Epson S5 Mid Range 6-Axis Robots Installation manual

RC180

Safety and Installation

Read this manual first

Rev.19

EM135B2509F

RC180 Safety and Installation

Rev.19

Copyright

© 2006-2013 SEIKO EPSON CORPORATION. All rights reserved.

RC180 Safety and Installation Rev.19 i

FOREWORD

Thank you for purchasing our robot products.

This manual contains the information necessary for the correct use of the Operator

Panel.

Please carefully read this manual and other related manuals before installing the robot system.

Keep this manual handy for easy access at all times.

WARRANTY

The robot system and its optional parts are shipped to our customers only after being subjected to the strictest quality controls, tests, and inspections to certify its compliance with our high performance standards.

Product malfunctions resulting from normal handling or operation will be repaired free of charge during the normal warranty period. (Please ask your Regional Sales

Office for warranty period information.)

However, customers will be charged for repairs in the following cases (even if they occur during the warranty period):

1. Damage or malfunction caused by improper use which is not described in the manual, or careless use.

2. Malfunctions caused by customers’ unauthorized disassembly.

3. Damage due to improper adjustments or unauthorized repair attempts.

4. Damage caused by natural disasters such as earthquake, flood, etc.

Warnings, Cautions, Usage:

1. If the robot system associated equipment is used outside of the usage conditions and product specifications described in the manuals, this warranty is void.

2. If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be responsible for any malfunction or accident, even if the result is injury or death.

3. We cannot foresee all possible dangers and consequences. Therefore, this manual cannot warn the user of all possible hazards. ii RC180 Safety and Installation Rev.19

TRADEMARKS

Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.

Other brand and product names are trademarks or registered trademarks of the respective holders.

TRADEMARK NOTATION IN THIS MANUAL

Microsoft® Windows® XP Operating system

Microsoft® Windows® Vista Operating system

Microsoft® Windows® 7 Operating system

Throughout this manual, Windows XP, Windows Vista, and Windows 7 refer to above respective operating systems. In some cases, Windows refers generically to Windows XP, Windows Vista, and Windows 7.

NOTICE

No part of this manual may be copied or reproduced without authorization.

The contents of this manual are subject to change without notice.

Please notify us if you should find any errors in this manual or if you have any comments regarding its contents.

INQUIRIES

Contact the following service center for robot repairs, inspections or adjustments.

If service center information is not indicated below, please contact the supplier office for your region.

Please prepare the following items before you contact us.

- Your controller model and its serial number

- Your manipulator model and its serial number

- Software and its version in your robot system

- A description of the problem

SERVICE CENTER

RC180 Safety and Installation Rev.19 iii

MANUFACTURER

Toyoshina Plant

Industrial Solutions Division

6925 Toyoshina Tazawa,

Azumino-shi, Nagano, 399-8285

JAPAN

SUPPLIERS

North & South America EPSON AMERICA, INC.

Factory Automation/Robotics

18300 Central Avenue, Carson, CA 90746 USA

Europe

China

EPSON DEUTSCHLAND GmbH

Factory Automation Division

Otto-Hahn-Str.4, D-40670 Meerbusch, Germany

EPSON China Co., Ltd


7F, Jinbao Building No. 89 Jinbao Street

Dongcheng District, Beijing

China, 100005 iv RC180 Safety and Installation Rev.19

Taiwan

India

EPSON Taiwan Technology & Trading Ltd.


14F, No.7, Song Ren Road, Taipei 110

Taiwan, ROC

Epson Singapore Pte Ltd.

Factory Automation System

1 HarbourFrontPlace, #03-02

HarbourFront Tower one, Singapore

098633

Korea

EPSON Korea Co, Ltd.

Marketing Team (Robot Business)

27F DaeSung D-Polis A, 606,

Seobusaet-gil, Geumcheon-gu, Seoul, 153-803

Korea

Japan

EPSON SALES JAPAN CORPORATION

Factory Automation Systems Department

Nishi-Shinjuku Mitsui Bldg.6-24-1

Nishishinjuku．Shinjuku-ku．Tokyo．160-8324

JAPAN

:

RC180 Safety and Installation Rev.19 v

For Customers in the European Union

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.

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.

For other countries, please contact your local government to investigate the possibility of recycling your product.

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

Controller manual / Manipulator manual (Maintenance section) vi RC180 Safety and Installation Rev.19

Before Reading This Manual

NOTE

Do not connect the followings to TP/OP port of RC180. 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**

NOTE

For RC180, be sure to install the EPSON RC+5.0 to the development PC first,

) then connect the development PC and RC180 with the USB cable.

If RC180 and the development PC are connected without installing the

EPSON RC+5.0 to the development PC, [Add New Hardware Wizard]

NOTE

)

NOTE

) 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.

RC180 Safety and Installation Rev.19 vii

NOTE

)

Every data of the Controller is stored to the Compact Flash inside the

Controller. When you execute the commands listed below, data is written to the Compact Flash. Frequent data writing to the Compact Flash may shorten the Compact Flash life. It is recommended to use the following commands only when it is necessary.

- Renew the Point files

(SavePoints)

- Change the Robot parameters

(Base, Local, LocalClr, CalPls, Calib, Hofs, ArmSet, ArmClr,

HomeSet, HomeClr, Hordr, MCOder, Weight, JRange, Range,

XYLim, TLSet, TLClr, Arm, Tool, Inertia, EcpSet, EcpClr, Box, BoxClr,

Plane, PlaneClr) viii RC180 Safety and Installation Rev.19

TABLE OF CONTENTS

1. Safety 1

1.1 Conventions.................................................................... 1

1.2 Design and Installation Safety ........................................ 2

1.3 Operation Safety............................................................. 3

1.4 Maintenance Safety ........................................................ 9

1.5 Emergency Stop ........................................................... 12

1.6 Labels ........................................................................... 14

1.7 Safety Features ............................................................ 27

2. Installation 30

System Example ................................................................... 31

2.1 Outline from Unpacking to Operation of Robot System ...................................... 32

2.2 Unpacking..................................................................... 33

2.3 Transportation............................................................... 34

2.4 Manipulator Installation ................................................. 40

2.5 Controller Installation .................................................... 54

2.6 Connection to EMERGENCY Connector (Controller) ... 58

2.7 AC power cable ........................................................... 65

2.8 Connecting Manipulator and Controller......................... 66

2.9 Power-on ...................................................................... 69

3. First Step 72

3.1 Installing EPSON RC+ 5.0 Software............................. 72

3.2 Development PC and Controller Connection ................ 75

3.3 Writing your first program.............................................. 79

4. Second Step 86

4.1 Connection with External Equipment ............................ 86

4.2 Ethernet Connection of Development PC and Controller ............................... 86

4.3 Connection and Display Language of Option TP1 and OP1 ................................................ 87

RC180 Safety and Installation Rev.19 ix

5. General Maintenance 88

5.1 Schedule for Maintenance Inspection........................... 88

5.2 Inspection Point ............................................................ 90

6. Manual

7. Directives and Norms

96

99

x RC180 Safety and Installation Rev.19

1. Safety

1. Safety

Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes.

Please read this manual and other related manuals before installing the robot system or before connecting cables.

Keep this manual handy for easy access at all times.

1.1 Conventions

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

WARNING

This symbol indicates that a danger of possible serious injury or death exists if the associated instructions are not followed properly.

WARNING

This symbol indicates that a danger of possible harm to people caused by electric shock exists if the associated instructions are not followed properly.

CAUTION

This symbol indicates that a danger of possible harm to people or physical damage to equipment and facilities exists if the associated instructions are not followed properly.

RC180 Safety and Installation Rev.19 1

1. Safety

1.2 Design and Installation Safety

Only trained personnel should design and install the robot system. Trained personnel are defined as those who have taken robot system training 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.

To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to the Installation and Design Precautions in the Safety chapter of the EPSON RC+ User’s Guide.

The following items are safety precautions for design personnel:

WARNING

■ Personnel who design and/or construct the robot system with this product must read the Safety chapter in the EPSON RC+ User’s

Guide to understand the safety requirements before designing and/or constructing the robot system. Designing and/or constructing the robot system without understanding the safety requirements is extremely hazardous, and may result in serious bodily injury and/or severe equipment damage to the robot system.

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

■ The robot system must be used within the installation requirements described in the manuals. Using the robot system outside of the installation requirements may not only shorten the life cycle of the product but also cause serious safety problems.

Refer

Further precautions for installation are mentioned in the following manuals.

Please read this chapter carefully to understand safe installation procedures before installing the robots and robotic equipment.

Relevant Manuals

This manual : 2. Installation

Manipulator manual : Setup & Operation 3. Environment and Installation

Controller manual : Setup & Operation 3. Installation

2 RC180 Safety and Installation Rev.19

1. Safety

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

■ Please carefully read the Safety-related Requirements in this manual before operating the robot system. Operating the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

■ Do not enter the operating area of the Manipulator while the power to the robot system is turned ON. Entering the operating area with the power ON is extremely hazardous and may cause serious safety problems as the Manipulator may move even if it seems to be stopped.

WARNING

■ Before operating the robot system, make sure that no one is inside the safeguarded area. The robot system can be operated in the mode for teaching even when someone is inside the safeguarded area.

The motion of the Manipulator is always in restricted status (low speeds and low power) to secure the safety of an operator. However, operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly.

■ Immediately press the Emergency Stop switch whenever the

Manipulator moves abnormally while the robot system is operated.

Continuing the operating the robot system while the Manipulator moves abnormally is extremely hazardous and may result in serious bodily injury and/or severe equipment change to the robot system.

WARNING

■ Be sure to connect the AC power cable to a power receptacle. DO

NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source.

Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system.


1. Safety

Safety-related Requirements

Specific tolerances and operating conditions for safety are contained in the manuals for the robot, controller and other devices. Be sure to read those manuals as well.

For the installation and operation of the robot system, be sure to comply with the applicable local and national regulations.

Robot systems safety standards and other examples are given in this chapter.

Therefore, to ensure that safety measures are complete, please refer to the other standards listed as well.

(Note: The following is only a partial list of the necessary safety standards.)

ENISO12100-1

ENISO12100-2

Safety of machinery - Basic concepts, general principles for design

Part 1. Basic terminology, methodology

Part 2. Technical principles and specifications

ENISO14121 Safety of machinery Principles for risk assessment

EN13849-1 Safety of machinery-Safety related parts of control systems

ENISO13850 Safety of machinery – Emergency stop – principles for design

ENISO13855 Safety of machinery - Positioning of safeguards with respect to the approach speeds of parts of the human body.

ENISO13857 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs.

ENISO 14120

(EN953)

General requirements for design and construction of guards

ISO10218 Robots for industrial environments -- Safety requirements

ANSI

/RIA R15.06

IEC204-1

(EN60204-1)

American National Standard; Industrial Robots and Robot Systems -

Safety Requirements

Safety of machinery - Electrical equipment of machines

Part 1. Specification for general requirements

EN55011 Limits and methods of measurement of radio disturbance characteristic of industrial scientific and medical (ISM) radio frequency equipment.

EN61000-6-2 Electromagnetic compatibility (EMC)

Part 6-2: Generic standards - Immunity for industrial environments


1. Safety

Part Names and Arm Motion

G series

The motion range of each arm is shown in the figure below. Take all necessary safety precautions.

Joint #2

(Rotate)

-

+

Arm #2

Joint #1

(Rotate)

-

+

Joint #3

+

(Up/Down)

-

-

Joint #4

(Rotate)

+

Shaft

Arm #1

(Figure : G6553S)


1. Safety

RS series


Joint #1

(rotating)

−

+

Joint #2

(rotating)

−

Base +

Arm #1

Arm #2

+

Joint #3

(up and down)

−

−

+

Joint #4

(rotating)

Shaft


Arm #6

Joint #6

1. Safety

C3 series


Upper Arm (Arms #3 to #6)

LED Lamp

This lamp lights up while the motors are ON.

Arm #4

J6

−

J5

+

Joint #4

J4

−

J3

+

Arm #3

J6

+

Arm #5

J5

−

Joint #5

J4

+

J3

−

J2

−

J2

+

Joint #3

Arm #2

(Lower Arm)

J1

+

Joint Motion

Joint #1 : The whole Manipulator revolves.

Joint #2 : The lower arm swings.

Joint #3 : The upper arm swings.

Joint #4 : The wrist revolves.

Joint #5 : The wrist swings.

Joint #6 : The wrist rotates.

Joint #2

Arm #1

Joint #1

Base

J1

−


1. Safety

LED Lamp

(This lamp lights up while the motors are ON.)

S5 series


Upper Arm (Arms #3 to #6)

J3

−

J4

+

Joint #5

J5

+

Arm #5

J6

+

Arm #3

Joint #6

Arm #6

J6

−

Ｊ 5

−

J3

+

Joint #3

Joint #4

J4

−

Arm #4

Arm #2 (Lower Arm)

J2

+

J2

−

Joint #1

Arm #1

J1

−

J1

+

Joint #2

Base

Arm Motion

Arm #1 : The whole Manipulator revolves.

Arm #2 : The lower arm swings.

Arm #3 : The upper arm swings.

Arm #4 : The wrist revolves.

Arm #5 : The wrist swings.

Arm #6 : The wrist rotates.


1. Safety

1.4 Maintenance Safety

Please read this section, Maintenance of the Manipulator manual, Maintenance of the Controller manual, and other related manuals carefully to understand safe maintenance procedures before performing any maintenance.

Only authorized personnel who have taken the safety training should be allowed to maintain the robot system. The safety training is the program for the industrial robot operator that follows the laws and regulations of each nation.

The personnel who have taken the safety training acquire knowledge of industrial robots (operations, teaching, etc.), knowledge of inspections, and knowledge of related rules/regulations. Only personnel who have completed the robot system-training and maintenance-training classes held by the manufacturer, dealer, or locally-incorporated company should be allowed to maintain the robot system.

■ Do not remove any parts that are not covered in this manual. Follow the maintenance procedure strictly as described in this manual, and the Maintenance of the Manipulator manual, and Maintenance of the

Controller manual. Improper removal of parts or improper maintenance may not only cause improper function of the robot system but also serious safety problems.

■ Keep away from the Manipulator while the power is ON if you have not taken the training courses. Do not enter the operating area while the power is ON. Entering the operating area with the power ON is extremely hazardous and may cause serious safety problems as the

Manipulator may move even though it seems to be stopped.

WARNING

■ When you check the operation of the Manipulator after replacing parts, be sure to check it while you are outside of the safeguarded area.

Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the

Manipulator may move unexpectedly.

■ Before operating the robot system, make sure that both the

Emergency Stop switches and safeguard switches function properly.

Operating the robot system when the switches do not function properly is extremely hazardous and may result in serious bodily injury and/or serious damage to the robot system as the switches cannot fulfill their intended functions in an emergency.


1. Safety

■ Be sure to connect the AC power cable to a power receptacle. DO

NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source.

Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

WARNING

■ Before performing any replacement procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source.

Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.

■ 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 contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

CAUTION

■Carefully use alcohol, liquid gasket, and adhesive following respective instructions and also instructions below. Careless use of alcohol, liquid gasket, or adhesive may cause a fire and/or safety problems.

- Never put alcohol, liquid gasket, or adhesive close to fire.

- Use alcohol, liquid gasket, or adhesive while ventilating the room.

- Wear protective gear including a mask, protective goggles, and oil-resistant gloves.

- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area thoroughly with soap and water.

- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth, flush your eyes or wash out your mouth with clean water thoroughly, and then see a doctor immediately.


1. Safety

CAUTION

■Wear protective gear including a mask, protective goggles, and oil-resistant gloves during grease up. If grease gets into your eyes, mouth, or on your skin, follow the instructions below.

If grease gets into your eyes :

Flush them thoroughly with clean water, and then see a doctor immediately.

If grease gets into your mouth:

If swallowed, do not induce vomiting. See a doctor immediately.

If grease just gets into your mouth, wash out your mouth with water thoroughly.

If grease gets on your skin:

Wash the area thoroughly with soap and water.


1. Safety

1.5 Emergency Stop

If the Manipulator moves abnormally during operation, immediately press the

Emergency Stop switch. The motor power will be turned OFF, and the arm motion by inertia will be stopped with the electromagnetic brake and dynamic brake.

However, avoid pressing the Emergency Stop switch unnecessarily while the

Manipulator is running normally. Otherwise, the Manipulator may hit the peripheral equipment since the operating trajectory while the robot system stops is different from that in normal operation.

To place the robot system in emergency mode during normal operation, press the

Emergency Stop switch when the Manipulator is not moving.

Refer to the Controller manual for instructions on how to wire the Emergency Stop switch circuit.

Do not press the Emergency Stop switch unnecessarily while the Manipulator is operating. Pressing the switch during the operation makes the brakes work.

This will shorten the life of the brakes due to the worn friction plates.

Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)

Before using the Emergency Stop switch, be aware of the followings.

- The Emergency Stop (E-STOP) switch should be used to stop the

Manipulator only in case of emergencies.

- To stop the Manipulator operating the program except in emergency, use

Pause (halt) or STOP (program stop) commands

Pause and STOP commands do not turn OFF the motors. Therefore, the brake does not function.

- For the Safeguard system, do not use the circuit for E-STOP.


For details of the Safeguard system, refer to the following manuals.

EPSON RC+ User’s Guide

2. Safety - Installation and Design Precautions - Safeguard System

Safety and Installation

2.6 Connection to EMERGENCY Connector

To check brake problems, refer to the following manuals.

Manipulator Manual Maintenance

2.2.2 Inspection While the Power is ON (Manipulator is operating)

Safety and Installation

5.2 Inspection Point - Inspection While the Power is ON

1. Safety

Free running distance in emergency

The operating Manipulator cannot stop immediately after the Emergency Stop switch is pressed.

However, remember that the values vary depending on conditions such as the weight of the end effector and work piece, Weight/Speed/Accel settings, operating pose, etc.


1. Safety

1.6 Labels

Labels are attached around the locations of the Controller and Manipulator where specific dangers exist.

Be sure to comply with descriptions and warnings on the labels to operate and maintain the Robot system safely.

Do not tear, damage, or remove the labels. Use meticulous care when handling those parts or units to which the following labels are attached as well as the nearby areas.

Label types differ according to the specifications.


1. Safety

Controller

Location Label Note

Residual voltage exists. To avoid electric shock, do not open the cover while the Power is ON, or for 2 minutes after the Power is

OFF.

A

Residual voltage exists. To avoid electric shock, do not open the cover while the Power is ON, or for 300 seconds after the

Power is OFF.

Disconnect and lockout main power before performing maintenance and repair.

B

C

RC180 Safety and Installation Rev.19

C

A

B

Do not connect the followings to

TP/OP port of RC180.

Connecting to the followings may result in malfunction of the device.

OPTIONAL DEVICE dummy plug, OP500, OP500RC,

JP500,and TP-3**

Refer to 4.2 Connection and

Display Language of Option TP1 and OP1

15

1. Safety

Manipulator

Location Label Note

Before loosening the base mounting screws, hold the arm and secure it tightly with a band to prevent hands or fingers from being caught in the

Manipulator.

Follow the directions in this manual for installation and transportation.

A


1. Safety

Location Label Note

Do not enter the operation area while the

Manipulator is moving. The robot arm may collide against the operator. This is extremely hazardous and may result in serious safety problems.

B

C

Hazardous voltage exists while the

Manipulator is ON. To avoid electric shock, do not touch any internal electric parts.


1. Safety

Location Label Note

You can catch your hand or fingers between the shaft and cover when bringing your hand close to moving parts.

D

Manipulators with bellows do not have this label for no danger of your hand or fingers being caught

Be careful of the arm falling due to the arm’s own weight while the brake release button is being pressed.

* This label is attached to the option brake release box.

E

Be careful of the shaft falling due to the hand’s own weight while the brake release button is being pressed.


1. Safety

Location Label Note

Do not lift without the shipping bracket.

To pick up the manipulator arm, use two wire ropes of equal length.

Remove the shipping brackets and eyebolts before turning power on.

Follow the directions in this manual for installation and transportation.

F


1. Safety

Location Label Note

Arm weight may cause arm to fall during disassembly operation.

Follow the directions in this manual for disassembly operation.

G

20

J

H

(Only UL model)

Only authorized personnel should perform sling work and operate a crane and a forklift.

When these operations are performed by unauthorized personnel, it is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

I


Location of Labels

G1

I

E

B

H

A

C

J

1. Safety


1. Safety

G3

Common

D

E

C

Table Top Mounting

I

Multiple Mounting

H

B

H

A

B

C

J

A I

J

C


G6

Table Top Mounting

G6-***S

C

E

D

B

H

A

Ceiling Mounting

G6-***SR

D

E

C

B

A

H

C

J

I

G10/G20

Table Top Mounting: G10/G20-****

E

C

D

F

B

A

I

J

Ceiling Mounting: G10/G20-****R

A

E

C

F

C

B

D

C

J

I

I

C

J

Wall Mounting

G6-***SW

D

E

C

J

B

A

I

H

Wall Mounting: G10/G20-****W

J

C

E

A

F

I

B

D

1. Safety


1. Safety

RS

Front

D

C

J

Top

C

C

H

Side

B (Both sides)

E

C

A

I

Bottom


C3

Front View

B

C

1. Safety

Top View

C

I

C

C

C

Lateral View

A

J

Back View

C


1. Safety

S5

C

F

C

B

I

A

Lateral View (Left side)

Lateral View (Right side)

G

D

C

Back View Front View


1. Safety

1.7 Safety Features

The robot control system supports safety features described below. However, the user 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 2.5 Controller Installation - Safety Door Switch and Latch

Release Switch.

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.


1. Safety

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.

Encoder Cable Disconnection Error Detection

The dynamic brake circuit is activated when the Motor Encoder Signal cable is disconnected.

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).

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.


1. Safety

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 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.


2. Installation

2. Installation

This chapter contains precautions for safe and accurate installation of the robot system.

The outline to install the robot system is indicated on 2.1 Outline from Unpacking to Operation of Robot System. Refer to each section and/or the Manipulator manual and the Controller manual for unpacking, transportation, and installation.


2. Installation

System Example

PLC (Sequencer) Operation Panel Motion Controller

*

G series

Option Unit

Expansion

I/O Board

Fieldbus

- Profibus

- Devicenet

- CC-LINK

- EtherNet/IP

RS-232C Board

USB2.0 or

Ethernet

PC

RC180

Standard Installation

- Standard I/O

- Remote I/O

- Ethernet

ProSix

Driver Unit

*

C3 series

*

S5 series

* Controls one of the robots.

OP1

(Option)

RS series

Windows *1

(XP or Vista or 7)

*

TP1

(Option)

EPSON RC+ 5.0

Software

Option

Connect OP1, TP1, and / or TP2

Ethernet

CV1

TP2

Requires preparation by uses

*1 EPSON RC+ 5.0 supports the following OS.

Windows XP Professional Service Pack 3 (EPSON RC+ 5.0 Ver.5.2.0 SP3 or after is required.)

Windows Vista Business Service Pack 2 (EPSON RC+ 5.0 Ver.5.3.1 or after is required.)

Windows 7 Professional (EPSON RC+ 5.0 Ver.5.3.4 or after is required.

(Option)


2. Installation

2.1 Outline from Unpacking to Operation of Robot System

2. Installation

Unpacking

Transportation

Installation

Power-on

Yes

Error?

No

Procedures to install the Robot system and turn ON the power properly

3. First Step

Procedures to install EPSON RC+5.0

to the development PC and enable the operation of the robot system

4. Second Step

Manual information to connect or setup the equipment and options


2. Installation

2.2 Unpacking


Using a cart or similar equipment, transport the Manipulator in the same conditions as it was delivered. Observe the following when unpacking the

Manipulator.

Package Components Example

The following figure illustrates the package at delivery.

Manipulator

Attached Equipment

Controller etc.

Unpacking Precautions

Transportation procedure

: Only authorized personnel should perform sling work and operate a crane or forklift. When these operations are performed by unauthorized personnel, it is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

Vibration at transportation

: Avoid excessive vibration or shock during Manipulator transporting.

Excessive vibration or shock may cause equipment damage to and/or malfunction of the Manipulator.

Anchor bolt

: When removing the anchor bolts, support the Manipulator to prevent falling.

Removing the anchor bolts without supporting the Manipulator may get hands, fingers, or feet caught as the Manipulator will fall.

Wire tie

: Do not remove the wire tie securing the arm until you finish the installation.

You may get your hands caught in the Manipulator when the wire tie is removed before completing the installation.


2. Installation

2.3 Transportation


Transportation Precautions

: Using a cart or similar equipment, transport the Manipulator in the same conditions as it was delivered. Observe the following when unpacking the Manipulator.

Only authorized personnel should perform sling work and operate a crane or forklift. When these operations are performed by unauthorized personnel, it is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

Vibration at transportation

: Avoid excessive vibration or shock during Manipulator transporting.

Excessive vibration or shock may cause equipment damage to and/or malfunction of the Manipulator.

Anchor bolt

: When removing the anchor bolts, support the Manipulator to prevent falling.

Removing the anchor bolts without supporting the Manipulator may get hands, fingers, or feet caught as the Manipulator will fall.

Wire tie

: Do not remove the wire tie securing the arm until you finish the installation.

You may get your hands caught in the Manipulator when the wire tie is removed before completing the installation.

Hoisting procedure

: Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is extremely hazardous and may results in serious bodily injury and/or severe equipment damage to the robot system as the fall of the

Manipulator.


G1

G3

2. Installation

Manipulator Transportation

To carry the Manipulator, secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand. Never hold the duct to carry the Manipulator.

Duct

DO NOT hold here for carrying

Hold here for carrying

G1-171* approx. 8 kg :18 lb.

G1-221* approx. 8 kg :18 lb.

To carry the Manipulator, have two or more people to work on it and secure the

Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand.

When holding the bottom of the base by hand, be very careful not to get your hands or fingers caught.

Table Top Mounting

G3-251* : approx. 14 kg: 31 lb.

G3-301* : approx. 14 kg: 31 lb.

G3-351* : approx. 14 kg: 31 lb.

Multiple Mounting

G3-301*M : approx. 14 kg: 31 lb.

G3-351*M : approx. 14 kg: 31 lb


2. Installation

G6


Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 / bottom of the base) by hand. When holding the bottom of the base by hand, be very careful not to get hands or fingers caught.

Table Top Mounting

G6-45**/G6-55**

Approx. 27 kg: 60 lb.

G6-65**


Wall Mounting

G6-45**W/G6-55**W


G6-65**W

Approx. 29.5 kg: 65 lb.

Ceiling Mounting

G6-45**R/G6-55**R


G6-65**R



2. Installation

G10 / G20

To carry the Manipulator, secure the Manipulator to the delivery equipment, or pass belts through the eyebolts and hoist it with your hands. Make sure to hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand.

RS

Table Top Mounting: *

Ceiling Mounting: R

Wall Mounting: W

G10

65**/**R : Approx. 46 kg : 102 lb

65**W : Approx. 51 kg : 113 lb

G10/G20

85**/**R : Approx. 48 kg : 106 lb

85**W : Approx. 53 kg : 117 lb

G20

A0**/**R : Approx. 50 kg : 111 lb

A0**W : Approx. 55 kg : 122 lb


Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand.

When holding the bottom of the base by hand, be very careful not to get your hands or fingers caught.

RS3-351* : approx. 17 kg : 38 lb.

RS4-551* : approx. 19 kg : 42 lb.


2. Installation

C3

To carry the Manipulator, have at least 2 people to work on it and secure the

Manipulator to the delivery equipment or hold it by hand.

Do not hold the bottom of the base (the screened parts in the figure). Holding these parts by hand is extremely hazardous and may cause your hands and fingers to be caught.

Manipulator weight

: 27 kg (59.5 lb.)

S5

DO NOT hold the bottom of the base by hand.

To carry the Manipulator, have at least 3 people to work on it and secure the

Manipulator to the delivery equipment or hold it by hand.

Do not hold the bottom of the base (the screened parts in the figure). Holding these parts by hand is extremely hazardous and may cause your hands and fingers to be caught or cut by the grounding electrode.

S5-A701**

Approx. 38 kg (Manipulator weight: 36 kg (80 lb.))

S5-A901**

Approx. 40 kg (Manipulator weight: 38 kg (84 lb.))

Shipping bolts and jigs

DO NOT hold the bottom of the base by hand.


2. Installation

Using a Crane

To hoist the Manipulator with a crane, secure the Manipulator with shipping bolts and jigs and posture the Manipulator as shown in the figures below (the posture at shipment from the manufacturer).

Use a cable threaded through the eyebolts attached to the Manipulator as shown.

(Make sure that they are not loose.)

18

°

45

°

Using a Forklift

Position the Manipulator as shown in the figures below (the posture at shipment from the manufacturer) and secure it onto a pallet with shipping bolts and jigs.

Insert the forklift claws under the pallet and transport the Manipulator together with the pallet. The pallet must have enough strength to bear the weight of the

Manipulator. Transporting of the Manipulator must be performed slowly in order to avoid overturning or slippage.

18

°

45

°

Bolt

(4-M10)

Pallet

Controller


Inset here the forklift claws.

39

2. Installation

2.4. Manipulator Installation


For details, refer to the Manipulator manual.

Installation Precautions

: To ensure safety, a safeguard must be installed for the robot system.

For details on the safeguard, refer to the Installation and Design

Precautions in the Safety chapter of the EPSON RC+ User’s Guide.

Space between safeguard and Manipulator

: Install the Manipulator at a location with sufficient space so that a tool or a work piece on the end effector does not reach a wall or a safeguard when the Manipulator extends its arm fully while holding a work piece.

Installing the Manipulator at a location with insufficient space is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system as a tool or a work piece may collide with a wall and a safeguard.

Manipulator check before installation

: Before installing and operating the Manipulator, make sure that all parts of the Manipulator are in place and have no external defects. Missing or defective parts may cause improper operation of the Manipulator.

Improper operation of the Manipulator is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

Side mounting and ceiling mounting

: When mounting the Manipulator on a wall or ceiling, secure the

Manipulator to the wall or ceiling that has enough strength and rigidity.

Mounting the Manipulator on a wall or ceiling that has insufficient strength and rigidity is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system as the

Manipulator may fall or vibrate.

Side mounting and ceiling mounting

: When mounting the Manipulator on a wall or ceiling, for safety purposes, attach the support to the Manipulator base to prevent the

Manipulator from falling. If the Manipulator falls, it is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.


2. Installation

: Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation. The

Manipulator without connecting them may result in electric shock and/or malfunction of the robot system as it cannot ensure IP65.

Noise level

Noise level by movement of manipulator.

G1

RS3 RS4

G3 G6 G10 G20

65

70

Under rated load,

4-joints, simultaneous motion, maximum speed, maximum acceleration, and duty 50%

Under rated load, operation, maximum speed, and duty 50%

In front of the Manipulator,

1000 mm apart from the motion range,

50 mm above the base-installed surface

1000mm apart from the Back of the Manipulator

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 torque and reaction force produced by the movement of the Manipulator are as follows:


2. Installation

G / RS series

G

RS

G1

G3 G6 G10

G20

RS3 RS4

Max. Reaction torque on the horizontal plate (Nm)

Max. Horizontal reaction force (N)

Max. Vertical reaction force (N)

100 300 500 1000 1000 500 500

200 2000 2500 4500 7500 1200 1400

300 1000 1500 2000 2000 1100 1100

Threaded holes for Mounting screw

M6 M8 M8 M12 M12 M6 M6

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 μm or less.

C3 / S5 series

Max. Reaction torque on the horizontal plate (Nm)

Max. Horizontal reaction force (N)

Max. Reaction torque on the vertical plate (Nm)

Max. Vertical reaction force (N)

Threaded holes for Mounting screw

C3

S5

701 901

500 600 900

800 1000 1400

600 800 900

2500

M8

3000

M10

3500

M10

The plate for the Manipulator mounting face should be 30 mm thick or more and made of steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or less.

Use mounting bolts with specifications conforming to ISO898-1 property class:

10.9 or 12.9.

The table must be secured on the floor or wall to prevent it from moving.

The Manipulator must be installed horizontally.

When using a leveler to adjust the height of the base table, use a screw with M16 diameter


G1

NOTE

)

2. Installation

Installation Procedure

When the Manipulator is Clean-model, unpack it outside of the clean room.

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, carry the Manipulator in the clean room. Connect an exhaust tube to the exhaust port after installation.

There are 4 threaded holes for the Manipulator base. Use M6 mounting bolts conforming to the strength, ISO898-1 property class: 6.9.

G1-177* 8kg: 18lb.

G1-221* 8kg: 18lb.


2. Installation

G3 : Table Top Mounting-

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.

G3-251* : approx. 14 kg: 31 lb.

G3-301* : approx. 14 kg: 31 lb.

G3-351* : approx. 14 kg: 31 lb.

(1) Secure the base to the base table with four bolts.

NOTE

)

Use bolts with specifications conforming to ISO898-1 Property

Class: 10.9 or 12.9.

10 mm

4-M8

×30

Spring

Washer

Plane

Washer

Screw Hole

(depth 20 mm

or more)

(2) Using nippers, cut off the wire tie binding the shaft and arm retaining bracket on the base.

(3) Remove the bolts securing the wire ties removed in step (2).

Wire tie

(4) Remove the shipping bolt and jigs.

Bolt

:M4

×15

Sheet


2. Installation

G3 : Multiple Mounting

■

Install the Multiple Mounting Manipulator with two or more people.


G3-301*M : approx. 14 kg: 31 lb.

G3-351*M : approx. 14 kg: 31 lb.

WARNING

■ 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.

(1) Unpack the manipulator with retaining the arm posture.

(2) Secure the base to the wall with four bolts.

NOTE

)


Class: 10.9 or 12.9.



Screw Hole

(depth 20 mm or more)

Plane Washer

Spring Washer

4-M8

×30

45

2. Installation

G6 : Table Top Mounting

WARNING

■ Install the Table Top Mounting Manipulator with two or more people.


G6-45** : Approximately 27 kg: 60 lb.



(1) Secure the base to the base table with four bolts.

NOTE

)

Use bolts with specifications conforming to ISO898-1 Property Class: 10.9 or 12.9.

4-M8×40

Spring

Washer

Plane

Washer

20 mm

Screw Hole



Bolt

:M4

×15

Sheet

Wire tie

Bolt

:M5

×15



2. Installation

G6 : Wall Mounting

■

Install the Wall Mounting Manipulator with two or more people.


G6-45**W : Approximately 29 kg: 64 lb.

G6-55**W : Approximately 29 kg: 64 lb.

G6-65**W : Approximately 29.5 kg: 65 lb.

WARNING

■ 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.


(2) Secure the base to the wall with six bolts.

NOTE

)


Class: 10.9 or 12.9.


Screw Hole


6-M8

×40

Plane Washer

Spring Washer


2. Installation

G6 : Ceiling Mounting

■ Install the Ceiling Mounting Manipulator with two or more people.


G6-45**R : Approximately 27 kg: 60 lb.



WARNING

■ When installing the Manipulator to the ceiling, support the



NOTE

)

(2) Secure the base to the ceiling with four bolts.

Use bolts with specifications

Screw Hole

(depth 20 mm or more) conforming to ISO898-1 Property

Class: 10.9 or 12.9.


Plane

Washer

Spring

Washer

4-M8

×40


2. Installation

G10/G20 : Table Top Mounting

■ Install the Table Top Mounting Manipulator with four or more people.

CAUTION


G10-65** : Approximately 46 kg :102 lb.

G10/G20-85** : Approximately 48 kg :106 lb.

G20-A0** : Approximately 50 kg :111 lb. bolts.

NOTE

)


Tightening torque

: 7350 N

⋅cm (750 kgf⋅cm)


4-M12×40

Spring

Washer

Plane

Washer

20 mm

Screw Hole


Bolt

: M4

×15

Washer

: M6

Wire tie

(3) Remove the bolts securing the wire ties removed in step (2).

Arm mounting bolt

: M12

×20


Eyebolt

(Attached at shipment)


2. Installation

G10/G20 : Wall Mounting

■

Install the Wall Mounting Manipulator with four or more people.


WARNING

G10-65**W : Approximately 51 kg :113 lb.

G10/G20-85**W : Approximately 53 kg :117 lb.

G20-A0**W : Approximately 55 kg :122 lb.

■ When installing the Manipulator to the wall, support the



(2) Secure the base to the wall with six bolts.

NOTE

)



6-M12

×40

Screw Hole


Plane Washer

Spring Washer


2. Installation

G10/G20 : Ceiling Mounting

■ Install the Ceiling Mounting Manipulator with four or more people.


G10-65**R : Approximately 46 kg :102 lb.

G10/G20-85**R : Approximately 48 kg :106 lb.

G20-A0**R : Approximately 50 kg :111 lb.

WARNING




(2) Secure the base to the ceiling with four bolts.

NOTE

)



Screw Hole


Plane

Washer

Spring

Washer

4-M12

×40


2. Installation

RS

CAUTION

■ Install the Manipulator with two or more people.


RS3-351*: approx. 17 kg : 38 Ib. (except cables)

RS4-551*: approx. 19 kg : 42 Ib. (except cables)



(1) Unpack the Manipulator with retaining the arm posture.

52

NOTE

)

(2) Secure the base to the wall with 6 bolts.

Intensity of the bolts should be equivalent to ISO898-1 Property

Class 10.9 or 12.9.


Screw hole

(Depth: 12 mm or more)

6-M6

×20


S5

C3

2. Installation

The shipping bolts and jigs are attached to the Manipulator as shown the figure below (points A, B) for protecting the Manipulator from various external forces during transportation.

Be sure to remove the bolts from the Point A first, and then, remove the bolts from Point B.

The jigs are painted yellow.

Point A : 6-M5×14 hexagon socket head cap bolts with plain washers and disc spring washers

Point B : 2-M6×10 hexagon socket head cap bolts with plain washers and disc spring washers

(° = degree)

59

°

29

°

60

°

Point A

Point B

There are four threaded holes for the Manipulator base.

Use M8 mounting bolts conforming to the strength of ISO898-1 property class 12.9.


2. Installation

2.5 Controller Installation

Installation Precautions

: 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.

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

: Before performing any installation procedure, turn OFF the

Controller and related equipment, and then pull out the power plug from the power source.


Cable

: 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.


2. Installation

Installation

- Mount the Controller mounting screws with 80 to 110 Ncm torque.

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

(A) (B)

Fixture L

Base Table

Fixture L

(C) (D)

Rack

Fixture L

Base Table

Base Table

Fixture S

There are two types of fixtures. Mount the fixture to the Controller with the four attached screws.

Fixture L: Used in (A), (B), and (D) / Fixture S: Used in (C)

NOTE

)

The length from the edge of fixture L differs by the side. Refer to the following figure and mount the side with shorter distance from the edge to the screw hole on the Upper side.


2. Installation

-

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

When mounting direction is (A) or (B)

Outline of the RC180

Unit [mm]

8-M5

59.8

57.2

76.1

57.2

59.8

57.2

76.1

57.2

(2)

(1)

(3)

24.7

When mounting direction is (C) : Fixture S:

4-M5

20.5

90.0

(6)

(5)

(4) 24.7

20.5

90.0

(3)

(2)

(1)

60.0

(Front Side)

(6)

(5)

(4)

No screw hole processing is required for mounting direction (D).

Secure it to the rack with screws and nuts.

No Option Unit

Option Unit

×1

Option Unit

×2

Controller Only

(1) 323 mm

(2) 378 mm

(3) 433 mm

60.0

(Front Side)

Controller + ProSix Driver Unit

(4) 398 mm

(5) 453 mm

(6) 508 mm


2. Installation

- Ensure the draft around the in/out and also install the controller by keeping the distance as follows to prevent the nose influence from other equipment such as large contactor and relay.

100 mm

100 mm

Air flow of the Controller Fan

100 mm

100 mm

Excluding the installation side such as base table

- Hot air with higher temperature than the ambient temperature (about 10 deg.C) comes out from the in/out of the Controller.

Make sure that heat sensitive devices are not placed near the outlet.


2. Installation

2.6 Connection to EMERGENCY Connector (Controller)

Connect a safeguard switch or Emergency Stop switch to the Controller

EMERGENCY connector for safety.

When nothing is connected to the EMERGENCY connector, Controller does not operate normally.

WARNING

■ 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.

Connector Standard

EMERGENCY connector

(Controller side)

Safety Door Switch

D-sub25 Pin (male)

Mounting style #4-40

WARNING

■ The interlock of the Safety Door must be functioning when the robot system is operated. Do not operate the system under the condition that the switch cannot be turned ON/OFF (e.g. The tape is put around the switch.). Operating the robot system when the switch is not functioning properly is extremely hazardous and may cause serious safety problems as the Safety Door input cannot fulfill its intended function.


NOTE

)

2. Installation

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 zoon. 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 following 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.

Latch Release Switch

The controller software latches the following conditions:

- The safety door is open.

- The operation mode is “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.


2. Installation

NOTE

)

Checking Latch Release Switch Operation

Refer to 3.2 Development PC and Controller Connection and connect the development PC and Controller before checking the function.

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 EPSON RC+ 5.0 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.

NOTE

)

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

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

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

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 TEACH mode.

In order to change the latched condition of the TEACH mode, turn the mode selector key switch on the Teach Pendant to “Auto”. Then, close the latch release input.

Emergency Stop Switch

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

Emergency Stop on the Teach Pendant and Operator Panel, make 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”.


NOTE

)

NOTE

)

2. Installation

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 Controller Manual

RC170 / RC180 Setup & Operation: 5.5 Circuit Diagrams.

Checking Emergency Stop Switch Operation

Refer to 3.2 Development PC and Controller Connection and connect the development PC and Controller before checking the function.

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 the seven-segment LED on the Controller displays

.

(3) Make sure that “E.Stop” is displayed on the EPSON RC+ 5.0 status bar.

(4) Release the Emergency Stop Switch.

(5) Select EPSON RC+ 5.0-[Tools]-[Robot Manager]-[Control Panel] and click the <Reset> button to execute the RESET command.

(6) Make sure that LED is turned OFF and that “E-Stop” is dimmed on the main window status bar.


2. Installation

Pin Assignments

The EMERGENCY connector pin assignments are as follows:

Pin

No.

1 ESW11

2 ESW12

Emergency Stop switch contact (1)

*3


*3

3 ESTOP1+ Emergency Stop circuit 1 (+)

4 ESTOP1

−

Emergency Stop circuit 1 (-)

5 NC

*1

6 NC

7 SD11

8 SD12

*1

Safety Door input (1)

*2


*2

9 24V

10 24V

+24V output

+24V output

11 24VGND

12 24VGND

13 NC

+24V GND output

+24V GND output

Signal Function

14 ESW21

15 ESW22

16 ESTOP2+

17 ESTOP2

−

18 SDLATCH1

19 SDLATCH2

20 SD21

21 SD22

22 24V

23 24V

24 24VGND

25 24VGND


*3


*3

Emergency Stop circuit 2 (+)

Emergency Stop circuit 2 (-)

Safety Door Latch Release

Safety Door Latch Release


*2


*2

+24V output

+24V output

+24V GND output

+24V GND output

*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.

Emergency Stop switch output rated load +30 V 0.3 A or under 1-2, 14-15 pin

Emergency Stop rated input voltage range

Emergency Stop rated input current

+24 V

±10%

47.5 mA/+24V input

3-4, 16-17 pin

Safety Door rated input voltage range

Safety Door rated input current

Latch Release rated input voltage range

Latch Release rated input current

+24 V

±10%

10 mA/+24 V input

+24 V

±10%

10 mA/+24 V input

7-8, 20-21 pin

18-19 pin

NOTE

)

The total electrical resistance of the Emergency Stop switches and their circuit should be 1

Ω or less.


2. Installation

Circuit Diagrams

Example 1: External emergency stop switch typical application

Controller

+24V

External Emergency

Stop switches

9

Emergency

Stop switch of an Operation

Unit

10

22

23

1

2

+5V

14

15

3

16

Main Circuit

Control

Motor Driver

+

+

−

AC Input

Emergency

Stop detection

NOTE:+24V GND

+ 5V GND


7

Safety Door input 1

8

4

17

11

12

24

25

20

Safety Door input 2

21

18

Latch release input

19

External

+24V

Latch release input Close :Latch off

Open :Latch on

External +24V

GND

63

2. Installation

Example 2: External safety relay typical application

Controller

+24V

Emergency

Stop switch of an Operation

Unit

Motor Driver

AC Input

Main Circuit

Control

+

+

−

Emergency

Stop detection

+5V

7

Safety Door input 1

8

20

Safety Door input 2

21

18

Latch Release input

19

4

17

11

12

24

25

External +24V

Fuse

14

15

3

16

9

10

22

23

1

2

External

+24V

GND

External

+24V

External safety relay

(The above diagram is simplified for representation.)

* 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

+24V

GND

External

+24V

NOTE:+24V GND

+ 5V GND

Latch release input Close :Latch off

Open :Latch on

External +24V

GND


2. Installation

2.7 AC power cable

WARNING

■

Be sure to connect the AC power cable to a power receptacle.

DO NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source. Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system

■

Make sure that cable manufacturing and connection are done by a qualified personal.

When proceeding, be sure to connect the earth wire of the AC power cable colored green/yellow on the Controller 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.

Always use a power plug and receptacle for power connecting cable. Never connect the Controller directly to the factory power supply. (Field wiring)

Plug (Set by the users)

To Controller

M4 Ring solderless terminal

(RC180-UL: M5 Ring solderless terminal)

The AC plug in not attached to the AC power cable delivered at shipment.

Refer to the wire connection specification and attach a proper plug to the cable that is suitable for the factory power supply. (A plug is prepared as option.)

Cable Wire Connection Specification

Purpose Color

AC power wire (2 cables)

Ground wire

Black

Green / Yellow

Cable length: 3 mm (Standard)

For RC180-UL

■

Branch Circuit protection (Rated current: 15 A or less) shall be installed in the external AC power supplying side in accordance with the National Electrical Code.

WARNING

A disconnecting means shall be installed in accordance with the

National Electrical Code and provide the ability for lockout and tagout.


2. Installation

2.8 Connecting Manipulator and Controller

Connecting Precautions

Before Connection

: 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.

Connecting procedure

: Before performing any connecting procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source.


Cable

: 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 contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.

Connection

: When connecting the Manipulator and 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 system but also safety problems.

The serial number of supported Manipulator is labeled on the controller.

If the G series Manipulator is connected to the Controller for the PS series

(ProSix), it may result in malfunction of the Manipulator.

Wiring

: Only authorized or certified personnel should be allowed to perform wiring.

Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system.

For Clean-model

: When the Manipulator is a Clean-model, use it with an exhaust system.

For details, refer to the Manipulator manual.


2. Installation

For Protected-model

: Connect the power cable connection and the signal cable connector to the

Manipulator immediately after the Manipulator installation. The

Manipulator without connecting them may result in electric shock and/or malfunction of the robot system as it cannot ensure IP65.

G series

G series Manipulator

(Figure: G6-553S)

M/C Power Cable

Controller RC180

RS series

Controller RC180

M/C Signal Cable

M/C Signal cable

M/C Power cable

Manipulator RS series

(Figure: RS3-351S)


2. Installation

C3 series

C3 series Manipulator

M/C power cable

Controller RC180

S5 series

S5 series Manipulator

M/C signal cable

Controller RC180

M/C power cable

M/C signal cable


2. Installation

2.9 Power-on

Power-on Precautions

Manipulator check before installation

: Before installing and operating the Manipulator, make sure that all parts of the

Manipulator are in place and have no external defects. Missing or defective parts may cause improper operation of the Manipulator. Improper operation of the Manipulator is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.

Shipping bolts and jigs check before turning ON

: Before first turning ON the power, be sure to remove the shipping bolts and jigs from the Manipulator. Turning ON the power while the shipping bolts and jigs are attached may result in equipment damage to the Manipulator.

Power activation

: Anchor the Manipulator before turning ON the power to or operating the

Manipulator. Turning ON the power to or operating the Manipulator that is not anchored is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system as the Manipulator may fall down

Power ON Procedure

(1) Check the M/C power cable connection.

(2) Check the M/C signal cable connection.

(3) Check the EMERGENCY connector connection.

(4) Connect the TP/OP bypass plug to the TP/OP port.

(5) Connect the AC power cable to the power supply socket.

(6) Switch the controller POWER switch to the right to turn ON the power.

(POWER switch is not available for RC180-UL. Instead, turn ON the external disconnecting means.)

(7) The seven-segment LED blinks as after Controller starts up normally.

approximately 30 seconds

When an error appears, check the connection in step (1) to (5) to turn ON the power again.

If an error appears after checking the connection contact the supplier.


2. Installation

G series (Figure: G6-553S)

(1)

(2)

RS series (Figure: RS3-351S)

(3)

(1) (5)

(4)

(3)

(5)

(2) (4)

70

C3 series

(2)

(3)

(5)

(1)

(4)


2. Installation

S5 series

(3)

(2)

(7) Seven-segment LED

(1)

(4)

(5)

(6) POWER Switch

* POWER switch is not available for RC180-UL.

Instead, turn ON the external disconnecting means.


3. First Step

3. First Step

This section indicates the procedure to install the development PC EPSON RC+

5.0, and execute simple program after connecting the development PC and

Controller with a USB.

Make sure that the Robot system is installed safely by following the description in

1. Safety and 2. Installation. Then, operate the Robot system in the following procedures.

3.1 Installing EPSON RC+ 5.0 Software

NOTE

)

The EPSON RC+ 5.0 software needs to be installed on your development PC.

EPSON RC+ 5.0 supports the following OS.

Windows XP Professional Service Pack 3

(EPSON RC+ 5.0 Ver.5.2.0 SP3 or after is required.)

Windows Vista Business Service Pack 2

(EPSON RC+ 5.0 Ver.5.3.1 or after is required.)

Windows 7 Professional

(EPSON RC+ 5.0 Ver.5.3.4 or after is required.)

1. Insert the EPSON RC+ 5.0 Setup CD in the CD drive.

2. If EPSON RC+ 5.0 was previously installed, you will be asked to uninstall the previous version, otherwise go to step 3.

After uninstalling, you will be prompted to restart the computer. Start the setup program again by double-clicking the installer CD icon in My Computer, or by re-inserting the CD.


3. First Step

3. The welcome dialog will be displayed as shown below. Click the Next button to continue.

4. Enter your user name and company name, then click Next.


3. First Step

5. Select the drive where you want to install EPSON RC+ 5.0 and click

Next.

NOTE

)

The installation directory is called EpsonRC50 and cannot be changed.

74

6. You will be prompted to confirm installation. Click Yes to continue.

7. If required, Windows Installer and Microsoft .NET Framework 2.0 are installed on your system. This may take several minutes.

NOTE

)

Adobe Reader needs to be installed on your PC in order to view the

EPSON RC+ 5.0 manuals. If the installer cannot find Adobe

Reader on your system, it will be installed at this time. Follow the instructions in the Adobe installer. Do not restart the system after the Adobe Reader installation has completed.

8. After the installation has completed, you may be prompted to restart your computer.

The EPSON RC+ 5.0 software installation is now completed.


3. First Step

3.2 Development PC and Controller Connection

Connect the development PC and the USB port for connection (USB B series connector).

Development PC connection Port

NOTE

)

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

RC+ 5.0 User’s Guide 5.12.1 PC to Controller Communications Command.

For RC180, be sure to install the EPSON RC+5.0 to the development PC first, then connect the development PC and RC180 with the USB cable.

If RC180 and the development PC are connected without installing the EPSON

RC+5.0 to the development PC, [Add New Hardware Wizard] appears. If this wizard appears, click the <Cancel> button.

About Development PC Connection Port

Development PC connection port supports following USB.

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

- USB1.1 FullSpeed

Interface Standard : USB specification Ver.2.0 compliant

(USB Ver.1.1 upward compatible)

Connect the Controller and development PC by a USB cable to develop the robot system or set the Controller configuration with the EPSON RC+ 5.0 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.


3. First Step

Precaution

When connecting the development PC and the Controller, make sure of the followings.

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

Do not use the USB hub or extension cable.

- Make sure that no other devices except development PC is used for development PC connection port.

- Use PC or 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 development PC and the Controller is connected, do not insert or remove other USB devices from the development PC. Connection with the

Controller may disconnect.

Software Setup and Connection Check

Connection of the development PC and the Controller is indicated.

(1) Make sure that software EPSON RC+ 5.0 (Ver.5.2 or later) or later is installed to the Controller connected to the development PC. (Install the software when it is not installed.)

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

(3) Turn ON the Controller.

(4) Start the software EPSON RC+ 5.0.

(5) Select the EPSON RC+ 5.0 menu-[Setup]-[PC to Controller Communications] to display the [PC to Controller Communications] dialog.


3. First Step

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

(7) After development PC and the 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 of the development PC and the Controller is completed. Now robot system can be used from EPSON RC+ 5.0.

Backup the initial condition of the Controller

Backup the Controller data configured before shipment.

Follow these steps to backup the project and system configuration:

(1) From the Project menu, select Copy.

(2) Change the Destination Drive to a certain drive.

(3) Click OK. The project will be copied to the external media.

(4) From the Tools menu, select Controller.

(5) Click on the Backup Controller button.

(6) Select the certain drive.

(7) Click OK. The system configuration will be backed up on the external media.


3. First Step

Disconnection of Development PC and Controller

Disconnection of the development PC and the Controller is indicated.

(1) Select the EPSON RC+ 5.0 menu-[Setup]-[PC to Controller Communications] to display the [PC to Controller Communications] dialog.

(2) Click the <Disconnect> button.

Controller and the development PC is disconnected and USB cable can be removed.

NOTE

)

If USB cable is removed when the Controller and the development PC is connected, stop occurs to the Robot. Make sure to click the <Disconnect> button in the [PC to Controller Communications] dialog before USB cable is removed.


3. First Step

3.3 Writing your first program

After installing the controller, robot, and EPSON RC+ 5.0 software on your PC, follow these instructions to create a simple application program so that you will become more familiar with the EPSON RC+ 5.0 development environment.

1. Connect your PC to the RC180 Controller

Install a USB cable between your PC and the Controller. Refer to the 3.2

Development PC Connection Port.

2. Start EPSON RC+ 5.0 Simple Mode

Double-click the EPSON RC+ 5.0 Simple icon on the desktop.

3. Create a new project

(1) Select New from the Project menu.

(2) Type in a name for a project, for example, FirstApp.

(3) Click OK to create the new project.

When the new project is created, a program called Program.prg is created.

You will see a window open with the title Program.prg with a cursor flashing in the upper left corner. Now you are ready to start entering your first program.


3. First Step

4. Edit the program

Type in the following program lines in the Program.prg edit window.

Function main

Print "This is my first program."

Fend


3. First Step

5. Run the program

Press F5 to run the program. (F5 is the hot key for the Run Window selection of the Run menu). You will see the Status window located at the bottom of the main window showing the build operation status.

During project build, your program is compiled and linked. Then communications is established with the controller and project files are sent to the controller. If there are no errors during build, the Run window will appear.

Click the Start button on the Run window to run the program.

You should see text similar to the following displayed in the Status window:

08:24:18 Task main started

08:24:18 All tasks stopped

On the Run window, you will see the output of the print statement.

Now let's teach some robot points and modify the program to move the robot.


3. First Step

6. Teach robot points

(1) Ensure that it is safe to operate the robot. Click the <Robot Manager> button on the toolbar. You will see the [Robot Manager] window with the [Control Panel] page displayed.

(2) Click on the <Motor On> button to turn on the robot motors. You will be prompted to confirm the operation.

(3) Answer <Yes> to continue.

(4) Click the [Jog & Teach] tab in the Robot Manager.


3. First Step

(5) Click the <Teach> button in the lower right corner to teach point P0.

You will be prompted for a point label and description.

(6) Jog the robot by clicking the <+Y> jog button. Hold the button down to continue jogging. Let go when the robot is about half way out in the work envelope.

(7) Jog the robot down by clicking the <-Z> button.

(8) Now change the current point to P1 by selecting P1 in the Point dropdown list next to the <Teach> button.

(9) Click the <Teach> button. You will see a confirmation message to teach the point.

(10) Answer <Yes>.

(11) Click the <+X> button to jog the robot in the +X direction.

(12) Change the current point to P2 by selecting P2 in the Point dropdown list.

(13) Click the <Teach> button. You will see a confirmation message to teach the point.

(14) Answer <Yes>.

(15) Click the <Save> Project toolbar button to save the changes.

7. Modify the program to include robot motion commands

(1) Insert three new Go statements into the Program.prg program as shown below:

Function main


Go P1

Go P2

Go P0

Fend

(2) Press F5 to display the [Run] window.

(3) Click on the <Start> button to run the program.

The robot should move to each of the points you taught.


3. First Step

8. Modify the program to change speed of robot motion commands

(1) Insert the Power, Speed, and Accel commands as shown in the program below:

Function main


Power High

Speed 20

Fend

Accel 20, 20

Go P1

Go P2

Go P0

(2) Press F5 to display the [Run] window.

(3) Click on the <Start> button to run the program.

The robot should go to each of the points you taught at 20% of speed, acceleration, and deceleration. The Power High statement enables your program to run the robot at high (normal) power, which in turn allows the robot speed and acceleration to be increased.


3. First Step

9. Backup the project and system configuration

Even though this is only a sample project, we will backup the project and controller configuration. This is easy to do with EPSON RC+ 5.0. It is important that you keep regular backups of your applications on external media such as USB memory.

Follow these steps to backup the project and system configuration:

(1) From the [Project] menu, select [Copy].

(2) Change the [Destination Drive] to a certain drive.

(3) Click <OK>. The project will be copied to the external media.

(4) From the [Tools] menu, select [Controller].

(5) Click on the <Backup Controller> button.

(6) Select the certain drive.

(7) Click <OK>. The system configuration will be backed up on the external media.

Now that you have written your first program.


4. Second Step

4. Second Step

Setup other necessary functions after operating the robot system as indicated in 3.

First Step.

Manuals that indicate necessary setups and procedures are guided in this section.

(For descriptions of each manual, refer to 6. Manual.)

4.1 Connection with External Equipment

Remote Control

EPSON RC+ 5.0 User’s Guide

10. Remote Control

ROBOT CONTROLLER RC180 manual

Setup & Operation 11. I/O Remote Set Up

I/O


9. I/O Setup

ROBOT CONTROLLER RC180

Setup & Operation 10. I/O Connector

Setup & Operation 12.2 Expansion I/O Board (Option)

Fieldbus I/O (Option)


Setup & Operation 12.3 Fieldbus I/O Board

Ethernet


4.5.3 Ethernet Communication


Setup & Operation 7. LAN Ethernet) Port

RS-232C (Option)


11. RS-232C Communication


Setup & Operation 12.4 RS-232C Board

4.2 Ethernet Connection of Development PC and Controller


4.5.3 Ethernet Communication


Setup & Operation 7. LAN (Ethernet) Port


4. Second Step

4.3 Connection and Display Language of Option TP1 and OP1

Controller RC180 TP1

OP1

Cable A

OP1 Connection

Cable B OP1+TP1 Connection

TP1 Connection

TP1

Connection


Setup & Operation 8. TP/OP Port

RC180 Option TP1 Function & Installation 3. Installation

NOTE

)

NOTE

)

Cable A and cable B have different connector shapes.

Changing Display Language

RC180 Option TP1

Operation 3.6 Program Mode

Operation 3.6.11 Change Display Language

Setup procedure is also indicated in For TP1 Purchaser packed with the product.

OP1

Connection


Setup & Operation 8. TP/OP Port

RC180 Option OP1

3. Installation

NOTE

)

Changing Display Language

RC180 Option OP1

4.8 Setup Screen

Setup procedure is also indicated in Operation Panel OP1 Safety and Installation packed with the product.


5. General Maintenance


This chapter describes maintenance inspections and procedures. Performing maintenance inspections and procedures properly is essential for preventing trouble and ensuring safety.

Be sure to perform the maintenance inspections in accordance with the schedule.

5.1 Schedule for Maintenance Inspection

G / C3 / RS series

Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and annual. The inspection points are added every stage.

If the Manipulator is operated for 250 hours or longer per month, the inspection points must be added every 250 hours, 750 hours, 1500 hours, and 3000 hours operation.

Daily Monthly Biannual Annual

1 month(250 h)

2 months(500 h)

3 months(750 h)

4 months(1000 h)

5 months(1250 h)

6 months(1500 h)

7 months(1750 h)

8 months(2000 h)

9 months(2250 h)

10 months(2500 h)

11 months(2750 h)

12 months(3000 h)

13 months(3250 h)

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√ √ h = hour



S5 series

Inspection points are divided into five stages: daily, four months, two years, four years, and eight years. If the Manipulator is operated for predetermined hours of operation, perform maintenance inspections.

Inspection Inspection Interval Hours of operation

Daily

4-month

24-month

48-month

96-month

Inspect every day

4 months 1000 hours

24 months

48 months

6000 hours

12000 hours

96 months 24000 hours



5.2 Inspection Point

Inspection While the Power is OFF (Manipulator is not operating)

M anipulator

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual

End effector mounting bolts

√ √ √ √ √

Check looseness or backlash of bolts/screws.

Tighten them if necessary.

Manipulator mounting bolts

Each arm locking bolts

√

√

√

√

√

√

√

√

√

√

(For the tightening torque, refer to

Tightening Hexagon

Socket Head Cap

Bolts.)

Bolts/screws around shaft

Bolts/screws securing motors, reduction gear units, etc.

√

√

Check looseness of connectors.

If the connectors are loosen, push it securely or tighten.

External connectors on Manipulator (on the connector plates etc.)

Manipulator cable unit

Visually check for external defects.

External appearance of Manipulator

Clean up if necessary. External cables

Check for bends or improper location.

Repair or place it properly if necessary.

Safeguard etc.

Check tension of timing belts.

Tighten it if necessary.

Grease conditions

Inside of Arm #2:

G1 G3 G6 G10 G20

RS

Inside of Base and

Arm #1, 2, 3, 4 : C3

Refer to Greasing.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Replace every 1.5 years: C3

90

S5, RS



C ontroller


Visually check for external defects.

Clean up if necessary.

External appearance of

Controller

√ √ √ √ √

Clean the fan filter -

√ √ √ √

years

Inspection While the Power is ON (Manipulator is operating)

M anipulator (G / C3 / RS series)


Check motion range Each joint √

Move the cables back and forth lightly to check whether the cables are disconnected.

Push each arm in

MOTOR ON status to check whether backlash exists.

Check whether unusual sound or vibration occurs.

Measure the accuracy repeatedly by a gauge.

Turn ON and OFF the

Brake Release switch and check the sound of the electromagnetic brake.

If there is no sound, replace the brake.

External cables

(including cable unit of the

Manipulator)

Each arm

Whole

Whole

Brake

√

√

√

√

√

√

√

√

√

√

√

√

√

√



M anipulator (S5 series)

Inspection Point

Check for tram mark misalignment or damage at the home position. (Visual)

Clean the area of motion range for each joint if dust or spatter is present.

Check for damage and outside cracks. (Visual)

Tighten loose bolts. Replace if necessary.

(Use Spanner, Wrench)

Tighten loose screws. Replace if necessary

(Use Spanner, Wrench)

Inspection Space

Tram mark

Motion range and Manipulator

Base plate mounting bolts

Cover mounting screws

Interval

Daily

Daily

4 month

4 month

4 month

Check for proper belt tension and wear.

(Manual)

Check for conduction between the main connector of base and intermediate connector.

Check for wear of protective spring.

(Visual, Multimeter)

Replace the battery unit when an error warning that low battery status is occurring at startup of the software or every three years.

Joint #1 - Joint #6 timing belts

48 month

Cable unit

Battery unit

48 month

―

C ontroller


Check whether unusual sound or vibration is

Entire Controller occurring.

Make a backup of data. Project and system data

√ √ √ √

Whenever data is changed.

√



Tightening Hexagon Socket Head Cap Bolts

Hexagon socket head cap bolts are used in places where mechanical strength is required. (A hexagon socket head cap bolt will be called a “bolt” in this manual.)

These bolts are fastened with the tightening torques shown in the following table.

When it is necessary to refasten these bolts in some procedures in this manual

(except special cases as noted), use a torque wrench so that the bolts are fastened with the appropriate tightening torques as shown below.

M3

M4

M5

M6

M8

M10

M12

245 N

⋅cm (25 kgf⋅cm)

490 N

⋅cm (50 kgf⋅cm)

980 N


1,760 N


3,720 N


7,350 N


12,740 N

⋅cm (1,300 kgf⋅cm)

Refer below for the set screw.

Set Screw Tightening Torque

M3

M4

M5

147 N

⋅cm (15 kgf⋅cm)

245 N

⋅cm (25 kgf⋅cm)

392 N

⋅cm (40 kgf⋅cm)

The bolts aligned on a circumference should be fastened in a crisscross pattern as shown in the figure below.

Bolt hole

3

5

7

1

8

6

4

Do not fasten all bolts securely at one time.

Divide the number of times that the bolts are fastened into two or three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench so that the bolts are fastened with tightening torques shown in the table above.

2



Greasing

The ball screw spline and reduction gear units need greasing regularly. Only use the grease specified.

Parts and Interval when the greasing is necessary have been described. Refer to the manipulator manual for details of the greasing procedure.

■

Keep enough grease in the Manipulator. Operating the

Manipulator with insufficient grease will damage sliding parts and/or result in insufficient function of the Manipulator. Once the parts are damaged, a lot of time and money will be required for the repairs.

■

If grease gets into your eyes, mouth, or on your skin, follow the instructions below.

CAUTION

If grease gets into your eyes :

Flush them thoroughly with clean water, and then see a doctor immediately.

If grease gets into your mouth :

If swallowed, do not induce vomiting. See a doctor immediately.

If grease just gets into your mouth, wash out your mouth with water thoroughly.

If grease gets on your skin

Wash the area thoroughly with soap and water.



G / RS series

Greasing part Greasing Interval Remarks

Joint #1, #2 Reduction gear units At the replacement of motor*

Joint #3 Ball screw spline shaft Every 6 months

Joint #4 Backlash less gear At greasing of Joint #3 Only G10

* Under normal conditions, the reduction gear units (G, RS series) shall be greased only when the motor is replaced. However, in case of severe working conditions (such as high duty, high speeds, large payloads, etc.), the reduction gear units must be greased every 10,000 hours.

C3 series

Greasing part

Joint #1, #2, #4 Reduction gear units

Joint #6 Bevel gear

Greasing Interval

When the reduction gear units are replaced*

Annually (every 8000 hours)

* Under normal conditions, the reduction gear units (C3 series) shall be greased only when the reduction gear units is replaced. However, in case of severe working conditions (such as high duty, high speeds, large payloads, etc.), the reduction gear units must be greased every 10,000 hours.

S5 series

Joint #1, #2, #3, #4, #5, #6

Greasing part

Reduction gear units

Greasing Interval

Every 6000 hours


6. Third Step

6. Manual

Descriptions of manual contents are indicated in this section.

Manuals are supplied by Acrobat PDF to use the Robot system.

Select EPSON RC+ 5.0-[Help]-[PDF Manual] to view the PDF manuals from a

PC. (Click <Start>-[Program]-[EPSON RC+ 5.0] from the Windows desktop.)

Software


This manual indicates descriptions of the Robot system and program development software.

- Safety

- Robot System Operation and Configuration

- Operation of Program Development Software EPSON RC+ GUI

- SPEL+ Language and Application

- Configuration of Robot, I/O, Communication etc.

EPSON RC+ 5.0 SPEL+ Language Reference

This manual indicates descriptions of the SPEL+ language for robot program.

- Details of the commands

- Error Messages

- Precaution of EPSON RC+ 4.0 Compatibility etc.

Software Option

Following manuals contain information on the software options and commands.

- VB Guide 5.0

- Vision Guide 5.0

- Vision Guide 5.0 Properties and Results Reference

- GUI Builder 5.0

- Remote Control Reference


6. Manual

Controller


This manual indicates descriptions of the Robot Controller RC180 and Robot system.

- Safety

- Specification, Installation, Operation, and Setup

- Backup and Restore

- Maintenance

- Verifying Robot System Operation

- Error Codes etc.

Option

RC180 Option Teach Pendant TP1

RC90/RC180 Option Teach Pendant TP2

This manual indicates descriptions of option Teach Pendant.

- Safety

- Specification, Installation, Operation, and Setup

- Teaching Procedure

- TEACH/AUTO mode

- Troubleshooting etc.

RC180 Option Operator Pedant OP1

This manual indicates descriptions of option Operator Panel.

- Safety

- Specification, Installation, and Operation

- Programming for Operator Panel

- Maintenance and Inspection etc.


6. Third Step

Manipulator

The manuals indicate descriptions of the manipulator(s) you purchased. There are manuals for each manipulator.

EPSON SCARA ROBOT : G1, G3, G6, G10/G20, RS

EPSON ProSix : C3, S5

- Safety

- Specification, Installation, Setting

- Maintenance

- Calibration etc.




These products conform to the following directives and norms.

For more details of Controllers and Manipulators, please refer to each manual.

Product Name Model

Controller RC180 series

RS series

C3 series

S5 series



Name Definition

Directive 2006/42/EC

Directive 2004/108/EC

ENISO12100-1(2003)

ENISO12100-2(2003)

ENISO10218-1(2008)

EN60204-1(2006)

ENISO13849-1(2008)

*

ENISO13850(2008)

Directive 2006/42/EC of the European Parliament and of the

Council of 17 May 2006 on machinery, and amending

Directive 95/16/EC

Directive 2004/108/EC relating to electromagnetic compatibility and repealing Directive 89/336/EEC

Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology

Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles

Robots for industrial environments -Safety requirements-Part

1: Robot

Safety of machinery - Electrical equipment of machines - Part

1: General requirements

Safety of machinery - Safety - related parts of control systems

- Part 1: General principles for design

Safety of machinery - Emergency stop - principles for design equipment - Electromagnetic disturbance characteristics -

Limits and methods of measurement standards - Immunity for industrial environments

*Emergency stop circuit category3, PL d

Safety Door circuit category3, PL d


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