ROBOT CONTROLLER
RC420
Rev.9
EM073C1492F
ROBOT CONTROLLER
RC420
Rev.9
ROBOT CONTROLLER
RC420
Rev.9
Copyright  2002-2007 SEIKO EPSON CORPORATION. All rights reserved.
RC420 Rev.9
i
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the RC420 robot
controller.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
WARRANTY
The robot system and its optional parts are shipped to our customers only after being
subjected to the strictest quality controls, tests, and inspections to certify its compliance
with our high performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1. Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2. Malfunctions caused by customers’ unauthorized disassembly.
3. Damage due to improper adjustments or unauthorized repair attempts.
4. Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1. If the robot system associated equipment is used outside of the usage conditions and
product specifications described in the manuals, this warranty is void.
2. If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3. We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.
ii
RC420 Rev.9
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® 2000 Operating system
Microsoft® Windows® XP Operating system
Throughout this manual, Windows 2000, and Windows XP refer to above respective operating
systems.
In some cases, Windows refers generically to Windows 2000, and Windows XP.
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
RC420 Rev.9
iii
MANUFACTURER & SUPPLIER
Japan & Others
SEIKO EPSON CORPORATION
Suwa Minami Plant
Factory Automation Systems Dept.
1010 Fujimi, Fujimi-machi,
Suwa-gun, Nagano, 399-0295
JAPAN
TEL
: +81-(0)266-61-1802
FAX
: +81-(0)266-61-1846
SUPPLIERS
North & South America
EPSON AMERICA, INC.
Factory Automation/Robotics
18300 Central Avenue
Carson, CA
90746
USA
TEL
: +1-562-290-5900
FAX
: +1-562-290-5999
E-MAIL : info@robots.epson.com
Europe
EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto-Hahn-Str.4
D-40670 Meerbusch
Germany
TEL
: +49-(0)-2159-538-1391
FAX
: +49-(0)-2159-538-3170
E-MAIL : robot.infos@epson.de
iv
RC420 Rev.9
TABLE OF CONTENTS
Setup & Operation
1. Safety .....................................................................3
1.1
1.2
1.3
Conventions ............................................................................. 3
Safety Precautions................................................................... 4
Safety Features........................................................................ 7
2. Part Names and Functions ...................................11
2.1
2.2
2.3
System Configuration ............................................................ 11
Standard Specifications......................................................... 11
Controller................................................................................ 13
2.3.1 Front Panel ................................................................ 13
2.3.2 Rear Panel ................................................................. 17
2.3.3 Dimensions ................................................................ 19
3. Installation ...........................................................21
3.1
3.2
3.3
3.4
Environmental Requirements .................................................21
Power Supply..........................................................................22
3.2.1 Specifications..............................................................22
3.2.2 Power Plug..................................................................23
Cable Connection ...................................................................23
3.3.1 Typical Cable Connection ..........................................24
3.3.2 Connecting the Manipulator to the Controller ............27
Noise Countermeasures.........................................................28
4. OPTIONAL DEVICE Connector............................29
4.1
4.2
4.3
4.4
OPTIONAL DEVICE Connector .............................................29
ATTEND (TEACH) Control Device.........................................30
OPTIONAL DEVICE Dummy Plug .........................................31
Pin Assignments .....................................................................32
5. EMERGENCY Connector .....................................33
5.1
5.2
5.3
5.4
RC420 Rev.9
Safety Door Switch and Latch Release Switch ......................33
5.1.1 Safety Door Switch .....................................................33
5.1.2 Latch Release Switch .................................................34
5.1.3 Checking Latch Release Switch Operation................34
Emergency Stop Switch..........................................................35
5.2.1 Emergency Stop Switch .............................................35
5.2.2 Checking Emergency Stop Switch Operation ............35
E. STOP Box...........................................................................36
5.3.1 E. STOP Box ..............................................................36
5.3.2 Checking E. STOP Box Operation .............................36
Pin Assignments .....................................................................37
v
5.5
Circuit Diagrams .....................................................................38
5.5.1 Example 1: External emergency stop switch
typical application....................................38
5.5.2 Example 2: External safety relay typical
application ...............................................39
6. STANDARD I/O Connector ..................................41
6.1
6.2
6.3
Input Circuit.............................................................................42
Output Circuit..........................................................................44
Pin Assignments.....................................................................46
6.3.1 STANDARD I/O connector - Pin Assignments ..........46
6.3.2 STANDARD I/O connector optional cable
for USA Specification - Pin Assignments ..................47
7. Expansion I/O Board - Optional ............................49
7.1
7.2
7.3
7.4
7.5
Expansion I/O Board ..............................................................49
Protected Expansion I/O Board..............................................50
7.2.1 Jumper Settings..........................................................50
7.2.2 Input Circuit ................................................................51
7.2.3 Output Circuit..............................................................53
Expansion I/O Board ..............................................................55
7.3.1 Jumper Settings..........................................................55
7.3.2 Input Circuit ................................................................55
7.3.3 Output Circuit..............................................................56
Expansion I/O Board: Pin Assignments .................................58
7.4.1 Pin Assignments (NPN type)......................................58
7.4.2 Pin Assignments (PNP type)......................................60
Expansion I/O Connector .......................................................62
7.5.1 Pin Layout of Expansion I/O Connector.....................62
7.5.2 Expansion I/O Connector Cable ................................62
7.5.3 Cable - Pin Assignments............................................63
8. I/O Remote Settings .............................................67
8.1
8.2
I/O Signal Description.............................................................68
8.1.1 Remote Input Signals .................................................68
8.1.2 Remote Output Signals ..............................................71
Timing Specifications .............................................................72
8.2.1 Design Notes for Remote Input Signals.....................72
8.2.2 Timing Diagram for Operation Execution
Sequence ...................................................................72
8.2.3 Timing Diagram for Program Execution
Sequence ...................................................................73
8.2.4 Timing Diagram for Safety Door Input Sequence......74
8.2.5 Timing Diagram for Emergency Stop Sequence .......74
8.2.6 Timing Diagram for RECOVER Sequence ................75
9. RS-232C Settings.................................................77
9.1
9.2
vi
RS-232C cable .......................................................................77
9.1.1 Pin Assignments.........................................................77
9.1.2 Connection Example ..................................................78
Preparation for Communication .............................................78
RC420 Rev.9
10. UPS (Uninterruptible Power Supply)...................79
10.1
10.2
10.3
10.4
UPS.........................................................................................79
Configuration of power Supplies ............................................79
Normal Shutdown of Robot System .......................................79
Automatic Shutdown by UPS service in Robot System .........79
10.4.1 While Windows is being booted up ............................80
10.4.2 After Windows is booted up........................................80
10.5 UPS Battery ............................................................................81
10.5.1 Safety Precautions for Battery....................................81
10.5.2 Charging Battery.........................................................81
10.5.3 Life Cycle of Battery....................................................81
10.5.4 Replacement of Battery ..............................................83
10.6 Setting up Windows ................................................................84
10.6.1 Installing RC420 UPS Drivers ....................................84
10.6.2 Basic Configuration of Windows ................................96
10.6.3 Setting up the Automatic Shutdown at the Time
of a Power Failure ......................................................98
10.6.4 UPS Setup Consideration ........................................102
Maintenance
1. Safety Precautions on Maintenance ...................107
1.1
1.2
1.3
Safety Precautions................................................................107
Lockout..................................................................................108
Tagout ...................................................................................108
2. Regular Maintenance Inspection ........................109
2.1
2.2
2.3
2.4
2.5
Schedule for Maintenance Inspection ..................................109
Inspection Point ....................................................................109
2.2.1 Inspection While the Controller is Turned OFF ......109
2.2.2 Inspection While the Controller is Turned ON ........109
Cleaning the Fan Filter .........................................................109
Replacing a Lithium Battery on the CPU Board...................109
Backup of Data .....................................................................112
3. Controller Internal Layout ...................................117
4. Pin Assignments for the System Connectors......119
4.1
4.2
M/C Power Cable..................................................................119
M/C Signal Cable..................................................................120
5. Switching Power Supply Module.........................121
5.1
5.2
5.3
RC420 Rev.9
Layout and Functions ...........................................................121
Inspection..............................................................................121
Replacement.........................................................................122
5.3.1 Replacing Switching Power Supply Module 1:.........122
5.3.2 Replacing Switching Power Supply Module 2:.........123
vii
6. Motor Driver Module ........................................... 125
6.1
6.2
Layout and Functions ...........................................................125
Replacing a Motor Driver Module.........................................126
7. DPB (Drive Power Board)................................... 129
7.1
7.2
Layout and Functions ...........................................................129
Adjusting Encoder Voltage ...................................................130
8. DMB (Drive Main Board) .................................... 131
8.1
8.2
Layout and Functions ...........................................................131
Replacing DMB.....................................................................132
9. Regeneration Module ......................................... 135
9.1
9.2
Layout and Functions ...........................................................135
Replacing a Regeneration Module.......................................135
10. Replacing Maintenance Parts........................... 137
10.1
10.2
10.3
10.4
Optional Board......................................................................137
CPU Board............................................................................137
HDD ......................................................................................139
Fan Filter...............................................................................140
11. Verifying Robot System Operation ................... 141
12. Recovering the HDD......................................... 143
12.1 Recovering Windows............................................................144
12.1.1 Recovery Procedure.................................................144
12.1.2 Windows Recovery
(With “EasyRestore” License Label) ......................144
12.1.3 Windows Recovery
(Without “EasyRestore” License Label) .................147
12.2 Configuring Windows ...........................................................151
12.3 Setting Up EPSON RC+ (Using the Network) .....................151
12.3.1 Necessary Items.......................................................151
12.3.2 Sharing Configuration ..............................................151
12.3.3 Network Configuration..............................................153
12.3.4 Starting EPSON RC+ Setup Program .....................157
12.3.5 Installing EPSON RC+ .............................................157
12.3.6 Reserving Address Resources of EPSON RC+
Options .....................................................................157
12.4 Setting Up EPSON RC+
(Using the CD-R/RW Drive with USB) .................................159
12.4.1 Necessary Items.......................................................159
12.4.2 Starting EPSON RC+ Setup Program .....................159
12.4.3 Installing EPSON RC+ .............................................159
12.4.4 Reserving Address Resources of EPSON RC+
Options .....................................................................159
13. Maintenance Parts List ..................................... 161
viii
RC420 Rev.9
Setup & Operation
This manual contains information for setup and operation
of the RC420 Robot Controller.
Setup & Operation
Setup & Operation
1. Safety
1. Safety
Installation and transportation of robots and robotic equipment shall be performed by
qualified personnel and should conform to all national and local codes.
Please read this manual and other related manuals before installing the robot system or
before connecting cables. Keep this manual in a handy location for easy access at all
times.
Read the Safety chapter in EPSON RC+ User’s Guide and confirm “Safety-related
requirements”.
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.
RC420 Rev.9
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.
3
Setup & Operation
1. Safety
1.2 Safety Precautions
Only trained personnel should design and install the robot system.
Trained personnel are defined as those who have taken robot system training and
maintenance training classes held by the manufacturer, dealer, or local representative
company, or those who understand the manuals thoroughly and have the same knowledge
and skill level as those who have completed the training courses.
The following items are safety precautions for qualified design or installation
personnel:
„ Personnel who design and/or construct the robot system with this product must
read the Safety chapter in User’s Guide to understand the safety requirements
before designing and/or constructing the robot system. Designing and/or
constructing the robot system without understanding the safety requirements is
extremely hazardous, may result in serious bodily injury and/or severe
equipment damage to the robot system, and may cause serious safety
problems.
„ The Manipulator and the Controller must be used within the environmental
conditions described in their respective manuals. This product has been
designed and manufactured strictly for use in a 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.
WARNING
„ 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.
„ The interlock of the Safety Door must be functioning when the robot system is
operated. Do not operate the system under the condition that the switch
cannot be turned ON/OFF. (I.E. the condition where the switch is disabled)
(Example: Tape is put around the switch to hold it closed.) Operating the robot
system when the switch is not functioning properly is extremely hazardous and
may cause serious safety problems as the Safety Door input cannot fulfill its
intended function.
„ Connect input signal wires for Emergency Stop and Safety Door to the
EMERGENCY connector so that the Emergency Stop switch in the operation
unit or the ATTEND (TEACH) control device connected to the OPTIONAL
DEVICE connector always functions. (Refer to the typical application diagram
in the Setup & Operation 5.5 Circuit Diagrams.)
4
RC420 Rev.9
Setup & Operation
1. Safety
The following items are safety precautions for qualified design or installation
personnel: (cont.)
„ Do not open the cover(s) of the Controller except while maintaining it.
Opening the cover(s) of the Controller is extremely hazardous and may result in
electric shock even when its main power is OFF because of the high voltage
charge inside the Controller.
„ Make sure that the power to the Controller is turned OFF and locked out before
connecting or disconnecting any cables. Connecting or disconnecting any
cables with the power ON is extremely hazardous and may result in electric
shock and/or malfunction of the Controller.
WARNING
„ If it is necessary to change the plug to fit the outlet in your factory, make sure
that it is done by qualified personnel. When changing the plug, 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. Never connect the Controller
directly to the factory power supply. (Field wiring)
„ 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.
„ Only install optional hardware specifically designed for the robot system. If any
other hardware is installed to the robot system, the robot system may function
improperly and also cause safety problems. (For EPSON RC+ Users, only the
hardware that has been approved by EPSON can be installed on the robot
system.)
CAUTION
„ Do not install any other software in the robot system except for the software that
was originally installed at ship time. If any other software is installed, the robot
system may function improperly and also cause safety problems. (For
EPSON RC+ Users, only the software that has been approved by EPSON can
be installed on the robot system.)
„ The serial number of the Manipulator that should be connected is indicated on
the Connection Check Label on the Controller. Connect the Controller and the
Manipulator correctly. Improper connection between the Controller and the
Manipulator may cause improper function of the robot system and also safety
problems.
RC420 Rev.9
5
Setup & Operation
1. Safety
The following items are safety precautions for qualified design or installation
personnel: (cont.)
CAUTION
WARNING
WARNING
6
„ When using remote I/O, always make sure of the following. Using the robot
system under unsatisfactory conditions may cause malfunction of the system
and/or safety problems.
- Assign remote functions to inputs/outputs correctly and wire correctly when
setting up remote I/O signals.
- Make sure that the functions correspond to the correct input/output signals
before turning ON the system.
- When verifying the robot system operation, prepare for failures with initial
settings or wiring. If the Manipulator functions unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to
stop the Manipulator.
The following items are safety precautions for qualified operator personnel:
„ The interlock of the Safety Door must be functioning when the robot system is
operated. Do not operate the system under the condition that the switch
cannot be turned ON/OFF. (I.E. the condition where the switch is disabled)
(Example: Tape is put around the switch to hold it closed.) Operating the robot
system when the switch is not functioning properly is extremely hazardous and
may cause serious safety problems as the Safety Door input cannot fulfill its
intended function.
„ Do not open the cover(s) of the Controller except while maintaining it. Opening
the cover(s) of the Controller is extremely hazardous and may result in electric
shock even when its main power is OFF because of the high voltage charge
inside the Controller.
RC420 Rev.9
Setup & Operation
1. Safety
1.3 Safety Features
The RC420 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.
Refer to the Setup & Operation 5.1 Safety Door Switch and Latch Release Switch and
Setup & Operation 5.2 Emergency Stop Switch for details.
ATTEND (TEACH) Control Device
To operate the Manipulator at a short distance without any operation unit (option) such as
an Operation Pendant, you should use the ATTEND (TEACH) control device and
connect it to the OPTIONAL DEVICE connector on the front of the Controller.
The
ATTEND (TEACH) control device should consist of the Emergency Stop switch,
3-position enable switch (dead-man switch), and ATTEND (TEACH) control device
enable/disable switch.
Emergency Stop Switch
The ATTEND (TEACH) control device must be equipped with the Emergency Stop
switch. The EMERGENCY connector on the Controller has expansion Emergency Stop
input terminals used for connecting the Emergency Stop switches.
These Emergency Stop inputs are internally connected to the relays for the dynamic brake.
Therefore, 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 ATTEND (TEACH) control
device enable/disable switch to “enable” or change the mode selector switch on the
operation unit to the mode for teaching and then engage the 3-position enable switch. In
this case, the Manipulator is operated in low power status.
Lockout
Turn OFF the power supply and use a lockout procedure to prevent anyone from turning
ON the power supply by mistake while someone else is in the safeguarded area for
maintenance or repairs.
The procedure for lockout is described in the Maintenance 1. Safety Precautions on
Maintenance.
RC420 Rev.9
7
Setup & Operation
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. When the
motor armatures are shorted, the power to the Motor Driver modules is cut off and the
reverse EMF caused by the short stops the motors.
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.
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.
8
RC420 Rev.9
Setup & Operation
1. Safety
CPU Irregularity Detection
Irregularity in the motor controlling CPU is monitored by a watch-dog timer. Also, the
system CPU and the motor controlling CPU inside the Controller are 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.
Over-Voltage Detection
The dynamic brake circuit is activated when the voltage of the Controller is above the
normal limit. (When a regeneration module is mounted.)
RC420 Rev.9
9
Setup & Operation
10
1. Safety
RC420 Rev.9
Setup & Operation
2.1 System Configuration (Part Names and Functions)
2. Part Names and Functions
2.1 System Configuration
The RC420 can control up to four AC Servo Motors simultaneously.
Example : One Controller and One Manipulator
2.2 Standard Specifications
Item
Model
Specification
RC420
PC compatible computer optimized for RC420:
CPU
CPU
: Celeron 850 MHz or faster
HDD
: 20 GB or more
RAM : 256 MB or more
Controllable Axes
Robot Manipulator
Control
Positioning Control
RC420 Rev.9
Up to four (4) connectable AC Servo Motors
Programming
EPSON RC+
Language and Robot
(a multi-tasking robot language)
Control Software
Simultaneous control over all the four (4) joints
Joint Control
Software AC servo control
PTP motion : Programmable in the range of
1% to 100%
Speed Control
CP motion : Programmable (Actual value to
be manually entered.)
PTP motion : Programmable in the range of
Acceleration/
1% to 100%; Automatic
Deceleration
CP motion : Programmable (Actual value to
Control
be manually entered.)
PTP (Pose-To-Pose control)
CP (Continuous Path control)
11
Setup & Operation
2.2 Standard Specifications (Part Names and Functions)
Item
Memory Capacity
Teaching Method
External Input/ Output
Signals
Communication Interface
Expansion Slots
Specification
Programmable Area : 4 MB
Point Data Area
: Max. 1000 points programmable
(per Manipulator)
Remote
Direct
MDI (Manual Data Input)
Input : 16
Standard I/O
Remote
Output : 16
functions
Expansion
Input : 32 (per board)
allowed
I/O
Output : 32 (per board)
2 channels
1 channel
2 ports
In case of ISA: 4 slots
4 slots
In case of PCI: 3 slots
- Emergency stop switch
RS-232C
Ethernet
USB
- Safety door input
- Low power mode
- Dynamic brake
- Encoder cable disconnection error detection
- Motor overload detection
- Irregular motor torque (out-of-control Manipulator)
detection
- Motor speed error detection
Safety Features
- Positioning overflow - servo error - detection
- Speed overflow - servo error - detection
- CPU irregularity detection
- Memory check-sum error detection
- Overheat detection at the Motor Driver Module
- Safety key lock on the ATTEND (TEACH) control device for
mode switch
- Lockout
- Over-Voltage Detection
(When a regeneration module is mounted.)
12
Power Source
AC 200V to AC 240V
Single phase 50/60 Hz
Maximum Power
Consumption
2000W (Depending on the Manipulator model)
Insulation Resistance
100 MΩ or more
Rated Ambient Temperature
5 to 40 deg.C
Rated Relative Humidity
20% to 80% (with no condensation)
RC420 Rev.9
Setup & Operation
Item
2.3 Controller (Part Names and Functions)
Specification
Weight
24 kg *
Size
For the Controller,
refer to the Setup & Operation 2.3.3 Dimensions.
Keyboard dimension
W347 × D116 × H18 (mm)
* Weight of the unit is indicated on the Controller Unit and the Drive Unit itself.
Make sure to check the weight before units transfer or relocation and prevent throwing out your
back at holding the unit.
Also, make sure to keep your hands, fingers, and feet safe from being caught or serious injury.
2.3 Controller
■ Only install optional hardware specifically designed for the robot system.
If any other hardware is installed to the robot system, the robot system may not
only function improperly but also cause safety problems.
(For EPSON RC+ Users, only the hardware that has been approved by EPSON
can be installed on the robot system.)
CAUTION
■ Do not install any other software in the robot system except for the software that
was originally installed at ship time. If any other software is installed, the robot
system may not only function improperly but also cause safety problems.
(For EPSON RC+ Users, only the software that has been approved by EPSON
can be installed on the robot system.)
2.3.1 Front Panel
The Controller has a door on the front panel, which can be opened/closed by a key
supplied with the unit.
Front Panel, Closed
Key Cylinder
RC420 Rev.9
13
Setup & Operation
2.3 Controller (Part Names and Functions)
Front Panel, Open
(1)
(2)
(4)
(3)
(5)
(6)
(8)
(7)
(12)
(9)
(11)
(10)
(1) Signature label (This label is attached on the left side of the Controller when you
face the front panel.)
The serial number of the Controller is recorded on the signature label.
(2) STATUS
Seven-segment LED as one-digit displays the error number, Manipulator number and
joint number. The numbers will be displayed with the LEDs blinking. Record all
the numbers and check the error that has occurred.
Timing of LED Blinking
Approx. 10 sec.
0.4 sec.
0.4 sec.
Approx.
1 sec.
Approx. 3 sec.
Manipulator Joint
number in number in
2 digits
2 digits
Error number in
4 digits
The above mentioned cycle (which lasts approximately 10 seconds) repeats and is
displayed until the error is canceled or the power is OFF.
Error Number
: Four-digit error numbers are displayed.
For details, refer to the error number table in the chapter
SPEL+ Error Messages in SPEL+ Language Reference.
Manipulator Number : Two-digit Manipulator numbers are displayed, starting from
01.
Joint Number
: Two-digit numbers are display, showing which joint of the
Manipulator has an error. The number starts from 01.
When an error occurs that has no relation to a Manipulator or joint, the error
number will appear, but the Manipulator number and joint number will both be
displayed as 00.
14
RC420 Rev.9
Setup & Operation
2.3 Controller (Part Names and Functions)
(3) LED
The LEDs indicate the following status when they are ON:
LED
ERROR
Color
Red
Description
There is an error.
Lights when the motor power is ON.
(Motor Power: The DC power supply that inputs
to the Motor Driver module to drive the motor.
This DC power is generated by regulating AC
200V or the local equivalent power.)
MOTOR POWER
D-E1
Indicates that an unresettable error relating to
motor control with/in any of the Manipulator
axes occurs.
D-E2
Indicates that a resettable error relating to motor
control with/in any of the Manipulator axes
occurs.
D-ERROR
Lights when the CPU of the motor control
detects an error.
RUN
E-STOP
Green
Red
Lights while the CPU is operating normally in
the Controller.
Lights when in the Emergency Stop condition.
POWER
Lights when the Controller is turned ON.
SAFE
SHUTDOWN
Lights when it is safe to turn OFF the Controller.
(4) Connection Check label
Example:
The details of the Manipulator to be connected are recorded on
MANIPULATOR
the label as shown below.
The label indicates the
Manipulator model and Manipulator serial number.
ES551S 00002
(5) Windows COA label
The Product Key that is required when you install Windows is recorded on this label.
(6) HDD (for the removable HD unit model)
The disk drive is mounted in a removable case. Refer to the Maintenance 10.3
HDD for the method of replacing HDD.
(7) MT label
The label indicates the specification number for the customized Manipulator and is
attached only to the customized Manipulator. If your Manipulator indicates this
label, it may require a specific maintenance procedure. In this case, make sure to
contact your dealer before performing any maintenance procedures.
(8) Power switch
Turns ON or OFF the Controller.
(9) USB connector
Connects the USB-enabled hardware (CD-ROM drive, etc.). There is another port
on the rear of the Controller.
RC420 Rev.9
15
Setup & Operation
2.3 Controller (Part Names and Functions)
(10) OPTIONAL DEVICE connector
Connects the optional operation unit or ATTEND (TEACH) control device or
OPTIONAL DEVICE Dummy Plug.
For details, refer to the Setup & Operation 4. OPTIONAL DEVICE Connector.
■ Do not connect the EPSON RC+ software key to the OPTIONAL DEVICE
CAUTION
connector. Connecting the EPSON RC+ software key to the OPTIONAL
DEVICE connector while the Controller is ON may cause damage to the
EPSON RC+ software key.
Connect the EPSON RC+ software key to the IEEE-1284 (parallel)
connector on the rear of the Controller.
(11) Cooling Fan Filter
A protective filter is installed in front of the cooling fan to filter out dust.
NOTE
)
Check condition of the filter regularly and clean it as necessary. A dirty filter may
result in the malfunction of the robot system as the temperature rises in the
Controller.
The filter needs regular check-up and cleaning. For details, refer to the
Maintenance 10.4 Fan Filter.
(12) Lockout metal hasp
To lock the power switch in OFF position, set the power switch to OFF position and
put the metal hasp down on the right and then close the door. Cut off the power in
this way for maintenance or repair of the robot system.
16
RC420 Rev.9
Setup & Operation
2.3 Controller (Part Names and Functions)
2.3.2 Rear Panel
The rear panel components are as follows:
The type of CPU board (connectors for mouse and keyboard) is different depending on
the shipping date. The Controller in which the parts have been replaced for maintenance
can be different from the figures below.
NOTE
)
(3)
(2)
(1)
(12)
(4)
(13)
(14)
(5)
(6)
(7)
(8)
(9)
(10)
(11)-2
(15)
(16)
(11)-1
(1) M/C POWER connector
A connector for the Manipulator power source. Connect the dedicated power cable
attached to the Manipulator.
(2) USB connector
Connects the USB-enabled hardware (CD-ROM drive, etc.). There is another port
on the front of the Controller.
(3) IEEE-1284 (parallel) connector
This connector is for the EPSON RC+ software key.
(4) EMERGENCY connector
This connector is used for input/output from/to Emergency Stop and Safety Door
switches. Refer to the Setup & Operation 5. EMERGENCY Connector for details.
(5) AC IN
The cable for AC 200V power input.
RC420 Rev.9
17
Setup & Operation
2.3 Controller (Part Names and Functions)
(6)
Protective Earth Terminal
External protective earth terminal
(7) M/C SIGNAL connector
This connector is used for signals such as the Manipulator’s motor encoders, the
origin sensor signals, etc. Connect the Manipulator’s dedicated signal cable.
(8) STANDARD I/O connector
This connector is used for input/output devices. There are 16 inputs and 16 outputs.
Refer to the Setup & Operation 6. STANDARD I/O Connector for details.
(9) Serial connector (RS-232C)
This connector facilitates data communication and centralized control by connecting
peripheral equipment and the host computer to the Controller.
For details, refer to the Setup & Operation 9. RS-232C Settings.
(10) System Expansion (Optional Board) Slots
Up to 4 slots are available for optional boards such as the Expansion I/O Board or
Pulse Generating Board. Do not mount boards other than the optional boards for
the RC420.
(11) CPU Board
For details, refer to the Setup & Operation 2.2 Standard Specifications.
The CPU board has different model numbers and appearances depending on the
dates of the shipping and the board changeover.
CPU Board
Connector for Mouse and Keyboard
Separate connectors
(11)-1
PC-686BX(PC)-EPC850
Integrated connector
(11)-2
SPI-6941-EPC
(12) Ethernet connector
This Ethernet connector is used for network communication via 100BASE-TX /
10BASE-T.
(13) VGA connector
Receptacle for VGA monitor cable.
(14) Mouse / Keyboard connector (CPU board (11)-2)
Receptacle for mouse and keyboard cable. Connect the cable to a mouse and a
keyboard following the symbols on the cable.
Do not lose a PS/2 exchange cable included in the accessories.
■ Connect the mouse and the keyboard properly when the power in OFF. If
CAUTION
the mouse or keyboard is connected when the power in ON or connected
incorrectly, the robot system cannot function properly.
(15) Mouse connector (CPU board (11)-1)
Receptacle for mouse cable.
(16) Keyboard connector (CPU board (11)-1)
Receptacle for keyboard cable. To connect a type AT connector keyboard, use the
dedicated adapter (AT keyboard adapter) included in the accessories.
18
RC420 Rev.9
Setup & Operation
2.3 Controller (Part Names and Functions)
12.0
189.0
101.6
470.0
2.3.3 Dimensions
383.0
35.0
415.0
483.0
9.9
433.0
[Unit: mm]
NOTE
)
RC420 Rev.9
Do not remove any rubber feet of the Controller.
19
Setup & Operation
20
2.3 Controller (Part Names and Functions)
RC420 Rev.9
Setup & Operation
3.1 Environmental Requirements (Installation)
3. Installation
3.1 Environmental Requirements
WARNING
■ The Manipulator and the Controller must be used within the environmental
conditions described in their manuals. This product has been designed and
manufactured strictly for use in a normal indoor environment. Using the
product in the environment that exceeds the conditions may not only shorten the
life cycle of the product but also cause serious safety problems.
In order to optimize the robot system’s performance for safety, the Controller must be
placed in an environment that satisfies the following conditions:
NOTE
)
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.
Item
Ambient temperature
Ambient relative
humidity
First transient burst
noise
Electrostatic noise
Environment
Base table
Space
NOTE
)
RC420 Rev.9
Condition
5 to 40 deg.C (with minimal variation)
20% to 80%
(with no condensation)
2 kV or less
(without mouse and keyboard)
6 kV or less (without mouse and keyboard)
- Install indoors only.
- Place in a well-ventilated area.
- Keep away from direct sunlight.
- Keep away from dust, oily smoke, oily mist, salinity,
metal powder or other contaminants.
- Keep away from flammable or corrosive liquid and gas.
- Keep away from water.
- Keep away from shocks or vibrations.
- Keep away from sources of electronic noise.
If the Controller must be used in an environment that does
not fulfill the conditions mentioned above, take adequate
countermeasures. For example, the Controller may be
enclosed in a cabinet with adequate ventilation and cooling.
Use a base table that is at least 100 mm off the floor.
Placing the Controller directly on the floor could allow dust
penetration leading to malfunction.
- Allow at least 50 mm on each side.
- There must be room in front of the Controller so that the
entire Controller can be pulled outward.
- There must also be room behind the Controller so that
one can attach and remove cables and boards.
- Do not block airflow to or from the fan.
The RC420 Controller must be normally placed horizontally.
Do not remove any rubber feet of the RC420 Controller.
21
Setup & Operation
3.2 Power Supply (Installation)
3.2 Power Supply
3.2.1 Specifications
Ensure that the available power meets the following specifications.
Item
Voltage
Phase
Frequency
Momentary Power
Interrupt
Power Consumption
Specification
AC 200V to AC 240V
Single phase
50/60 Hz
10msec. or less
Max. 2000 W
The Controller itself consumes a maximum of
approximately 200 W, but actual consumption depends on
the rated capacity of the motor and Controller.
Please refer to Manipulator power consumption in the
Manipulator manual and use the following equation to
determine total consumption:
Rated consumption
= 200 W
+ total Manipulator consumption (rated) × 1.2
Peak Current
Leakage Current
Ground Resistance
When power is turned ON: approximately 50A (2msec.)
When motor is ON: approximately 150A (5msec.)
Max. 3.5 mA
100 Ω or less
Install an earth leakage circuit breaker or a circuit breaker in the AC power cable line at
20A or less rated electric current. Both should be a two-pole disconnect type. If you
install an earth leakage circuit breaker, make sure to use an inverter type that does not
operate by induction of a 10kHz or more leakage current. If you install a circuit breaker,
please select one that will handle the above mentioned “peak current”.
The power receptacle shall be installed near the equipment and shall be easily accessible.
22
RC420 Rev.9
Setup & Operation
3.2 Power Supply (Installation)
3.2.2 Power Plug
The AC power cable of the Controller is equipped with a power plug. Make sure that
the plug is compatible with the power receptacle in your area. If not, replace the
attached plug with the one that is suitable in your area.
WARNING
■ If it is necessary to change the plug to fit the outlet in your factory, make sure
that it is done by a qualified personal. When changing the plug 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. Never connect the Controller directly
to the factory power supply. (Field wiring)
Plug Specification:
Terminal
X terminal
Y terminal
Z terminal
W terminal
Description
AC power
Open
AC power
Protective earth wire
Color
Brown
–
Blue
Green/Yellow
3.3 Cable Connection
■ Make sure that the power to the Controller is turned OFF and locked out before
connecting or disconnecting any cables. Connecting or disconnecting any
cables with the power ON is extremely hazardous and may result in electric
shock and malfunction of the Controller.
WARNING
CAUTION
RC420 Rev.9
■ 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 system.
■ The serial number of the Manipulator that should be connected is indicated on
the Connection Check Label on the Controller. Connect the Controller and the
Manipulator correctly. Improper connection between the Controller and the
Manipulator may cause not only improper function of the robot system but also
safety problems.
23
Setup & Operation
3.3 Cable Connection (Installation)
3.3.1 Typical Cable Connection
The Manipulator must be connected as follows in order to operate properly. The
diagram indicates a standard cable connection for a single Manipulator configuration.
Connection appearances of the mouse and the keyboard are different depending on the
dates of the shipping and the board changeover.
Separate connectors for mouse and keyboard
Controller
M/C POWER
M/C SIGNAL
STANDARD I/O
EMERGENCY
INPUT
Protective Earth
Terminal
(1) M/C Power Cable
(2) M/C Signal Cable
(3) STANDARD I/O
(4) EMERGENCY
(5) AC Power Cable
(6) Protective Earth
Expansion I/O (option)
OPTIONAL DEVICE
E-STOP switch
Safety Door switch
AC200V power
Protective earth
Monitor
(8) Mouse Cable
(9) Keyboard Cable
(7)
Input/output unit
Input/output unit
MONITOR
MOUSE/KEYBOARD
Manipulator
Mouse
Keyboard
ATTEND (TEACH)
Control Device
or Operation Unit
or Dummy Plug
24
RC420 Rev.9
Setup & Operation
3.3 Cable Connection (Installation)
Integrated connector for mouse and keyboard
Controller
M/C POWER
M/C SIGNAL
STANDARD I/O
EMERGENCY
INPUT
Protective Earth
Terminal
(1) M/C Power Cable
(2) M/C Signal Cable
(3) STANDARD I/O
(4) EMERGENCY
(5) AC Power Cable
(6) Protective Earth
Expansion I/O (option)
Input/output unit
E-STOP switch
Safety Door switch
AC200V power
Protective earth
Input/output unit
MONITOR
MOUSE/KEYBOARD
Manipulator
Monitor
(10) Mouse/Keyboard Cable
Mouse
Keyboard
(7)
OPTIONAL DEVICE
ATTEND (TEACH)
Control Device
or Operation Unit
or Dummy Plug
RC420 Rev.9
25
Setup & Operation
3.3 Cable Connection (Installation)
(1) M/C Power cable
This cable has round connectors with 17 pins on both ends. Connect the female
connector to the POWER connector at the Manipulator and the male connector to the
M/C POWER connector at the Controller. Insert the connectors and rotate
clockwise until you hear a “click”.
(2) M/C Signal cable
This cable has rectangular connectors with 68 pins on both ends. Connect the signal
cable to the SIGNAL connector of the Manipulator and the M/C SIGNAL connector
of the Controller.
(3) STANDARD I/O connector
This connector is for the user’s input/output devices. For details about STANDARD
I/O, refer to the Setup & Operation 6. STANDARD I/O Connector.
(4) EMERGENCY connector
The EMERGENCY connector has inputs to connect the Emergency Stop switch and
the Safety Door switch. For safety reasons, connect proper switches for these input
devices. For details, refer to the Setup & Operation 5. EMERGENCY Connector.
(5) AC Power cable
Cables for AC 200V (or the local equivalent) power supply to the Controller.
(6)
Protective Earth Terminal connector
The Protective Earth terminal connects to the earth ground wire. The Protective
Earth terminal is better to be connected when a peripheral control unit such as a
sequencer is used in the system. Use a cable of size equal to or greater than AWG
#16 for the Protective Earth terminal.
(7) OPTIONAL DEVICE connector
Connect to optional operation units (e.g. ATTEND (TEACH) control device) or the
OPTIONAL DEVICE Dummy Plug. If neither is connected, the Manipulator will
be in the Emergency Stop condition and will not operate. For details, refer to the
Setup & Operation 4. OPTIONAL DEVICE Connector.
(8) Mouse cable (Separate connectors)
Cable for a mouse.
(9) Keyboard cable (Separate connectors)
Cable for a keyboard.
(10) Mouse / Keyboard cable (Integrated connector)
This branch cable is for a mouse and a keyboard. Connect the cable to a mouse and
a keyboard following the symbols on the cable.
■ Connect the mouse and the keyboard properly when the power in OFF. If the
CAUTION
26
mouse or keyboard is connected when the power in ON or connected
incorrectly, the robot system cannot function properly.
RC420 Rev.9
Setup & Operation
3.3 Cable Connection (Installation)
3.3.2 Connecting the Manipulator to the Controller
Connect the Manipulator to the Controller by using the Power cable and the Signal cable.
■ Make sure that the power to the Controller is turned OFF and locked out before
connecting or disconnecting any cables. Connecting or disconnecting any
cables with the power ON is extremely hazardous and may result in electric
shock and malfunction of the Controller.
WARNING
CAUTION
■ 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 system.
■ The serial number of the Manipulator that should be connected is indicated on
the Connection Check Label on the Controller. Connect the Controller and the
Manipulator correctly. Improper connection between the Controller and the
Manipulator may cause not only improper function of the robot system but also
safety problems.
The configuration data for the Manipulator and Manipulator model are stored in the
Controller. Therefore the Controller should be connected to the Manipulator whose
serial number is specified in the Connection Check label attached on the front of the
Controller.
NOTE
)
The Manipulator’s serial number is indicated on the signature label on the back of the
Manipulator.
RC420 Rev.9
27
Setup & Operation
3.4 Noise Countermeasures (Installation)
3.4 Noise Countermeasures
To minimize electrical noise conditions, the following items must be observed in the
system’s cable wiring:
- The earth wire of the power supply should be grounded. (Ground resistance: 100Ω or
less)It is important to ground the frame of Controller not only for prevention from
electric shock, but also for reducing the influence of electric noise around the
Controller. Therefore, be sure to connect the earth wire (yellow/green) of the
Controller’s power cable to the ground terminal of the factory power supply. For
details about the plug and AC power cable, refer to the Setup & Operation “3.2.2
Power Plug.
- Do not tap power from a power line that connects to any equipment which may cause
noise.
- When you tap power for the Controller and the single-phase AC motor from the same
power line, change the phase of one or the other. Ensure that they will not be the
same phase.
- Use a twisted pair motor power line.
- Do not run AC power lines and DC power lines in
the same wiring duct, and separate them by at least
200 mm. For example, separate the AC motor
power line and the Controller power line by at least
200 mm from the sensor or valve I/O lines; and do
not bundle both sets of wiring with the same cable
tie. If more than one duct/cable must cross each
other, they should cross perpendicularly. The
preferable example is shown in the right figure.
AC Line duct
200 mm or more
DC line duct
- For I/O lines, wire as short as possible and use a shielded cable and clamp the shield to
the attached connector interior.
- Use a shielded cable for the EMERGENCY connector and clamp the shield to the
interior of the connector.
- Make sure that the induction elements used to connect to the Controller’s I/O (such as
relays and solenoid valves) have surge suppressors. If an induction element without
surge suppressor has be used, make sure to connect a rectifying diode right in front of
the induction element. In selecting a rectifying diode, make sure that it can handle
the voltage and current incurred by the induction load.
- To start and change revolutions of the conveyer’s (or the like’s) AC motor (ex: an
induction motor or three-phase induction motor) regularly or abruptly, make sure to
install a spark suppressor between the wires. The spark suppressor is more effective
when placed closer to the motor.
- As they are easily influenced by static electricity or the noise from power source, keep
the mouse and keyboard away from peripheral noise sources.
NOTE
)
28
It is sometimes effective in suppressing such noise to wind the keyboard or mouse cables
around a ferrite core several times.
RC420 Rev.9
Setup & Operation
4. OPTIONAL DEVICE Connector
4. OPTIONAL DEVICE Connector
The details of safety requirements for this section are described in the Safety chapter in
User’s Guide. Please refer to them to keep the robot system safe.
4.1 OPTIONAL DEVICE Connector
■ Do not connect the EPSON RC+ software key to the OPTIONAL DEVICE
CAUTION
connector. Connecting the EPSON RC+ software key to the OPTIONAL
DEVICE connector while the Controller is ON may cause damage to the
EPSON RC+ software key.
Connect the EPSON RC+ software key to the IEEE-1284 (parallel) connector
on the rear of the Controller.
The OPTIONAL DEVICE connector is used for an optional operation unit, ATTEND
(TEACH) control device or OPTIONAL DEVICE Dummy Plug.
The “OPTIONAL DEVICE Dummy Plug”, an accessory that comes with the Controller,
must be connected to this connector if an operation unit or ATTEND (TEACH) control
device is not used. The robot system will be in the Emergency Stop condition when this
connector is left unconnected.
RC420 Rev.9
29
Setup & Operation
4. OPTIONAL DEVICE Connector
4.2 ATTEND (TEACH) Control Device
The name of the control device depends on the software used in your Controller as shown
below
EPSON RC+ : TEACH control device
SPEL CT : ATTEND control device
To operate the Manipulator at a short distance without any operation unit (option), you
should use the ATTEND (TEACH) control device. Create the ATTEND (TEACH)
control device that consists of the following switches and connect it to the OPTIONAL
DEVICE connector.
- Emergency Stop switch
- 3-position enable switch (dead-man switch)
- ATTEND (TEACH) control device enable/disable switch
Refer to the following the figure for the internal circuit and refer to the Setup &
Operation 4.4 Pin Assignments for the signal.
OPTIONAL DEVICE
Connector
ATTEND (TEACH) Control Device
EStop Switch
E_SW11
6
E_SW21
9
E_SW12
10
E_SW22
11
SG
13
ENABLE
14
SG
15
KEY1
18
KEY2
19
3-Position Enable Switch (dead-man switch)
ATTEND (TEACH) Control Device
Enable/Disable Switch
NOTE
)
30
The 3-position enable switch is available when the ATTEND (TEACH) control device is
enabled. The Emergency Stop switch is always available whether the ATTEND
(TEACH) control device is enabled or disabled.
RC420 Rev.9
Setup & Operation
4. OPTIONAL DEVICE Connector
4.3 OPTIONAL DEVICE Dummy Plug
The OPTIONAL DEVICE Dummy Plug is connected to the OPTIONAL DEVICE
connector when an operation unit or ATTEND (TEACH) control device is not used.
When manufacturing robotic systems without using the operation unit or ATTEND
(TEACH) control device, you can use the dummy plug, as shown below, to disable the
Emergency Stop input for the OPTIONAL DEVICE port, and the ATTEND (TEACH)
control device enable/disable input.
In this case, however, you cannot operate the Manipulator while the safety door is open.
When designing and manufacturing robotic systems, follow the descriptions of the Safety
chapter in EPSON RC+ User’s Guide.
OPTIONAL DEVICE
Connector
OPTIONAL DEVICE Dummy Plug
E_SW11
6
E_SW21
9
E_SW12
10
E_SW22
11
SG
13
ENABLE
14
SG
15
KEY2
19
Connector
OPTIONAL DEVICE Dummy Plug
RC420 Rev.9
Standard
D-sub 25 pin
#4-40 screw
31
Setup & Operation
4. OPTIONAL DEVICE Connector
4.4 Pin Assignments
In case you wish to connect the ATTEND (TEACH) control device enable/disable switch
to the OPTIONAL DEVICE connector, refer to the following pin assignments.
Pin number
Signal name
Pin number
Signal name
1
FG
14
ENABLE
2
Not to be used
15
SG
3
Not to be used
16
Not to be used
4
Not to be used
17
Not to be used
5
Not to be used
18
KEY1
6
E_SW11
19
KEY2
7
SG
20
Not to be used
8
Not to be used
21
Not to be used
9
E_SW21
22
Not to be used
10
E_SW12
23
Not to be used
11
E_SW22
24
Not to be used
12
Not to be used
25
+12V
13
SG
Each mode is dictated by the signals at KEY1 and KEY2 as follows:
Operation Condition
KEY1
KEY2
The ATTEND (TEACH) Enabled
control device
Disabled
Connect to SG (13 pin)
Open
Open
Connect to SG (13 pin)
If you are connecting an Emergency Stop switch, connect it to the EMERGENCY
connector on the rear of the Controller.
32
RC420 Rev.9
Setup & Operation
5.1 Safety Door Switch and Latch Release Switch (EMERGENCY Connector)
5. EMERGENCY Connector
NOTE
)
The details of safety requirements for this section are described in the Safety chapter in
User’s Guide. Please refer to them to keep the robot system safe.
5.1 Safety Door Switch and Latch Release Switch
The EMERGENCY connector has input terminals for the Safety Door switch and the
Emergency Stop switch. Be sure to use these input terminals to keep the system safe.
Use only the connector that comes as a standard accessory.
Connector
EMERGENCY connector
Standard
Rectangular, half-pitch, M2.6 screw
5.1.1 Safety Door Switch
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.
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.
RC420 Rev.9
-
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.
33
Setup & Operation
5.1 Safety Door Switch and Latch Release Switch (EMERGENCY Connector)
5.1.2 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.
NOTE
)
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.
5.1.3 Checking Latch Release Switch Operation
After connecting the safety door switch and latch release switch to the EMERGENCY
connector, be sure to check the switch operation for safety by following the procedures
described below before operating the Manipulator.
(1) Turn ON the Controller while the safety door is open in order to boot the controller
software.
(2) Make sure that “Safety” is displayed on the main window status bar.
(3) Close the safety door, and turn ON the switch connecting to the latch release input.
Make sure that the “Safety” is dimmed on the status bar.
The information that the safety door is open can be latched by software based on the latch
release input condition.
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.
NOTE
)
34
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
switch on the operation unit to the AUTO mode or turn the ATTEND (TEACH) control
device enable/disable switch to “disable”. Then, close the latch release input.
RC420 Rev.9
Setup & Operation
5.2 Emergency Stop Switch (EMERGENCY Connector)
5.2 Emergency Stop Switch
WARNING
■ Connect input signal wires for Emergency Stop and Safety Door to the
EMERGENCY connector so that the Emergency Stop switch in the operation
unit or the ATTEND (TEACH) control device connected to the OPTIONAL
DEVICE connector always functions. (Refer to the typical application diagram
in the Setup & Operation 5.5 Circuit Diagrams.)
5.2.1 Emergency Stop Switch
If it is desired to create an external Emergency Stop switch in addition to the Emergency
Stop that an operation unit or ATTEND (TEACH) control device provides, make sure to
connect such Emergency Stop switches to the proper pins 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
)
The signal from the Emergency Stop switch is designed to use two redundant circuits.
If the signals at the two circuits differ by two seconds or more, the system recognizes it as
a critical error. Therefore, make sure that the Emergency Stop switch has double
contacts and that each circuit connects to the specified pins on the EMERGENCY
connector at the Controller. Refer to the Setup & Operation 5.5 Circuit Diagrams.
5.2.2 Checking Emergency Stop Switch Operation
Once the Emergency Stop switch is connected to the EMERGENCY connector, continue
the following procedure to make sure that the switch functions properly. For the safety
of the operator, the Manipulator must not be powered ON until the following test is
completed.
(1) Turn ON the Controller to boot the controller software while pressing the Emergency
Stop switch.
(2) Make sure that the “E-STOP” LED on the front of the Controller is ON.
(3) Make sure that “E.Stop” is displayed on the status bar on the main window.
(4) Release the Emergency Stop Switch.
(5) Execute the RESET command.
(6) Make sure that “E-STOP” LED is turned OFF and that “E-Stop” is dimmed on the
main window status bar.
NOTE
)
For the emergency condition to work with the peripheral equipment at the input of the
Emergency Stop at the Controller via the EMERGENCY connector, make sure that the
desired equipment is connected to the Emergency Stop output terminals. The relay
contacts at the EMERGENCY connector (#5 & #6) (normally closed) will open at the
input of Emergency Stop state.
RC420 Rev.9
35
Setup & Operation
5.3 E. STOP Box (EMERGENCY Connector)
5.3 E. STOP Box
WARNING
■ The E. STOP box is a temporary method until the safeguard, safety door, and
emergency stop devices are installed in the robot system. The E. STOP box
cannot thoroughly keep the robot system safe by itself. Therefore, be sure to
install proper safeguard, safety door, and emergency stop devices in the robot
system.
5.3.1 E. STOP Box
The E. STOP box is a unit for performing an emergency stop. When using the E. STOP
box, connect it to the EMERGENCY connector.
The E. STOP box is provided with the Controller as a standard accessory when the
Controller you purchased is UL specifications.
When connecting the Safety Door switch or Emergency Stop switch to the
EMERGENCY connector, remove the E. STOP box from the connector.
Cable (4 m)
E. STOP Box
Connect to
EMERGENCY connector
5.3.2 Checking E. STOP Box Operation
Once the E. STOP box is connected to the EMERGENCY connector, continue the
following procedure to make sure that the E. STOP box 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 Control Unit and the Drive Unit to boot the Controller while pressing
the E. STOP box switch.
(2) Make sure that the “E-STOP” LED on the Controller’s front panel is ON.
(3) Make sure that “E.Stop” is displayed on the status bar on the monitor window.
(4) Release the E. STOP box switch.
(5) Execute the RESET command.
(6) Make sure that “E-STOP” LED is turned OFF and the “E.Stop” is no longer visible
(or dimmed) from the status bar.
36
RC420 Rev.9
Setup & Operation
5.4 Pin Assignments (EMERGENCY connector)
5.4 Pin Assignments
The EMERGENCY connector pin assignments are as follows:
Pin No.
Signal
Function
1
2
E_SW11
E_SW12
Emergency Stop switch output (1) *3
3
4
E.STOP1+
E.STOP1-
Emergency Stop input 1 (+)
Emergency Stop input 1 (-)
5
E.STOP OUT
6
E.STOP OUT
Emergency Stop condition output
(Relay contact) *1
7
GUARD11
8
GUARD12
9
+24V
+24 V output
10
+24VGND
+24 V GND output
11
E_SW21
12
E_SW22
13
14
E.STOP2+
E.STOP2-
15
RELEASE
16
RELEASE
17
GUARD21
18
GUARD22
19
+24V
+24 V output
20
+24VGND
+24 V GND output
Safety Door input (1) *2
Emergency Stop switch output (2) *3
Emergency Stop input 2 (+)
Emergency Stop input 2 (-)
Latch Release input
Safety Door input (2) *2
*1 The Emergency Stop condition is output via relay contact when it is open (it is
normally closed).
*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 The signal from the Emergency Stop switch is designed to use two redundant circuits.
An error occurs if the statuses of the two redundant circuits are different for two or
more seconds. They must be connected to the same switch with two sets of
contacts.
Emergency Stop switch output rated load
Emergency Stop rated input voltage range
Emergency Stop rated input current
Safety Door rated input voltage range
Safety Door rated input current
Latch Release rated input voltage range
Latch Release rated input current
Emergency Stop output relay contact rated
load
NOTE
+30V 1A or under
+24V ±10%
10mA/24V input
+12 to 24V ±10%
10mA/24V input
+12 to 24V ±10%
10mA/24V input
+30V 0.5A or under
1-2, 11-12 pin
3-4, 13-14 pin
7-8, 17-18 pin
15-16 pin
5-6 pin
)
The total electrical resistance of the Emergency Stop switches and their circuit should be
1Ω or less.
RC420 Rev.9
37
Setup & Operation
5.5 Circuit Diagrams (EMERGENCY Connector)
5.5 Circuit Diagrams
5.5.1 Example 1: External emergency stop switch typical application
External
Emergency
Stop switches
Controller
Emergency Stop
switches of an
operation unit
+24V
9
19
1
2
11
12
3
Dynamic brake relay
of motor driver
13
+24V
Emergency
Stop detection
5
Dynamic
brake
control
Emergency
Stop detection
6
Emergency
Stop
detection
4
14
10
20
Dynamic
brake
control
External
+24V
8
Safety Door input 1
7
18
Safety Door input 2
17
16
Latch release input
15
Latch release input
Close: latch off
Open: latch on
38
External
+24V GND
RC420 Rev.9
Setup & Operation
5.5 Circuit Diagrams (EMERGENCY Connector)
5.5.2 Example 2: External safety relay typical application
Controller
Emergency
Stop
switches of
an operation
unit
External +24V
+24V
9
Fuse *1
19
1
2
External
+24V
GND
11
12
Dynamic brake relay
of motor driver
3
External
+24V
13
+24V
Emergency
stop detection
5
External safety relay
(The above diagram
is simplified for
representation.)
*1 For the protection of
the emergency stop
circuit, the fuse’s
capacity should be
as follows:
- Meets the capacity
of the external
safety relay.
- 1A or less.
Dynamic
brake
control
Emergency
stop detection
6
Emergency
stop
detection
4
14
10
20
Dynamic
brake
control
External
+24V
GND
External
+24V
8
Safety Door input 1
7
18
Safety Door input 2
17
16
Latch release input
15
Safety Door latch release input
Close: latch off
Open: latch on
RC420 Rev.9
External
+24V GND
39
Setup & Operation
40
5.5 Circuit Diagrams (EMERGENCY Connector)
RC420 Rev.9
Setup & Operation 6. STANDARD I/O Connector
6. STANDARD I/O Connector
The STANDARD I/O connector is for connecting your input/output equipment to the
system. It has pins for 16 inputs and 16 outputs.
The STANDARD I/O corresponds to the input/output bit numbers 0-15.
Refer to the Setup & Operation 7. Expansion I/O Board - Optional for the specified
model of an expansion I/O Board.
For cable wiring, refer to the Setup & Operation 3.4 Noise Countermeasures in order to
prevent noise.
RC420 Rev.9
41
Setup & Operation 6.1 Input Circuit (STANDARD I/O Connector)
6.1 Input Circuit
Input Voltage Range
: +12 to 24 V ±10%
ON Voltage
: +10.8 V (min.)
OFF Voltage
: +5 V (max.)
Input Current
: 10 mA (TYP) at +24 V input
■ Use the PNP-type wiring diagram for CE conformance. Be sure to wire
correctly. Improper wiring may cause safety problems as it may make the
Manipulator move unusually.
CAUTION
■ When the wiring for PNP or NPN type is changed, the jumper settings don’t
require changing.
Typical Input Circuit Application 1: NPN
I/O-1
GND +DC
1 Input No. 0 to 7 common
2 Input No. 0
(Same)
3 Input No. 1
(Same)
4 Input No. 2
(Same)
5 Input No. 3
(Same)
6 Input No. 4
(Same)
7 Input No. 5
(Same)
8 Input No. 6
(Same)
9 Input No. 7
10 Input No. 8 to 15 common
(Same)
11 Input No. 8
12 Input No. 9
~
~
42
~ ~
~ ~
(Omit)
~
~
RC420 Rev.9
Setup & Operation 6.1 Input Circuit (STANDARD I/O Connector)
Typical Input Circuit Application 2: PNP
I/O-1
GND +DC
1 Input No. 0 to 7 common
2 Input No. 0
(Same)
3 Input No. 1
(Same)
4 Input No. 2
(Same)
5 Input No. 3
(Same)
6 Input No. 4
(Same)
7 Input No. 5
(Same)
8 Input No. 6
(Same)
9 Input No. 7
10 Input No. 8 to 15 common
(Same)
11 Input No. 8
12 Input No. 9
~
~
RC420 Rev.9
~ ~
~ ~
(Omit)
~
~
43
Setup & Operation 6.2 Output Circuit (STANDARD I/O Connector)
6.2 Output Circuit
Rated Output Voltage
: +12 V to 24 V ±10%
Maximum Output Current
: TYP 120 mA/1 output
Output Driver
: Photo MOS Relay
On-State Resistance (average) : 23.5 Ω or less
CAUTION
■ Use the PNP-type wiring diagram for CE conformance. Be sure to wire
correctly. Improper wiring may cause safety problems as it may make the
Manipulator move unusually.
Typical Output Circuit Application 1: NPN
I/O-1
GND +DC
19 Output No. 0
20 Output No. 1
(Same)
L
21 Output No. 2
(Same)
22 Output No. 3
(Same)
23 Output No. 4
(Same)
24 Output No. 5
(Same)
25 Output No. 6
(Same)
26 Output No. 7
(Same)
28 Output No. 8
(Same)
29 Output No. 9
(Same)
~
~
L
Load
~~
~~
(Omit)
~
~
44 Output common (GND)
45 Output common (GND)
46 Output common (GND)
44
RC420 Rev.9
Setup & Operation 6.2 Output Circuit (STANDARD I/O Connector)
Typical Output Circuit Application 2: PNP
I/O-1
GND +DC
19 Output No. 0
(Same)
(Same)
(Same)
(Same)
~
L
21 Output No. 2
22 Output No. 3
23 Output No. 4
24 Output No. 5
(Same)
25 Output No. 6
(Same)
26 Output No. 7
(Same)
~
20 Output No. 1
(Same)
(Same)
L
Load
28 Output No. 8
29 Output No. 9
~
~ ~
(Omit)
~ ~ ~
44 Output common (+DC)
45 Output common (+DC)
46 Output common (+DC)
RC420 Rev.9
45
Setup & Operation 6.3 Pin Assignments (STANDARD I/O Connector)
6.3 Pin Assignments
6.3.1 STANDARD I/O connector - Pin Assignments
Pin No.
Signal Name
Pin No.
1
Input common No. 0 to 7
26
Output No. 7
2
Input No. 0
27
NC
3
Input No. 1
28
Output No. 8
4
Input No. 2
29
Output No. 9
5
Input No. 3
30
NC
6
Input No. 4
31
Output No.10
7
Input No. 5
32
Output No.11
8
Input No. 6
33
NC
9
Input No. 7
34
Output No.12
10
Input common No. 8 to 15
35
NC
11
Input No. 8
36
Output No.13
12
Input No. 9
37
NC
13
Input No. 10
38
Output No. 14
14
Input No. 11
39
NC
15
Input No. 12
40
NC
16
Input No. 13
41
Output No. 15
17
Input No. 14
42
NC
18
Input No. 15
43
NC
19
Output No. 0
44
Output common
20
Output No. 1
45
Output common
21
Output No. 2
46
Output common
22
Output No. 3
47
+24V Output
23
Output No. 4
48
+24V Output
24
Output No. 5
49
+24V GND Output
25
Output No. 6
50
+24V GND Output
Connector
STANDARD I/O Connector
46
Signal Name
Standard
D-Sub 50 pin
#4-40 screw
RC420 Rev.9
Setup & Operation
6.3 Pin Assignments (D-I/O Connector)
6.3.2 STANDARD I/O connector optional cable for USA Specification
- Pin Assignments
The STANDARD I/O cable is an optional part and for USA specification.
Pin No.
RC420 Rev.9
Signal Name
Pin No.
Signal Name
1
Input common No. 0 to 7
26
Output No. 7
2
Input No. 0
27
NC
3
Input No. 1
28
Output No. 8
4
Input No. 2
29
Output No. 9
5
Input No. 3
30
NC
6
Input No. 4
31
Output No.10
7
Input No. 5
32
Output No.11
8
Input No. 6
33
NC
9
Input No. 7
34
Output No.12
10
Input common No. 8 to 15
35
NC
11
Input No. 8
36
Output No.13
12
Input No. 9
37
NC
13
Input No. 10
38
Output No. 14
14
Input No. 11
39
NC
15
Input No. 12
40
NC
16
Input No. 13
41
Output No. 15
17
Input No. 14
42
NC
18
Input No. 15
43
NC
19
Output No. 0
44
Output common
20
Output No. 1
45
Output common
21
Output No. 2
46
Output common
22
Output No. 3
47
+24V Output
23
Output No. 4
48
+24V Output
24
Output No. 5
49
+24V GND Output
25
Output No. 6
50
+24V GND Output
47
Setup & Operation 6.3 Pin Assignments (STANDARD I/O Connector)
48
RC420 Rev.9
Setup & Operation 7.1 Expansion I/O Board (Expansion I/O Board - Optional)
7. Expansion I/O Board - Optional
7.1 Expansion I/O Board
Install an expansion I/O board in an ISA slot in the Controller when extra inputs or
outputs are desired.
Each additional expansion I/O board provides 32 inputs and 32 outputs. The number of
I/Os that can be expanded is subject to the number of ISA slots available in the type of
Controller used.
The input and output bit #s are assigned as follows.
Input Bit #
Output Bit #
Applicable Hardware
0 to 15
0 to 15
Controller Standard I/O
48 to 79
48 to 79
The 1st Expansion I/O board
80 to 111
..
.
80 to 111
..
.
The 2nd Expansion I/O board
..
.
The types of the optional expansion I/O board are listed below.
Board Name
Input/Output
Type
Protected Expansion
I/O board
NPN
Hybrid IC SEP007
Available
Protected Expansion
I/O board
PNP
Hybrid IC SEP008
Available
Expansion I/O
board
NPN
Transistor array and photo
coupler
Output Circuit
Overcurrent
Protection
Not Available
■ Use the PNP-type of protected Expansion I/O Board for CE conformance.
CAUTION
RC420 Rev.9
■ Be sure to wire the output circuit properly. Especially the expansion I/O board
has no protection circuitry for short-circuit and reverse-connection. Improper
wiring may cause malfunction of the parts on the board and then improper
function of the robot system.
49
Setup & Operation 7.2 Protected Expansion I/O Board (Expansion I/O Board - Optional)
7.2 Protected Expansion I/O Board
7.2.1 Protected Expansion I/O Board : Jumper Settings
The I/O board address is defined by the jumpers JP1, 2, and 3.
JP1, JP2
The table below shows the settings for JP1 and JP2 on each board. The table is oriented
the same way that the jumpers are on the board (address bit increases from left to right).
JP 1
Board #
Address
1-2
3-4
5-6
7-8
9-10
11-12
13-14
15-16
A8
A9
A10
A11
A12
A13
A14
A15
1
700
Short
Short
Short
Short
Short
2
710
Short
Short
Short
Short
Short
3
720
Short
Short
Short
Short
Short
4
730
Short
Short
Short
Short
Short
JP 2
Board #
Address
1-2
A3
A4
A5
A6
A7
1
700
Short
Short
Short
Short
Short
2
710
Short
Short
Short
Short
3
720
Short
Short
Short
4
730
Short
Short
Short
3-4
Short
5-6
7-8
9-10
Short: Short-circuit, Blank: Open
JP3
Short-circuit 1-2, 4-5, 7-8 and 10-11.
JP4, 5, 6
Normally open.
When the Expansion I/O Board is used, the appropriate software settings must be done in
addition to the jumper settings. For details about software settings, refer to the section,
Expansion I/O Board Software Configuration in the chapter, I/O Systems in EPSON RC+
User’s Guide.
50
RC420 Rev.9
Setup & Operation 7.2 Protected Expansion I/O Board (Expansion I/O Board - Optional)
7.2.2 Protected Expansion I/O Board : Input Circuit
The following diagrams illustrate cases where #48 through #79 (for the first Expansion
I/O Board) are assigned to the Protected Expansion I/O Board’s (or Expansion I/O
Board’s) inputs and outputs. The I/O number assignment depends on the controller
software settings.
Input Voltage Range
ON Voltage
OFF Voltage
Input Current
CAUTION
: + 12 V to 24 V ±10%
: + 10.8 V (Min.)
: + 5 V (Max.)
: 10 mA (TYP) at + 24 V input
■ Use the PNP-type of wiring diagram for CE conformance. Be sure to wire
correctly. Improper wiring may cause safety problems as it may make the
Manipulator move unusually.
Protected Expansion I/O Board
Typical Input Circuit Application 1: NPN
GND +DC
1 Input No.48 to 51 common
470 Ω
2.2 kΩ
3 Input No.48
(Same)
4 Input No.49
(Same)
5 Input No.50
(Same)
6 Input No.51
51 Input No.52 to 55 common
(Same)
53 Input No.52
(Same)
54 Input No.53
~
(Omit)
RC420 Rev.9
~
~
51
Setup & Operation 7.2 Protected Expansion I/O Board (Expansion I/O Board - Optional)
Protected Expansion I/O Board
Typical Input Circuit Application 2: PNP
1 Input No.48 to 51 common
GND +DC
470 Ω
2.2 kΩ
3 Input No.48
(Same)
4 Input No.49
(Same)
5 Input No.50
(Same)
6 Input No.51
51 Input No.52 to 55 common
(Same)
53 Input No.52
(Same)
54 Input No.53
~
(Omit)
52
~
~
RC420 Rev.9
Setup & Operation 7.2 Protected Expansion I/O Board (Expansion I/O Board - Optional)
7.2.3 Protected Expansion I/O Board : Output Circuit
The following diagrams illustrate cases where #48 through #79 (for the first Expansion
I/O Board) are assigned to the Protected Expansion I/O Board’s inputs and outputs. The
I/O number assignment depends on the controller software settings.
CAUTION
■ Use the PNP-type of wiring diagram for CE conformance. Be sure to wire
correctly. Improper wiring may cause safety problems as it may make the
Manipulator move unusually.
Protected Expansion I/O Board
Typical Output Circuit Application 1: NPN
GND
27 Output No. 48
28 Output No. 49
(Same)
+DC
L
L
29 Output No. 50
(Same)
30 Output No. 51
(Same)
25 Output No.48 to 51 common (+DC)
26 Output No.48 to 51 common (GND)
77 Output No. 52
(Same)
~ ~
(Omit)
Rated Output Voltage
Maximum Output current
Output Driver
Saturation Voltage
RC420 Rev.9
~
~
: + 12 V to 24 V ±10%
: 250 mA/1 output
: N channel power MOS FET
: 1.0 V or under
53
Setup & Operation
7.2 Protected Expansion I/O Board (Expansion I/O Board - Optional)
Protected Expansion I/O Board
Typical Output Circuit Application 2: PNP
GND
27 Output No. 48
28 Output No. 49
(Same)
+DC
L
L
29 Output No. 50
(Same)
30 Output No. 51
(Same)
25 Output No.48 to 51 common (GND)
26 Output No.48 to 51 common (+DC)
77 Output No. 52
(Same)
~~
(Omit)
Rated Output Voltage
Maximum Output current
Output Driver
Saturation Voltage
54
~
~
: + 12 V to 24 V ±10%
: 250 mA/1 output
: P channel power MOS FET
: 1.0 V or under
RC420 Rev.9
Setup & Operation
7.3 Expansion I/O Board (Expansion I/O Board - Optional)
7.3 Expansion I/O Board
7.3.1 Expansion I/O Board : Jumper Settings
The I/O board address is defined by the jumpers JP1, JP2, and JP3.
JP1, JP2
The table below shows the settings for JP1 and JP2 on each board. The table is oriented
the same way that the jumpers are on the board (address bit increases from left to right).
JP 1
Board #
Address
1-2
3-4
5-6
7-8
9-10
11-12
13-14
15-16
A8
A9
A10
A11
A12
A13
A14
A15
1
700
Short
Short
Short
Short
Short
2
710
Short
Short
Short
Short
Short
3
720
Short
Short
Short
Short
Short
4
730
Short
Short
Short
Short
Short
Board #
Address
JP 2
1-2
3-4
5-6
7-8
9-10
A3
A4
A5
A6
A7
Short
Short
Short
Short
Short
Short
Short
Short
Short
Short
Short
1
700
Short
2
710
Short
3
720
Short
4
730
Short
Short
Short: Short-circuit, Blank: Open
JP3
Short-circuit 1-2, 4-5, 7-8 and 10-11.
JP4, 5, 6
Normally open.
When an Expansion I/O Board is used, the appropriate software settings must be done in
addition to the jumper settings. For details about software settings, refer to the section,
ISA I/O Board Software Configuration in the chapter, I/O Systems in EPSON RC+ User’s
Guide.
7.3.2 Expansion I/O Board : Input Circuit
The input circuit is the same as the NPN type of the protected expansion I/O board.
Refer to the Setup & Operation 7.2.2 Protected Expansion I/O board : Input Circuit for
details.
RC420 Rev.9
55
Setup & Operation
7.3 Expansion I/O Board (Expansion I/O Board - Optional)
7.3.3 Expansion I/O Board : Output Circuit
The following diagrams illustrate cases where #48 through #79 (for the first Expansion
I/O Board) are assigned to the Expansion I/O Board’s inputs and outputs. The I/O
number assignment depends on the software settings.
Expansion I/O Board
I/O Typical Output Circuit Application 1:
Output #48 to #55 (the 8 points from the first point in among the 32 points in a
board)
CAUTION
■ Be sure to wire the output circuit properly because it has no protection circuitry
for short-circuit and reverse-connection.
Improper wiring may cause
malfunction of the parts on the board and then improper function of the robot
system.
GND +DC
Transistor array
27 Output No. 48
28 Output No. 49
(Same)
L
L
29 Output No. 50
(Same)
30 Output No. 51
(Same)
25 Output No. 48 to 51 common (+DC)
26 Output No. 48 to 51 common (GND)
(Same)
77 Output No. 52
~~
(Omit)
Rated Output Voltage
~
~
: + 12 V to 24 V ±10%
Maximum Output current : 250 mA/1 output
56
Output Driver
: Transistor array
Saturation Voltage
: 1.6 V or under
RC420 Rev.9
Setup & Operation
7.3 Expansion I/O Board (Expansion I/O Board - Optional)
Expansion I/O Board
Typical Output Circuit Application 2:
Output #56 to #79 (the 24 points from the last thirty-second point in a board)
CAUTION
■ Be sure to wire the output circuit properly because it has no protection circuitry
for short-circuit and reverse-connection.
Improper wiring may cause
malfunction of the parts on the board and then improper function of the robot
system.
GND +DC
33 Output No. 56
34 Output No. 57
(Same)
L
L
35 Output No. 58
(Same)
36 Output No. 59
(Same)
32 Output No. 56 to 59 common
83 Output No. 60
(Same)
L
84 Output No. 61
(Same)
~
(Omit)
Rated Output Voltage
~
~
: + 12 V to 24 V ±10%
Maximum Output Current : 100 mA/1 output
RC420 Rev.9
Output Driver
: Photo coupler
Saturation Voltage
: 1.6 V or under
57
Setup & Operation
7.4 Expansion I/O Board : Pin Assignments (Expansion I/O Board - Optional)
7.4 Expansion I/O Board : Pin Assignments
7.4.1 Expansion I/O Board : Pin Assignments (NPN type)
NPN : Pin No. 1-50
Pin No.
Signal Name
58
Pin No.
Signal Name
1
Input common A (No. 48 to 51)
26
Output common A (GND: No. 48 to 51)
2
NC
27
Output No.48
3
Input No.48
28
Output No.49
4
Input No.49
29
Output No.50
5
Input No.50
30
Output No.51
6
Input No.51
31
Output common C (+DC: No. 56 to 59)
7
Input common C (No. 56 to 59)
32
Output common C (GND: No. 56 to 59)
8
NC
33
Output No.56
9
Input No.56
34
Output No.57
10
Input No.57
35
Output No.58
11
Input No.58
36
Output No.59
12
Input No.59
37
Output common E (+DC: No. 64 to 67)
13
Input common E (No. 64 to 67)
38
Output common E (GND: No. 64 to 67)
14
NC
39
Output No.64
15
Input No.64
40
Output No.65
16
Input No.65
41
Output No.66
17
Input No.66
42
Output No.67
18
Input No.67
43
Output common G (+DC: No. 72 to 75)
19
Input common G (No. 72 to 75)
44
Output common G (GND: No. 72 to 75)
20
NC
45
Output No.72
21
Input No.72
46
Output No.73
22
Input No.73
47
Output No.74
23
Input No.74
48
Output No.75
24
Input No.75
49
FG
25
Output common A (+DC: No. 48 to 51)
50
FG
RC420 Rev.9
Setup & Operation
7.4 Expansion I/O Board : Pin Assignments (Expansion I/O Board - Optional)
NPN : Pin No. 51-100
Pin No.
Signal Name
Pin No.
Signal Name
51
Input common B (No. 52 to 55)
76
Output common B (GND: No. 52 to 55)
52
NC
77
Output No.52
53
Input No.52
78
Output No.53
54
Input No.53
79
Output No.54
55
Input No.54
80
Output No.55
56
Input No.55
81
Output common D (+DC: No. 60 to 63)
57
Input common D (No. 60 to 63)
82
Output common D (GND: No. 60 to 63)
58
NC
83
Output No.60
59
Input No.60
84
Output No.61
60
Input No.61
85
Output No.62
61
Input No.62
86
Output No.63
62
Input No.63
87
Output common F (+DC: No. 68 to 71)
63
Input common F (No. 68 to 71)
88
Output common F (GND: No. 68 to 71)
64
NC
89
Output No.68
65
Input No.68
90
Output No.69
66
Input No.69
91
Output No.70
67
Input No.70
92
Output No.71
68
Input No.71
93
Output common H (+DC: No. 76 to 79)
69
Input common H (No. 76 to 79)
94
Output common H (GND: No. 76 to 79)
70
NC
95
Output No.76
71
Input No.76
96
Output No.77
72
Input No.77
97
Output No.78
73
Input No.78
98
Output No.79
74
Input No.79
99
FG
75
Output common B (+DC: No. 52 to 55)
100
FG
RC420 Rev.9
59
Setup & Operation
7.4 Expansion I/O Board : Pin Assignments (Expansion I/O Board - Optional)
7.4.2 Expansion I/O Board : Pin Assignments (PNP type)
PNP : Pin No. 1-50
Pin No.
60
Signal Name
Pin No.
Signal Name
1
Input common A (No. 48 to 51)
26
Output common A (+DC: No. 48 to 51)
2
NC
27
Output No.48
3
Input No.48
28
Output No.49
4
Input No.49
29
Output No.50
5
Input No.50
30
Output No.51
6
Input No.51
31
Output common C (GND: No. 56 to 59)
7
Input common C (No. 56 to 59)
32
Output common C (+DC: No. 56 to 59)
8
NC
33
Output No.56
9
Input No.56
34
Output No.57
10
Input No.57
35
Output No.58
11
Input No.58
36
Output No.59
12
Input No.59
37
Output common E (GND: No. 64 to 67)
13
Input common E (No. 64 to 67)
38
Output common E (+DC: No. 64 to 67)
14
NC
39
Output No.64
15
Input No.64
40
Output No.65
16
Input No.65
41
Output No.66
17
Input No.66
42
Output No.67
18
Input No.67
43
Output common G (GND: No. 72 to 75)
19
Input common G (No. 72 to 75)
44
Output common G (+DC: No. 72 to 75)
20
NC
45
Output No.72
21
Input No.72
46
Output No.73
22
Input No.73
47
Output No.74
23
Input No.74
48
Output No.75
24
Input No.75
49
FG
25
Output common A (GND: No. 48 to 51)
50
FG
RC420 Rev.9
Setup & Operation
7.4 Expansion I/O Board : Pin Assignments (Expansion I/O Board - Optional)
PNP : Pin No. 51-100
Pin No.
Signal Name
Pin No.
Signal Name
51
Input common B (No. 52 to 55)
76
Output common B (+DC: No. 52 to 55)
52
NC
77
Output No.52
53
Input No.52
78
Output No.53
54
Input No.53
79
Output No.54
55
Input No.54
80
Output No.55
56
Input No.55
81
Output common D (GND: No. 60 to 63)
57
Input common D (No. 60 to 63)
82
Output common D (+DC: No. 60 to 63)
58
NC
83
Output No.60
59
Input No.60
84
Output No.61
60
Input No.61
85
Output No.62
61
Input No.62
86
Output No.63
62
Input No.63
87
Output common F (GND: No. 68 to 71)
63
Input common F (No. 68 to 71)
88
Output common F (+DC: No. 68 to 71)
64
NC
89
Output No.68
65
Input No.68
90
Output No.69
66
Input No.69
91
Output No.70
67
Input No.70
92
Output No.71
68
Input No.71
93
Output common H (GND: No. 76 to 79)
69
Input common H (No. 76 to 79)
94
Output common H (+DC: No. 76 to 79)
70
NC
95
Output No.76
71
Input No.76
96
Output No.77
72
Input No.77
97
Output No.78
73
Input No.78
98
Output No.79
74
Input No.79
99
FG
75
Output common B (GND: No. 52 to 55)
100
FG
RC420 Rev.9
61
Setup & Operation
7.5 Expansion I/O Connector (Expansion I/O Board - Optional)
7.5 Expansion I/O Connector
7.5.1 Pin Layout of Expansion I/O Connector
1
50
51
100
NOTE
)
Internal power is not connected to the Expansion I/O connector. Therefore, an external
power source must be supplied.
7.5.2 Expansion I/O Connector Cable
The Expansion I/O connector cable is an optional part. It has a 100-pin connector on
one end and two 50-pin connectors on the other end.
50-pin × 2
100-pin
Expansion
[1]
[3]
[2]
[4]
I/O board
2m
62
RC420 Rev.9
Setup & Operation
7.5 Expansion I/O Connector (Expansion I/O Board - Optional)
7.5.3 Expansion I/O Connector Cable – Pin Assignments
Expansion I/O connector cable - Pin Assignments: NPN
Connector on the cable side [1]
Pin No.
Signal Name
Pin No.
Signal Name
1
(1)
Input common A (No. 48 to 51)
26
(25) Output common A (+DC: No. 48 to 51)
2
(2)
NC
27
(26) Output common A (GND: No. 48 to 51)
3
(3)
Input No.48
28
(27) Output No.48
4
(4)
Input No.49
29
(28) Output No.49
5
(5)
Input No.50
30
(29) Output No.50
6
(6)
Input No.51
31
(30) Output No.51
7
(51)
Input common B (No. 52 to 55)
32
(75) Output common B (+DC: No. 52 to 55)
8
(52)
NC
33
(76) Output common B (GND: No. 52 to 55)
9
(53)
Input No.52
34
(77) Output No.52
10
(54)
Input No.53
35
(78) Output No.53
11
(55)
Input No.54
36
(79) Output No.54
12
(56)
Input No.55
37
(80) Output No.55
13
(7)
Input common C (No. 56 to 59)
38
(31) Output common C (+DC: No. 56 to 59)
14
(8)
NC
39
(32) Output common C (GND: No. 56 to 59)
15
(9)
Input No.56
40
(33) Output No.56
16
(10)
Input No.57
41
(34) Output No.57
17
(11)
Input No.58
42
(35) Output No.58
18
(12)
Input No.59
43
(36) Output No.59
19
(57)
Input common D (No. 60 to 63)
44
(81) Output common D (+DC: No. 60 to 63)
20
(58)
NC
45
(82) Output common D (GND: No. 60 to 63)
21
(59)
Input No.60
46
(83) Output No.60
22
(60)
Input No.61
47
(84) Output No.61
23
(61)
Input No.62
48
(85) Output No.62
24
(62)
Input No.63
49
(86) Output No.63
25
(49)
FG
50
(50) FG
The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin
connector.
RC420 Rev.9
63
Setup & Operation
7.5 Expansion I/O Connector (Expansion I/O Board - Optional)
Expansion I/O connector cable - Pin Assignments: NPN
Connector on the cable side [2]
Pin No.
Signal Name
Pin No.
Signal Name
1
(13) Input common E (No. 64 to 67)
26
(37)
Output common E (+DC: No. 64 to 67)
2
(14) NC
27
(38)
Output common E (GND: No. 64 to 67)
3
(15) Input No.64
28
(39)
Output No.64
4
(16) Input No.65
29
(40)
Output No.65
5
(17) Input No.66
30
(41)
Output No.66
6
(18) Input No.67
31
(42)
Output No.67
7
(63) Input common F (No. 68 to 71)
32
(87)
Output common F (+DC: No. 68 to 71)
8
(64) NC
33
(88)
Output common F (GND: No. 68 to 71)
9
(65) Input No.68
34
(89)
Output No.68
10 (66) Input No.69
35
(90)
Output No.69
11 (67) Input No.70
36
(91)
Output No.70
12 (68) Input No.71
37
(92)
Output No.71
13 (19) Input common G (No. 72 to 75)
38
(43)
Output common G (+DC: No. 72 to 75)
14
39
(44)
Output common G (GND: No. 72 to 75)
15 (21) Input No.72
40
(45)
Output No.72
16 (22) Input No.73
41
(46)
Output No.73
17 (23) Input No.74
42
(47)
Output No.74
18 (24) Input No.75
43
(48)
Output No.75
19 (69) Input common H (No. 76 to 79)
44
(93)
Output common H (+DC: No. 76 to 79)
20
45
(94)
Output common H (GND: No. 76 to 79)
21 (71) Input No.76
46
(95)
Output No.76
22 (72) Input No.77
47
(96)
Output No.77
23 (73) Input No.78
48
(97)
Output No.78
24 (74) Input No.79
49
(98)
Output No.79
25 (99) FG
50
(100) FG
(20) NC
(70) NC
The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin
connector.
64
RC420 Rev.9
Setup & Operation
7.5 Expansion I/O Connector (Expansion I/O Board - Optional)
Expansion I/O connector cable – Pin Assignments: PNP
Connector on the cable side [1]
Pin No.
Signal Name
Pin No.
Signal Name
1
(1)
Input common A (No. 48 to 51)
26
(25) Output common A (GND: No. 48 to 51)
2
(2)
NC
27
(26) Output common A (+DC: No. 48 to 51)
3
(3)
Input No.48
28
(27) Output No.48
4
(4)
Input No.49
29
(28) Output No.49
5
(5)
Input No.50
30
(29) Output No.50
6
(6)
Input No.51
31
(30) Output No.51
7
(51) Input common B (No. 52 to 55)
32
(75) Output common B (GND: No. 52 to 55)
8
(52) NC
33
(76) Output common B (+DC: No. 52 to 55)
9
(53) Input No.52
34
(77) Output No.52
10
(54) Input No.53
35
(78) Output No.53
11
(55) Input No.54
36
(79) Output No.54
12
(56) Input No.55
37
(80) Output No.55
13
(7)
Input common C (No. 56 to 59)
38
(31) Output common C (GND: No. 56 to 59)
14
(8)
NC
39
(32) Output common C (+DC: No. 56 to 59)
15
(9)
Input No.56
40
(33) Output No.56
16
(10) Input No.57
41
(34) Output No.57
17
(11) Input No.58
42
(35) Output No.58
18
(12) Input No.59
43
(36) Output No.59
19
(57) Input common D (No. 60 to 63)
44
(81) Output common D (GND: No. 60 to 63)
20
(58) NC
45
(82) Output common D (+DC: No. 60 to 63)
21
(59) Input No.60
46
(83) Output No.60
22
(60) Input No.61
47
(84) Output No.61
23
(61) Input No.62
48
(85) Output No.62
24
(62) Input No.63
49
(86) Output No.63
25
(49) FG
50
(50) FG
The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin
connector.
RC420 Rev.9
65
Setup & Operation
7.5 Expansion I/O Connector (Expansion I/O Board - Optional)
Expansion I/O connector cable – Pin Assignments: PNP
Connector on the cable side [2]
Pin No.
Signal Name
Pin No.
Signal Name
1
(13)
Input common E (No. 64 to 67)
26
(37)
Output common E (GND: No. 64 to 67)
2
(14)
NC
27
(38)
Output common E (+DC: No. 64 to 67)
3
(15)
Input No.64
28
(39)
Output No.64
4
(16)
Input No.65
29
(40)
Output No.65
5
(17)
Input No.66
30
(41)
Output No.66
6
(18)
Input No.67
31
(42)
Output No.67
7
(63)
Input common F (No. 68 to 71)
32
(87)
Output common F (GND: No. 68 to 71)
8
(64)
NC
33
(88)
Output common F (+DC: No. 68 to 71)
9
(65)
Input No.68
34
(89)
Output No.68
10
(66)
Input No.69
35
(90)
Output No.69
11
(67)
Input No.70
36
(91)
Output No.70
12
(68)
Input No.71
37
(92)
Output No.71
13
(19)
Input common G (No. 72 to 75)
38
(43)
Output common G (GND: No. 72 to 75)
14
(20)
NC
39
(44)
Output common G (+DC: No. 72 to 75)
15
(21)
Input No.72
40
(45)
Output No.72
16
(22)
Input No.73
41
(46)
Output No.73
17
(23)
Input No.74
42
(47)
Output No.74
18
(24)
Input No.75
43
(48)
Output No.75
19
(69)
Input common H (No. 76 to 79)
44
(93)
Output common H (GND: No. 76 to 79)
20
(70)
NC
45
(94)
Output common H (+DC: No. 76 to 79)
21
(71)
Input No.76
46
(95)
Output No.76
22
(72)
Input No.77
47
(96)
Output No.77
23
(73)
Input No.78
48
(97)
Output No.78
24
(74)
Input No.79
49
(98)
Output No.79
25
(99)
FG
50 (100) FG
The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin
connector.
66
RC420 Rev.9
Setup & Operation
8. I/O Remote Settings
8. I/O Remote Settings
This section describes the functions and timings of input and output signals.
The remote functions may be assigned to your standard or expansion I/O board(s) to
enhance robot control - either from an operational unit of your choice or a sequencer.
The user defines the I/O number that a remote function is assigned to using software
configuration. For further details, refer to the section, Remote Control Software
Configuration in the chapter, Remote Control in EPSON RC+ User’s Guide.
For details about I/O cable connection, refer to sections on Setup & Operation 6.
STANDARD I/O Connector, and Setup & Operation 7. Expansion I/O Board - Optional
in this manual.
For details about communication with external equipment, refer to the chapter, Remote
Control in EPSON RC+ User’s Guide.
CAUTION
NOTE
■ When using remote I/O, always make sure of the following. Using the robot
system under unsatisfactory conditions may cause malfunction of the system
and/or safety problems.
- Assign remote functions to inputs/outputs correctly and wire correctly when
setting up remote I/O signals.
- Make sure that the functions correspond to the correct input/output signals
before turning ON the system.
- When verifying the robot system operation, prepare for failures with initial
settings or wiring. If the Manipulator functions unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to
stop the Manipulator.
)
When you set up a remote I/O signal, please either keep a written record of the settings or
store the data in a file for later reference.
RC420 Rev.9
67
Setup & Operation
8.1 I/O Signal Description (I/O Remote Settings)
8.1 I/O Signal Description
You may use either Standard I/O or Expansion I/O for remote control. To use all signals,
you will need to add Expansion I/O.
8.1.1 Remote Input Signals
Remote inputs are used to control the Manipulators and start programs. Certain
conditions must be met before inputs are enabled, as shown in the table below.
NOTE
)
When an error occurs, you must execute a Reset to clear the error condition before any
more remote input commands can be executed. Therefore, it is recommended that the
remote equipment uses the Error output and Reset input to monitor and clear error
conditions.
The remote input signals for EPSON RC+ are as follows:
Name
68
Description
MotorOn
Turns motors on for the current robot. The MotorOff input must be
off. Disabled when tasks are running.
MotorOff
Turns motors off for the current robot and disables MotorOn.
Disabled when tasks are running.
PowerHigh
Sets high motor power mode for the current robot. The motors must
be on and the PowerLow input must be off.
Disabled when tasks are running.
PowerLow
Turns off high power mode for the current robot and disables
PowerHigh.
Disabled when tasks are running.
Mcal
Executes MCal command.
Disabled when tasks are running.
Home
Executes Home command.
Disabled when tasks are running.
Start
Starts the current program group.
Disabled when tasks are running. (*2)
Pause
Pauses all tasks that are configured to pause.
Enabled only when tasks are running.
Cont
Continues tasks that have been paused.
Enabled only when tasks are running.
AbortAll
Aborts all tasks or the current command.
Reset
Resets the Controller and error condition.
This is the only command accepted when the Error output is turned on.
SelRobot
Selects the current robot for robot commands, according to the 4 inputs
SelRobot0 to SelRobot3. The robot number is 0 based, with 0
corresponding to Robot 1 (default). (*1)
SelRobot0
Robot Bit 0, weight 1. (*3)
SelRobot1
Robot Bit 1, weight 2. (*3)
SelRobot2
Robot Bit 2, weight 4. (*3)
SelRobot3
Robot Bit 3, weight 8. (*3)
RC420 Rev.9
Setup & Operation
8.1 I/O Signal Description (I/O Remote Settings)
Name
Description
SelGroup
Selects the current program group to be started with the Start input
according to the 4 inputs SelGroup0 to SelGroup3.
SelGroup0
Group Bit 0, weight 1. (*4)
SelGroup1
Group Bit 1, weight 2. (*4)
SelGroup2
Group Bit 2, weight 4. (*4)
SelGroup3
Group Bit 3, weight 8. (*4)
Recover
Initiates a position recovery after the safeguard has been closed.
Shutdown
Shuts down the Controller. Disabled when tasks are running.
Reboot
Reboots the Controller. Disabled when tasks are running.
(*1) The SelRobot input is used to select the Manipulator for executing Motor Mode,
Power Mode, MCALComplete, AtHOME, the output of CurrRobot0 to 3 for remote
output and Motor ON, Motor OFF, Mcal, Home for remote input.
(*2) The Start input is enabled for the group number specified with SelGroup0-3 bits.
(*3) Specify the manipulator number with SelRobot0 - 3 as shown in the table below.
Specified
Manipulator
SelRobot0
SelRobot1
SelRobot2
SelRobot3
1
0
0
0
0
2
1
0
0
0
3
0
1
0
0
4
1
1
0
0
5
0
0
1
0
6
1
0
1
0
7
0
1
1
0
8
1
1
1
0
9
0
0
0
1
10
1
0
0
1
11
0
1
0
1
12
1
1
0
1
13
0
0
1
1
14
1
0
1
1
15
0
1
1
1
16
1
1
1
1
0 : OFF, 1 : ON
RC420 Rev.9
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Setup & Operation
8.1 I/O Signal Description (I/O Remote Settings)
(*4) Specify the group number with SelGroup0-3 referring to the table below.
Specified
Group No.
SelGroup0
SelGroup1
SelGroup2
SelGroup3
1
0
0
0
0
2
1
0
0
0
3
0
1
0
0
4
1
1
0
0
5
0
0
1
0
6
1
0
1
0
7
0
1
1
0
8
1
1
1
0
9
0
0
0
1
10
1
0
0
1
11
0
1
0
1
12
1
1
0
1
13
0
0
1
1
14
1
0
1
1
15
0
1
1
1
16
1
1
1
1
0 : OFF, 1 : ON
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8.1 I/O Signal Description (I/O Remote Settings)
8.1.2 Remote Output Signals
Remote outputs provide status for the current Manipulator and Controller.
The remote output signals for EPSON RC+ are as follows:
Function
Description
MotorOn
Indicates that motors are on for the current robot.
PowerHigh
Indicates that motor power is set to high for the current robot.
McalComplete
Indicates that MCal has been completed for the current robot. If
the robot uses absolute encoders, then this output will always be
on.
AtHome
Indicates that the current robot is at its home position.
CmdRunning
Indicates that a remote input command is in cycle.
TasksRunning
Indicates that tasks are running in the Controller.
Paused
Indicates that tasks have been paused.
Safeguard
Indicates that the safeguard circuit is open.
EstopOn
Indicates that emergency stop has occurred.
Error
Indicates that an error had occurred. You must execute a Reset
input to clear the error condition.
AutoMode
Indicates that remote input commands will be accepted.
TeachMode
Indicates that the system is in Teach mode.
EnableOn
Indicates that the enable switch (dead man) is on during Teach
mode.
CurrRobor0
Robot Bit 0, weight 1. (*3)
CurrRobor1
Robot Bit 1, weight 2. (*3)
CurrRobor2
Robot Bit 2, weight 4. (*3)
CurrRobor3
Robot Bit 3, weight 8. (*3)
CurrGroup0
Group Bit 0, weight 1. (*4)
CurrGroup1
Group Bit 1, weight 2. (*4)
CurrGroup2
Group Bit 2, weight 4. (*4)
CurrGroup3
Group Bit 3, weight 8. (*4)
MotorMode
Indicates the current motor setting. Sometimes the motors are
turned off by the system, such as when the safeguard is opened.
But MotorMode signals the current user setting.
PowerMode
Indicates the current power setting. Sometimes the power is set
to low by the system. But PowerMode signals the current user
setting.
RecoverReqd
Indicates that a recover position can be executed after the
safeguard has been closed.
RecoverInCycle
Indicates that recover position is in cycle.
(*3) (*4): Refer to the tables in the Setup & Operation 8.1.1 Remote Input Signals.
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Setup & Operation
8.2 Timing Specifications (I/O Remote Settings)
8.2 Timing Specifications
8.2.1 Design Notes for Remote Input Signals
The following charts indicate timing sequences for the primary operations of the
Controller.
The indicated time lapses (time durations) should be referred to only as reference value
since the actual timing values vary depending on the number of Manipulators and the
number of tasks running, as well as CPU speed of the Controller. Check carefully and
refer to the following charts for the timing interrelation when you enter an input signal.
During system design, make sure that you actuate only one remote input operation at a
time, otherwise an error will occur.
The pulse width of an input signal must be 25 or more milliseconds to be detected.
8.2.2 Timing Diagram for Operation Execution Sequence
CmdRunning
20
Output
300
20
150
Power High
40
Output
MotorOn
Output
AtHome
Output
20
20
20
12
20
20
50
About 1000
Depending on
HOME motion
About 1000
MotorOn
Input
MotorOff
Input
Home
Input
PowerHigh
Input
PowerLow
Input
[Unit: msec]
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Setup & Operation
8.2 Timing Specifications (I/O Remote Settings)
8.2.3 Timing Diagram for Program Execution Sequence
CmdRunning
20
10
Output
CurrGroup
20
10
20
30
20
10
20
10
600
Output
TasksRunning
60
600
Output
Paused
Output (*1)
34
40
SelGroup
Input
Start
Input
Pause
Input
Cont
Input
AbortAll
Input
[Unit: msec]
*1: The duration varies depending on the Quick Pause (QP) setting and the program’s
operating status at the time of Pause input.
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8.2 Timing Specifications (I/O Remote Settings)
8.2.4 Timing Diagram for Safety Door Input Sequence
Paused
10
Output
30
10
SafeGuard
Output
MotorOn
Depending on Program
600
Output
Safety Input
Input
Latch Input
Input
Cont
Input
[Unit: msec]
8.2.5 Timing Diagram for Emergency Stop Sequence
TasksRunning
60
Output
MotorOn
Output
EStopOn
Output
10
10
50
Emergency
Input
Reset
Input
[Unit: msec]
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8.2 Timing Specifications (I/O Remote Settings)
8.2.6 Timing Diagram for RECOVER Sequence
Remote Auto Recover
22
Paused
Output
SafeGuard
11
6
21
Output
RecoverReqd
25
20
Output
RecoverInCycle
18
Output
Safety Input
Input
Latch Input
Input
Recover
Input
Start
Input
[Unit: msec]
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8.2 Timing Specifications (I/O Remote Settings)
Remote Manual Recover
22
Paused
Output
SafeGuard
11
6
21
Output
RecoverReqd
25
20
Output
RecoverInCycle
18
Output
Safety Input
Input
Latch Input
Input
Recover
Input
Start
Input
[Unit: msec]
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Setup & Operation
9.1 RS-232C cable (RS-232C Settings)
9. RS-232C Settings
The Standard RC420 Controller comes with two RS-232C channels to facilitate
controlling of the data communication among the host computer, robot system and their
peripheral equipment.
9.1 RS-232C cable
RS-232C cables are not included with the standard RC420 Controller. The user must
prepare them as necessary.
Connector
Standard
D-sub 9 pin
Communication connector
#4-40 screw
The cable must be shielded twisted pair. Clamp the shield to the connector hood to
prevent noise.
9.1.1 Pin Assignments
Pin assignments for RS-232C connectors are as follows:
RC420 Rev.9
Pin No.
Abbr.
Signal Name
Signal Direction
1
CD
Data carrier detect
Input
2
RD
Receive data
Input
3
SD
Send data
Output
4
ER
Terminal ready
Output
5
SG
Signal ground
–
6
DR
Data set ready
Input
7
RS
Request to send
8
CS
Clear to send
Input
9
RI
Ring indicator
Input
Output
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Setup & Operation
9.2 Preparation for Communication (RS-232C Settings)
9.1.2 Connection Example
Example 1: Standard
[Controller]
[Peripheral equipment]
Signal Name
Pin No.
Pin No.
Signal Name
SD
3
2
SD
RD
2
3
RD
SG
5
7
SG
RS
7
4
RS
CS
8
5
CS
DR
6
6
DR
CD
1
8
CD
ER
4
20
ER
1
FG
Clamp Hood
Example 2: H/W Flow Control
[Controller]
[Peripheral equipment]
Signal Name
Pin No.
Pin No.
Signal Name
SD
3
2
SD
RD
2
3
RD
SG
5
7
SG
RS
7
4
RS
CS
8
5
CS
DR
6
6
DR
CD
1
8
CD
ER
4
20
ER
1
FG
Clamp Hood
9.2 Preparation for Communication
For communication via RS-232C between the Controller and peripheral equipment to work,
the port configuration on both units must be the same.
For details on the set-up procedure and communication commands, refer to the section,
RS-232 Software Configuration in the chapter, RS-232 Communications in EPSON RC+
User’s Guide.
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10. UPS (Uninterruptible Power Supply)
10. UPS (Uninterruptible Power Supply)
10.1 UPS
The UPS (Uninterruptible Power Supply) protects the hard disk data (including Windows
and applications) from being damaged by power failure or power-off without shutdown.
CAUTION
■ Utilize the UPS only for protecting the data from damages caused by power
failure or power-off without shutdown. If the UPS is turned OFF over and over
intentionally while Windows is operating, the life cycle of UPS battery will be
shortened and the UPS may perform insufficiently.
■ Complete the shutdown of Windows within three minutes. If Windows is not
shut down within the battery backup time of the UPS, the data may be
damaged.
10.2 Configuration of Power Supplies
The Controller is equipped with the 24V output power supply, battery, and output power
supply for 5V and 12V. The UPS consists of the battery and the output power supply
for 5V and 12V. The UPS provides backup power only for the 5V and 12V power
supplies that are necessary to operate the CPU and hard disk. The UPS does not back
up the power for the Manipulator or Encoder Power Supply. Therefore, when a power
failure or power-off without shutdown occurs while the Manipulator is operating, an error
such as an encoder cable disconnection error occurs and the Manipulator makes an
emergency stop.
10.3 Normal Shutdown of Robot System
Exit EPSON RC+ and shut down Windows. After the Controller is ready to be turned
OFF, turn OFF the power switch of the Controller. Then, all the power supplies except
for the UPS will be turned OFF immediately and the UPS power supply will be turned
OFF approximately five seconds later.
10.4 Automatic Shutdown by UPS service in Robot System
For RC420, the UPS service of Windows functions and automatically shuts down the
system when a power failure or power-off without shutdown occurs. The UPS service
has already been configured at the factory before shipment. The process of
automatically shutting down the system depends on the conditions of Windows and
power supply. (For details of the shutdown processes, refer to the sections 10.4.1 and
10.4.2.)
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10. UPS (Uninterruptible Power Supply)
10.4.1 While Windows is being booted up
A power failure or voltage drop occurs.
→ The power does not recover.
The power switch is turned OFF accidentally.
→ The switch is left OFF.
Windows is booted up and then it is shut down automatically.
CAUTION
■ When Windows is hung, even if you turn OFF the Controller, Windows remains
hung until the battery is completely discharged. In this case, turn OFF the
UPS ON/OFF switch. Then, turn ON the UPS ON/OFF switch again after the
UPS is turned OFF. Since the power is not output from the UPS while the UPS
ON/OFF switch is OFF, Windows does not start even though the Controller is
turned ON.
UPS ON/OFF Switch
10.4.2 After Windows is booted up
A power failure or voltage drop occurs.
→ The power recovers during the automatic shutdown.
The power switch is turned OFF accidentally.
→ The power switch is turned ON during the automatic shutdown.
The UPS automatically shuts down Windows when detecting power-off. Once the
shutdown is started, the shutdown cannot be stopped even though the power failure
condition has been corrected. After Windows is shut down, the SHUTDOWN LED
on the front panel of the Controller lights and remains ON. When the Controller is
turned OFF, the UPS power is turned OFF approximately five seconds later.
A power failure or voltage drop occurs.
→ The power does not recover during the automatic shutdown.
The power switch is turned OFF accidentally.
→ The power switch is left OFF.
The UPS automatically shuts down Windows when detecting power-off. After
Windows is shut down, the SHUTDOWN LED on the front panel of the Controller
lights.
Approximately five seconds later, the UPS power is turned OFF
automatically.
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10. UPS (Uninterruptible Power Supply)
10.5 UPS Battery
10.5.1 Safety Precautions for Battery
CAUTION
■ Be sure to follow the precautions listed below when handling the battery. Not
following the precautions may result in extremely hazardous conditions such as
excess heat generation, and a possible explosion of the battery.
- Do not throw the battery into fire or expose it to high temperature.
- Do not allow the connector terminals of the battery to short circuit.
- Use the battery only for RC420 Controller.
- Do not apply a strong shock to the battery.
- Stop using the battery if you see any signs of change of color or damage to
the battery.
Recycling of Battery
Dispose of the used battery appropriately in accordance with the laws and acts of your
national or local government. If you cannot dispose of a used battery properly, please
inquire of your EPSON robot supplier how to dispose of it.
10.5.2 Charging Battery
Turning ON the Controller will automatically charge the UPS battery.
It takes approximately 80 minutes to completely charge a discharged UPS battery.
charge the battery fully, turn ON the Controller and keep it energized continuously.
To
10.5.3 Life Cycle of Battery
The life cycle of the battery depends on the ambient temperature, number of backup
cycles, current-carrying capacity during backup, and backup time.
To prolong the life cycle of the battery, please follow the points shown below:
- The ambient temperature of the Controller should be 5 to 30 deg.C.
Refer to the relation between the ambient temperature and the life cycle of battery as
shown below:
Suppose that the life cycle of battery is 100% when the ambient temperature is 20
deg.C.
When the ambient temperature is 30 deg.C: approximately 70%
When the ambient temperature is 40 deg.C: approximately 40%
- Do not turn OFF the power while Windows is operating.
- Keep the total current-carrying capacity of optional boards under the following range.
5V : 4A or less
12V : 0.5A or less
- Complete the shutdown of Windows within three minutes.
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Setup & Operation
10. UPS (Uninterruptible Power Supply)
Replacement timing according to the number of backup cycles and usable years
Replace the battery according to the following number of backup cycles and years
when the robot system is used in the standard condition (no option is used) and at
ordinary temperature.
Number of backup cycles (How many times the battery can be charged and
discharged.) : Approximately 500 times
Usable years : Approximately three years
Replacement timing according to the backup time
Measuring the battery backup time will show the approximate life cycle of battery.
Measure the backup time using the procedure described below and record it as an
initial value before using the Controller in your system.
Measure the backup time regularly and replace the battery when the measured backup
time is approximately 60% of the initial value.
How to measure the backup time:
(1)
Turn ON the Controller in the actual configuration of your system, and keep the
Controller energized for approximately 80 minutes.
(2)
From the Windows 2000 task bar, click the <Start> button and select the
[Settings] - [Control Panel]. The [Control Panel] window will appear.
(3)
Double-click the <System> icon in the [Control Panel] window to show the
[System Properties] dialog. Then, click the [Hardware] tab.
(4)
Click the <Device Manager> button to show the [Device Manager] dialog.
(5)
Select the [SPEL RESOURCE Drivers] - [SPEL VSRCSHUT] in the [Device
Manager] dialog.
(6)
Right-click on the [SPEL VSRCSHUT] and select the “Disable” from the
pop-up menu.
(7)
Selecting the “Disable” will show the message dialog.
in the message dialog.
(8)
Close all the dialogs and shut down Windows.
(9)
Make sure that Windows is shut down and the Controller is safe to be turned
OFF. Then, turn OFF the Controller. Measure how long all the LEDs on the
front panel of the Controller take to light OFF after the Controller is turned OFF.
Then, record the time.
Click the <Yes> button
(10) Turn ON the Controller and keep it energized for approximately 80 minutes to
charge the UPS battery.
(11) Set the driver [SPEL VSRCSHUT] whose setting was “Disable” in Step (6) to
the “Enable”. (Right-click on the [SPEL VSRCSHUT] and select the “Enable”
from the pop-up menu.)
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10. UPS (Uninterruptible Power Supply)
10.5.4 Replacement of Battery
(1)
Shut down Windows, and turn OFF the Controller.
(2)
Turn OFF the UPS ON/OFF switch.
(5)
UPS ON/OFF Switch
(4) Battery Connector
(3) Wait for about 1 minute until the high voltage charged area is completely discharged.
Remove four mounting screws, and remove the front cover from the Controller.
(4)
Remove the battery connector.
(5)
Remove six mounting screws, and remove the battery cover.
(6)
Pull out the battery from the Controller.
(7)
Remove the U-shaped plate from the front of the battery, and mount it onto a new
battery.
U-shaped Plate
(8)
Insert the new battery into the Controller
(9)
Secure the battery cover to the Controller with the six mounting screws.
(10) Connect the battery connector.
(11) Secure the front cover to the Controller with the four mounting screws.
(12) Turn ON the UPS ON/OFF switch.
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Setup & Operation
10. UPS (Uninterruptible Power Supply)
10.6 Setting up Windows
NOTE
)
10.6.1 Installing RC420 UPS Drivers
NOTE
)
COM4 configuration and UPS driver installation have been done before shipping.
Normally, it is not necessary to install the UPS drivers following the procedure described
in this section.
When the UPS is installed in the RC420 Controller, you must configure COM4 to allow
communication with the device and also install the UPS driver following the procedure
below.
NOTE
The installation procedure differs according to the version of the EPSON RC+.
)
84
The display of the setup procedures and setting items may differ according to the version
of the EPSON RC+.
EPSON RC+4.1 or before (Windows 2000)
(1) Restart the Controller and enter the BIOS.
(2) In the PCI configuration, set IRQ11 to “Legacy”. This will reserve IRQ11 for
COM4.
(3) Reboot the Controller and start Windows.
(4) Double-click the <Add / Remove Hardware> icon in the [Control Panel]. The
[Add / Remove Hardware Wizard] dialog will appear.
(5) Click the <Next> button.
(6) Select the <Add / Troubleshoot a device> option button, then click the <Next>
button.
RC420 Rev.9
Setup & Operation
10. UPS (Uninterruptible Power Supply)
(7) Select the “Add a new device”, then click the <Next> button.
(8) Select the <No, I want to select the hardware from a list> option button, then click
the <Next> button.
(9) Select the “Ports [COM & LPT]”, then click the <Next> button.
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85
Setup & Operation
10. UPS (Uninterruptible Power Supply)
(10) Select the “Communications Port” in the [Models] box, then click the <Next>
button.
(11) You will receive a warning message “Windows could not detect settings”. Ignore
the message and click the <OK> button.
(12) Select “Basic configuration 0008” in the [Setting based on] box in the [Add New
Hardware Wizard Properties] dialog.
(13) Click the “Input/Output Range” in the [Resource settings] box in the [Add New
Hardware Wizard Properties] dialog.
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RC420 Rev.9
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10. UPS (Uninterruptible Power Supply)
(14) Click the <Change Setting …> button.
will appear.
The [Edit Input / Output Range] dialog
(15) Enter “2E8-2EF” for the [Value] box and click the <OK> button.
(16) Select the “Interrupt Request” in the [Resource settings] box in the [Add New
Hardware Wizard Properties] dialog.
(17) Click the <Change Setting …> button in the [Add New Hardware Wizard
Properties] dialog. The [Edit Interrupt Request] dialog will appear.
(18)
(19)
(20)
(21)
Enter “11” for the [Value] box and click the <OK> button.
Click the <Next> button in the wizard and finish the installation.
Reboot the system when prompted to do so.
Double-click the <Add / Remove Hardware> icon in the [Control Panel].
[Add / Remove Hardware Wizard] dialog will appear.
(22) Click the <Next> button.
RC420 Rev.9
The
87
Setup & Operation
10. UPS (Uninterruptible Power Supply)
(23) Select the <Add / Troubleshoot a device> option button, then click the <Next>
button.
(24) Select the “Add a new device”, then click the <Next> button.
(25) Select the <No, I want to select the hardware from a list> option button, then click
the <Next> button.
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10. UPS (Uninterruptible Power Supply)
(26) Select the “Other devices”, then click the <Next> button.
(27) Click the <Have disk...> button.
(28) Enter or browse for the target path for the “VSRCShut.inf” file located in
“c:\EpsonRc\RC420\Drivers”. Then click the <Next> button.
(29) Reboot the system when prompted.
EPSON RC+4.2 or after (Windows XP)
(1) Restart the Controller and enter the BIOS.
(2) In the PCI configuration, set IRQ11 to “Legacy”. This will reserve IRQ11 for
COM4.
(3) Reboot the Controller and start Windows.
(4) Open the [Control Panel] and select [Switch to Classic View].
(5) Double-click the <Add Hardware> icon.
(6) The [Add Hardware Wizard] dialog will appear. Click the <Next> button.
(7) Select the <Yes, I have already connected the hardware> button, then click the
<Next> button.
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Setup & Operation
10. UPS (Uninterruptible Power Supply)
(8) Select the “Add a new hardware device”, then click the <Next> button.
(9) Select the <Install the hardware that I manually select from a list> option button,
then click the <Next> button.
(10) Select the “Ports [COM & LPT]”, then click the <Next> button.
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RC420 Rev.9
Setup & Operation
10. UPS (Uninterruptible Power Supply)
(11) Select the “Communications Port” in the [Models] box, then click the <Next> button.
(12) Click the <Next> button in the Add Hardware Wizard.
(13) Click [View or change resources for this hardware] in the Add Hardware Wizard.
(14) Click the <Set Configuration Manually> button.
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91
Setup & Operation
10. UPS (Uninterruptible Power Supply)
(15) Select “Basic configuration 0008” in the [Setting based on] box.
(16) Click the “Input/Output Range” in the [Resource settings] box in the dialog of step
(15) and click the <Change Setting …> button.
The [Edit Input / Output Range] dialog will appear.
(17) Enter “02E8-02EF” for the [Value] box and click the <OK> button.
(18) Select the “Interrupt Request” in the [Resource settings] box in the dialog of step
(15) and click the <Change Setting …> button.
The [Edit Interrupt Request] dialog will appear.
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10. UPS (Uninterruptible Power Supply)
(19) Enter “11” for the [Value] box and click the <OK> button.
(20) Click the <OK> button.
(21) Click the <Finish> button in the dialog in step (13) and finish the installation.
(22) Reboot the system when prompted to do so.
(23) Open the [Control Panel].
(24) Double-click the <Add Hardware> icon.
(25) Click the <Next> button on [Add Hardware Wizard].
(26) Select [Yes, I have already connected the hardware], then click the <Next> button.
(27) Select [Add a new hardware device], then click the <Next> button.
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Setup & Operation
10. UPS (Uninterruptible Power Supply)
(28) Select [Install the hardware that I manually select from a list], then click the <Next>
button.
(29) Select [Show All Devices], then click the <Next> button.
(30) Click the <Have disk...> button.
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10. UPS (Uninterruptible Power Supply)
(31) Enter or browse for the target path for the VSRCShut.inf file located in
c:\EpsonRc\RC420\Drivers.
Then click Next.
(32) Click the <Next> button in the wizard and finish the installation.
(33) Reboot the system when prompted.
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Setup & Operation
10. UPS (Uninterruptible Power Supply)
10.6.2 Basic Configuration of Windows
NOTE
)
96
The UPS has been enabled before shipping. Normally, it is not necessary to configure
Windows following the procedure described in this section.
(1)
Open the Control Panel.
When using EPSON RC+4.2 (Windows XP), select [Switch to Classic View].
(2)
Double-click the <Power Options> icon in the [Control Panel].
Options properties] dialog will appear.
(3)
Select the [UPS] tab in the [Power Options Properties] dialog.
The [Power
RC420 Rev.9
Setup & Operation
RC420 Rev.9
10. UPS (Uninterruptible Power Supply)
(4)
Click the <Select…> button in the [UPS] panel.
appear.
The [UPS Selection] dialog will
(5)
Select the “SEIKO EPSON CORPORATION” from the [Select manufacturer] box.
(6)
Select the “RC420 UPS” from the [Select model] box.
(7)
Select the “COM4” from the [On port] box.
(8)
Click the <Finish> button in the [UPS Selection] dialog.
Properties] dialog will appear.
The [Power Options
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Setup & Operation
10. UPS (Uninterruptible Power Supply)
10.6.3 Setting up the Automatic Shutdown at the Time of a Power Failure
NOTE
)
The Controller has been configured so that the system is automatically shut down at the
time of a power failure. Normally, it is not necessary to configure the Controller
following the procedure described in this section. When the computer name, user name,
or password is changed, however, configure the Controller following the procedure
below.
(1) Open the Control Panel.
When using EPSON RC+4.2 (Windows XP), select [Switch to Classic View].
(2) Double-click the <Power Options> icon in the [Control Panel].
Options Properties] dialog will appear.
The [Power
(3) Select the [UPS] tab.
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(4) Click the <Configure…> button.
10. UPS (Uninterruptible Power Supply)
The [UPS Configuration] dialog will appear.
(5) Check the [When the alarm occurs, run this program] checkbox.
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10. UPS (Uninterruptible Power Supply)
(6) Click the <Configure…> button. The [UPS System Shutdown Program] dialog
will appear. When changing either the Controller’s computer name or the user
name, input the new computer name or the user name in the [Run as] box.
EPSON RC+4.1 or before (Windows 2000)
SN*****
: This is the default computer name. The actual computer
name varies depending on serial number at shipping or user
setting.
Administrator
: This is the default user name.
logging on the Controller.
Specify the user name for
EPSON RC+4.2 or after (Windows XP)
SN*****
: This is the default computer name. The actual computer
name varies depending on serial number at shipping or user
setting.
EPSON RC User : This is the default user name.
logging on the Controller.
Specify the user name for
(7) Enter the file name for the [Run] box.
EPSON RC+4.1 or before (Windows 2000) : C:\WINNT\system32\UPSshut.exe
EPSON RC+4.2 or after (Windows XP)
: C:\WINDOWS\system32\UPSshut.exe
100
RC420 Rev.9
Setup & Operation
10. UPS (Uninterruptible Power Supply)
(8) Click the <OK> or <Apply> button. The [Set Account Information] dialog will
appear. The password should be same as the Windows login password. Set each
item correctly to function UPS properly.
(9) Click the <OK> button.
The [UPS Configuration] dialog will appear.
(10) Click the <OK> button.
(11) Click the <OK> or <Apply> button in the [Power Options Properties] dialog.
(12) Double-click the file name.
EPSON RC+ : C:\EpsonRC\RC420\drivers\UPS.reg
SPEL CT
: C:\PSPELWORK\SYS\REG\UPS folder\Wait0.reg
(13) Click the <Yes> button.
(14) Click the <OK> button.
RC420 Rev.9
101
Setup & Operation
10. UPS (Uninterruptible Power Supply)
10.6.4 UPS Setup Consideration
When the [UPS Configuration] dialog is displayed after the automatic shutdown at
the time of a power failure is set up in the section 10.6.3:
Executing “UPS.reg” in step (11) in the section 10.6.3 Setting up the Automatic Shutdown
at the Time of a Power Failure makes the [Minutes on battery before critical alarm] check
box ([Control Panel] - <Power Options> icon - [UPS] tab - [UPS Configuration] dialog)
selected. It also enters “0” for the [Minutes on battery before critical alarm] box.
When you click the <OK> button in the [UPS Configuration] dialog in this condition, the
following error message appears.
Click the <OK> button in the error message.
[UPS Configuration] dialog.
Then, click the <Cancel> button in the
When “2” is entered for the [Minutes on battery before critical alarm] box, the shutdown
procedure starts two minutes later after a power failure occurs. If this time is set to longer
than 2 minutes, execute the “UPS.reg” and set the time to “0” referring to step (11) in the
section 10.6.3 Setting up the Automatic Shutdown at the Time of a Power Failure.
102
RC420 Rev.9
Setup & Operation
10. UPS (Uninterruptible Power Supply)
[For users who use the RC420 Controller with UPS]
The RC420 Controller is configured at factory as shown below:
EPSON RC+4.1 or before
(Windows 2000)
Computer Name SN***** (Serial No.*)
User Name
Administrator
Password
Not set
EPSON RC+4.2 or after
(Windows XP)
Computer Name SN***** (Serial No.*)
User Name
EPSON RC User
Password
epson
* Serial No. (SN*****)
: ***** denotes a five-digit number and it is unique to each Controller.
When the computer name, user name, or password is changed, the UPS will not
automatically shut down the RC420 Controller in the case of a power failure despite its
setting.
After you change the computer name, user name, or password, configure the UPS again
so that it will automatically shut down the RC420 Controller in the case of a power
failure. For details, refer to the section 10.6.3 Setting up the Automatic Shutdown at the
Time of a Power Failure.
RC420 Rev.9
103
Setup & Operation
104
10. UPS (Uninterruptible Power Supply)
RC420 Rev.9
Maintenance
This manual contains maintenance procedures for
the RC420 Robot Controller.
97
Maintenance
106
RC420 Rev.9
Maintenance
1. Safety Precautions on Maintenance
1. Safety Precautions on Maintenance
1.1 Safety Precautions
■ Only authorized personnel who have taken the safety training should be allowed
to maintain the robot system.
The safety training is the program for 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.
The personnel who have completed the robot system-training and
maintenance-training classes held by the manufacturer, dealer, or
locally-incorporated company are allowed to maintain the robot system.
WARNING
■ Make sure to use only dedicated/specified maintenance parts especially for the
optional boards or any other parts in the Controller to be replaced. Using
non-specified parts may cause serious damage to the robot system and/or
serious safety problems.
■ Do not remove any parts that are not covered in this manual. Follow the
maintenance procedure strictly as described in this manual. Do not proceed
using any methods other than described in this manual when you do replace a
part or maintain the equipment. Improper removal of parts or improper
maintenance may cause not only improper function of the robot system but also
serious safety problems.
WARNING
■ Before performing any maintenance procedure, always make sure that the main
power of the Controller is turned OFF and that the high voltage charged area is
completely discharged. Performing any maintenance procedure while the main
power is ON or the high voltage charged area isn’t discharged completely is
extremely hazardous and may result in electric shock and/or cause serious
safety problems.
■ Do not touch directly the Motor Driver modules and the Switching Power Supply
in the Controller. The Motor Driver modules and the Switching Power Supply
can become very hot and may result in a burn. If you maintain them, examine
the surface temperatures and wear protective gloves if necessary.
CAUTION
RC420 Rev.9
■ Do not shock, shake, or drop any parts during maintenance. When the parts
related with data (the FDD, HDD, etc.) are shocked physically, they may be
damaged and may also cause data loss during data loading/saving.
■ Do not lose the screws removed at maintenance. When the screw is dropped
into the Controller, be sure to take it out. Leaving the screw in the Controller
may cause short circuit and may result in equipment damage to the parts and/or
robot system.
107
Maintenance
1. Safety Precautions on Maintenance
■ Make sure that the power rating (wattage) of a new Motor Driver module is
correct. Using a Motor Driver module with improper power rating (wattage) in
the Controller may not only cause improper function of the robot system but also
damage to the system.
CAUTION
NOTE
)
■ The serial number of the Manipulator that should be connected is indicated on
the Connection Check Label on the Controller. Connect the Controller and the
Manipulator correctly. Improper connection between the Controller and the
Manipulator may cause not only improper function of the robot system but also
serious safety problems.
Before performing maintenance on the Controller, all the data must be copied as a backup.
The details of data backup/restore are described in the Maintenance 2.5Backup of Data
1.2 Lockout
The lockout is a method to prevent any one from turning ON the robot system by mistake
while someone else is within the safeguarded area for maintenance or repair.
When the robot system is locked out, the POWER switch of the Controller is locked in the
OFF position. The procedure for lockout is shown below.
(1) Turn OFF the Controller.
(2) Tilt the lockout metal hasp in the direction of the arrow indicated below.
Lockout metal hasp
(3) Close the front door while the metal hasp comes out as shown below.
Lockout metal hasp
1.3 Tagout
The tagout method is attaching a tag or sign plate to the Power switch to prevent any one from
turning ON the robot system by mistake while someone else is within the safeguarded area for
maintenance or repair.
108
RC420 Rev.9
Maintenance
2. Regular Maintenance Inspection
2. Regular Maintenance Inspection
Performing the inspection steps properly is essential to preventing trouble and maintaining
safety. This chapter describes schedule for maintenance inspection and the procedures.
Be sure to perform the maintenance inspection in accordance with the schedule.
2.1 Schedule for Maintenance Inspection
Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and
annual. The inspection points are added every stage.
If the robot system 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.
Inspection Point
Monthly
Quarterly
Biannual
Annual
inspection
inspection
inspection
inspection
inspection
9
2 months (500 h)
9
3 months (750 h)
9
4 months (1000 h)
9
5 months (1250 h)
9
9
9
9
11 months (2750 h)
9
12 months (3000 h)
9
13 months (3250 h)
9
…
9
…
10 months (2500 h)
…
9
9
9
9
9
…
9 months (2250 h)
9
…
8 months (2000 h)
9
9
…
7 months (1750 h)
Inspect every day
1 month (250 h)
6 months (1500 h)
RC420 Rev.9
Daily
109
Maintenance
2. Regular Maintenance Inspection
2.2 Inspection Point
2.2.1 Inspection While the Controller is Turned OFF
Inspection Point
Visually check for
external defects.
Clean up if necessary.
Cleaning of the fan filter
Battery Replacement on
the CPU Board
Inspection Place
External
appearance of
Controller
Fan filter on the
Controller
CPU Board
Daily Monthly
9
Quarterly Biannual Annual
9
9
9
9
9
9
9
9
Ever 5 years
2.2.2 Inspection While the Controller is Turned ON
Inspection Point
Check whether unusual
sound or vibration
occurs.
Make a backup of data.
Inspection Place
Whole of the
Controller
Project and
system data
Daily Monthly
9
9
Quarterly Biannual Annual
9
9
9
Whenever data are changed.
2.3 Cleaning the Fan Filter
NOTE
)
Check condition of the filter regularly and clean it as necessary. A dirty filter may result
in the malfunction of the robot system as the temperature rises in the Controller.
Refer to the Maintenance 10.4. Fan Filter for details on cleaning the fan filter.
2.4 Replacing a Lithium Battery on the CPU Board
The button type lithium battery is mounted on the CPU board for backup of BIOS settings.
The battery life is five years. Replace the battery every five years.
CAUTION
110
■ Lithium batteries contain flammable materials such as lithium, organic
solvents, etc. If misused, batteries may generate heat, explode or catch fire.
Observe the following precautions for safe use of lithium batteries.
- Use the specified type of battery or equivalent.
CR2032 (Panasonic)
- Connect the positive (+) and negative (-) electrodes correctly.
- Do not allow the positive (+) and negative (-) electrodes to short circuit at
maintenance.
- Do not throw batteries into fire or heat them to high temperature.
- Do not disassemble or alter batteries.
- When discarding batteries, insulate the terminals by wrapping them with
tape, etc.
RC420 Rev.9
Maintenance
2. Regular Maintenance Inspection
(1) Remove the CPU board from the Control Unit.
Replacing CPU Board for details.
Refer to the Maintenance 10.2
CPU Board:SPI-6941-EPC
Lithium battery
CPU Board :PC686BX(PC)-EPC850
Lithium battery
(2)
Replace the lithium battery with new one.
(3)
After replacing the lithium battery, set up the BIOS.
3-1. Turn ON the Control Unit while pressing the <Delete> key on the keyboard.
The [BIOS] dialog will appear.
3-2. Select the “Standard COMS Features” and press the <Enter> key.
3-3. Set the “Date” and “Time” to current date and time. (Use the <Page Up> key
for changing the setting items and the arrow keys <↑> <↓> <→> <←> for
moving a cursor.)
3-4. Press the <Esc> key. The [BIOS] dialog will appear.
3-5. Select the “PnP/PCI Configurations” and press the <Enter> key.
3-6. Select the “IRQ Resources [Press Enter]” and press the <Enter> key.
3-7. Set the “IRQ-5”, “IRQ-10”, and “IRQ-11” to the “Legacy ISA”. (Use the
<Page Up> key for changing the setting items and the arrow keys <↑> <↓>
<→> <←> for moving a cursor.)
3-8. Press the <Esc> key twice. The [BIOS] dialog will appear.
3-9. Press the <F10> key. The message “SAVE to COMS and EXIT (Y/N)?” will
appear.
3-10. Press the <Y> key and then <Enter> key. The system will be automatically
restarted.
RC420 Rev.9
111
Maintenance
2. Regular Maintenance Inspection
2.5 Backup of Data
The system hardware and manipulator configuration data are saved in a backup file that
can be used to restore the whole system.
■
Save a backup data of your project and system settings in a floppy disk while
the Control Unit operates properly. Then, keep the floppy disk in case of
damage to the data in HDD. Be sure to back up the latest data whenever you
change the project and system settings.
If the latest data is not backed up, it takes a lot of time to restore the robot
system data once the robot system has a trouble. The robot system data after
the trouble may fail to be backed up. Even if the robot system data is backed
up successfully, the backed up data is unreliable and the robot system data
cannot be restored completely with it.
■
Do not restore the backup data in any other system. The data includes the
original configuration of the system. If the data is restored in the other system,
the system may function improperly or EPSON RC+ may fail to start up.
If EPSON RC+ is downgraded and its version is different even though the
backup data is for the same system, an error may occur and the data may fail
to be restored.
CAUTION
For EPSON RC+, you can save and restore the system configuration using the MKVER
and SETVER commands. Before servicing the system, you should execute MKVER and
store the system configuration on a floppy disk. If required, you can use SETVER to
restore previously stored data.
NOTE
)
When you attempt to make backup copies of the system configurations using the MKVER
and SETVER commands, the configuration data in the following tabs cannot be backed up.
Record such configurations data displaying the [System Configuration] dialog. (Select
the [System Configuration] in the [Setup] menu to display the [System Configuration]
dialog.)
[Start Up] tab
[Vision] tab (option)*
[Security] tab (option)
* [Vision] tab (option):
If your EPSON RC+ is
4.1.0 or higher,
recording the items on
the [Vision] is not
necessary.
After restoring the backup data, configure the settings for the recorded items in the
respective tabs.
112
RC420 Rev.9
Maintenance
2. Regular Maintenance Inspection
Back up system configurations
MKVER: Backs up (saves) system configurations.
(1) Select either one of the following to open the [Maintenance] dialog.
1. Select the [Maintenance] in the [Tools] menu.
2. Click the <
> icon.
(2) Click the <MKVER> button to open the [MKVER] dialog.
(3) Type in a unique name to identify the system in the [MKVER Name] text box.
(4) Select the disk drive where you want to save the information in the [Drive] box. (You
can select any drive except for C drive.)
(5) Click the <OK> button to save the system configuration.
RC420 Rev.9
113
Maintenance
2. Regular Maintenance Inspection
Restore system configurations
SETVER: Restores system configurations.
(1) Select either one of the following to open the [Maintenance] dialog.
1. Select the [Maintenance] in the [Tools] menu.
2. Click the <
> icon.
(2) Click the <SETVER> button to open the [SETVER] dialog.
(3) Select the drive where the backed-up information is stored in the [Drive] box.
(4) Select the system configuration from the [Select MKVER files] list box.
(5) Click the <OK> button to restore the system configuration.
114
RC420 Rev.9
Maintenance
2. Regular Maintenance Inspection
Backing up / Restoring a Project
You can back up the whole of stored project and restore it. You can also move your
developing EPSON RC+ applications into another system.
Back up a project
Follow the steps below to make a backup copy of the current project.
(1) Select the [Copy] command in the [Project] menu to open the [Copy Project] dialog.
(2) Select the drive where a backup copy will be made in the [Destination Drive] box.
(3) Enter the current project name for the [Destination Project Name] box.
(4) Click the <OK> button.
NOTE
)
)
The currently open project is the original project stored in the C drive, not a backed-up
project stored in the destination drive specified in step (2).
RC420 Rev.9
115
NOTE
If there is more than one project, back up every project separately.
Maintenance
2. Regular Maintenance Inspection
Restore a project
Follow the steps below to restore the backed-up project.
(1) Select the [Open] command in the [Project] menu to open the [Open Project] dialog.
(2) Select the drive where the backed-up project is stored in the [Select Drive] box and
open the backed-up project.
NOTE
)
The currently open project is the backed-up project stored in the drive you select in the
[Select Drive] box.
(3) Select the [Save As] command in the [Project] menu to open the [Save Project As]
dialog.
(4) Select the “C drive” in the [New Project Drive] box.
(5) Enter a project name for the [New Project Name] box.
(6) Click the <OK> button.
NOTE
)
116
The currently open project is the project stored in the C drive.
RC420 Rev.9
Maintenance
3. Controller Internal Layout
3. Controller Internal Layout
The internal layout for the Controller is shown in following three pictures.
You can see the layout as shown in the picture below when removing the Top Cover.
Regeneration
Module
CPU Board
Optional Board Slot
DMB
Motor Driver
Module
DPB
(Front)
(Front)
NOTE
)
When required, the Regeneration module
must be mounted in the last Motor Driver
module slot, as shown above.
You can see the DMB and the DPB after
removing the Motor Driver modules.
You can see the layout as shown in the picture below when removing the Bottom Cover.
Switching Power Supply Module 1
Switching Power Supply Module 2
(Front)
RC420 Rev.9
117
118
CPU
Board
1:USB
2:Parallel
Panel
Board
X400
HDD
+12V
Cooling
Fan
Cooling
Fan
DPB
+24V +5V
X311 X310
X303
X300
X306
X307
FS1
FS2
X308
X304
Motor Power Control
X309
Rectification
Circuit
X302
+12V
-5V +5V
DC-DC
X317 X316
X315
X312
X313
Motor Driver
Optional Device
USB Connector
FDD
5V,12V
Regeneration
Module
X305
X114
X109 X110
+24V
+24V
X108
DMB
Encoder
5V
X107
DC-DC
X301
+24V
X102 X103
X104
X105B
X105A
Standard I/O M/C SIGNAL EMERGENCY
Motor Driver
FDD Cable
+24V
X209
DC-DC
-12V
5V,±12V
Back
Plane
X208B
X208A
ISA BUS
Motor Driver
5V,12V,24V
PCI BUS
ISA BUS
3:COM 1
4:COM 2
Motor Driver
IDE Cable
1234
SSR
Resistor
Battery
Switching
Power
Supply
(+5V,
+12V)
M/C Power
Switching
Power
Supply
(+24V)
Earth
Leakage
Circuit
Breaker
Noise
Filter
AC200-240V
Maintenance 3. Controller Internal Layout
RC420 Block Diagram
RC420 Rev.9
Maintenance
4. Pin Assignments for the System Connectors
4. Pin Assignments for the System Connectors
4.1 M/C Power Cable
The following tables show the pin assignments for the M/C power connector and M/C
signal connector. As for the pin assignments of the connectors not covered in this
section, refer to the Setup & Operation.
Pin No.
Signal Name
Pin No.
Signal Name
1
1U
9
3W
2
4V
10
2U
3
1V
11
NC
4
4U
12
NC
5
SHIELD
13
3V
6
1W
14
2V
7
4W
15
3U
8
NC
16
2W
FG
RC420 Rev.9
119
Maintenance
4. Pin Assignments for the System Connectors
4.2 M/C Signal Cable
NOTE
)
120
Pin No.
Signal Name
Pin No.
Signal Name
Pin No.
Signal Name
1
EG
26
1S
51
2B
2
4A
27
1HOME
52
2Z
3
4B
28
ENC+5V
53
2S
4
4Z
29
NC
54
NC
5
4S
30
NC
55
ENC+5V
6
4HOME
31
NC
56
EG
7
ENC+5V
32
EMB1
57
1A
8
EG
33
+24V
58
1B
9
3A
34
RG
59
1Z
10
3B
35
EG
60
1S
11
3Z
36
4A
61
HCOM
12
3S
37
4B
62
ENC+5V
13
3HOME
38
4Z
63
NC
14
ENC+5V
39
4S
64
NC
15
EG
40
NC
65
NC
16
2A
41
ENC+5V
66
EMB2
17
2B
42
EG
67
+24V
18
2Z
43
3A
68
RG
19
2S
44
3B
20
2HOME
45
3Z
21
ENC+5V
46
3S
22
EG
47
NC
23
1A
48
ENC+5V
24
1B
49
EG
25
1Z
50
2A
The Controller’s and Manipulator’s pin numbering layout differs: one is lined horizontally
and the other is lined vertically.
RC420 Rev.9
Maintenance
5. Switching Power Supply Module
5. Switching Power Supply Module
5.1 Layout and Functions
Switching Power Supply Module 1: AES100W-24
Switching Power Supply module 1 rectifies AC200V (or the local equivalent) and outputs
+24V. The +24V is converted by the DPB to supply power to the control power
sources: the motor driver (-5V) and the encoder (5V).
Switching Power Supply Module 2: NSP7-100-X2S2
Switching Power Supply module 2 rectifies AC200V (or the local equivalent) and outputs
+12V, +5V.
Switching Power Supply Module 1
Switching Power Supply Module 2
(Front)
5.2 Inspection
Inspect the Switching Power Supply modules by following the steps below:
(1) Turn ON the Controller.
(2) From the Controller’s front panel, check if the POWER LED (green) is ON.
NOTE
)
NOTE
)
If this LED is either OFF or dim, suspect that the +24V power output is not normal.
(3) From the Controller’s front panel, check if the RUN LED (green) is blinking.
If this LED is not blinking or it is dim, the +5V and +12V power outputs may be not
normal.
STATUS
MOTOR
ERROR POWER
1
2
D-ERROR
RUN
E-STOP POWER
(3) RUN LED (Green)
RC420 Rev.9
SAFE
SHUTDOWN
(2) POWER LED (Green)
121
Maintenance
5. Switching Power Supply Module
5.3 Replacement
5.3.1 Replacing Switching Power Supply Module 1:
WARNING
■ Before performing any maintenance procedure, always make sure that the main
power of the Controller is turned OFF and that the high voltage charged area is
completely discharged.
Performing any maintenance procedure while the main power is ON or the high
voltage charged area isn’t discharged completely is extremely hazardous and
may result in electric shock and/or cause serious safety problems.
(1) Shut down Windows, and turn OFF the Controller.
(2) Disconnect all the cables from the back of the Controller.
(3) Turn OFF the UPS ON/OFF
switch.
(7)
UPS ON/OFF switch
(6) Battery Connector
(4) Wait for about 1 minute until the high voltage charged area is completely discharged.
Remove four mounting screws, and remove the front cover from the Controller.
(5) Remove the connector (X400) of the board for display from the front cover.
(6) Remove the battery connector.
(7) Remove six mounting screws, and remove the battery cover.
(8) Pull out the battery from the
Controller.
Battery
(9) Remove six mounting screws, and remove the Bottom Cover.
(10) Remove the CN1 and CN2
connectors.
(11) Remove the screws 1 and 2, and
remove the Switching Power Supply
module 1.
122
CN1
Screw 1
CN2
Screw 2
RC420 Rev.9
Maintenance
5. Switching Power Supply Module
(12) Remove four mounting screws, and
remove the metal plates from the
Switching Power Supply module 1.
(13) Secure the metal plates to a new
Switching Power Supply module 1
with the four mounting screws.
Metal Plate
Metal Plate
(14) Mount the new Switching Power Supply module 1 in the same position.
(15) Secure the new Switching Power Supply module 1 with the screws 1 and 2.
(16) Connect the CN1 and CN2 connectors.
(17) Secure the Bottom Cover to the Controller with the six mounting screws.
(18) Insert the battery into the Controller.
(19) Secure the battery cover to the Controller with the six mounting screws.
(20) Connect the battery connector to the battery.
(21) Connect the connector (X400) of the board for display to the front cover.
(22) Secure the front cover to the Controller with the four mounting screws.
(23) Turn ON the UPS ON/OFF switch.
(24) Connect the all the cables to the back of the Controller.
5.3.2 Replacing Switching Power Supply Module 2:
WARNING
■ Before performing any maintenance procedure, always make sure that the main
power of the Controller is turned OFF and that the high voltage charged area is
completely discharged.
Performing any maintenance procedure while the main power is ON or the high
voltage charged area isn’t discharged completely is extremely hazardous and
may result in electric shock and/or cause serious safety problems.
(1) Perform the step (1) through (9) in the previous section 5.3.1 Replacing Switching
Power Supply Module 1.
(2) Remove five connectors from the
Switching Power Supply module 2.
CN7 and CN8 connectors:
Projections on the upper side
CN15 connector:
Projections on the lower side
Connectors
RC420 Rev.9
123
Maintenance
5. Switching Power Supply Module
(3) Remove four mounting screws, and
remove the Switching Power Supply
module 2.
On the front side
On the rear side
(4) Remove two mounting screws, and
remove the metal plate from the
Switching Power Supply module 2.
Metal Plate
(5) Secure the metal plate to a new
Switching Power Supply module 2 with
the two mounting screws.
(6) Mount the new Switching Power Supply module 2 in the same position. Then,
secure it with the four mounting screws.
(7) Connect the five connectors to the new Switching Power Supply module 2.
(8) Secure the Bottom Cover to the Controller with the six mounting screws.
(9) Insert the battery into the Controller.
(10) Secure the battery cover to the Controller with the six mounting screws.
(11) Connect the battery connector to the battery.
(12) Connect the connector of the board for display to the front cover.
(13) Secure the front cover to the Controller with the four mounting screws.
(14) Turn ON the UPS ON/OFF switch.
(15) Connect the all the cables to the back of the Controller.
124
RC420 Rev.9
Maintenance
6. Motor Driver Module
6. Motor Driver Module
6.1 Layout and Functions
Layout
CT data
Signature Label
Fuse
Signature Label
The Signature Label on the heat sink indicates capacity in wattage for each Motor Driver
module.
Model
Capacity (W)
CACR-A5-SU3C
50 W
CACR-01-SU3C
100 W
CACR-02-SU3CY1
200 W
CACR-04-SU3C
400 W
CACR-08-SU3C
750 W
The power rating (wattage) of the mounted Motor Driver module corresponds to the
wattage of its driving motor. However, a 150W motor requires either a 100W or 200W
Motor Drive module depending on the Manipulator models. For details, refer to the
maintenance parts list in the Manipulator manual.
CT data
The CT data beside the signature label indicates specific information to each Motor
Driver module. In order to optimize the Controller’s control over the Manipulator, the
exact same values as indicated here must be set up in the Controller after the motor Driver
module is replaced.
There are two kinds of CT data as follows:
4B-****
: “CT OFFSET”.
4D-****
: “CTGAIN”.
The mark, “*”, on the CT data is indicated with “0” to “9” and “A” to “F”.
The indication is different depending on the Driver module.
NOTE
)
Record the CT data to be entered in the Controller before placing the Top Cover back on
the Controller when replacing the Motor Driver module. After the replacement, refer to
User’s Guide and set up the CT data.
RC420 Rev.9
125
Maintenance
6. Motor Driver Module
6.2 Replacing a Motor Driver Module
Replace a Motor Driver module by following the steps described below.
CAUTION
■ Make sure that the power rating (wattage) of a new Motor Driver module is
correct. Using a Motor Driver module with improper power rating (wattage) in
the Controller may not only cause improper function of the robot system but
also damage to the system.
(1) Shut down Windows, and turn OFF the Controller
(2) Disconnect all the cables from the back of the Controller.
(3) Wait for about 1 minute until the high voltage is completely discharge.
Remove the Top Cover by removing the six mounting screws.
(4) Remove the two mounting screws for the Motor Driver module as shown in the
picture below.
Motor Driver Module
Mounting Screws
(5) Pull the Motor Driver module up far enough so that the cable connected on the back
can be disconnected. Compress the projections on both sides of the connector to
disconnect the cable.
(6) Connect the cable to a new Motor Driver module.
126
RC420 Rev.9
Maintenance
6. Motor Driver Module
(7) Press down the module carefully and gradually to match the connectors on DPB and
DMB.
(8) M4 screws
(9) CT data
(7) DPB connector
(7) DMB connector
(8) Secure the new Motor Driver module.
(9) Record the CT data.
(10) Mount the Top Cover.
(11) Set up the CT data. For details, refer to the section, RC420 Drive Module Software
Configuration in the chapter, Motion Systems in EPSON RC+ User’s Guide.
RC420 Rev.9
127
Maintenance
128
6. Motor Driver Module
RC420 Rev.9
Maintenance
7. DPB (Drive Power Board)
7. DPB (Drive Power Board)
7.1 Layout and Functions
X312
X300
X304
X305
X316
X317
X313
X306
X307
X308
Connector No.
X300
Function
The connector to input the AC200V from the power switch
X301-X304
The connectors to supply motor power to the Motor Driver module.
X305
The connector to supply motor power to the Regeneration module.
X312
The connector to input the +5V and +12V to the backplane.
X313
The connector to connect the DMB interface cable.
X316
The connector to connect the Cooling Fan on the left side as you
face the front.
X317
The connector to connect the Cooling Fan on the right side as you
face the front.
The connectors are on the back side of the DPB as shown below. Remove the Bottom
Cover from the Controller to check these connectors.
X307
X306
X308
X315
X309
X310
RC420 Rev.9
X311
129
Maintenance
7. DPB (Drive Power Board)
Connector No.
X306, X307
Function
The connector to output the AC200V to the Switching Power
Supply.
X308
The connector to output to the discharging resistor.
X309
The connector for the SSR (Solid State Relay) Control Signal.
X310
The connector to input the +5 V and +12 V from the Switching
Power Supply module.
X311
The connector to input the +24V from the Switching Power Supply
module.
X315
The connector to input the +5 V and +12 V to the HDD and FDD.
7.2 Adjusting Encoder Voltage
You may adjust the Encoder Power Supply voltage using a control, VR1 as follows:
(1) Turn ON the Controller to boot the controller software while pressing the Emergency
Stop switch. Make sure that the encoder power is being supplied by checking LED1
on the Manipulator’s relay board. (The LED must be ON.)
(2) Measure the voltage between the encoder +5V and the GND pin on the Encoder
Signal connector of the longest motor cable in the Manipulator. (As for which pins
to use, refer to the Manipulator manual.)
If the encoder voltage is not within the range of 4.9 V to 5.2 V, adjust it as follows:
(3) The VR1 control used to adjust the Encoder voltage can be accessed from the rear
panel of the Controller, as shown below.
VR1
(4) If the measured voltage is lower than 4.9 V, turn VR1 in the “+” direction by 1/2 turn
to increase the voltage. If the measured voltage is higher than 5.2V, turn VR1 in the
“-” direction by 1/2 turn to lower the voltage.
(5) Repeat step (2) to ensure that the voltage is between 4.9 V and 5.2 V.
(6) If necessary, repeat steps (4) and (5) until the voltage is within the range of 4.9 V to
5.2 V.
130
RC420 Rev.9
Maintenance
8. DMB (Drive Main Board)
8. DMB (Drive Main Board)
8.1 Layout and Functions
TP21
Face
TP20
X114
LED1
LED2
JP1
TP19
TP14
TP18
JP2
TP16
X102
TP17
TP15
X104
Backside
X103
X105B
X105A
The test pins for voltage check
No.
Test pins for
voltage check
TP14
+5V
+5V for DMB
TP15
−5V
-5V for the Motor Driver module
TP16
+24V
+24V output voltage of the Switching Power Supply module
TP17
GND
GND for all the control power sources
TP18
+12V
+12V for the system panel
TP19
+5V
+5V for the Motor Driver module
TP20
+5.6V
Encoder power supply voltage
TP21
GND
GND for all the control power sources
RC420 Rev.9
Description
131
Maintenance
8. DMB (Drive Main Board)
Jumper (JP1)
1-2
3-4
5-6
Short
Short: Short-circuit
Jumper (JP2)
Condition
Description
JP2 short
If the regeneration module is not installed.
JP2 open
If the regeneration module is installed.
Connector
No.
Description
X102
The connector for the Signal cable of the Regeneration module.
X103
The connector for the interface cable for the front panel and the
OPTIONAL DEVICE connector (Backside)
X104
The connector for the DPB interface cable
X105A
The connector for the interface cable for the backplane (Backside)
X105B
The connector for the interface cable for the backplane (Backside)
X114
The connector for the interface cable for the switching power supply
module2
LED
No.
Description
1
ON while the power for Encoder is output.
2
ON while the Manipulator’s electromagnetic brake is released.
8.2 Replacing DMB
WARNING
■ Before performing any maintenance procedure, always make sure that the main
power of the Controller is turned OFF and that the high voltage charged area is
completely discharged. Performing any maintenance procedure while the
main power is ON or the high voltage charged area isn’t discharged completely
is extremely hazardous and may result in electric shock and/or cause serious
safety problems.
Replace DMB by following the steps described below.
(1) Shut down Windows, and turn OFF the Controller.
(2) Disconnect cables connected at the back of the Controller.
(3) Wait for about 1 minute until the high voltage is discharged.
(4) Turn over the Controller.
(5) Remove the six mounting screws of the Bottom Cover and remove the Bottom Cover.
(6) Disconnect the cables (X103, X105A, and X105B) from the backside of the DMB.
132
RC420 Rev.9
Maintenance
8. DMB (Drive Main Board)
(7) Turn over the Controller again.
(8) Remove the six mounting screws of the Top Cover and remove the Top Cover
(9) Remove the two DMB mounting screws on the back of the Controller as shown
below.
(10) As shown below, remove the mounting screws for the motor drivers for four axes in
the Controller.
Axis Axis Axis Axis
#1 #2 #3 #4
(11) If a Regeneration module is installed, remove it by following the steps, (4) and (5), in
the section Maintenance 9.2 Replacing a Regeneration Module.
(12) Keep a written record of the corresponding axis number, CT data, and wattage for
each module so that the modules can later be re-installed correctly.
(13) Pull each Motor Driver module up and disconnect the cables from the back.
Compress the projections on both sides of the connector to disconnect the cable.
RC420 Rev.9
133
Maintenance
8. DMB (Drive Main Board)
(14) Disconnect the flat cables (X104, X114) that connect to DMB.
(15) Remove six mounting screws securing the DMB to the Controller.
(16) Remove the old DMB.
(17) Install the new DMB and mount it with six mounting screws in the inside and two
screws at the back loose enough so that it can still be moved around a little for
positioning.
(18) Re-install the Motor Drivers for axis #1 and axis #3 just to position the DMB
(19) Tighten the eight mounting screws that are still loose from step (17).
(20) Connect the (X104, X114) cables that were disconnected in step (14).
(21) If the Regeneration module was removed in step (11), re-install it by referring to steps
(6) and (7) described in the section Maintenance 9.2 Replacing a Regeneration
Module.
(22) Fasten the mounting screws to secure the Motor Drivers.
(23) Mount the Top Cover to the Controller.
(24) Turn over the Controller.
(25) Connect the cables to the backside of the DMB.
(26) Mount the Bottom Cover to the Controller.
(27) Turn over the Controller again.
(28) Connect the cables to the back of the Controller.
134
RC420 Rev.9
Maintenance
9. Regeneration Module
9. Regeneration Module
9.1 Layout and Functions
LED2 (Red)
LED No.
NOTE
)
LED3 (Green)
LED1 (Orange)
LED Color
Description
LED1
Orange
This LED is ON when the system is in the regenerative
process.
(This process is to reduce the regenerated electricity by
using resistors when the motor is decelerating so that the
circuit can be protected.)
LED2
Red
This LED is ON when the system is detecting over-voltage.
LED3
Green
This LED is ON when the motor power is ON.
(It may flicker while the Manipulator(s) is/are operating.)
If a Regeneration module is installed, JP2 on the DMB (Drive Main Board) must be
“open”.
9.2 Replacing a Regeneration Module
Replace the Regeneration module by following the steps described below.
(1) Shut down Windows, and turn OFF the Controller.
(2) Disconnect all the cables from the back of the Controller.
(3) Wait for about 1 minute until the high voltage is completely discharged.
Then, remove the Top Cover by removing the six mounting screws.
(4) Remove the two mounting screws for the Regeneration module.
(5) Pull the Regeneration module up carefully, and disconnect the connector X102 from
the DMB.
X102
RC420 Rev.9
X305
135
Maintenance
9. Regeneration Module
(6) Connect the X102 connector of a new Regeneration module to the DMB.
(7) The new Regeneration module must be pushed in carefully, while making it sure that
the X305 connector engages properly.
X102
X305
(8) Mount the Regeneration module securely. Place the Top Cover back on.
136
RC420 Rev.9
Maintenance
10. Replacing Maintenance Parts
10. Replacing Maintenance Parts
10.1 Optional Board
(1) Shut down Windows. Turn OFF the Controller.
(2) Disconnect the cable for the optional board from the back of the Controller.
(3) Remove the Top Cover from the Controller.
(4) Remove the four screws circled in the picture below for the board holder assembly
and remove the assembly from the Controller.
Board holder assembly
(5) Disconnect all cables from the CPU board.
(6) Remove the mounting screw for the optional board and remove the board from its
slot.
Board mounting screw
(7) Install the new board in the slot and install the mounting screw.
(8) Connect the cables that were disconnected in step (5) to the CPU board.
(9) Mount the board holder assembly to the Controller.
(10) Mount the Top Cover to the Controller.
(11) Connect the cables that were disconnected before the board replacement to the back
of the Controller.
10.2 CPU Board
(1) Shut down Windows. Turn OFF the Controller.
(2) Disconnect the cables for the CPU board from the back of the Controller.
(3) Remove the Top Cover from the Controller.
(4) Remove the four mounting screws for the board holder assembly and remove it.
RC420 Rev.9
137
Maintenance
10. Replacing Maintenance Parts
(5) Disconnect all cables from the CPU board.
COM2, and USB.)
CPU Board: SPI-6941-EPC
(HDD, FDD, Parallel Port, COM1,
HDD
FDD
Serial Port
COM2
Serial Port
COM1
USB
Parallel Port
HDD
CPU Board: PC686BX(PC)-EPC850
FDD
Serial Port
COM2
Serial Port
COM1
USB
Parallel Port
(6) Remove the mounting screw for the CPU board on the back of the Controller and
remove the CPU board from the slot.
(7) Install the new CPU board in the slot. Then, mount the board to the slot with the
mounting screw.
(8) Connect the cables that were disconnected in step (5) to the CPU board.
(9) Mount the board holder assembly in the Controller.
(10) Mount the Top Cover to the Controller.
(11) Connect the cables that were disconnected before the board replacement to the back
of the Controller.
< Safety Precautions for Lithium Batteries >
■ Lithium batteries contain flammable materials such as lithium, organic solvents,
etc. If misused, batteries may generate heat, explode or catch fire. Observe
the following precautions for safe use of lithium batteries.
CAUTION
138
- Use the specified type of battery and connect the positive (+) and negative (-)
electrodes correctly.
- Do not allow the positive (+) and negative (-) electrodes to short circuit at
maintenance.
- Do not throw batteries into fire or heat them to high temperature.
- Do not disassemble or alter batteries.
- When discarding batteries, insulate the terminals by wrapping them with tape,
etc.
RC420 Rev.9
Maintenance
10. Replacing Maintenance Parts
10.3 HDD
CAUTION
NOTE
)
■ Do not shock, shake, or drop the HDD during maintenance. When the HDD is
shocked physically, it may be damaged and may also cause data loss during
data loading/saving.
Back up the necessary data of the project and system before replacing the HDD. Then,
restore the data of the project and system after the replacement.
The details of data backup/restore are described in the Maintenance 2.5Backup of Data.
(1) Shut down Windows. Turn OFF the Controller.
(2) Open the front panel door.
(3) Insert the key to the HDD key lock and turn the key to the right.
HDD Key Lock
(4) Pull out the HDD.
(5) Install a new HDD.
(6) Insert the key to the HDD key lock and turn the key to the left.
NOTE
)
RC420 Rev.9
Refer to the instructions supplied with the new HDD for new hard disk settings.
139
Maintenance
10. Replacing Maintenance Parts
10.4 Fan Filter
When you clean and replace the Fan Filter, follow the procedure below:
140
(1)
Shut down Windows. Then, turn OFF the power on the Controller.
(2)
Open the front panel door.
(3)
Pull out the filter from the fan filter holder forward.
(4)
Clean or replace the filter. When you clean the filter, use a vacuum cleaner.
(5)
Insert the filter back into the filter holder. Make sure the filter is placed inside the
hook.
RC420 Rev.9
Maintenance
11. Verifying Robot System Operation
11. Verifying Robot System Operation
When either the Manipulator or Controller has been maintained or, when any parts were
replaced in those units, it must be checked according to the procedure in this section to ensure
that the new setting(s) operates normally.
(1) Completely connect all the necessary cables for the system.
WARNING
CAUTION
■ When verifying the robot system operation, prepare for failures with initial
settings or wiring. If the Manipulator operates unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to stop
the Manipulator.
Verify the robot system operation in the restricted (low speeds and low power)
status. Verifying the robot system operation at high speeds may damage the
robot system and/or cause serious safety problems as the Manipulator cannot
stop operating immediately in case of abnormal operation of the Manipulator.
■ The serial number of the Manipulator that should be connected is indicated on
the Connection Check Label on the Controller. Connect the Controller and the
Manipulator correctly. Improper connection between the Controller and the
Manipulator may cause not only improper function of the robot system but also
serious safety problems.
(2) Turn ON the Controller. Boot the Controller. During this process, watch and monitor
the LED status as described in the following list:
Controller – Front Panel LED
RC420 Rev.9
From power-on to boot
While running
7 segment
(STATUS)
When the main power is turned
ON, “8” lights up momentarily
and turns OFF.
The displayed data must change
from “0” in order to indicate
the system condition that is
checked at the beginning of the
Controller.
The LED is OFF under normal
conditions.
In case of system error, it must
display the status of the error by the
designated number. (For details,
refer to the SPEL+ Error Messages
in SPEL+ Language Reference.)
ERROR
When the main power is turned
ON, the LED will turn ON
momentarily and will turn OFF.
The LED is OFF under normal
conditions. It must turn ON when
there is a system error.
E-STOP
When the main power is turned ON, this LED will turn ON
momentarily and will turn OFF unless there is an Emergency Stop input.
If there is an Emergency Stop input at this time, the LED will stay ON.
This LED turns ON when there is an Emergency Stop input to the
Controller’s OPTIONAL DEVICE connector and EMERGENCY
connector.
141
Maintenance
11. Verifying Robot System Operation
From power-on to boot
While running
D-E1
The LED must be OFF.
The LED must turn ON when there
is an unresettable error in the motor
control system.
D-E2
The LED must be OFF.
The LED turns ON when there is a
resettable error in the motor control
system.
The LED must be blinking.
The LED must be OFF.
D-ERROR
It must turn ON when the motor controlling CPU detects an error in the
system processing.
RUN
The LED must be blinking.
The LED must be ON.
MOTOR
POWER
The LED must be OFF.
The LED must be OFF when the
motor is turned off.
POWER
The LED will be ON if the system is operating properly.
When the LED is OFF, suspect that either there is an input/output
failure in the Switching Power Supply module or a wiring failure in the
Control Power Supply circuit.
SAFE
SHUT
DOWN
This LED is ON only when the Controller is ready to be turned OFF.
(3) Execute MOTOR ON and check the following:
- No error is displayed.
- The MOTOR POWER LED on the Controller’s Front Panel turns ON.
- The Manipulator operates normally, and there is excitation.
(4) Execute various motion commands (such as JUMP, etc.). The Manipulator must operate
accordingly and normally without vibration or unusual sounds.
142
RC420 Rev.9
Maintenance
12. Recovering the HDD
12. Recovering the HDD
This chapter describes the procedure for recovering the current HDD in the RC420
Embedded OS installed in.
Follow the procedure below to recover the HDD.
Recovery Procedure
Reference
1 Backing Up the Current Data Setting Maintenance 2.5 Backup of Data
2 Recovering Windows
Maintenance 12.1 Recovering Windows
3 Configuring Windows
Maintenance 12.2 Configuring Windows
Setting Up EPSON RC+
Maintenance 12.3 Setting Up EPSON RC+
Using the Network
(Using the Network)
4
Maintenance 12.4 Setting Up EPSON RC+
Using the CD-R/RW Drive
(Using the CD-R/RW Drive with USB)
with USB
5 Setting Up UPS
6 Restoring the Backup Data
Setup & Operation 10.6. Configuring Windows
Maintenance 2.5 Backup of Data
Please prepare the parts below.
Parts
Recovery startup disk (FD) for RC420
EPSON RC+ setup CD-ROM
PS/2 keyboard
PS/2 mouse
Note
Attachment to RC420
Only USB keyboard users
Only USB mouse users
NOTE
USB keyboard and USB mouse cannot be used for Windows recovery.
PS/2 keyboard and PS/2 mouse.
NOTE
Data for recovery incorporated in the HDD for the RC420 Embedded OS installed in may
not be recovered by the HDD condition. Replace the HDD when recovery is unable.
)
)
)
NOTE
RC420 Rev.9
HDD for RC420 that installs Windows XP does not support recovery.
recovery is necessary.
Be sure to use
Contact us when
143
Maintenance
12. Recovering the HDD
12.1 Recovering Windows
CAUTION
■ When the Windows is recovered, all the data in the HDD will be erased. Make
sure to make a back up of data before recovering Windows. The procedure for
backup is described in Maintenance 2.5 Backup of Data.
12.1.1 Recovery Procedure
There are Robot Controllers with “EasyRestore” license label (following label) and
without the label for RC420 (Embedded OS).
The recovery procedure for each Controller (with and without label) is different. Check
which type your product is and follow the relevant recovery procedure.
NOTE
)
)
NOTE
When “EasyRestore” license label is labeled on the RC420.
Refer to 12.1.2 Windows Recovery (With “EasyRestore” License Label).
When “EasyRestore” license label is NOT labeled on the RC420.
Refer to 12.1.3 Windows Recovery (Without “EasyRestore” License Label).
12.1.2 Windows Recovery (With “EasyRestore” License Label)
NOTE
)
When you accidentally turn on the RC420 with the Recovery startup disk in its FD drive,
the RC420 will start from the recovery startup disk. In this case, turn OFF the Controller
before the restore begins. The restore will not begin until you click the <Yes> button in
the following procedure (9).
(1) Connect the PS/2 keyboard and the PS/2 mouse to the RC420.
(The USB keyboard and the USB mouse cannot be used in Windows recovery.)
(2) Set the recovery start up disk in to the FD drive.
(3) Turn ON the RC420.
(4) The message “USB Key Board and USB Mouse are not available. Please use the PS/2
Key Board and PS/2 Mouse.” appears. Read the message and press the <Enter> key
after “Strike a key when ready...” appears.
144
RC420 Rev.9
Maintenance
12. Recovering the HDD
(5) After “SKIP BAD SECTOR CHECK [Y, N]” appears, press the <Y> or the <N> key.
NOTE
)
The time required will change by the key selection since the process changes.
required is only a measure.
Key
Y
N
NOTE
)
Contents
Skip the bad sector check
Do not skip the bad sector check
The
Time Required
About 3 minutes
About 20 minutes
For the recovery of the HDD that has been used in the RC420, selecting “N” is
recommended.
(6) Terms of use appears.
Follow the procedure and press the <Enter> key three times.
(7) Easy Restore starts.
(8) Click the <Continue> button.
NOTE
)
RC420 Rev.9
If you click the <Cancel> button, the Easy Restore ends. When you accidentally
turned ON the RC420 with the recovery disk in the FD drive, click the <Cancel>
button in this window.
145
Maintenance
12. Recovering the HDD
(9) Check the contents of the [Warning] dialog and click the <Yes> button.
NOTE
)
If clicking the <No> button, the Easy Restore ends. When you accidentally turned
ON the RC420 with the recovery disk in the FD drive, click the <No> button in this
dialog.
(10) Restore starts.
(11) After the restore is completed, “A:\>” appears.
Remove the recovery startup disk and reboot the RC420.
(12) Select the <Agree> option button in the [License Agreement] dialog and click the
<Next> button.
146
RC420 Rev.9
Maintenance
12. Recovering the HDD
(13) Enter the “Product Key” recorded on the COA label attached on the front of the
Controller (inside the front door) in the [Product Key] dialog and click the <Next>
button.
(14) Input the serial number (SN*****) of the RC420 to the [Computer Name] box in the
[Computer Name and Administrator Password] dialog and click the <Next> button.
(15) After rebooting, click the <OK> button in the [Windows Login] dialog.
(16) Windows starts.
NOTE
)
NOTE
)
If the EPSON RC+ is not installed, the [Install the Robot Control Software] dialog appears
when the Controller is started. Make sure to install the EPSON RC+ in the Controller.
If it is not installed, Windows will automatically shutdown in 30 minutes.
12.1.3 Windows Recovery (Without “EasyRestore” License Label)
When you accidentally turn on the RC420 with the Recovery startup disk in its FD drive,
the RC420 will start from the recovery startup disk. In this case, turn OFF the Controller
before the restore begins. The restore will not begin until you click the <Y> key in the
following procedure (7).
(1) Connect the PS/2 keyboard and the PS/2 mouse to the RC420.
(The USB keyboard and the USB mouse cannot be used in Windows recovery.)
(2) Set the recovery start up disk in to the FD drive.
(3) Turn ON the RC420.
(4) The message “USB Key Board and USB Mouse are not available. Please use the PS/2
Key Board and PS/2 Mouse.” appears. Read the message and press the <Enter> key
after “Strike a key when ready...” appears.
(5) After “SKIP BAD SECTOR CHECK ?” appears, press the <Y> or the <N> key.
NOTE
)
RC420 Rev.9
The time required will change by the key selection since the process changes.
required is only a measure.
Key
Contents
Y
Skip the bad sector check
N
Do not skip the bad sector check
The
Time Required
About 4 minutes
About 45 minutes
147
Maintenance
12. Recovering the HDD
For the recovery of the HDD that has been used in the RC420, selecting “N” is
recommended.
(6) The message “Select “CONTINUE” to Start the Recovery process.
“CANCEL” to exit.” Appears. Read the message and press the <Y> key.
NOTE
)
Select
If you press the <N> key, Windows recovery will not be executed. When you
accidentally turned ON the RC420 with the recovery CD in its CD drive, click the
<Cancel> button in this window.
When you press the <Y> key in step (5), “BAD SECTOR TEST WILL BE
SKIPPED” appears on the left top.
When you press the <N> key in step (5), “BAD SECTOR TEST WILL BE
EXECUTED” appears on the left top.
148
RC420 Rev.9
Maintenance
12. Recovering the HDD
(7) If you press the <Y> key, recovery starts and deletes all the data in the HDD.
the <Y> key to start the recovery.
NOTE
)
Press
If you press the <N> key, Windows recovery will not be executed. When you
accidentally turned ON the RC420 with the recovery disk in the FD drive, click the
<N> key in this window.
(8) Restore starts.
Please wait
(9) After the restore is completed, “A:\>” appears.
Remove the recovery startup disk and reboot the RC420.
RC420 Rev.9
149
Maintenance
12. Recovering the HDD
(10) Select the <Agree> option button in the [License Agreement] dialog and click the
<Next> button.
(11) Enter the “Product Key” recorded on the COA label attached on the front of the
Controller (inside the front door) in the [Product Key] dialog and click the <Next>
button.
(12) Input the serial number (SN*****) of the RC420 to the [Computer Name] box in the
[Computer Name and Administrator Password] dialog and click the <Next> button.
(13) After rebooting, click the <OK> button in the [Windows Login] dialog.
(14) Windows starts.
NOTE
)
150
If the EPSON RC+ is not installed, the [Install the Robot Control Software] dialog appears
when the Controller is started. Make sure to install the EPSON RC+ in the Controller.
If it is not installed, Windows will automatically shutdown in 30 minutes.
RC420 Rev.9
Maintenance
12. Recovering the HDD
12.2 Configuring Windows
Disabling the Automatic Restart at System Error
(1) Double-click the <My Computer> - <Control Panel> - <System> icons.
(2) Select the [Advanced] tab in the [System Properties] dialog, and click the <Startup
and Recovery> button.
(3) Uncheck the [Automatically reboot] check box in the [System Failure] group box in
the [Startup and Recovery] dialog. Then, click the <OK> button.
(4) Another dialog appears.
Click the <OK> button.
(5) Click the <OK> button in the [System Properties] dialog.
(6) Click the <No> button in the [System Settings Change] dialog.
NOTE
)
Following items are set up by Windows recovery.
- Change the display configurations
- Power configurations
- Setting the Network to disabled
- Disabling the Check Disk during Windows start
- Changing the Communication Port COM3 configuration
- Disabling the automatic update
12.3 Setting Up EPSON RC+ (Using the Network)
This section describes the easiest procedure for setting up EPSON RC+ with “NetBEUI”
protocol using the network.
12.3.1 Necessary Items
Prepare the following items for the EPSON RC+ installation.
Items
EPSON RC+ Setup CD-ROM
PC connected to the network with the
magneto-optical disk drive that is
available for CD-ROM read
Network cable
Note
Attachment to RC420
OS:
Windows 95, Windows 98, Windows NT,
Windows 2000, Windows XP
For cross cabling
12.3.2 Sharing Configuration
Set the CD-ROM drive on your PC to “Sharing” following the procedure below.
(1) Start Explore and select the “CD-ROM drive”.
(2) Select the [File] - [Properties].
(3) Select the [Sharing] tab and select the <Share this folder> option button.
(4) Click the <OK> button.
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The sharing setup of Windows XP differs to other Windows. The following is the
procedure to set up the “Sharing” CD-ROM drive by the prepared PC.
(1) Start the Explorer and select the CD-ROM drive.
(2) Select the [File] - [Properties].
(3) Select the [Sharing] tab and click the <If you understand the risk but still want to
share the root of the drive, click here>.
(4) Click the <If you understand the security risk but want to share files without running
the wizard, click here.> in the [Network sharing and security] group box.
(5) Select the <Just enable file sharing> option button in the [Enable File Sharing] dialog
and click the <OK> button.
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(6) Check the [Share this folder on the network] check box in the [Network sharing and
security] group box and click the <OK> button.
12.3.3 Network Configuration
Configure the network to use “NetBEUI” protocol in RC420 and your PC.
For RC420, refer to the procedure from step (2) in 5. Windows XP. Procedure in step (1)
is already configured at shipment.
For your PC, refer to the applicable section according to Windows version installed in
your PC.
1.
Windows 95
(1) Double-click the <My computer> - <Control Panel> - <Network> icons.
(2) Select the [Configuration] tab in the [Network] dialog.
(3) Confirm that the “NetBEUI” exists.
If the “NetBEUI” exists, click the <OK> button and finish the network configuration.
If the “NetBEUI” doesn’t exist, click the <Add> button.
(4) Select the [Protocol] in the [Select Network Component Type] dialog and click the
<Add> button.
(5) Select the “Microsoft” for the [Manufactures] and the “NetBEUI” for the [Network
Protocols]. Then, click the <OK> button.
(6) Confirm that the “NetBEUI” is added in the [Configuration] panel in the [Network]
dialog. Then, click the <OK> button.
2.
Windows 98
(1) Double-click the <My computer> - <Control Panel> - <Network> icons.
(2) Select the [Configuration] tab in the [Network] dialog.
(3) Confirm that the “NetBEUI” exists.
If the “NetBEUI” exists, click the <OK> button and finish the network configuration.
If the “NetBEUI” doesn’t exist, click the <Add> button.
(4) Select the [Protocol] in the [Select Network Component Type] dialog and click the
<Add> button.
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(5) Select the “Microsoft” for the [Manufactures] and the “NetBEUI” for the [Network
Protocols]. Then, click the <OK> button.
(6) Confirm that the “NetBEUI” is added in the [Configuration] panel in the [Network]
dialog. Then, click the <OK> button.
3.
Windows NT
(1) Double-click the <My computer> - <Control Panel> - <Network> icons.
(2) Select the [Services] tab in the [Network] dialog.
(3) Confirm that the “NetBIOS Interface” exists.
If the “NetBIOS Interface” exists, click the <OK> button and finish the network
configuration.
If the “NetBIOS Interface” doesn’t exist, click the <Add> button.
(4) Select the [NetBIOS Interface] in the [Select Network Service] dialog and click the
<OK> button.
(5) If the [Windows NT Setup] dialog appears, set the Windows NT CD-ROM in the
drive and click the <Continue> button.
(6) Confirm that the “NetBIOS Interface” is added in the [Services] panel in the
[Network] dialog. Then, click the <Close> button.
4.
Windows 2000
(1) Select the [My computer] - [Control Panel] - [Network and Dial-up Connections]
dialog. Right-click the icon for the network the “NetBEUI” will be installed in and
select the [Properties].
(2) Confirm that the “Net BEUI Protocol” exists in the [Local Area Connection
Properties] dialog.
If the “Net BEUI Protocol” exists, click the <OK> button and finish the network
configuration.
If the “Net BEUI Protocol” doesn’t exist, click the <Install> button.
(3) Select the [Protocol] in the [Select Network Component Type] dialog and click the
<Add> button.
(4) Select the [NetBEUI Protocol] in the [Select Network Protocol] dialog and click the
<OK> button.
(5) Confirm that the [Client Microsoft Networks], [File and Printer Sharing for
Microsoft Networks], and [NetBEUI Protocol] check boxes are checked in the [Local
Area Connection Properties] dialog. Then, click the <Close> button.
5.
154
Windows XP
Copy the necessary files from the Windows XP installation CD-ROM since the
“NetBEUI” protocol is not a standard support for Windows XP. After copying the
files, install the “NetBEUI” protocol in Windows XP.
The NetBEUI protocol is installed in the “\VALUEADD\MSFT\NET\NETBEUI” in
the Windows XP installation CD-ROM.
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(1) Copy the following files to the respective folders.
(The “%SystemRoot%” folder is the folder Windows XP is installed in. The default
is “C:\windows”.)
Copy the “NETNBF.INF” file to the “%SystemRoot%\INF” folder.
Copy the “NBF.SYS” file to the “%SystemRoot%\System32\Drivers” folder.
NOTE
)
In case of missing the copy destination folder in the Explorer, the “hidden files and
folders” setup might be set as a hidden folder. Check the setup to show all folders.
(2) After completing the copy, open the [Control Panel] and click the <Network and
Internet Connections> icon.
(3) Click the <Network Connections> icon in the [Network and Internet Connections]
window.
(4) Right-click the icon of the network to install the “NetBEUI” and select the
[Properties].
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(5) Select the [General] tab in the [Local Area Connection Properties] dialog and click
the <Install> button.
(6) Select the “Protocol” in the [Select Network Component Type] dialog and click the
<Add> button.
(7) Select the “NetBEUI Protocol” in the [Select Network Protocol] dialog and click the
<OK> button.
(8) The [Check if the “NetBEUI Protocol” is added in the [Local Area Connection]
dialog and click the <Close> button.
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12.3.4 Starting EPSON RC+ Setup Program
(1) Start Windows in your PC and set the EPSON RC+ setup CD-ROM in the drive.
(2) Start Explorer in the RC420 Controller and open the following folder.
\My Network\Entire Network\Microsoft Windows Network\Workgroup name of
your PC\Name of your PC \Drive name\EPSON RC
NOTE
)
If you cannot see the name of your PC in Explorer window, check the NetBEUI
configuration and network cable connection.
(3) Double-click the “Setup.exe” in the EPSON RC folder.
12.3.5 Installing EPSON RC+
(1) Click the <Next> button in the [Welcome to the EPSON RC+ Installation] dialog.
(2) Confirm that the Name is “EPSON RC User” and the Organization is “SEIKO
EPSON CORP” in the [Customer Information] dialog. Then, click the <Next>
button.
(3) Confirm that the destination location drive is “C” in the [Choose Destination
Location] dialog. Then, click the <Next> button.
(4) Check the check box for the option you want to use in the [Select Options] dialog.
Then, click the <Next> button.
(5) When you checked the [Install Vision Guide] check box in the [Select Options]
dialog, the [Select Vision System Type] dialog appears. Select the type you want to
use and click the <Next> button.
(6) Click the <Next> button in the [Start Copying Files] dialog.
(7) The [Information] dialog appears.
Click the <OK> button.
(8) Click the <Next> button in the [Acrobat Reader Setup] dialog.
(9) Click the <Next> button in the [Choose Destination Location] dialog.
(10) The [Information] dialog appears.
Click the <OK> button.
(11) Select the <Yes, I want to restart my computer now.> option button in the
[InstallShield Wizard Complete] dialog. Then, click the <Finish> button.
(12) After Windows restarts, double-click the <EPSON RC+> icon and confirm that
EPSON RC+ starts.
12.3.6 Reserving Address Resources of EPSON RC+ Options
To use the EPSON RC+ options “Expansion I/O Board” and “Pulse Generating Board”,
reserve address resources of each option.
(1) Double-click the <My computer> - <Control Panel> - <System> icons.
(2) Select the [Hardware] tab in the [System Properties] dialog and click the <Hardware
Wizard> button.
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(3) Click the <Next> button in the [Welcome to the Add/Remove Hardware Wizard]
dialog.
(4) Select the <Add/Troubleshoot a device> option button in the [Choose a Hardware
Task] dialog. Click the <Next> button.
(5) Select the “Add a new device” in the [Choose a Hardware Device] dialog.
the <Next> button.
Click
(6) Select the <No, I want to select the hardware from a list> option button in the [Find
New Hardware] dialog. Click the <Next> button.
(7) Select the “SPEL RESOURCE Drivers” in the [Hardware Type] dialog.
<Next> button.
Click the
(8) Select the applicable Models for each option in the [Select a Device Driver] dialog.
Click the <Next> button.
Expansion I/O Board : SPEL RESOURCE IO *
Pulse Generating Board : SPEL RESOURCE PG *
(The asterisk * indicates each board number.)
(9) Another dialog appears.
Click the <OK> button.
(10) Click the <OK> button in the [Add New Hardware Wizard Properties] dialog.
(11) Click the <Yes> button in the [Creating a Forced Configuration] dialog.
(12) Click the <Next> button in the [Start Hardware installation] dialog.
(13) Click the <Finish> button in the [Completing the Add/Remove Hardware Wizard]
dialog.
(14) When you continue reserving address resources of the EPSON RC+ options, click
the <No> button in the [System Setting Change] dialog and repeat the same steps
from (2) for each option.
When you finish reserving address resources of the EPSON RC+ options, click the
<Yes> button in the [System Setting Change] dialog and restart Windows.
NOTE
)
158
After setting up EPSON RC+, set up UPS and restore the back-up data. For details,
refer to the Setup & Operation 10.6 Configuring Windows and Maintenance 2.5 Backup
of Data.
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12.4 Setting Up EPSON RC+ (Using the CD-R/RW Drive with USB)
This section describes the procedure for setting up EPSON RC+ with the CD-R/RW drive
that is connected to USB.
12.4.1 Necessary Items
Prepare the following items for the EPSON RC+ installation.
Items
EPSON RC+ Setup CD-ROM
USB connection CD-R/RW drive
Note
Attachment to RC420
Use the CD-R/RW drive that is run by the
standard driver in Windows 2000.
12.4.2 Starting EPSON RC+ Setup Program
(1) Connect the CD-R/RW drive to the USB connector on the RC420 Controller.
(2) Set the EPSON RC+ setup CD-ROM in the CD-R/RW drive.
(3) The [EPSON RC+ Setup] dialog is automatically opened. (If the dialog is not
automatically opened, select the [Start] - [Run] and enter the “d\epsonrc\setup.exe”
in the [Open] box, and then click the <OK> button.)
12.4.3 Installing EPSON RC+
Install EPSON RC+ following the procedure in the section 12.3.5 Installing EPSON
RC+.
12.4.4 Reserving Address Resources of EPSON RC+ Options
Reserve address resources of the EPSON RC+ options following the procedure in the
section 12.3. 6 Reserving Address Resources of EPSON RC+ Options.
NOTE
)
RC420 Rev.9
After setting up EPSON RC+, set up UPS and restore the back-up data. For details,
refer to the Setup & Operation 10.6 Configuring Windows and Maintenance 2.5 Backup
of Data.
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13. Maintenance Parts List
13. Maintenance Parts List
Name
Switching Power Supply
Motor Driver
Code
Note
+24V
R13A060600300
AES100W-24
+5V
R13A060600600
NSP7-100-X2S2 (for UPS)
50 W
R12R520DRU003
CACR-A5-SU3C
100 W
R12R520DRU004
CACR-01-SU3C
200 W
R12R520DRU005
CACR-02-SU3CY1
400 W
R12R520DRU006
CACR-04-SU3C
750 W
R12R520DRU007
CACR-08-SU3C
DMB
R13A040200100
Regeneration Module
R12R520DRU008
Cooling Fan
R13A060500700
Air Filter
R13A060500800
Board No.SKP375
PNP type
R12R520DIO001
Board No.SKP376
NPN type
R12R520DIO002
Board No.SKP376
Expansion I/O Board
R13R500DIO003
Board No.SKP349
Expansion I/O Cable
R12R500DIO004
Terminal Block
R12R500DIO005
Expansion I/O Connector
R12R500DIO006
Protected Expansion I/O Board
Software Options Key
R13A090300700
For EPSON RC+ Ver. 3.4 or 3.5
R13A090301300
For EPSON RC+ Ver. 3.6 or higher
OPTIONAL DEVICE Dummy Plug
R12R500CUP018
EMERGENCY Connector
R13R520DRU014
E. STOP Box
R12B020201
Standard accessory for
UL specifications
Battery
R13A060000100
For UPS
Standard IO Cable for RC420 (3 m)
R12B020205
For USA specification
Terminal Block (USA specification)
R12B061001
For USA specification
Connector for Mouse
Model Number
Serial Number
Code
and Keyboard
CPU
Separate Connectors
PC-686BX(PC)-EPC850 From S/N00001 to S/N10000 R13A040000200
Board Integrated Connector SPI-6941-EPC
S/N10001 or later
R13B040002
The CPU board has different model numbers and appearances depending on the dates of the shipping and the
board changeover.
When the CPU board has been replaced for maintenance, the type of CPU board cannot be distinguished only
by serial number. In such a case, see the type of connector for mouse and keyboard or the model number
printed on the CPU board to distinguish the CPU board type.
Name
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Maintenance 13. Maintenance Parts List
Name
2.5" HDD
Serial Number
Language
-
-
2.5" HDD with Windows XP Installation
S/N30001 or later
Recovery HDD for RC420
From S/N20001
to S/N30000
Name
2.5" HDD with
Windows 2000
Installation
CPU board
Serial Number
PC-686BX(PC)-EPC850
Separate Connectors for
Mouse and Keyboard
From S/N00001
to S/N10000
SPI-6941-EPC
Integrated Connector for
Mouse and Keyboard
From S/N10001
to S/N20000
Code
R13A110401000
Japanese
R13B110415
English
R13B110416
Japanese
R13B110411
English
R13B110412
Language
Code
Japanese
R13A110401300
English
R13A110401400
Japanese
R13B110403
English
R13B110404
The code of the 2.5" HDD installing Windows 2000 varies depending on the type of CPU board in the
Controller.
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