes from ON to OFF, all tasks and commands will stop.

(*9) This function changes the output condition of MotorsOn, AtHome, PowerHigh, and MCalReqd.

68 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

By setting this signal with the condition selected using SelRobot1 - SelRobot16, you can switch the output

condition. Once you select the condition, it will be kept until you change it or turn off / restart the Controller. All manipulators are selected as default.

Setup & Operation 12. I/O Remote Settings

Alarm #

Target

SelAlarm1

SelAlarm2

SelAlarm4

SelAlarm8

Controller battery

1 0 0

0 1 0

1 1 0

Battery of the robot connected to DU1

0 0 1 0 5

Grease of the robot connected to DU1

1 0 1

Battery of the robot connected to DU2

0 1 1

Grease of the robot connected to DU2

1 1 1 0 8

Battery of the robot connected to DU3

0 0 0

Grease of the robot connected to DU3

1 0 0

commands

0 0 1→0

Stop

Low only

0 1 1→0

Continue

High/Low

0 1 0→1

Temp. stop

Low only

Not accept 1 0

1→0

Stop

Low only

Not accept

1 0 0→1

Stop

Low only

1 1 1→0

Temp. stop

Low only

Not accept

1 1 0→1

Continue

High/Low

(*10) The values specified by “SelAlarm1, 2, 4, and 8” correspond to the alarm numbers.

Battery of the robot connected to CU

Grease of the robot connected to CU

0=OFF, 1=ON

The following parts are subject to grease up.

Ball screw spline unit on the Joint # 3

(*11) The specified alarm can be canceled by selecting the conditions using SelAlarm1-SelAlarm8 and setting

this signal.

(*12) Operation of all tasks and commands, power mode of the robot, and PowerHigh command are executed

by the setting value of the controller preferences.

Preferences (1): “Motor power low when ForcePowerLow signal OFF”

Preferences (2): “ForcePowerLow signal change pauses all tasks”

For details of the controller preferences, refer to EPSON RC+ 7.0 User’s Guide

[Setup]-[System Configuration]-[Controller]-[Preferences] in 5.12.2 [System Configuration] Command (Setup Menu).

Preferences (1) Preferences (2) ForcePowerLow

All tasks and

Power mode PowerHigh

0 0 0→1 Stop Low only

Not accept

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 69

Setup & Operation 12. I/O Remote Settings

Name

Initial

Description

Turns ON when the controller startup completes and no task is running.

Turns ON when task is running. However, turns OFF when “Paused output” is ON.

Paused

Turns ON when pause task exists.

Turns ON when an error occurs. Use “Reset input” to recover from the error.

EStopOn

Turns ON at Emergency Stop.

SafeguardOn

Turns ON when the safeguard is open.

Turns ON when critical error occurs.

does not

function. Reboot the controller to recover.

Turns ON when warning occurs.

sure to eliminate the cause of the warning as soon as possible.

MotorsOn

Not set

Turns ON when the motor is ON. (*5)

AtHome

Not set

Turns ON when the robot is in the home position. (*5)

PowerHigh

Not set

Turns ON when the robot’s power mode is High. (*5)

MCalReqd

Not set

Turns ON when the robot hasn’t executed MCal. (*5)

Turns ON when at least one robot is waiting for Recover RecoverInCycle

Not set

Turns ON when at least one robot is executing Recover.

CmdRunning

Not set

Turns ON when an input command is executing.

CmdError

Not set

Turns ON when an input command cannot be accepted.

AutoMode

Not set

Turns ON in remote input acceptable status. (*2)

TeachMode

Not set

Turns ON in TEACH mode.

ErrorCode1

ErrorCode8192

InsideBox1

InsideBox15

12.1.2 Remote Output Signals

Remote outputs provide status for the Manipulator and Controller.

Remote outputs provide the assigned function using with any control device The outputs

execute automatically. Therefore, no special programming is needed.

Ready 0

Running 1

Error 3

SError 6

Warning 7

RecoverReqd

CurrProg1 CurrProg2 CurrProg4 CurrProg8 CurrProg16 CurrProg32

Not set

When a critical error occurs, “Reset input”

The task runs as normal with the warning. However, be

after the safeguard is closed.

Indicates the running or the last main function number (*1)

. . .

70 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Not set

Indicates the error number.

Turns ON when the robot is in the approach check area. (*3)

Setup & Operation 12. I/O Remote Settings

Name

Initial

Description

InsidePlane1

InsidePlane15

Alarm

Not set

Turns ON when any of the alarms is occurring. (*9)

Alarm1

Not set

Turns ON when a battery alarm of the controller is occurring.

Turns ON when a battery alarm of the robot connected to CU is occurring.

Turns ON when a grease alarm of the robot connected to CU

Turns ON when a battery alarm of the robot connected to DU1

Turns ON when a grease alarm of the robot connected to DU1

(*10)

Turns ON when a battery alarm of the robot connected to DU2 is occurring.

Turns ON when a grease alarm of the robot connected to DU2

Turns ON when a battery alarm of the robot connected to DU3

Turns ON when a grease alarm of the robot connected to DU3

(*10)

Outputs current X coordinate in the World coordinate system (*6) (*7)

Outputs current Y coordinate in the World coordinate system

Outputs current Z coordinate in the World coordinate system

Outputs current U coordinate in the World coordinate system

Outputs current V coordinate in the World coordinate system (*6) (*7)

Outputs current W coordinate in the World coordinate

Torque1

Not set

Outputs the current torque value of Joint #1 (*6) (*7)

Torque2

Not set

Outputs the current torque value of Joint #2 (*6) (*7)

Torque3

Not set

Outputs the current torque value of Joint #3 (*6) (*7)

Torque4

Not set

Outputs the current torque value of Joint #4 (*6) (*7)

Torque5

Not set

Outputs the current torque value of Joint #5 (*6) (*7)

Torque6

Not set

Outputs the current torque value of Joint #6 (*6) (*7)

CPU

Not set

Outputs the CPU load factor of the user program (*8)

Outputs how many times emergency stops have been

Output signal for alive monitoring of the controller. The

signal.

. . .

Not set

Turns ON when the robot is in the approach check plane. (*4)

Alarm2

Alarm3

Alarm4

Alarm5

Alarm6

Alarm7

Alarm8

Alarm9

Not set

PositionX Not set

PositionY Not set

PositionZ Not set

PositionU Not set

is occurring. (*10)

is occurring.

is occurring. (*10)

is occurring.

(*6) (*7)

PositionV Not set

PositionW Not set

ESTOP Not set

ALIVE Not set

system (*6) (*7)

executed.

signal input by ALIVE input will be output. The master equipment can perform alive monitoring of the controller by switching the input periodically and checking the output

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 71

Setup & Operation 12. I/O Remote Settings

Function name

CurrProg1

CurrProg2

CurrProg4

CurrProg8

CurrProg16

CurrProg32

Main

0 0 0 0 0

Main1

1 0 0 0 0

Main2

0 1 0 0 0 0 Main3

1 1 0 0 0

. . .

Main60

0 0 1 1 1 1 Main61

1 0 1 1 1 1 Main62

0 1 1 1 1 1 Main63

1 1 1 1 1

(SelRobot1- SelRobot16) condition when inputting SelRobot

0: All robots are selected

1 - 16: Particular robot number is selected

Turns ON when at least one motor is ON.

Turns ON when the motor of the selected robot is ON.

Turns ON when all robots are in the home position.

Turns ON when the selected robot is in the home position.

Turns ON when at least one robot’s power mode is High.

Turns ON when the selected robot’s power mode is High.

Turns ON when at least one robot hasn’t executed MCal.

Turns ON when the selected robot hasn’t executed MCal.

(*1) Outputs the current or the last function number of CurrProg1, 2, 4, 8, 16, or 32.

0=OFF, 1=ON

(*2) Remote function is available in the followings conditions.

- The setting is Auto mode and the control device is remote.

- The setting is Program mode and Remote I/O is enabled.

(*3) For details, refer to EPSON RC+ 7.0 Online Help or Box in SPEL

(*4) For details, refer to EPSON RC+ 7.0 Online Help or Plane in SPEL

Language Reference.

(*5) Manipulator status is output as follows, according to the condition selected in SelRobot.

Wait at least 40 ms before inputting the signal after changing the condition in SelRobot.

Name

MotorsOn

AtHome

PowerHigh

MCalReqd

(*6) Outputs information of the selected robot when SelRobot1, SelRobot2, SelRobot4, SelRobot8, and

SelRobot16 are set. If not, information of Robot 1 will be output.

(*7) Outputs information in Real format.

(*8) Outputs the total load factor of the user created tasks. For details on the CPU load factor, refer to the task

manager.

(*9) The signal turns on when the alarm occurs either in the controller alarm information or the robot alarm

information.

(*10) The following parts are subject to grease up.

Ball screw spline unit on the Joint # 3

72 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

940

924

Depending on HOME motion

MotorsOn

Output

AtHome

Output

SetMotorsOn

Input

SetMotorsOff

Input

Home

Input

107

162

Ready

Output

CurrProg1

Output

Running

Output

* Paused

Output

SelProg1

Input

Start

Input

Pause

Input

Continue

Input

Stop

Input

162

12.2 Timing Specifications

12.2.1 Design Notes for Remote Input Signals

The following charts indicate the timing sequences for the primary operations of the

Controller.

The indicated time lapses (time durations) should be referred to only as reference values

since the actual timing values vary depending on the number of tasks running, as well as

CPU speed of the Controller. Check carefully and refer to the following charts for the

timing interrelation when you enter an input signal.

During system design, make sure that you actuate only one remote input operation at a time,

otherwise an error will occur.

The pulse width of an input signal must be 25 or more milliseconds to be detected.

12.2.2 Timing Diagram for Operation Execution Sequence

Setup & Operation 12. I/O Remote Settings

[Unit: msec]

12.2.3 Timing Diagram for Program Execution Sequence

* The duration varies depending on the Quick Pause (QP) setting and the program’s

operating status at the time of Pause input

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 73

Setup & Operation 12. I/O Remote Settings

1052

500

928

Running

Output

Paused

Output

SafeguardOn

Output

MotorsOn

Output

Safety Input

Latch Input

Continue

Input

920

Running

Output

MotorsOn

Output

EStopOn

Output

Emergency Input

Reset

Input

12.2.4 Timing Diagram for Safety Door Input Sequence

12.2.5 Timing Diagram for Emergency Stop Sequence

74 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Input Bit #

Output Bit #

Applicable Hardware

0 to 23

0 to 15

STANDARD I/O

64 to 87

64 to 79

The 1st Expansion I/O board

96 to 119

96 to 111

The 2nd Expansion I/O board

DSW2

DSW1

CN3

Setup the DSW1 and DSW2. CN3 is all open.

1st board

2nd board

SW1 SW2 SW3 SW4

DSW1

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

DSW2

CN3

SW1 SW2 SW3 SW4

DSW2

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

DSW1

CN3

13. Option Slots

13.1 About Option Slots

Use the Option Slot to install the optional boards of RC90 / RC90-B Controller.

Up to two option boards can be installed in the controller. The types of the option boards

are as follows:

13.2 Expansion I/O Board

13.3 Fieldbus I/O Board

13.4 RS-232C Board

13.5 Analog I/O Board

13.6 EUROMAP67 Board

13.2 Expansion I/O Board

13.2.1 About Expansion I/O Board

Each additional expansion I/O board provides 24 inputs and 16 outputs.

You can install up to two expansion I/O boards in the controller.

Setup & Operation 13. Option Slots

The input and output bit numbers are assigned as follows. (Bit number is assigned from

CN1.)

13.2.2 Board Configuration (Expansion I/O)

Board Appearance Switch and Jumper Configuration

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 75

Setup & Operation 13. Option Slots

13.2.3 Confirmation with EPSON RC+ 7.0

When an expansion I/O board is mounted to the option unit, the Controller software

automatically identifies the expansion I/O board. Therefore, no software configuration is

needed.

Correct identification can be confirmed from EPSON RC+ 7.0.

(1) Select the EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the

[System Configuration] dialog.

(2) Select [Controller]-[Inputs / Outputs].

(3) Make sure that “Yes” is displayed in the Installed column.

The expansion I/O board is identified by the Controller software. Corresponding Input

and Output is available.

13.2.4 Input Circuit

Input Voltage Range : + 12 V to 24 V ±10%

ON Voltage : + 10.8 V (Min.)

OFF Voltage : + 5 V (Max.)

Input Current : 10 mA (TYP) at + 24 V input

Two types of wiring are available for use with the two-way photo coupler in the input circuit.

76 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 13. Option Slots

1 Input No.64 to 71 common

2 Input No.64

3 Input No.65

4 Input No.66

5 Input No.67

6 Input No.68

7 Input No.69

8 Input No.70

9 Input No.71

Expansion I/O board-1

(Same)

Omit

GND +DC

18 Input No.72 to 79 common 19 Input No.72

20 Input No.73

(Same)

1 Input No.64 to 71 common

2 Input No.64

3 Input No.65

4 Input No.66

5 Input No.67

6 Input No.68

7 Input No.69

8 Input No.70

9 Input No.71

Expansion I/O board -1

(Same)

Omit

GND +DC

18 Input No.72 to 79 common 19 Input No.72

20 Input No.73

(Same)

Typical Input Circuit Application 1

Typical Input Circuit Application 2

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 77

Setup & Operation 13. Option Slots

■

The output circuit has two types: Sink type and Source type. The either type has been configured in the controller before the shipment. Before routing the cables, make sure that the I/O output type of your controller co connection devices. If you route the cables with wrong output type, the parts on the board will be broken and the robot system won

■

Use the wiring diagram of correctly. Improper wiring may cause Manipulator

■

Be for of the parts on the board and then

13.2.5 Output Circuit

Rated Output Voltage : +12 V to 24 V ±10%

Maximum Output Current : TYP 100 mA/1 output

Output Driver : Photo coupler

CAUTION

move unusually.

sure to wire the output circuit properly because it has no protection circuitry

short-circuit and reverse-connection. Improper wiring may cause malfunction

nforms to the external

’t operate normally.

2: Source Type for CE conformance. Be sure to wire

safety problems as it may make the

improper function of the robot system.

78 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Setup & Operation 13. Option Slots

10 Output No.64

12 Output No.66

11 Output No.65

13 Output No.67

29 Output No.72

17 Output No.64 to 71 Common (GND)

30 Output No.73

GND +DC

Omit

～

14 Output No.68

15 Output No.69

27 Output No.70

28 Output No.71

(Same)

Typical Output Circuit Application 1: Sink Type (NPN)

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 79

Setup & Operation 13. Option Slots

17 Output No.64 to 71 Common

11 Output No.65

10 Output No.64

12 Output No.66

13 Output No.67

GND +DC

33 Output No.72 to 79 Common

Omit

～

29 Output No.72

14 Output No.68

15 Output No.69

27 Output No.70

30 Output No.73

(Same)

28 Output No.71

Typical Output Circuit Application 2: Source Type (PNP)

80 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Input common No.64 to 71

Input common No.72 to 79

Input common No.80 to 87

Output No.65

Output No.71

Output No.76

Output No.68

Output No.74

Output No.79

Output common No.64 to 71

D-sub 50 male pin

13.2.6 Pin Assignments

Pin Assignment table of the 1st Expansion I/O board.

Connector 1 Pin Assignments

Setup & Operation 13. Option Slots

No.

Signal Name

No.

Signal Name

No.

2 Input No.64 19 Input No.72 35 Input No.80

3 Input No.65 20 Input No.73 36 Input No.81

4 Input No.66 21 Input No.74 37 Input No.82

Input No.67

Input No.68

Input No.69

Input No.70

Input No.71

Output No.64

Output No.66

Output No.67

Output No.69

Not Used

Input No.75

Input No.76

Input No.77

Input No.78

Input No.79

Output No.70

Output No.72

Output No.73

Not Used

Output common No.72 to 79

Input No.83

Input No.84

Input No.85

Input No.86

Input No.87

Output No.75

Output No.77

Output No.78

Not Used

Connector Standard

Signal Name

I/O Connector (Controller side)

Screwlock #4 - 40

* The I/O connector, I/O connector cable, terminal block, and I/O connector kit are offered as options.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 81

Setup & Operation 13. Option Slots

Port No.

Supported hardware

#2, #3

First RS-232C board

#4, #5

Second RS-232C board

Board Appearance

Switch and Jumper Configuration

CN1

CN5 (#2 or #4)

CN4 (#3 or #5)

JMP1

DSW2

DSW1

CN3

1st board

2nd board

SW1 SW2 SW3 SW4

DSW1

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

DSW2

IRQ5 IRQ7 IRQ10 IRQ 11 IRQ15

JMP1

JP1 JP2 JP3 JP4 JP5

CN3

SW1 SW2 SW3 SW4

DSW2

SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

DSW1

IRQ5 IRQ7 IRQ10 IRQ 11 IRQ15

JMP1

JP1 JP2 JP3 JP4 JP5

13.3 Fieldbus I/O Board

Fieldbus I/O supports the following models.

- DeviceNet

™

- PROFIBUS-DP

- PROFINET

- CC-LINK

- EtherNet/IP

- EtherCAT

™

- Modbus (This is not optional but a standard feature.)

Refer to the following manuals.

Robot Controller RC700/RC90 option Fieldbus I/O EPSON RC+ 7.0 User’s Guide 11.7 Fieldbus Slave I/O

13.4 RS-232C Board

13.4.1 RS-232C Board

One standard RS-232C port is not available with the Controller.

You need to mount the RS-232C board in the Option Slot to communicate with external equipment using two or more port RS-232C.

The RS-232C board accepts two ports expansion per board. A maximum of two boards, four ports expansion is available for RS-232C board.

Port numbers are assigned as follows.

13.4.2 Board Setup (RS-232C)

82 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

Set DSW1, DSW2 and JMP1. CN3 is all open.

Setup & Operation 13. Option Slots

Item

Specification

Baud Rates

110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200

Data bit length

7, 8

Stop bit length

1, 2

Parity

Odd, even, NA

Terminator

CR, LF, CRLF

13.4.3 Confirmation with EPSON RC+ 7.0 (RS-232C)

When an RS-232C board is mounted in as option unit, the Controller software automatically

identifies the RS-232C board. Therefore, no software configuration is needed. Correct

identification can be confirmed from EPSON RC+ 7.0.

(1) Select the EPSON RC+ 7.0 menu-[Setup]-[System Configuration] to display the

[System Configuration] dialog.

(2) Select the [RS232]-[CU].

13.4.4 RS-232C Software Communication Setup (RS-232C)

Available communication settings are as follows.

Refer to EPSON RC+ 7.0 Online Help or Users Guide – 13. RS-232C Communications for

RS-232C communication from the Robot application.

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 83

Setup & Operation 13. Option Slots

Connector

Standard

(Controller side)

D-sub 9 male pin

Screwlock #4 - 40

Pin No

Signal

Function

Signal Direction

DCD

Data carrier detect

Input

RXD

Receive data

Input

TXD

Send data

Output 4 DTR

Terminal ready

Output

GND

Signal ground

DSR

Data set ready

Input 7 RTS

Request to send

Output

CTS

Clear to send

Input

Ring indicator

Input

NOTE

13.4.5 Communication Cable (RS-232C)

Prepare a communication cable as described in this section.

RS-232C Connector

Use twisted pair cable for shielded wire.

Clamp the shield to the hood for noise prevention.

Pin assign of the RS-232C connector is as follows.

84 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

External

equipment 1 *

External

equipment 2 *

External

equipment 3 *

External

equipment 4 *

Robot Controller

Analog I/O Board 4CH (Optional Board)

PC for

Development

MC Signal

MC Power

Manipulator

ADC CH2 DAC CH2 ADC CH1 DAC CH1

*: Voltage/Current Input

13.5 Analog I/O Board

13.5.1 About Analog I/O Board

Analog input/output function is available when mounting analog I/O board to the option slot.

You can install a maximum of four analog I/O boards in the option slot.

Analog I/O Board (1CH): “DAC: 1ch” is available for one board.

Analog I/O Board (4CH): “DAC: 2ch, ADC: 2ch” is available for one board.

DAC: Analog signal output (voltage/current)

ADC: Analog signal input (voltage/current)

Connection Example of Analog I/O Board (4CH)

Setup & Operation 13. Option Slots

RC90 / RC90-B (EPSON RC+ 7.0) Rev.26 85

Setup & Operation 13. Option Slots

Overview of Analog I/O Board Circuit

Rv: Voltage Input Terminating Resistance (100kΩ), Rc: Current Input Terminating Resistance

13.5.2 Board Configuration (Analog I/O Board)

86 RC90 / RC90-B (EPSON RC+ 7.0) Rev.26

EPSON RC90, RC90-B Users guide

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

WARRANTY

TRADEMARKS

TRADEMARK NOTATION IN THIS MANUAL

NOTICE

MANUFACTURER

CONTACT INFORMATION

Before Reading This Manual

Control System Configuration

Safety

1. Safety 3

2. Conventions 3

3. Safety Precautions 4

Setup & Operation

1. Specifications 9

2. Part Names and Functions 13

Table of Contents

3. Installation 18

4. Operation Mode (TEACH/AUTO/TEST) 29

5. Development PC Connection Port 33

6. Memory Port 36

7. LAN (Ethernet Communication) Port 40

8. TP Port 44

9. EMERGENCY 45

9.4.1 Example 1: External emergency stop switch typical application50

10. Standard RS-232C Port 52

11. I/O Connector 54

12. I/O Remote Settings 65

13. Option Slots 75

13.6.11 Emergency stop connecter Pin Assignments

Maintenance

1. Safety Precautions on Maintenance 107

2. Regular Maintenance Inspection 110

3. Controller Structure 111

4. Backup and Restore 115

5. Firmware Update 120

6. Alarm 130

7. Maintenance Parts Replacement Procedures 140

8. Verifying Robot System Operation 157

9. Troubleshooting 158

10. Maintenance Parts List 295

Safety

1. Safety

2. Conventions

3. Safety Precautions

Setup & Operation

1. Specifications

1.1 System Example

1.2 Standard Specifications

1.3 Outer Dimensions

2. Part Names and Functions

2.1 Part Names

2.2 Functions

2.3 LED

2.4 Safety Features

Emergency Stop Switch

Safety Door Input

Low Power Mode

Dynamic Brake

Motor Overload Detection

Irregular Motor Torque (out-of-control manipulator) Detection

Motor Speed Error Detection

Positioning Overflow –Servo Error- Detection

Speed Overflow –Servo Error- Detection

CPU Irregularity Detection

Memory Check-sum Error Detection

Overheat Detection at the Motor Driver Module

Relay Deposition Detection

Over-Voltage Detection

AC Power Supply Voltage Drop Detection

Temperature Anomaly Detection

Fan Malfunction Detection

3. Installation

3.1 Unpacking

3.2 Environmental Requirements

3.2.1 Environment