EPSON RC700D Controller Instruction Manual

EPSON RC700D Controller

Product Information

Specifications

• Model: RC700-D
• Manual Revision: 5
• Manufacturer: Seiko Epson Corporation
• Trademark: Microsoft, Windows, Windows logo

FAQ

• Q: Where can I find the contact information for the manufacturer?
  • A: The manufacturer’s contact information is described in the “Suppliers” section of the Robot System Safety Manual.
• Q: How should I dispose of this product?
  • A: When disposing of this product, follow the laws and regulations of your country. For battery disposal, refer to the Maintenance Manual for the battery removal/replacement procedure.
• Q: Are there any special considerations for California customers?
  • A: Yes, the lithium batteries in this product contain Perchlorate Material. Special handling may apply. Visit www.dtsc.ca.gov/hazardouswaste/perchlorate for more information.

Product Usage Instructions

Foreword

Thank you for purchasing the RC700-D Robot Controller. This manual provides all the necessary information for the correct use of the robot controller. Before installing the robot system, please read this manual and other related manuals carefully. Keep this manual accessible at all times for easy reference.

Quality Controls and Compliance

The robot system and its optional parts undergo strict quality controls, tests, and inspections to ensure compliance with high performance standards. Please note that the product’s basic performance may be affected if used outside the specified usage conditions and product specifications mentioned in the manuals.

Safety Precautions

• This manual contains information about possible dangers and consequences.
• It is essential to comply with the safety precautions mentioned in this manual to ensure the safe and correct use of the robot system.

Trademarks

The following trademarks are mentioned in this manual:

• 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 their respective holders.

Manufacturer Contact Information

• Contact information can be found in the “Suppliers” section of the first pages of the Robot System Safety Manual.

Disposal

• When disposing of this product, follow the laws and regulations of your country.
• For battery disposal, refer to the Maintenance Manual for the battery removal/replacement procedure.

Note for European Union customers

• Please separate used batteries from other waste streams to ensure environmentally sound recycling.
• Contact your local government office or the retailer where you purchased this product for more information on available collection facilities.

Note for California customers

• The lithium batteries in this product contain Perchlorate Material, and special handling may apply.
• Visit www.dtsc.ca.gov/hazardouswaste/perchlorate for more information.

Cyber Security Measures

Before Reading This Manual:

It is necessary to implement organizational measures for cyber security. Take the following steps:

• Perform risk analysis based on security threats and vulnerabilities related to your organization’s assets.
• Develop a security policy to address risks and educate and train appropriate personnel.
• Create guidelines for how to respond when security issues arise and make them known throughout your organization.

Security Measures for Network Connections

• This information will be provided in the subsequent sections of the manual.

FOREWORD

Thank you for purchasing our robot products. This manual contains the information necessary for the correct use of the robot controller. Please carefully read this manual and other related manuals before installing the robot system. Keep this manual handy for easy access at all times.

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. Please note that the basic performance of the product will not be exhibited if our robot system is used outside of the usage conditions and product specifications described in the manuals.

This manual describes possible dangers and consequences that we can foresee. Be sure to comply with safety precautions on this manual to use our robot system safety and correctly.

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 Microsoft® Windows® 11 operating system Throughout this manual, Windows 8, Windows 10 and Windows 11 refer to above respective operating systems. In some cases, Windows refers generically to Windows 8, Windows 10 and Windows 11.

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.

DISPOSAL

When disposing this product, dispose in accordance with the laws and regulations of each country.

Regarding battery disposal

The battery removal/replacement procedure is described in the following manuals: Maintenance Manual

For European Union customers only

The crossed out wheeled bin label that can be found on your product indicates that this product and incorporated batteries should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health please separate this product and its batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner. For more details on available collection facilities please contact your local government office or the retailer where you purchased this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used in the battery.

NOTE

This information only applies to customers in the European Union, according to Directive 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and accumulators and repealing Directive 91/157/EEC and legislation transposing and implementing it into the various national legal systems, and to customers in countries in Europe, Middle East and Africa (EMEA) where they have implemented equivalent regulations. For other countries, please contact your local government to investigate the possibility of recycling your product.

For Users in Taiwan region

Please separate used batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner. For more details on available collection facilities please contact your local government office or the retailer where you purchased this product.

For California customers only

The lithium batteries in this product contain Perchlorate Material – special handling may apply, See www.dtsc.ca.gov/hazardouswaste/perchlorate

Before Reading This Manual

CAUTION

Necessity of organizational measures for cyber security
The following organizational measures should be taken to address cyber security risks:

• Perform risk analysis based on security threats and vulnerabilities related to your organization’s assets.
• Develop a security policy to address risks and educate and train appropriate personnel.
• Create guidelines for how to respond when security issues arise and make them known throughout your organization.

Security measures for network connections

Epson robot systems are designed to be used within a closed local area network. Please refrain from connecting to networks with Internet access. If a connection to the Internet is required, please implement the necessary technical measures to protect from malicious attacks and vulnerabilities over the Internet. : These measures include, but are not limited to, access controls, firewalls, data diodes, and so on.

NOTE

• Do not connect the followings to the TP port of RC700-D. 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 RC700-D, be sure to install the EPSON RC+7.0 to the development PC first, then connect the development PC and RC700-D with the USB cable. If RC700-D 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 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.

Structure of Robot System

• Controller RC700-D can be used with the following version. EPSON RC+ 7.0 Ver.7.5.1B or later
• Each Manipulator can be used with the following version. GX4, GX8 series: EPSON RC+ 7.0 Ver.7.5.1B

The Manuals of This Product

The following are typical manual types for this product and an outline of the descriptions.

Safety Manual (book, PDF) This manual contains safety information for all people who handle this product. The manual also describes the process from unpacking to operation and the manual you should look at next. Read this manual first. – Safety precautions regarding robot system and residual risk – Declaration of conformity – Training – Flow from unpacking to operation

RC700-D series Manual (PDF) This manual explains the installation of the entire robot system and the specifications and functions of the controller. The manual is primarily intended for people who design robot systems. – The installation procedure of the robot system (specific details from unpacking to operation) – Daily inspection of the controller – Controller specifications and basic functions

GX series Manual (PDF) This manual describes the specifications and functions of the Manipulator. The manual is primarily intended for people who design robot systems. – Technical information, functions, specifications, etc. required for the Manipulator installation and design – Daily inspection of the Manipulator

Status Code/Error Code List (PDF) This manual contains a list of code numbers displayed on the controller and messages displayed in the software message area. The manual is primarily intended for people who design robot systems or do programming.

Manuals About Maintenance, Service Manuals about Maintenance or Service does not come with the products. Only authorized personnel who have taken maintenance training held by the manufacturer or dealer should be allowed to perform the robot maintenance. Please contact the supplier of your region for more information.

Installation

This section describes outline from unpacking to operation of Robot System and design of Robot System.

Safety

Please read “Safety Manual” and check safety considerations before installing the robot system or before connecting cables. Keep this manual handy for easy access at all times. This product is intended for transporting and assembling parts in a safely isolated area.

Conventions

Important safety considerations are indicated throughout the manual by the following symbols. Be sure to read the descriptions shown with each symbol.

WARNING CAUTION

• 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.
• 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.

System Example

Option

• Expansion I/O Board Pulse Output Board
• Fieldbus PROFIBUS-DP DeviceNet CC-Link EtherNet/IP PROFINET EtherCAT
• Analog I/O Board Force Sensor I/F Board EUROMAP67 Board

Requires preparation by uses

TP3 (Option)

1. For system requirements, refer to the following manual: EPSON RC+ 7.0 User’s Guide
2. Any one of the Teach pendant can be controlled.
3. When connecting to RC700-D, a dedicated conversion cable is required.

Unpacking

Unpacking of the Manipulators and robotic equipment shall be performed by personnel who has taken robot system training held by us and suppliers and should conform to all national and local codes. Please read “Safety Manual” and check safety considerations before installing the robot system or before connecting cables.

Transportation

Transportation Precautions

Transporting of the Manipulators and robotic equipment shall be performed by personnel who has taken robot system training held by us and suppliers and should conform to all national and local codes. Please read “Safety Manual” and check safety considerations before installing the robot system or before connecting cables. During unpacking and relocation, avoid applying external force to the arms and motors of the Manipulator. When transporting the Manipulator for a long distance, secure it to the delivery equipment so that the Manipulator cannot fall. If necessary, pack the Manipulator in the same way as it was delivered.

Number of people and position to hold, when transporting manipulator

• Where to hold
• Under the arm 1 and bottom of the base *(shade part)
• When hold bottom of the base, be careful not caught your hands or fingers.
• Minimum number of people : 2 people

GX8 How to transfer

• Where to hold
  • Minimum number of people Do not hold

Top Mounting

• Pass belts through the eyebolts and hoist it with your hands.
• Under the arm 1 and bottom of the base (shade part) When hold bottom of the base, be careful not caught your hands or fingers.

Manipulator Installation

Transportation Precautions

Installing of the Manipulators and robotic equipment shall be performed by personnel who has taken robot system training held by us and suppliers and should conform to all national and local codes. Please read “Safety Manual” and check safety considerations before installing the robot system or before connecting cables.

Environment

A suitable environment is necessary for the robot system to function properly and safely. Be sure to install the robot system in an environment that meets the following conditions:

• Install indoors.
• Keep away from direct sunlight.
• Keep away from dust, oily smoke, salinity, metal powder or other contaminants.
• Keep away from flammable or corrosive solvents and gases.
• Keep away from water.
• Keep away from shocks or vibrations.
• Keep away from sources of electric noise.
• Keep away from explosive area
• Keep away from a large quantity of radiation

When the product is used in a low temperature environment around the minimum temperature of the product specification, or when the product is suspended for a long time on holidays or at night, a collision detection error may occur due to the large resistance of the drive unit immediately after the start of operation. In such a case, it is recommended to warm up for about 10 minutes.

NOTE

Manipulators are not suitable for operation in harsh environments such as painting areas, etc. When using Manipulators in inadequate environments that do not meet the above conditions, please contact the supplier of your region. – If there are conductive things such as fences or ladders within 2.5 m of the Manipulator, ground the things.

WARNING

Special Environmental Conditions The surface of the Manipulator has general oil resistance. However, if your requirements specify that the Manipulator must withstand certain kinds of oil, please contact the supplier of your region. Rapid change in temperature and humidity can cause condensation inside the Manipulator. If your requirements specify that the Manipulator handles food, please contact the supplier of your region to check whether the Manipulator will damage the food or not.

The Manipulator cannot be used in corrosive environments where acid or alkaline is used. In a salty environment where the rust is likely to gather, the Manipulator is susceptible to rust. Use an earth leakage breaker on the AC power cable of the Controller to avoid the electric shock and circuit breakdown. Prepare the earth leakage breaker that pertains the Controller you are using. For details, refer to the Robot Controller manual.

CAUTION

When cleaning the Manipulator, do not rub it strongly with alcohol or benzene. It may lose luster on the coated face.

Noise level

• About noise level due to manipulator operation, refer to the following manual. Manipulator manual Appendix A. Specifications Table

Base Table

A base table for anchoring the Manipulator is not supplied. Please make or obtain the base table for your Manipulator. The shape and size of the base table differs depending on the use of the robot system. For your reference, we list some Manipulator table requirements here. The base table must not only be able to bear the weight of the Manipulator but also be able to withstand the dynamic movement of the Manipulator when it operates at maximum acceleration. Ensure that there is enough strength on the base table by attaching reinforcing materials such as crossbeams. The torque and reaction force produced by Manipulator motion are as follows:

• GX4
• GX8

Max. Reaction torque on the horizontal plate (N·m) Max. Horizontal reaction force (N) Max. Vertical reaction force (N) Threaded holes for Mounting screw

• Use the mounting bolts conforming to the strength of ISO898-1 property class 10.9 or 12.9.
• The plate for the Manipulator mounting face should be 20 mm thick or more and made of steel to reduce vibration. The surface roughness of the steel plate should be 25 m or less.

When using the Manipulator in the cleanroom, follow the steps below before the installation

1. Unpack the Manipulator outside of the cleanroom.
2. Secure the Manipulator to delivery equipment such as a pallet with bolts so that the Manipulator does not fall over.
3. Wipe off the dust on the Manipulator with a little alcohol or distilled water on a lintfree cloth.
4. Transport the Manipulator into the cleanroom.
5. Secure the Manipulator to the base table.

Installation Procedure

When the Manipulator is cleanroom model, unpack it outside of the cleanroom. Secure the Manipulator not to fall, and then wipe off the dust on the Manipulator with a little alcohol or distilled water on a lint-free cloth. After that, transport the Manipulator into the cleanroom. Connect an exhaust tube to the exhaust port after installation.

CAUTION

Install the Table Top Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. GX4-A251: approx.15 kg : 33 lbs. GX4-A301: approx.15 kg : 33 lbs. GX4-A351**: approx.16 kg : 35 lbs.

Standard Specification

1. Secure the base to the base table with four bolts. Be sure to use washers.

NOTE: Use bolts with specifications conforming to ISO898-1 property class: 10.9 or 12.9.

Tightening torque: 32.0 N·m (326 kgf·cm)

WARNING

Install the Multiple Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. GX4-A301M : approx. 17 kg : 38 lbs. GX4-A351M : approx. 17 kg : 38 lbs.
When installing the Manipulator to the wall, support the Manipulator, and then secure the anchor bolts. Removing the support without securing the anchor bolts properly is extremely hazardous and may result in fall of the Manipulator.

NOTE: Make sure that the base table on which the multiple mounting is installed does not interfere with the cables and conduit tubes that connect to the manipulator.

Designing a Safe Robot System

It is important to operate robots safely. It is also important for robot users to give careful consideration to the safety of the overall robot system design.
This section summarizes the minimum conditions that should be observed when using EPSON robots in your robot systems.
Please design and manufacture robot systems in accordance with the principles described in this and the following sections.

Environmental Conditions

Carefully observe the conditions for installing robots and robot systems that are listed in the “Environmental Conditions” tables included in the manuals for all equipment used in the system.

System Layout

When designing the layout for a robot system, carefully consider the possibility of error between robots and peripheral equipment. Emergency stops require particular attention, since a robot will stop after following a path that is different from its normal movement path. The layout design should provide enough margins for safety. Refer to the manuals for each robot, and ensure that the layout secures ample space for maintenance and inspection work.
When designing a robot system to restrict the area of motion of the robots, do so in accordance with the methods described in each Manipulator manual. Utilize both software and mechanical stops as measures to restrict motion.
Install the emergency stop switch at a location near the operation unit for the robot system where the operator can easily press and hold it in an emergency.
Do not install the Controller at a location where water or other liquids can leak inside the Controller. In addition, never use liquids to clean the Controller.
For safe lockouts during service and maintenance, disconnectors should be placed outside the safeguard wherever possible.

Installation

Disabling Power to the System using lock out / tag out

The power connection for the Robot Controller should be such that it can be locked and tagged in the off position to prevent anyone from turning ON power while someone else is in the safeguarded area. UL-compliant Controller (RC700-D-UL): Perform lockout using the following procedure. A padlock for lockout should be prepared by users. Applicable shackle diameter: 4.0 to 6.5 mm

1. Remove a fixing screw of the lockout bracket A by hand.
2. Rotate the lockout bracket A.
3. Set the screw removed in the step (1) to the lockout bracket B so as not to lose it.

End Effector Design

Provide wiring and piping that will prevent the robot end effector from releasing the object held (the work piece) when the robot system power is shut off.
Design the robot end effector such that its weight and moment of inertia do not exceed the allowable limits. Use of values that exceed the allowable limits can subject the robot to excessive loads. This will not only shorten the service life of the robot but can lead to unexpectedly dangerous situations due to additional external forces applied to the end effector and the work piece.
Design the size of the end effector with care, since the robot body and robot end effector can interfere with each other.

Peripheral Equipment Design

When designing equipment that removes and supplies parts and materials to the robot system, ensure that the design provides the operator with sufficient safety. If there is a need to remove and supply materials without stopping the robot, install a shuttle device or take other measures to ensure that the operator does not need to enter a potentially dangerous zone.
Ensure that an interruption to the power supply (power shutoff) of peripheral equipment does not lead to a dangerous situation. Take measures that not only prevent a work piece held from being released as mentioned in “End effector Design” but that also ensure peripheral equipment other than the robots can stop safely. Verify equipment safety to ensure that, when the power shuts off, the area is safe.

Remote Control

For the safety of the overall system, however, safety measures are needed to eliminate the risks associated with the start-up and shutdown of peripheral equipment by remote control.
With this product, the robot system can be operated remotely by assigning a remote function to the controller I/O. To prevent danger from unintended remote control, the remote function will not be enabled without proper settings. Also when remote is valid, motion command execution and I/O output are available only from remote.

Safeguard

To ensure safe operation, install a safety system using safety doors, light curtains, safety floor mats, etc. When installing the safeguard system, strictly observe the following points: Install the safeguard which has safety function more than PLd.

• Safety function of Safety Door Input: Category 3, PLd (reference ISO13849-1 2015)
• Stop category of Safety Door Input: Category 1 (reference IEC60204-1 2016)

NOTE: Test pulse cannot be used with the safeguard input of this model.

Refer to each manipulator manual and install the safeguard system outside the maximum space. Carefully consider the size of the end effector and the work pieces to be held so that there will be no error between the moving parts and the safeguard system.
Manufacture the safeguard system to withstand calculated external forces (forces that will be added during operation and forces from the surrounding environment).
When designing the safeguard system, make sure that it is free of sharp corners and projections, and that the safeguard system itself is not a hazard.
Make sure that the safeguard system can only be removed by using a tool.
There are several types of safeguard devices, including safety doors, safety barriers, light curtains, safety gates, and safety floor mats. Install the interlocking function in the safeguard device. The safeguard interlock must be installed so that the safeguard interlock is forced to work in case of a device failure or other unexpected accident. For example, when using a door with a switch as the interlock, do not rely on the switch’s own spring force to open the contact. The contact mechanism must open immediately in case of an accident.
Connect the interlock switch to the safeguard input of the drive unit’s EMERGENCY connector. The safeguard input informs the robot controller that an operator may be inside the safeguard area. When the safeguard input is activated, the robot stops immediately and enters pause status, as well as either operation-prohibited status or restricted status (low power status).
Make sure to install the safeguard interlock in the area where workers steps in the inside of safeguard.
Make sure the safeguard interlock is locked once it is activated, until it is intentionally released. EMERGENCY connector of the Controller has latch release input to release latch of safeguard interlock. Install a switch to release latch of safeguard interlock outside of the safety door, and wire to latch release input.

WARNING

It is dangerous to allow someone else to release the safeguard interlock by mistake while the operator is working inside the safeguarded area. To protect the operator working inside the safeguarded area, take measures to lock out and tag out the latch-release switch. The EMERGENCY connector on the controller has a safeguard input circuit to connect the safety device interlock switch. To protect operators working near the robot, be sure to connect the interlock switch and make sure that it works properly.

• Do not open the safeguard unnecessarily while motor is ON. Frequent safeguard inputs affect the life of the relay.
• Rough normal relay life: Approximately 20,000 times
• For the safeguard, do not use the E-STOP circuit. For details of wiring instructions, refer to the “11Emergency”.
• For details of the safeguard, refer to the following manuals as well.

Connection to EMERGENCY Connector

The Manipulator in operation cannot stop immediately after the safeguard is opened. In addition, stopping time and stopping distance vary by following factors:

• Hand weight
• WEIGHT Setting ACCEL Setting
• Workpiece weight SPEED Setting Posture etc.
• For stopping time and stopping distance of the Manipulator refer to the following manual.
• Manipulator Manual Appendix C: Time and Distance of Free Running When the Safeguard is Opened.

Presence Sensing Device

The above mentioned safeguard interlock is a type of presence sensing device, since it indicates the possibility of somebody being inside the safeguard system. When separately installing a presence sensing device, however, perform a satisfactory risk assessment and pay thorough attention to its dependability.

Here are precautions that should be noted:

• Design the system so that when the presence sensing device is not activated or a dangerous situation still exists that no personnel can go inside the safeguard area or place their hands inside it.
• Design the presence sensing device so that regardless of the situation the system operates safely.
• If the robot stops operating when the presence sensing device is activated, it is necessary to ensure that it does not start again until the detected object has been removed. Make sure that the robot cannot automatically restart.

Resetting the Safeguard

Ensure that the robot system can only be restarted through careful operation from outside the safeguarded system. The robot will never restart simply by resetting the safeguard interlock switch. Apply this concept to the interlock gates and presence-sensing devices for the entire system.

Robot Operation Panel

• Ensure that the robot system can be operated from outside of the safeguard.

Connecting

NOTE: The details of safety requirements for this section are described in Safety Manual. Please refer to them to keep the robot system safe.

CAUTION

• Not only when turning ON the device, but also changing use environment such as add options or replace parts for maintenance, make sure that the emergency stop or safety door work properly.
• Connect a safeguard switch or Emergency Stop switch to the EMERGENCY connector of the Controller for safety. When nothing is connected to the EMERGENCY connector, Controller does not operate normally.
• Before connecting the connector, make sure that the pins are not bent. Connecting with the pins bent may damage the connector and result in malfunction of the robot system.

EMERGENCY connector

• 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.

Backup the project and system configuration

Even though this is only a sample project, we will backup the project and Controller configuration. Backup can be done easily with EPSON RC+ 7.0. It is important that you keep regular backups of your applications on an external media such as a USB memory key.

Follow the steps below to back up the project and system configuration: (1) Select the EPSON RC+ 7.0 menu – [Project] – [Copy]. (2) Change the [Destination Drive] to an arbitrary drive. (3) Click . The project will be copied to the external media. (4) Select the EPSON RC+ 7.0 menu – [Tools] – [Controller]. (5) Click on the button. (6) Select the arbitrary drive. (7) Click . The system configuration will be backed up on the external media.

Firmware Update

This chapter describes the firmware upgrade procedure and data file initialization when firmware or Robot configuration errors cause Controller startup or operation failure.

Updating Firmware

• Firmware (software stored in non-volatile memory) and data files necessary to control the Controller and the Robot are preinstalled in the Controller. Controller configuration set from EPSON RC+ 7.0 is always saved in the Controller.
• Controller firmware is supplied by CD-ROM as needed. Please contact the supplier of your region for information.
• You must use a PC running EPSON RC+ 7.0 connected to a Controller with USB to update the Controller firmware. Firmware cannot be updated with an Ethernet connection.
• When installing the firmware Ver.7.5.0.x or later, be sure to use the PC which EPSON RC+ 7.0 Ver.7.5.0 or later is installed.

Firmware Upgrade Procedure

The firmware upgrade procedure is described as follows: (1) Connect the development PC and the Controller with a USB cable (the firmware cannot be changed with an Ethernet connection). (2) Turn ON the Controller. (Do not start the development software EPSON RC+ 7.0 until the firmware upgrade is completed.) (3) Insert the “firmware CD-ROM” in the development PC CD-ROM drive. (4) Execute “Ctrlsetup70.exe”. The following dialog appears. (5) Select the option button and click the button.

Controller Recovery

If the Controller becomes inoperable, use the procedures described in this section to recover.
Controller Backup is recommended for easy recovery of the Controller operation. For details of Controller Backup, refer to Regular Inspection 2. Backup and Restore.

The following two conditions describe the Controller error status after turning ON the Controller. Condition A The Controller automatically changes to Recovery mode and the LED of ERROR, TEACH, and PROGRAM are lighting. You are able to communicate with the development PC though the Controller does not operate properly. Condition B The LED of TEACH, AUTO, and PROGRAM do not blink. Cannot communicate with the Controller using the development PC.

Ethernet

EPSON RC+ 7.0 User’s Guide “1.9 Security for Controller Ethernet Connection” “1.10 Security for Compact Vision CV2-A Ethernet Connection” “1.11 Security for Feeder Ethernet Connection” “4.3.3 Ethernet Communication”
Function “7. LAN (Ethernet Communication) Port”

• RS-232C (Option)
  • EPSON RC+ 7.0 User’s Guide “RS-232C Communication”
  • Function “14.4 RS-232C Board”
• Analog I/O board (Option)
  • Function “14.6 Analog I/O board”
• Force Sensor I/F board (Option)
  • Function “14.7 Force Sensor I/F board”

Safety Function

The following safety features which robot system has are particularly important. Make sure that these and other features function properly before operating the robot system.
Emergency Stop Switch The EMERGENCY connector on the Drive Unit 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. Use the emergency switch which has safety function more than PLd. The safety function of Emergency Stop Input: Category 3, PLd (reference ISO13849-1 2015) Stop category of Emergency Stop input: Category 1 (reference IEC60204-1 2016)

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 Drive Unit. 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 motor can be turned on only when the enable switch is on. In this case, the Manipulator is operated in low power status. Use the Safety Door Input which has safety function more than PLd. The safety function of Safety Door Input: Category 3, PLd (reference ISO13849-1 2015) Stop category of Safety door input: Category 1 (reference IEC60204-1 2016) Even when using a light curtain as a safety door, keep the operation-prohibited status until the latched condition is released, as with the safety door.

Protection Features

The robot control system supports protection features described below. However, these features are prepared for unexpected occurrence.

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 the overload status of the motor.

Irregular Motor Torque (out-of-control Manipulator) Detection The dynamic brake circuit is activated when irregular motor torque (motor output) is detected.

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 Drive Unit 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.

Part Names and Functions

• 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 Drive Unit 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.

Environmental Requirements

WARNING

Do not disassemble the parts not described in the manual or perform maintenance in a method different from the description. Incorrect disassembly and maintenance can cause the robot system not only to malfunction, but also to cause serious safety problems.

WARNING

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. Using the product in the environment that exceeds the conditions may not only shorten the life cycle of the product but also cause serious safety problems.

Environment

NOTE

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. – Install the controller outside of the safeguard. – If there are conductive things such as fences or ladders within 2.5 m of the Controller,
  ground the things.

2 kV or less (Power supply wire)

1 kV or less (Signal wire) 4 kV or less Use a base table that is at least 100 mm off the floor. Placing the Controller directly on the floor could allow dust penetration leading to malfunction. Tilt 0.5° or less (When installing upright, you put your hand on it, it may fall over.) 2000 m or less

Installation

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.

Upright Mounting (C) Rack Mounting

• The rubber foot needs to be replaced. Attach the rubber foot with the flat side facing the controller. Remove the screws that interfere the rubber foot. The size of the screw that secure the rubber foot is M4×8. When replacing the rubber foot, be careful not to lose the screw. Also, do not use a screw of size other than M4×8.

*A plate for rack mounting is required.

Functions

NOTE

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

• Ensure the air flow around the supply and exhaust ports, and install the Controller while leaving space from other equipment or walls as below. * Keep the space about 200 mm or more on the top to maintenance.
• 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.

Installation

Wall Mounting Option

• The controller has a wall mounting option. For more information, please contact the supplier of your region.
• Controller outer dimensions when using the wall mounting option Dimensions of the mounting holes for the wall
• Ensure the air flow around the supply and exhaust ports, and install the Controller while leaving space from other equipment or walls as below.
• Keep the space about 200 mm or more on the top to maintenance.
• Wall mounting with the front side down
• Wall mounting with the front side up

Power Supply

• Specifications Ensure that the available power meets following specifications.

Item Voltage

• Phase Frequency Momentary Power Interrupt Rated Capacity

Max. load current

Short-circuit current rating Maximum Supply Source Impedance Inrush Current Leakage Current Ground Resistance

When power is turned ON : approximately 85 A (2 ms.) When motor is ON : approximately 75 A (2 ms.) Less than 3.5 mA TN Ground (100 or less)

Install an earth leakage circuit breaker in the AC power cable line at 15 A or less rated. 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 “inrush current”. The power receptacle shall be installed near the equipment and shall be easily accessible.

Functions Installation

AC Power Cable Make sure that operations are done by a qualified personal. Be sure to connect the earth wire (green/yellow) of the AC power cable to the
earth terminal of the factory power supply. The equipment must be grounded properly at all times to avoid the risk of electric shock.

WARNING Always use a power plug or a disconnecting device for power connecting cable.

Never connect the Controller directly to the factory power supply. Select the plug or a disconnecting device which conform safety standards for nations. When connecting the plug of the AC power cable to the Controller, insert until it clicks as shown in the figure below.

References

• dtsc.ca.gov/hazardouswaste/perchlorate
• /index.html
• OPC Foundation RCL License
• The MIT License – Open Source Initiative

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