RC180 ROBOT CONTROLLER Rev.14 EM11ZC2255F

RC180 ROBOT CONTROLLER  Rev.14 EM11ZC2255F

ROBOT CONTROLLER

RC180

Rev.14 EM11ZC2255F

ii

ROBOT CONTROLLER

RC180

Rev.14

Copyright © 2006-2011 SEIKO EPSON CORPORATION. All rights reserved.

RC180 Rev.14 i

FOREWORD

WARRANTY

Thank you for purchasing our robot products.

This manual contains the information necessary for the correct use of the robot controller.

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

Keep this manual handy for easy access at all times.

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

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

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

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

2. Malfunctions caused by customers’ unauthorized disassembly.

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

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

Warnings, Cautions, Usage:

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

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

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

RC180 Rev.14

TRADEMARKS

Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of

Microsoft Corporation in the United States and/or other countries. Other brand and product names are trademarks or registered trademarks of the respective holders.

TRADEMARK NOTATION IN THIS MANUAL

Microsoft® Windows® XP Operating system

Microsoft® Windows® Vista Operating system

Microsoft® Windows® 7 Operating system

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

Windows Vista and Windows 7.

NOTICE

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

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

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

INQUIRIES

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

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

Please prepare the following items before you contact us.

- Your controller model and its serial number

- Your manipulator model and its serial number

- Software and its version in your robot system

- A description of the problem

SERVICE CENTER

RC180 Rev.14 iii

MANUFACTURER & SUPPLIER

Japan & Others

Suwa Minami Plant

Factory Automation Systems Dept.

1010 Fujimi, Fujimi-machi,

Suwa-gun, Nagano, 399-0295

JAPAN

SUPPLIERS

North & South America EPSON AMERICA, INC.

18300 Central Avenue

Carson, CA 90746

USA

Europe EPSON DEUTSCHLAND GmbH

Factory Automation Division

Otto-Hahn-Str.4

D-40670 Meerbusch

Germany

China

Taiwan

EPSON China Co., Ltd

Factory Automation Division

7F, Jinbao Building No. 89 Jinbao Street

Dongcheng District, Beijing,

China, 100005

EPSON Taiwan Technology & Trading Ltd.

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

Taiwan, ROC iv

RC180 Rev.14

Southeast Asia

India

EPSON Singapore Pte Ltd.

Factory Automation System

1 HarbourFrontPlace, #03-02

HarbourFront Tower one, Singapore

098633

Korea EPSON Korea Co, Ltd.

11F Milim Tower, 825-22

Yeoksam-dong, Gangnam-gu, Seoul, 135-934

Korea

RC180 Rev.14 v

NOTE

)

NOTE

)

Before Reading This Manual

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

NOTE

) may result in malfunction of the device since the pin assignments are different.

OPTIONAL DEVICE dummy plug

Operation Pendant OP500

Operator Pendant OP500RC

Jog Pad JP500

Teaching Pendant TP-3**

NOTE

)

NOTE

)

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

If RC180 and the development PC are connected without installing the EPSON RC+5.0 to the development PC, [Add New Hardware Wizard] appears. If this wizard appears, click the <Cancel> button.

Concerning the security support for the network connection:

The network connecting function (Ethernet) on our products assumes the use in the local network such as the factory LAN network. Do not connect to the external network such as Internet.

In addition, please take security measure such as for the virus from the network connection by installing the antivirus software.

Security support for the USB memory:

Make sure the USB memory is not infected with virus when connecting to the Controller.

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

- Renew the Point files (SavePoints)

- Change the Robot parameters (Base, Local, LocalClr, CalPls, Calib, Hofs,

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

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

PlaneClr) vi

RC180 Rev.14

Table of Contents

TABLE OF CONTENTS

Safety

1. Safety

2. Conventions

3. Safety Precautions

Setup & Operation

1. Specifications 9

Dimensions .................................................................................12

2. Part Names and Functions 13

2.2 Functions .............................................................................................. 14

2.3 LED and Seven-segment LED .............................................................. 17

2.3.1 LED and Seven-segment Display ............................................. 17

Features..................................................................................... 18

3. Installation 21

3.1 Unpacking............................................................................................. 21

3.2.1 Environment.............................................................................. 21

3.2.2 Installation................................................................................. 22

3.3.1 Specifications............................................................................25

3

3

4

RC180 Rev.14 vii

Table of Contents

4. Operation Mode (TEACH/AUTO) 33

4.1 Overview .............................................................................................. 33

4.3.1 What is Program Mode (AUTO)?.............................................. 34 viii

4.4.1 What is Auto mode (AUTO)?.................................................... 35

4.4.3 Setup

5. Development PC Connection Port 37

5.2 Precaution ............................................................................................ 38

5.3 Software Setup and Connection Check................................................ 38

5.4 Disconnection of Development PC and Controller ............................... 39

6. Memory Port 40

6.1 What is Controller Status Storage Function?........................................ 40

6.2 Before Using Controller Status Storage Function................................. 40

6.2.1 Precautions .............................................................................. 40

6.3.1 Controller Status Storage with Trigger Button .......................... 41

6.3.2 Controller Status Storage with Teach Pendant (Option)........... 41

6.3.3 Load Data with EPSON RC+ 5.0.............................................. 42 of Data...................................................................................... 44

7. LAN (Ethernet Communication) Port 45

7.1 About LAN (Ethernet Communication) Port.......................................... 45

7.4 Connection of Development PC and Controller with Ethernet .............. 48

7.5 Disconnection of Development PC and Controller with Ethernet ........................................................................................ 49

RC180 Rev.14

Table of Contents

8. TP/OP Port 50

8.1 What is TP/OP Port?............................................................................. 50

8.3 Operator Panel Connection................................................................... 51

9. EMERGENCY 52

9.1 Safety Door Switch and Latch Release Switch ..................................... 53

9.1.3 Checking Latch Release Switch Operation ............................... 54

9.2 Emergency Stop Switch Connection..................................................... 55

9.2.2 Checking Emergency Stop Switch Operation ........................... 55

RC180 Rev.14

External emergency stop switch typical application .................. 57

External safety relay typical application .................................... 58

10. I/O Connector 59

10.1 Input Circuit........................................................................................... 59

10.2 Output Circuit ........................................................................................ 61

10.3 Pin Assignment ..................................................................................... 63

11. I/O Remote Set Up 64

11.1 I/O Signal Description ...........................................................................65

11.1.1 Remote Input Signals .............................................................. 65

11.1.2 Remote Output Signals ........................................................... 67

11.2 Timing Specifications ............................................................................69

11.2.1 Design Notes for Remote Input Signals................................... 69

11.2.2 Timing Diagram for Operation Execution Sequence................ 69

11.2.3 Timing Diagram for Program Execution Sequence ................. 69

11.2.4 Timing Diagram for Safety Door Input Sequence .................... 70

11.2.5 Timing Diagram for Emergency Stop Sequence ..................... 70 ix

Table of Contents

Maintenance

12. Option Units 71

12.1 What are Option Units? ........................................................................ 71

12.2 Expansion I/O Board ............................................................................ 71

12.2.1 About Expansion I/O Board .................................................... 71

12.2.2 Board Configuration (Expansion I/O) ...................................... 71

12.2.3 Confirmation with EPSON RC+5.0 ......................................... 72

12.2.4 Input Circuit............................................................................. 72

12.2.5 Output Circuit.......................................................................... 74

12.2.6 Pin Assignments ..................................................................... 76

12.3 Fieldbus I/O Board ............................................................................... 78

12.3.1 Overview of Fieldbus I/O......................................................... 78

12.3.2 Response Speed of Fieldbus I/O ............................................ 78

12.3.3 Fieldbus I/O Board Configuration............................................ 79

12.3.4 DeviceNet ............................................................................... 80

12.3.5 PROFIBUS-DP ....................................................................... 84

12.3.6 CC-Link................................................................................... 88

12.3.7 EtherNetI/P ............................................................................. 97

12.3.8 PROFInet.............................................................................. 101

12.3.9 Operation (DeviceNet, PROFIBUS-DP, EtherNetI/P) ........... 105

12.4 RS-232C Board .................................................................................. 107

12.4.1 About RS-232C Board .......................................................... 107

12.4.2 Board Setup (RS-232C)......................................................... 107

12.4.3 Verify with EPSON RC+5.0 (RS-232C) ................................. 108

12.4.4 RS-232C Software Communication Setup (RS-232C)............ 108

12.4.5 Communication Cable (RS-232C) ......................................... 109

1. Safety Precautions on Maintenance 113

/ Tagout................................................................................. 114

2. Regular Maintenance Inspection 115

2.1 Schedule for Maintenance Inspection ................................................ 115

2.2 Inspection Point.................................................................................. 116

2.2.1 Inspection While the Controller is Turned OFF....................... 116

2.2.2 Inspection While the Controller is Turned ON ........................ 116 x

RC180 Rev.14

3. Controller Structure

Table of Contents

117

3.2 Diagram of Cable Connections ........................................................... 119

3.3.2 M/C

4. Backup and Restore 124

4.1 What is Backup Controller? ................................................................ 124

4.3 Backup................................................................................................ 125

4.3.2 Backup from the Teach Pendant (Option)............................... 126

4.4 Restore ............................................................................................... 128

4.4.2 Restore from Teach Pendant (Option) .................................... 129

5. Firmware Update 132

RC180 Rev.14

6. Maintenance Parts Replacement Procedures 138

6.1 Fan and Fan Filter...............................................................................139

6.1.1 Cleaning and Replacing Fan Filter .......................................... 139

6.1.2 Replacing Fan Unit.................................................................. 140

6.1.3 Cleaning and Replacing Fan Filter of Option Unit ................... 142

6.2 Battery ................................................................................................ 143

6.3.2 Replacing Motor Driver (Axis from 1 to 4) ............................... 145

6.3.3 Replacing Motor Driver (Axis 5 and 6) .................................... 150

6.6 Fuse.................................................................................................... 156 xi

Table of Contents

7. Verifying Manipulator Operation

8. Trouble Shooting

165

166

8.1.1 Events .................................................................................... 167

8.1.2 Warnings ................................................................................ 169

8.1.3 Controller Main ....................................................................... 170

8.1.4 Operator Panel ....................................................................... 174

8.1.5 Teach Pendant ....................................................................... 175

8.1.6 PC .......................................................................................... 176

8.1.7 Interpreter............................................................................... 177

8.1.8 Parser..................................................................................... 194

8.1.10 Servo ...................................................................................... 209

8.1.11 Points ..................................................................................... 215

8.1.12 Fieldbus.................................................................................. 217

8.1.13 Vision...................................................................................... 218

8.1.14 Simulator ................................................................................ 220

8.1.15 GUI Builder............................................................................. 221

8.1.16 Hardware................................................................................ 222

8.2 Cannot Connect the Development PC and the Controller using the USB cable........................................................................... 225

8.2.2 When recognized under “Other devices” in Windows Device Manager .................................................. 228

9. Maintenance Parts List 229

xii

RC180 Rev.14

Safety

This section contains information for safety of the Robot System.

Safety 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+ 5.0 User’s Guide and confirm Safety-related

requirements.

2. Conventions

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

WARNING

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

WARNING

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

CAUTION

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

RC180 Rev.14 3

Safety 3. Safety Precautions

3. Safety Precautions

Only trained personnel should design and install the robot system.

Trained personnel are defined as those who have taken robot system training class held by the manufacturer, dealer, or local representative company, or those who understand the manuals thoroughly and have the same knowledge and skill level as those who have completed the training courses.

The following items are safety precautions for qualified design or installation personnel:

WARNING

„ 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.

„ 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 Operator

Panel or Teach Pendant connected to the TP/OP port always functions. (Refer to the typical application diagram in Setup & Operation 9.4 Circuit Diagrams.)

4 RC180 Rev.14

Safety 3. Safety Precautions

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

WARNING

CAUTION

„ 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 before connecting or disconnecting any cables. Connecting or disconnecting any cables with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the Controller.

„ Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or a contact failure is extremely hazardous and may result in electric shock and/or improper function of the system.

„ When connecting the plug to fit the outlet in your factory, make sure that it is done by qualified personnel. When connecting the plug, be sure to connect the earth wire of the AC power cable colored green/yellow on the Controller to the earth 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)

„ 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.

„ 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.

RC180 Rev.14 5

Safety 3. Safety Precautions

The following items are safety precautions for qualified operator personnel:

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. (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.

WARNING

„ 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.

6 RC180 Rev.14

Setup & Operation

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

Setup & Operation 1. Specifications

1. Specifications

1.1 System Example

PLC (Sequencer) Operation Panel Motion Controller

*

G series

Option Unit

Expansion

I/O Board

Fieldbus

- Profibus

- Devicenet

- CC-LINK

- EtherNet/IP

RS-232C Board

USB2.0 or

Ethernet

PC

RC180

Standard Installation

- Standard I/O

- Remote I/O

- Ethernet

ProSix

Driver Unit

*

C3 series

*

S5 series

* Controls one of the robots.

RS series

OP1

(Option)

Windows *1

(XP or Vista or 7)

*

TP1

(Option)

Connect OP1, TP1, and / or TP2

EPSON RC+ 5.0

Software

Option

Vision Guide 5.0

Option

VB Guide 5.0

Option

GUI Builder 5.0

Ethernet

CV1

TP2

Requires preparation by uses

*1 EPSON RC+ 5.0 supports the following OS.

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

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

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

(Option)

RC180 Rev.14 9

Setup & Operation 1. Specifications

1.2 Standard Specifications

Model

Item Specification

Robot Controller RC180

(UL specification: RC180-UL)

CPU

Controllable axes

Robot manipulator control

Positioning control

Memory capacity

Teaching method

External input/output signals (standard)

32 bits Ultra Low Voltage Processor

Up to six (6) connectable AC servo motors

Programming language and

Robot control software

EPSON RC+ 5.0

(a multi-tasking robot language)

Joint Control

Speed Control

Acceleration/ deceleration control

Up to six (6) joints Simultaneous control

Software AC servo control

PTP motion : Programmable in the range of

1 to 100%

CP motion : Programmable (Actual value to be manually entered.)

PTP motion : Programmable in the range of

1 to 100%; Automatic

CP motion : Programmable (Actual value to be manually entered.)

PTP (Point-To-Point control)

CP (Continuous Path control)

Maximum Object Size : 4 MB

Point data area : 1000 points (per file)

Backup variable area : Max. 100 KB (Includes the memory area for the management table.)

Approx. 1000 variables (Depends on the size of array variables.)

Remote

Direct

MDI (Manual Data Input)

Standard I/O

Output : 16

Including 8 inputs,

8 outputs with remote function assigned

Assignment change allowed

Communication interface (standard)

I/O

Input : 32 per board

Output : 32 per board

RS-232C : 4ch per board

Addition of

4 boards allowed

Addition of

2 boards allowed

Options

(Max. 4 slots)

Communication interface

Fieldbus I/O : 1ch per board

PROFINET

PROFIBUS-DP

DeviceNet

CC-Link

EtherNet/IP

Addition of

1 board allowed

10 RC180 Rev.14

Setup & Operation 1. Specifications

Item Specification

- Emergency stop switch

- 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

- Relay welding detection

- Over-voltage detection

- AC power supply voltage reduction detection

- Temperature error detection

- Fan error detection

Power Source

AC 200 V to AC 240 V

Single phase 50/60 Hz

Maximum Power Consumption 2.5 kVA (Depending on the Manipulator model)

Insulation Resistance 100 M

Ω or more

Rated Ambient Temperature 5 to 40 deg.C

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

For SCARA robot *2 9.0 kg Base unit without option

Weight *1

For Six-axis robot *3 10.5 kg Base unit + ProSix Driver Unit

Option unit 1.0 kg Incase of installing 2 option boards

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

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

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

*2 Including RS series.

*3 Including C3 series, S5 series.

RC180 Rev.14 11

Setup & Operation 1. Specifications

1.3 Outer Dimensions

Dimension of RC180-UL is the same as RC180.

Base Unit (Four-axis robot construction)

5

302

130.5

170.5

Base Unit + ProSix Driver Unit (Six-axis robot construction)

5

376

RC180: Base Unit + Option Unit

5

411

110

55

12

75

130.5

170.5

130.5

170.5

RC180 Rev.14

Setup & Operation 2. Part Names and Functions

2. Part Names and Functions

2.1 Part Names

RC180

(1)-2

(1)-1

(2)

(4) (5)

(3)

(6)

(7)

(8)

(9) (10)

(11)

(14)

(15)

(13)

(12)-1 (12)-2

(1)-2

(1)-2

(16)

RC180-UL

(17) (18) (19) (20) (21) (22) (23) (24)

(4) (5)

(1)-1

(2)

(3)

(7)

(8)

(9) (10)

(6)

(11)

(12)-1

(15)

(12)-2

(1)-2

(16)

(17) (18) (19) (20) (21) (22) (23) (24)

RC180 Rev.14 13

Setup & Operation 2. Part Names and Functions

2.2 Functions

(1) -1 Fan Filter (Without Option Unit)

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

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

Controller.

For inspection, cleaning, and replacement, refer to the Maintenance 6.1 Fan and Fan

Filter.

(1) -2 Fan Filter (With Option Unit)

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

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

Controller.

For inspection, cleaning, and replacement, refer to the Maintenance 6.1 Fan and Fan

Filter.

(2) LED

The LED indicates current operation mode (TEACH, AUTO, or PROGRAM mode).

For details, refer to Setup & Operation 2.3 LED and Seven-segment LED.

(3) Seven-segment LED

Four-digit seven-segment LED displays the line number and the status of the controller (error number, warning number, status of Emergency Stop and Safety

Door).

For details, refer to Setup & Operation 2.3 LED and Seven-segment LED.

(4) Signature label (top panel)

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

(5) MT label (top panel)

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.

(6) Controller Number label

The serial number of the Controller is indicated.

(7) M/C POWER connector

A connector for the Manipulator power source.

Connect the dedicated power cable attached to the Manipulator.

(8) Connection Check label

The details of the Manipulator to be connected are recorded on the label as shown in the right. The label indicates the

Manipulator model and Manipulator serial number.

MANIPULATOR

G6-551S 00002

14 RC180 Rev.14

RC180 Rev.14

Setup & Operation 2. Part Names and Functions

NOTE

)

(9) 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.

(10) EMERGENCY connector

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

(11) AC IN

The cable for AC 200V power input.

For details, refer to Setup & Operation 3.3.2 AC Power Cable.

(12) Thumb Head screw

This is two of the four screws used to attach the front cover of the Controller. Use these screws to pull out the Motor Driver module and CPU board unit.

- A spacer is attached to the thumb head screw on Controllers S/N01001 or later.

Do not remove the spacer.

Installing the front cover using a thumb head screw without a spacer may result in a cable being stuck and/or malfunction of the Controller.

- Installing the front cover using other screws may result in cable being stuck and/or malfunction of the Controller.

(13) POWER switch

Turns ON or OFF the Controller.

* This is not available for RC180-UL. For details, refer to the Setup & Operation

3.3.2 AC Power Cable, For RC180-UL.

(14) Power Switch metal hasp

To lock the power switch in the OFF position, set the power switch to the OFF position and mount the metal hasp. Lock the power off for maintenance or repair of the robot system.

* This is not available for RC180-UL. For details, refer to the Setup & Operation

3.3.2 AC Power Cable, For RC180-UL.

(15) Cable Clamp

This can be used to secure the M/C Signal Cable and the EMERGENCY cable if necessary.

(16) Option Unit

Option boards such as expansion I/O board, Fieldbus I/O board, RS-232C board can be installed. Two slots per unit are available. Up to two units (four slots) are supported.

For details, refer to Setup & Operation 12.Option Unit.

(17) Development PC connection port

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

Do not connect other devices except the Development PC.

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

15

Setup & Operation 2. Part Names and Functions

(18) LAN (Ethernet communication) port

This port connects the Controller and the Development PC using an Ethernet cable.

100BASE-TX / 10BASE-T communication are available.

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

(19) Memory port

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

Do not connect other USB devices except the USB memory.

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

(20) Trigger Switch

This switch is for Controller status storage function using the USB memory.

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

(21) TP/OP port

Connects Teach Pendant TP1 (Option) TP2 (Option), Operator Panel OP1 (Option), and TP/OP bypass plug.

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

NOTE

)

Do not connect the following to the TP/OP port of RC180. Connecting to the followings may result in malfunction of the device since the pin assignments are different.

OPTIONAL DEVICE dummy plug

Operation Pendant OP500

Operator Pendant OP500RC

Jog Pad JP500

Teaching Pendant TP-3**

(22) I/O connector

This connector is used for input/output device. There are 24 inputs and 16 outputs.

For details, refer to Setup & Operation 10. I/O Connector.

(23) Battery

This is a lithium battery for data backup.

For replacement, refer to Maintenance 6.2 Battery.

(24) ProSix Driver Unit

This unit is used for PS series, C3 series, and S5 series manipulators.

Motor driver for two axes is installed.

16 RC180 Rev.14

Setup & Operation 2. Part Names and Functions

2.3 LED and Seven-segment LED

2.3.1 LED and Seven-segment Display

Three LEDs and a four-digit seven-segment LED display are located on the front panel of the Controller.

LED : LED (TEACH, AUTO, PROGRAM) turns ON according to the current operation mode (TEACH, Auto, Program).

Seven-segment : Indicates the line number and Controller status (error number, warning number, Emergency Stop or Safeguard status).

From turning ON the Controller to completing startup

LED : All three LEDs blink.

Seven-segment : All four LED digits turn OFF the lights.

After Controller Startup

LED : LED (TEACH, AUTO, PROGRAM) turns ON according to the current operation mode (TEACH, Auto, Program).

Seven-segment : Display changes according to the Controller status.

When several Controller statuses occurred at one time, the status indicated earlier on the following table is displayed. For an example, when both Emergency Stop and Safeguard statuses occurred at one time,

is displayed.

Controller status

Execute Controller status storage function to the USB memory

Complete Controller status storage to USB memory

Failure of Controller status storage to USB memory

Displays repeatedly.

Displays

Displays

Display of seven-segment

and

(for 2 seconds)

(for 2 seconds)

Emergency Stop

Safety Door

READY

START

PAUSE and

*1

(0.4 sec) repeatedly.

*1

(0.4 sec) repeatedly.

Blink

Blink

Blink line number

Blink *2 line number

Blink *2

*1 For error numbers and warning numbers, refer to Maintenance 8.1 Error Code Table

.

*2 In initial status, execution line of task number 1 is displayed in three-digit.

Use Ton statement to change the displayed task number.

For details, refer to EPSON RC+ 5.0 SPEL+ Language Reference, or Online Help.

RC180 Rev.14 17

Setup & Operation 2. Part Names and Functions

2.3.2 Particular Status Display

When particular status occurs, seven-segment displays the followings.

**

Controller startup failure

**

Controller startup failure

Controller in Recovery mode

Refer to Maintenance 4. Backup and Restore.

AC power supply drop is detected and software shut down.

2.4 Safety Features

Software shut down is specified from the EPSON RC+ 5.0

(software) or the Teach Pendant (option).

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

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

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

Emergency Stop Switch

The EMERGENCY connector on the Controller has expansion Emergency Stop input terminals used for connecting the Emergency Stop switches.

Pressing any Emergency Stop switch can shut off the motor power immediately and the robot system will enter the Emergency Stop condition.

Safety Door Input:

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

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

18 RC180 Rev.14

Setup & Operation 2. Part Names and Functions

Low Power Mode

The motor power is reduced in this mode.

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

Dynamic Brake

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

Encoder Cable Disconnection Error Detection

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

Motor Overload Detection

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

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

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

Motor Speed Error Detection

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

Positioning Overflow –Servo Error- Detection

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

Speed Overflow –Servo Error- Detection

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

CPU Irregularity Detection

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

Memory Check-sum Error Detection

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

RC180 Rev.14 19

Setup & Operation 2. Part Names and Functions

Overheat Detection at the Motor Driver Module

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

Relay Deposition Detection

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

Over-Voltage Detection

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

AC Power Supply Voltage Drop Detection

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

Temperature Anomaly Detection

The temperature anomaly is detected.

Fan Malfunction Detection

Malfunction of the fan rotation speed is detected.

20 RC180 Rev.14

Setup & Operation 3. Installation

3. Installation

3.1 Unpacking

TP/OP bypass plug 1 unit

Controller mounting metal hasp 1 set

EMERGENCY port connector 1 set

3.2 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.

3.2.1 Environment

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

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

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

Item Condition

Ambient temperature 5 to 40 deg.C (with minimal variation) humidity

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

1 kV or les (Signal wire)

Electrostatic noise

Base table

4 kV or less

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

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

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

- Install indoors only.

- Place in a well-ventilated area.

- Keep away from direct sunlight and radiation heat.

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

- Keep away from water.

- Keep away from shocks or vibrations.

- Keep away from sources of electronic noise

- Prevent the occurrence of strong electric or magnetic field.

RC180 Rev.14 21

Setup & Operation 3. Installation

3.2.2 Installation

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

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

(A) (B)

NOTE

)

Fixture L

Base Table

Fixture L

(C) (D)

Rack

Fixture L

Base Table

Base Table

Fixture S

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

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

Fixture S: Used in I

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

22 RC180 Rev.14

Setup & Operation 3. Installation

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

When mounting direction is (A) or (B)

Unit [mm]

59.8

59.8

8-M5

57.2 57.2

76.1 76.1

57.2 57.2

(2)

(1)

(3)

24.7

When mounting direction is (C) : Fixture S

4-M5

20.5

90.0

(6)

(5)

(4) 24.7

20.5

90.0

(3)

(2)

(1)

60.0

(Front Side)

(6)

(5)

(4)

60.0

(Front Side)

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

Secure it to the rack with screws and nuts.

No Option Unit

Option Unit

× 1

Option Unit

× 2

Controller Only

(1) 323 mm

(2) 378 mm

(3) 433 mm

Controller + ProSix Driver Unit

(4) 398 mm

(5) 453 mm

(6) 508 mm

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

100 mm

RC180 Rev.14

100 mm

Wind Direction of the Controller Fan

100 mm

100 mm

Excluding the installation side such as base table

23

Setup & Operation 3. Installation

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

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

3.2.3 Install inside a Cabinet

When installing the Controller inside a Cabinet, make sure to satisfy the condition indicated in 3.2.1 Environment, 3.2.2 Installation and also the following conditions.

- The distance from the mounting surface and the inside of the door must be 220 mm or more (190 mm when using the option I/O connector).

220 mm or more*

Mounting

Surface

I/O Connector (Option)

Product No: R12B040710

* When using the I/O connector (option), 190 mm or more

- Set the temperature inside the Controller box to 40 deg.C or less by referring the cooling method in the following example.

Controller

Fan

Air Filter

24 RC180 Rev.14

Setup & Operation 3. Installation

3.3 Power Supply

3.3.1 Specifications

Ensure that the available power meets following specifications.

Item Specification

Voltage AC 200 V to AC 240 V

Momentary Power

Interrupt

Leakage Current

Ground Resistance

10 msec. Or less

Power Consumption Max. 2.5 kVA

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

Rated consumption

= ( 150 W + total Manipulator rated consumption ) / 0.6

The rated consumption for G10 and G20 is 2.5 kVA.

Refer to Manipulator manual for Manipulator rated consumption.

Peak Current When power is turned ON : approximately 150 A (2 msec.)

When motor is ON :approximately 60 A (5 msec.)

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

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

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

RC180 Rev.14 25

Setup & Operation 3. Installation

3.3.2 AC Power Cable

WARNING

To Controller

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

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

The equipment must be grounded properly at all times to avoid the risk of electric shock. Always use a power plug and receptacle for power connecting cable.

Never connect the Controller directly to the factory power supply. (Field wiring)

Plug (Set by the users)

M4 Ring solderless terminal

(RC180-UL: M5 Ring solderless terminal)

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

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

Cable Wire Connection Specification

Purpose Color

AC power wire (2 cables) Black

Ground wire Green / Yellow

Cable length: 3 mm (Standard)

WARNING

For RC180-UL

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

A disconnecting means shall be installed in accordance with the National Electrical

Code and provide the ability for lockout and tagout.

3.4 Cable Connection

WARNING

■ Make sure that the power to the Controller is turned OFF and the power plug is disconnected 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.

■ 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.

CAUTION

■ 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.

■ Before connecting the connector, make sure that the pins are not bent.

Connecting with the pins bent may damage the connector and result in malfunction of the robot system.

26 RC180 Rev.14

RC180 Rev.14

Setup & Operation 3. Installation

3.4.1 Typical Cable Connection

Disconnectable connector

Cable attached at delivery

Cable prepared by users

Controller

*1

(1) AC Power Terminal Block

(2) M/C Power Cable

AC200V-240V

(3) M/C Signal Cable

(4) EMERGENCY

(5) PC for Development

(6) USB Memory

(7) LAN (Ethernet Communication)

(8) I/O Connector

Manipulator

Emergency Stop

Safety Door, etc.

PC for Development

Connect by (5) or (7)

Input/Output Device

(9) TP Cable B

Teach

Pendant

(10) OP Cable

Operator

Panel

(9) TP Cable A

Teach

Pendant

Option Unit

FieldBus

Expansion I/O

RS-232C

*1 For this connection, only one of the connectors (9) TP cable B or (10) OP cable is connectable to the TP/OP port.

For details of connection of Operator Panel or Teach Pendant to the TP/OP port, refer to Setup & Operation 8.1 What is TP/OP Port?

(1) AC Power terminal block

Terminal block for AC 200V power input to the Controller.

(2) M/C Power cable

The cable with 50-pin connector on the Controller side.

Connect the POWER connector on the Manipulator and the M/C POWER connector on the Controller. Insert the connectors until you hear a “click”.

(3) M/C Signal cable

The cable with 50-pin connector on the Controller side.

Connect the signal cable to the SIGNAL connector on the Manipulator and the M/C

SIGNAL connector on the Controller.

27

Setup & Operation 3. Installation

(4) EMERGENCY

The EMERGENCY connector has inputs to connect the Emergency Stop switch and the Safety Door switch. For safety reasons, connect proper switches for these input devices.

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

(5) PC for development

Connect the PC for development.

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

Connect the USB memory.

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

(7) LAN (EtherNet Communication)

Connect the EtherNet cable.

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

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

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

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

For details, refer to the Setup & Operation 10. I/O Connector.

Connect the option Teach Pendant.

There are two types of connector shapes for the Teach Pendant.

TP cable A : Circular connector

TP cable B : D-sub 25pin

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

Connect the option Operator Panel.

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

28 RC180 Rev.14

Setup & Operation 3. Installation

3.4.2 Connecting Manipulator to Controller

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

WARNING

■ Make sure that the power to the Controller is turned OFF before connecting or disconnecting any cables. Connecting or disconnecting any cables with the power

ON is extremely hazardous and may result in electric shock and malfunction of the

Controller.

Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or 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.

CAUTION

NOTE

)

When connecting the Manipulator to the Controller, make sure that the serial numbers on each equipment match. Improper connection between the

Manipulator and Controller may not only cause improper function of the robot system but also serious safety problems. The connection method varies with the

Controller used. For details on the connection, refer to the Controller manual.

If the SCARA Manipulator is connected to the Controller for the 6-axis Manipulator, it may result in malfunction of the Manipulator.

The configuration data for the Manipulator and Manipulator model are stored in the

Controller. Therefore the Controller should be connected to the Manipulator whose serial number is specified in the Connection Check label attached on the front of the

Controller.

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

Manipulator.

RC180 Rev.14 29

Setup & Operation 3. Installation

PS series

PS series Manipulator

(The figure is PS3)

Power Cable Connector

M/C Power Cable

RC180

Controlle r

Signal Cable Connector

G series

G series Manipulator

(the figure is G6-553S)

M/C Signal Cable

M/C Power Cable

RC180 Controller

M/C Signal Cable

RS series

RC180 Controller

M/C Signal Cable

M/C Power Cable

RS series Manipulator

(the figure is RS3-351S)

30 RC180 Rev.14

Setup & Operation 3. Installation

C3 series and

C3 series Manipulator

M/C Power Cable

RC180 Controller

M/C Signal Cable

S5 series

S5 series Manipulator

RC180 Controller

M/C power cable

M/C signal cable

RC180 Rev.14 31

Setup & Operation 3. Installation

3.5 Noise Countermeasures

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

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

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

Ω or less) It is important to ground the frame of Controller not only for prevention from electric shock, but also for reducing the influence of electric noise around the

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

Controller’s power cable to the ground terminal of the factory power supply. For details about the plug and AC power cable, refer to the Setup & Operation 3.3 Power

Supply.

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

- When you tap power for the Controller and the single-phase AC motor from the same power line, change the phase of one or the other. Ensure that they will not be the same phase.

- Use a twisted pair motor power line.

- Do not run AC power lines and DC power lines in the same wiring duct, and separate them 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

- Wire as short as possible to the I/O connector and EMERGENCY connector. Use a shielded cable and clamp the shield to the attached connector interior. Make sure to keep away from the peripheral noise source as far as possible.

- Make sure that the induction elements used to connect to the Controller’s I/O (such as relays and solenoid valves) have surge suppressors. If an induction element without a surge suppressor is used, make sure to connect a rectifying diode located at the induction element in parallel with it. 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 cable such as USB, Ethernet, RS-232C, or fieldbus away from peripheral noise sources.

32 RC180 Rev.14

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

4. Operation Mode (TEACH/AUTO)

4.1 Overview

The Robot system has two operation modes TEACH mode and AUTO mode.

TEACH mode

Controller Program mode

AUTO mode

Auto mode

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

Robot using the Teach Pendant.

In this mode the Robot operates in Low power status.

AUTO mode This mode enables automatic operation (program execution) of the

Robot system for the manufacturing operation, and also programming, debug, adjustment, and maintenance of the Robot system.

This mode cannot operate the Robots or run programs with the Safety

Door open.

4.2 Switch Operation Mode

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

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

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

The operating Robot stops by Quick Pause.

AUTO mode Turn the mode selector key switch to “Auto” and turn on the latch release input signal for AUTO mode.

RC180 Rev.14 33

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

4.3 Program Mode (AUTO)

4.3.1 What is Program Mode (AUTO)?

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

Procedures for switching to the Program mode are the followings.

NOTE

)

A : Set the start mode of the EPSON RC+ 5.0 to “Program” and start the Controller connection. (Refer to 4.3.2 Setup from EPSON RC+ 5.0.)

B : Select the “Program mode” from the Teach Pendant main menu.

(Refer to 4.3.3 Setup from Teach Pendant.)

When EPSON RC+ 5.0 is used for switching to Program mode, the Teach Pendant cannot switch modes. Also, when the Teach Pendant is used for switching to Program mode,

EPSON RC+ 5.0 cannot switch modes.

4.3.2 Setup from EPSON RC+ 5.0

Switch the mode to Program mode from the EPSON RC+ 5.0.

(1) Select EPSON RC+ 5.0 menu-[Setup]-[Configuration] to display the [Preference] dialog.

(5)

(2)

(4)

(3)

34

(2) Select [Startup].

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

(4) Click the <Apply> button.

(5) Click the <Close> button.

4.3.3 Setup from Teach Pendant

Switch the mode to Program mode from the Teach Pendant.

(Only TP1. TP2 does not support this function.)

(1) Press the <F4> key on the Print window to display the Main menu window.

(2) Select the “Program mode …” by the <

↑↓> key.

(3) Press the <OK> key.

RC180 Rev.14

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

4.4 Auto Mode (AUTO)

4.4.1 What is Auto mode (AUTO)?

NOTE

)

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

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

A :Set the start mode of the EPSON RC+ 5.0 to “Auto” and start the EPSON RC+ 5.0.

(Refer to 4.4.2 Setup from EPSON RC+ 5.0.)

B : Offline the EPSON RC+ 5.0.

Execute and stop the program from the control device specified by the EPSON RC+ 5.0.

(Refer to 4.4.3 Setup Control Device.)

4.4.2 Setup from EPSON RC+ 5.0

Switch the mode to Auto mode (AUTO) from the EPSON RC+ 5.0.

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

(5)

(2)

(4)

(3)

(2) Select [Startup].

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

(4) Click the <Apply> button.

(5) Click the <Close> button.

RC180 Rev.14 35

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

4.4.3 Setup from Control Device

Set the control device from EPSON RC+ 5.0.

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

(5)

(2)

(4)

(3)

(2) Select [Configuration].

(3) Select [Setup Controller]-[Control Device] to select the control device from the following three types.

PC

Remote (I/O)

OP (Option: Operator Panel)

(4) Click the <Apply> button.

(5) Click the <Close> button.

36 RC180 Rev.14

Setup & Operation 5. Development PC Connection Port

5. Development PC Connection Port

Development PC connection USB port (USB B series connector)

Development PC connection Port

NOTE

)

For other details of development PC and Controller connection, refer to EPSON RC+ 5.0

User’s Guide 5.12.1 PC to Controller Communications Command.

NOTE

)

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

If RC180 and the development PC are connected without installing the EPSON RC+ 5.0 to the development PC, [Add New Hardware Wizard] appears. If this wizard appears, click the <Cancel> button.

5.1 About Development PC Connection Port

The development PC connection port supports the following USB types.

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

USB1.1 FullSpeed

Interface Standard : USB specification Ver.2.0 compliant

(USB Ver.1.1 upward compatible)

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

Development PC connection port supports hot plug feature. Cables insert and remove from the development PC and the Controller is available when the power is ON.

However, stop occurs when USB cable is removed from the Controller or the development

PC during connection.

RC180 Rev.14 37

Setup & Operation 5. Development PC Connection Port

5.2 Precaution

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

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

Do not use the USB hub or extension cable.

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

PC connection port.

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

HighSpeed mode.

- Do not pull or bend the cable strongly.

- Do not allow unnecessary strain on the cable.

- When the development PC and the Controller are connected, do not insert or remove other USB devices from the development PC. Connection with the Controller may be lost.

5.3 Software Setup and Connection Check

Connection of the development PC and the Controller is indicated.

(1) Make sure that software EPSON RC+ 5.0 (Ver.5.2 or later) is installed to the

Controller connected to the development PC. (Install the software when it is not installed.)

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

(3) Turn ON the Controller.

(4) Start EPSON RC+ 5.0.

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

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

38 RC180 Rev.14

Setup & Operation 5. Development PC Connection Port

(7) After the development PC and the Controller connection has completed, “Connected” is displayed at [Connection status]. Make sure that “Connected” is displayed and click the <Close> button to close the [PC to Controller Communications] dialog.

The connection between the development PC and the Controller is completed. Now the robot system can be used from EPSON RC+ 5.0.

5.4 Disconnection of Development PC and Controller

NOTE

)

Disconnection of the development PC and the Controller communication.

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

(2) Click the <Disconnect> button.

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

If the USB cable is removed when the Controller and the development PC are connected, the Robot will stop. Be sure to click the <Disconnect> button in the [PC to Controller

Communications] dialog before USB cable is removed.

RC180 Rev.14 39

Setup & Operation 6. Memory Port

6. Memory Port

Connect a commercial USB memory to the Controller memory port for following functions. (Only TP1. TP2 does not support this function.)

- Function for Controller status storage to the USB memory.

- Transfer Programs and various data.

Option TP1 Teach Pendant is required. For programs and various data transfer using

TP1, refer to manual RC180 Option Teach Pendant TP1.

6.1 What is Controller Status Storage Function?

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

Data saved in USB memory is loaded to EPSON RC+ 5.0 to get the status of the

Controller and the program simply and accurately.

The saved data can also be used for restoring the Controller. For details, refer to

Maintenance 4.4 Restore.

6.2 Before Using Controller Status Storage Function

CAUTION

6.2.1 Precautions

■ Controller status storage function is available at any time and in any Controller status after starting the Controller.

However, operations form the console including stop and pause are not available while executing this function.

Also, this function influences the robot cycle time and the communication with

EPSON RC+ 5.0. Other than only when it is necessary, do not execute this function when operating the robot.

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

Controller is a universal USB port.

- Insert the USB memory directly into the Controller memory port. Connection with cables or hubs between the Controller and the USB memory is not assured.

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

- Do not edit the saved files with an editor. Operation of the robot system after data restoration to the Controller is not assured.

6.2.2 Adoptable USB Memory

Use USB memory that meets following conditions.

- USB2.0 supported

- Without security function

USB memory with password input function cannot be used.

- No installation of a driver or software is necessary for Windows XP or Windows

Vista.

40 RC180 Rev.14

Setup & Operation 6. Memory Port

6.3 Controller Status Storage Function

CAUTION

6.3.1 Controller Status Storage with Trigger Button

■ Controller status storage function is available at any time and in any Controller status after starting the Controller.

However, operations form the console including stop and pause are not available while executing this function.

Also, this function influences the robot cycle time and the communication with

EPSON RC+ 5.0. Other than only when it is necessary, do not execute this function when operating the robot.

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

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

NOTE

)

NOTE

)

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

(3) Press the trigger button on the Controller.

The seven-segment displays and repeatedly during the data transfer. Wait until the display returns back to the former display. (Transfer time differs depending on the amount of data, such as the project size.)

(4) When the storage has been completed, for two seconds.

is displayed on the seven-segment

When the storage has failed, seconds.

is displayed on the seven-segment for two

(5) Remove the USB memory from the Controller.

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

When storage is executed during Motor ON status, it may fail to store the status. Use another USB memory or execute the storage during Motor OFF status.

6.3.2 Controller Status Storage with Teach Pendant (Option)

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

(1) Insert the USB memory into the Controller.

(2) In the [Main Menu] screen, move the cursor to [Controller States...], and press the

<OK> key. The following screen appears.

RC180 Rev.14

(3) Select a folder to save the data.

The root directory is selected by default.

(4) Press the <OK> key to save the status.

41

Setup & Operation 6. Memory Port

6.3.3 Load Data with EPSON RC+ 5.0

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

RC+ 5.0 and display the Controller status.

(1) Insert the USB memory into the PC with EPSON RC+ 5.0.

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

S_ serial number_data status was saved

→ Exmaple: S_12345_200608074410

(3) Copy the folder confirmed in procedure (2) to the “\EpsonRC50\Status” folder.

(4) Select the EPSON RC+ 5.0 menu-[Tools]-[Controller] to display the [Controller

Tools] dialog.

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

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

42 RC180 Rev.14

Setup & Operation 6. Memory Port

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

For details, refer to View Controller Status in EPSON RC+ 5.0 User’s Guide 5.11.7

Controller Command (Tools Menu).

NOTE

)

6.3.4 Transfer with E-mail

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

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

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

S_serial number_data status was saved

→ Example: S_12345_200608074410

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

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

This function is used to send the data to the system director and EPSON from the end users for problem analysis.

RC180 Rev.14 43

Setup & Operation 6. Memory Port

6.4 Details of Data

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

File Name Outline for restore

CurrentMnp01.PRM Robot parameter Saves information such as ToolSet.

CurrentStatus.txt Save status Saves program and I/O status.

InitFileSrc.txt

MCSys01.MCD

Initial setting

Robot setting

SrcmcStat.txt Hardware information

ProjectName.obj OBJ file

Saves various settings of the Controller.

Saves information of connected robot.

Saves installation information of hardware.

Result of project build.

Prg file is not included.

Saves values of Global Preserve variables. GlobalPreserves.dat Global Preserve

*1 variables

MCSRAM.bin

MCSYSTEMIO.bin

MCTABLE.bin

MDATA.bin

Inner information of Robot operation

SERVOSRAM.bin

VXDWORK.bin

All files related to project except

ProjectName.obj *2

Project When [Include project files when status exported] check box is checked in EPSON

RC+ 5.0 menu-[Setup]-[Setup Controller]-

[Preference], the project file is stored.

Includes program files.

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

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

44 RC180 Rev.14

Setup & Operation 7. LAN (Ethernet Communication) Port

7. LAN (Ethernet Communication) Port

NOTE

)

- Refer to EPSON RC+ 5.0 User’s Guide 5.12.1 PC to Controller Communications

Command (Setup Menu) for other details for the development PC and Controller connection.

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

RC+ 5.0 Online Help or User’s Guide 12. TCP/IP Communications.

- Refer to Vision Guide 5.0 manual for other details of connection of the Controller and

CV1.

- This port is not used for EtherNet/IP. Use the port for fieldbusI/O board. For other details, refer to Setup & Operation 12.3.7 EtherNet/IP.

7.1 About the LAN (Ethernet Communication) Port

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

This port is used for three different purposes.

Connection with development PC

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

Equivalent operation is available to connect between the Controller and the development PC with the development PC connection port.

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

Connection with other Controller or PC

The LAN (Ethernet communication) port can be used as an Ethernet (TCP/IP) communication port to communicate between multiple controllers from robot application software.

Connection with CV1

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

CV1.

RC180 Rev.14 45

Setup & Operation 7. LAN (Ethernet Communication) Port

7.2 IP Address

Set the proper IP address or subnet mask depending on the Controller and development PC configuration to use the LAN port.

Do not input a random value for the IP address of the network configured TCP/IP. This is the only address that specifies the computer using an Internet connection.

The IP address is assigned from the company or organization that has control of IP address.

Use an address from the following Internet private environment such as P2P or line.

Make sure that the address is not redundantly assigned inside the closed network.

Private Address List

172.16.0.1 to 172.31.255.254

192.168.0.1 to 192.168.255.254

The following is the configuration of the controller at delivery.

IP Address : 192.168.0.1

IP Mask : 255.255.255.0

IP Gateway : 0.0.0.0

7.3 Changing Controller IP Address

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

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

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

Operation 5.3 Connection of Development PC and Controller.

(2) Select the EPSON RC+ 5.0 menu-[Setup]-[Controller] to display the [Setup

Controller] dialog.

46 RC180 Rev.14

Setup & Operation 7. LAN (Ethernet Communication) Port

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

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

NOTE

)

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

(5) Connect the Ethernet cable to the Controller LAN port.

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

Controller IP address can also be changed. However, Controller and the development PC do not connect automatically after rebooting the Controller at Ethernet connection.

RC180 Rev.14 47

Setup & Operation 7. LAN (Ethernet Communication) Port

7.4

Connection of Development PC and Controller with Ethernet

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

(1) Connect the development PC and the Controller. (Set the IP address in the same subnet before hand.)

(2) Turn on the Controller.

(3) Start EPSON RC+ 5.0.

(4) Display the [PC-Controller Connection] dialog from [Setup] in EPSON RC+ 5.0 menu.

(5) Click the <Add> button.

48

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

Name : Valid value to identify the controller to connect

IP Address : IP address for Controller to connect

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

RC180 Rev.14

Setup & Operation 7. LAN (Ethernet Communication) Port

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

(9) After the development PC and Controller connection is completed, “Connected” is displayed in the [Connection status:]. Make sure that “Connected” is displayed and click the <Close> button to close the [PC to Controller Communications] dialog.

Connection between the development PC and the Controller is complete. Now the robot system can be used via an Ethernet connection from EPSON RC+ 5.0.

7.5 Disconnection of Development PC and Controller

NOTE

)

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

(1) Display [PC-Controller Connection] dialog from [Setup] in EPSON RC+ 5.0 menu.

(2) Click the <Disconnect> button.

Communication between the Controller and the development PC is disconnected and the Ethernet cable can be removed.

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

Emergency Stop occurs and the Robot stops. Be sure to click the <Disconnect> button in the [PC to Controller Communications] dialog before the Ethernet cable is removed.

RC180 Rev.14 49

Setup & Operation 8. TP/OP Port

8. TP/OP Port

8.1 What is the TP/OP Port?

50

The TP/OP port connects the Teach Pendant and / or the Operator Panel to the Controller.

NOTE

)

NOTE

)

NOTE

)

NOTE

)

When nothing is connected to the TP/OP port, Emergency Stop status occurs in the

Controller. When the Teach Pendant or the Operator Panel is not connected, connect the

TP/OP bypass plug.

Typical cable connection (TP1 is only B.)

A: Only using Teach Pendant (TP Cable A)

TP Cable

Controller

A

Teach

Pendant

Conversion Kit CK1

B: Only using Teach Pendant (TP Cable B)

Controller

TP Cable

B

Teach

Pendant

C: Only using Operator Panel

Controller

OP Cable

Operator

Panel

D: Using Teach Pendant and Operator Panel

Controller

OP Cable

Operator

Panel

TP Cable

A

Teach

Pendant

The cable connectors used in connection A, D and connection B are different.

TP Cable A : Circular connector used to connect to the Operator Panel.

(Direct connection is available with conversion kit CK1.)

TP Cable B : D-sub connector to connect directly to the Controller.

When the Teach Pendant with Operator Panel cable is inserted to the TP port of the

Operator Panel, both Operator Panel and Teach Pendant are available.

(Connection D)

Do not connect the following devices to the TP/OP port of RC180. Connecting these devices may result in malfunction of the device since the pin assignments are different.

OPTIONAL DEVICE dummy plug

Operation Pendant OP500

Operator Pendant OP500RC

Jog Pad JP500

Teaching Pendant TP-3**

RC180 Rev.14

Setup & Operation 8. TP/OP Port

8.2 Teach Pendant Connection

NOTE

)

NOTE

)

A cable for connection to the RC180 Controller is attached to the Teach Pendant.

Connect this cable connector to the TP/OP port.

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

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

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

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

Controller power is ON.

When the Teach Pendant connector is removed from the Controller with the mode selector key switch of the Teach Pendant in the “Teach” position, the operation mode will remain in the TEACH mode. The operation mode cannot be switched to AUTO mode. Be sure to remove the Teach Pendant after switching the operation mode to “Auto” mode.

For details, refer to manual

RC180 Option Teach Pendant TP1

.

RC90/RC180 Option Teach Pendant TP2

.

8.3 Operator Panel Connection

NOTE

)

A cable for connection to the RC180 Controller is attached to the Operator Panel OP1.

Connect this cable connector to the TP/OP port.

Communication is set automatically. Enable the Operator Panel as follows.

- Insert the Operator Panel cable connector to the Controller and turn ON the Controller.

Make sure that the Controller is turned OFF when inserting or removing the Operator

Panel.

For details, refer to manual RC180 Option Operator Panel OP1.

RC180 Rev.14 51

Setup & Operation 9. EMERGENCY

9. EMERGENCY

NOTE

)

WARNING

The details of safety requirements for this section are described in EPSON RC+ 5.0 2.

Safety

. Please refer to them to keep the robot system safe.

Connect a safeguard switch or Emergency Stop switch to the Controller EMERGENCY connector for safety.

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

■ Before connecting the connector, make sure that the pins are not bent.

Connecting with the pins bent may damage the connector and result in malfunction of the robot system.

EMERGENCY Connector

52 RC180 Rev.14

Setup & Operation 9. EMERGENCY

9.1 Safety Door Switch and Latch Release Switch

WARNING

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

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

Connector Standard

EMERGENCY connector

(Controller side)

D-sub 25 male pin

Mounting style #4 - 40

* The E-STOP BOX, connector cable, terminal block, and connector kit are offered as options.

9.1.1 Safety Door Switch

■ 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 zone. The Safety Door that is described in this manual is one of the safeguards and an interlock of the Safety Door is called a Safety Door switch. Connect the Safety Door switch to the Safety Door input terminal on the EMERGENCY connector.

The Safety Door switch has safety features such as temporary hold-up of the program or the operation-prohibited status that are activated whenever the Safety Door is opened.

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

- For the Safety Door switch, select a switch that opens as the Safety Door opens, and not by the spring of the switch itself.

- The signal from the Safety Door (Safety Door input) is designed to input to two redundant signals. If the signals at the two inputs differ by two seconds or more, the system recognizes it to be a critical error. Therefore, make sure that the Safety Door switch has two separate redundant circuits and that each connects to the specified pins at the EMERGENCY connector on the Controller.

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

RC180 Rev.14 53

Setup & Operation 9. EMERGENCY

NOTE

)

NOTE

)

9.1.2 Latch Release Switch

The controller software latches these conditions:

- The safety door is open.

- The operation mode is set to “TEACH”.

The EMERGENCY connector has an input terminal for a latch release switch that cancels the latched conditions.

Open : The latch release switch latches conditions that the safety door is open or the operation mode is “TEACH”.

Closed : The latch release switch releases the latched conditions.

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

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

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

9.1.3 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 the condition that the safety door is open.

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

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

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

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

54 RC180 Rev.14

Setup & Operation 9. EMERGENCY

9.2 Emergency Stop Switch Connection

9.2.1 Emergency Stop Switch

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

Stop on the Teach Pendant and Operator Panel, be sure to connect such Emergency Stop switch(es) to the Emergency Stop input terminal on the EMERGENCY connector.

NOTE

)

The Emergency Stop switch connected must comply with the following:

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

- A button that does not automatically return or resume.

- The button must be mushroom-shaped and red.

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

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

If the signals at the two circuits differ by two seconds or more, the system recognizes it as a critical error. Therefore, make sure that the Emergency Stop switch has double contacts and that each circuit connects to the specified pins on the EMERGENCY connector at the Controller. Refer to the Setup & Operation 5.5 Circuit Diagrams.

9.2.2 Checking Emergency Stop Switch Operation

Once the Emergency Stop switch is connected to the EMERGENCY connector, continue the following procedure to make sure that the switch functions properly. For the safety of the operator, the Manipulator must not be powered ON until the following test is completed.

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

Stop switch.

(2) Make sure that the seven-segment LED on the Controller displays

(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 main window status bar.

LED is turned OFF and that “E-Stop” is dimmed on the

9.2.3 Recovery from Emergency Stop

To recover from the emergency stop condition, follow the procedure of safety check as required by the system.

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

- Release the Emergency Stop Switch

- Execute the RESET command

RC180 Rev.14 55

Setup & Operation 9. EMERGENCY

9.3 Pin Assignments

The EMERGENCY connector pin assignments are as follows:

Pin No. Signal Function Pin No.

Signal Function

1 ESW11 Emergency Stop switch contact (1)

*3

2 ESW12 Emergency Stop switch contact (1)

*3

14

15

ESW21

ESW22

Emergency Stop switch contact (2)

*3

Emergency Stop switch contact (2)

*3

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

4

ESTOP1

− Emergency Stop circuit 1 (-) 17 −

Emergency Stop circuit 2 (-)

5 NC

6 NC

7

8

SD11

SD12

*1

*1

Safety Door input (1)

*2

Safety Door input (1)

*2

18

19

20

21

SDLATCH1 Safety Door Latch Release

SDLATCH2 Safety Door Latch Release

SD21

SD22

Safety Door input (2)

*2

Safety Door input (2)

*2

9 24V

10 24V

+24V output

+24V output

22 24V

23 24V

+24V output

+24V output

11

12

24VGND +24V GND output

24VGND +24V GND output

13 NC

24 24VGND +24V GND output

25 24VGND +24V GND output

*1 Do not connect anything to these pins.

*2 A critical error occurs if the input values from the Safety Door 1 and Safety Door 2 are different for two or more seconds. They must be connected to the same switch with two sets of contacts.

*3 A critical error occurs if the input values from the Emergency Stop switch contact 1 and Emergency Stop switch contact 2 are different for two or more seconds. They must be connected the same switch with two sets of contacts.

Emergency Stop switch output rated load

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

+30 V 0.3 A or under

+24 V

±10%

47.5 mA /+24 V input

+24 V

±10%

10 mA/+24 V input

+24 V

±10%

10 mA/+24 V input

1-2, 14-15 pin

3-4, 16-17 pin

7-8, 20-21 pin

18-19 pin

NOTE

)

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

Ω or less.

56 RC180 Rev.14

Setup & Operation 9. EMERGENCY

9.4 Circuit Diagrams

9.4.1 Example 1: External emergency stop switch typical application

Controller

+24V

External Emergency

Stop switches

Emergency

Stop switch of an Operation

Unit

+5V

14

15

3

16

9

10

22

23

1

2

Main Circuit

Control

NOTE:+24V GND

+ 5V GND

Motor Driver

+

+

AC Input

Emergency

Stop detection

7

Safety Door input 1

8

4

17

11

12

24

25

20

Safety Door input 2

21

18

Latch release input

19

External

+24V

Latch release input Close :Latch off

Open :Latch on

External

+24V

GND

RC180 Rev.14 57

Setup & Operation 9. EMERGENCY

9.4.2 Example 2: External safety relay typical application

Controller

+24V

Emergency

Stop switch of an Operation

Unit

+5V

14

15

3

16

9

10

22

23

1

2

Motor Driver

NOTE:+24V GND

+ 5V GND

AC Input

Main Circuit

Control

+

+

Emergency

Stop detection

External +24V

Fuse

External

+24V

GND

External

+24V

7

Safety Door input 1

8

17

11

12

24

25

External safety relay

(The above diagram is simplified for representation.)

* For the protection of the emergency stop circuit, the fuse’s capacity should be as follows:

- Meets the capacity of the external safety relay

- 0.4A or less

4

External

+24V

GND

External

+24V

20

Safety Door input 2

21

18

Latch Release input

19

Latch release input Close :Latch off

Open :Latch on

External

+24V

GND

58 RC180 Rev.14

Setup & Operation 10. I/O Connector

10. I/O Connector

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

Input

Output

24

16

0 to 23

0 to 15

Refer to Setup & Operation 12.2. Expansion I/O board.

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

Remote function is initially assigned to both input and output from 0 to 7. For further details, refer to 11. I/O Remote Settings.

10.1 Input Circuit

Input Voltage Range

ON Voltage

OFF Voltage

Input Current

: +12 to 24 V

±10%

: +10.8 V (min.)

: +5 V (max.)

: 10 mA (TYP) at +24 V input

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

Typical Input Circuit Application 1

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

I/O-1

GND +DC

1 Input No.0 to 7 common

2 Input No.0

3 Input No.1

4 Input No.2

5 Input No.3

6 Input No.4

7 Input No.5

8 Input No.6

9 Input No.7

18 Input No.8 to 15 common

19 Input No.8

20 Input No.9

Omit

RC180 Rev.14

59

Setup & Operation 10. I/O Connector

Typical Input Circuit Application 2

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

I/O-1

GND +DC

1 Input No.0 to 7 common

2 Input No.0

3 Input No.1

4 Input No.2

5 Input No.3

6 Input No.4

7 Input No.5

8 Input No.6

9 Input No.7

18 Input No.8 to 15 common

19 Input No.8

20 Input No.9

Omit

60

RC180 Rev.14

Setup & Operation 10. I/O Connector

10.2 Output Circuit

Rated Output Voltage : +12 V to 24 V

±10%

Maximum Output Current : TYP 100 mA/1 output

Output Driver : PhotoMOS Relay

On-State Resistance (average) : 23.5 Ω or less

Two types of wiring are available for use with the nonpolar photoMOS relay in the output circuit.

Typical Output Circuit Application 1

I/O-1

10 Output No.0

L

Load

GND +DC

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

11 Output No.1

12 Output No.2

13 Output No.3

L

14 Output No.4

15 Output No.5

27 Output No.6

28 Output No.7

17 Output No.0 to 7 common (GND)

29 Output No.8

30 Output No.9

Omit

33 Output No.8 to 15 common (GND)

RC180 Rev.14

61

Setup & Operation 10. I/O Connector

Typical Output Circuit Application 2

I/O-1

10 Output No.0

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

L

Load

GND +DC

11 Output No.1

12 Output No.2

13 Output No.3

L

14 Output No.4

15 Output No.5

27 Output No.6

28 Output No.7

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

29 Output No.8

30 Output No.9

Omit

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

62

RC180 Rev.14

Setup & Operation 10. I/O Connector

10.3 Pin Assignments

Pin

No.

Signal Name

1 Input common No. 0 to 7

2 Input No. 0 (Start)

3 Input No. 1 (SelProg1)

4 Input No. 2 (SelProg2)

5 Input No. 3 (SelProg4)

6 Input No. 4 (Stop)

7 Input No. 5 (Pause)

8 Input No. 6 (Continue)

Pin

No.

Signal Name

Pin

No.

Signal Name

18 Input common No. 8 to 15 34 Input common No. 16 to 23

19 Input No. 8

20 Input No. 9

35

36

Input No. 16

Input No. 17

21 Input No. 10

22 Input No. 11

23 Input No. 12

24 Input No. 13

25 Input No. 14

37

38

39

40

41

Input No. 18

Input No. 19

Input No. 20

Input No. 21

Input No. 22

9 Input No. 7 (Reset)

10 Output No. 0 (Ready)

11 Output No. 1 (Running)

12 Output No. 2 (Paused)

26 Input No. 15

27 Output No. 6 (SError)

28 Output No. 7 (Warning)

29 Output No. 8

42 Input No. 23

43 Output No.11

44 Output No.12

45 Output No.13

13 Output No. 3 (Error)

14 Output No. 4 (EstopOn)

30 Output No. 9

31 Output No.10

46 Output No.14

47 Output No.15

15 Output No. 5 (SafeguardOn) 32 NC

16 NC 33 Output common No. 8 to 15

48

49

NC

NC

17 Output common No. 0 to 7 50 NC

Remote function inside ( ) in the table above is initially assigned to both input and output from 0 to 7. For further details, refer to 11. I/O Remote Settings.

Connector Standard

D-sub 50 male pin

I/O Connector (Controller side)

Mounting style #4 - 40

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

RC180 Rev.14

63

Setup & Operation 11. I/O Remote Settings

11. I/O Remote Settings

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

The remote functions may be assigned to your standard I/O board(s), expansion I/O board(s), or fieldbus I/O board(s) to enhance robot system control - either from an operational unit of your choice or a sequencer.

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

To accept external remote inputs, assign the remote function and the control device is remote. For further details, refer to the section, Remote Control Software Configuration in EPSON RC+ 5.0 User’s Guide 10. Remote Control.

The user defines the I/O number that a remote function is assigned to using software configuration. For further details, refer to the section, Remote Control Software

Configuration in EPSON RC+ 5.0 User’s Guide 10. Remote Control.

For details about I/O cable connection, refer to sections on Setup & Operation 10. I/O

Connector and 12.2. Expansion I/O Board (Option) and 12.3 Fieldbus I/O Board

(Option).

For details about communication with external equipment, refer to EPSON RC+ 5.0

User’s Guide 10. Remote Control.

CAUTION

■ 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.

NOTE

)

NOTE

)

NOTE

)

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

When you set up a remote I/O signal, please either keep a written record of the settings or store the data in a file for later reference.

When you set up a fieldbus I/O signal to the remote function, response depends on the baud rate of the fieldbus. For details of fieldbus response, refer to Setup & Operation

12.3.2 Response Speed of Fieldbus I/O.

64

RC180 Rev.14

Setup & Operation 11. I/O Remote Settings

11.1 I/O Signal Description

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

To change the function assignment from the initial setting, use EPSON RC+ 5.0.

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

11.1.1 Remote Input Signals

Remote inputs are used to control the Manipulators and start programs. Certain conditions must be met before inputs are enabled, as shown in the table below.

To accept external remote inputs, assign the remote function and set remote to the control device. When external remote input is available, “AutoMode output” turns ON.

Except “SelProg”, the signals execute each function when the signal starts in input acceptance condition. The function executes automatically. Therefore, no special programming is needed.

NOTE

)

When an error occurs, you must execute a “Reset” to clear the error condition before any other remote input commands can be executed. Use the “Error output” and “Reset input” to monitor the error status and clear error conditions from the remote device.

Name Initial

Description

Execute function selected at SelProg.

Start 0

(*2)

Input Acceptance Condition

(*1)

Ready output ON

Error output OFF

EStopOn output OFF

SafeguardOn output OFF

Pause input OFF

Stop input OFF

SelProg1

SelProg2

SelProg4

1

2

3

Specify the executing Main function number. (*2)

Stop 4

(*3) Running output ON

Continue the paused task.

Continue 6

Paused output ON

Pause input OFF

Stop input OFF

Reset 7

Ready output ON

Turn ON robot motors.

SetMotorOn NA

(*5) Ready output ON

EStopOn output OFF

SafeguardOn output OFF

SetMotorOff input OFF

Ready output ON

Move the Robot Arm to the home position defined by the user.

Home NA

Ready output ON

Error output OFF

EStopOn output OFF

SafeguardOn output OFF

MotorsOn output ON

Pause input OFF

Stop input OFF

RC180 Rev.14

65

Setup & Operation 11. I/O Remote Settings

Name Initial

ForcePowerLow

(*6)

NA

Description

Stops all tasks and commands.

Sets the motor power at Low.

The status is Low power mode while the input is ON even executing

Power High command.

Input Acceptance Condition

(*1)

Any time

This input is acceptable even

AutoMode output is OFF.

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

(*2) “Start input” executes Function specified by the “SelPlog1, 2, 4, and 3” bits.

Function SelProg1 SelProg2 SelProg4

0=OFF, 1=ON

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

For details, refer to EPSON RC+ 5.0 Online Help or Pause in SPEL

+

Language Reference.

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

For details, refer to EPSON RC+ 5.0 Online Help or Reset in SPEL

+

Language Reference.

(*5) Initializes the robot parameter.

For details, refer to EPSON RC+ 5.0 Online Help or Motor in SPEL

+

Language Reference.

(*6) This is for the experienced. Make sure that you fully understand the input specification before using.

When the input changes from ON to OFF, all tasks and commands will stop.

It is supported by EPSON RC+ 5.0 Ver.5.4 and Firmware Ver. 1.10.*.*.

66

RC180 Rev.14

RC180 Rev.14

Setup & Operation 11. I/O Remote Settings

11.1.2 Remote Output Signals

Remote outputs provide status for the Manipulator and Controller.

Remote outputs provide the assigned function using with any control device The outputs execute automatically. Therefore, no special programming is needed.

Name Initial Description

Paused 2 Turns ON when pause task exists.

EStopOn

SafeguardOn

4

5

Turns ON at Emergency Stop.

Turns ON when the safeguard is open.

Turns ON when critical error occurs. function. Reboot the controller to recover.

Turns ON when warning occurs.

Warnig 7 sure to eliminate the cause of the warning as soon as possible.

MotorsOn NA Turns ON when the motor is ON.

AtHome

CurrProg1

CurrProg2

CurrProg4

AutoMode

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

NA

Indicates the running or the last main function number

(*1)

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

NA Turns ON in TEACH mode.

Indicates the error number.

TeachMode

ErrorCode1

.

.

.

ErrorCode8192

InsideBox1

.

.

.

InsideBox15

NA

NA

Turns ON when the robot is in the approach check area.

For details, refer to EPSON RC+ 5.0 Online Help or Box in SPEL

+

Language Reference.

InsidePlane1

.

.

.

InsidePlane15

NA

Turns ON when the robot is in the approach check plane.

For details, refer to EPSON RC+ 5.0 Online Help or

Plane in SPEL

+

Language Reference.

Power High (*4) NA

Turns ON when the power status is High.

67

Setup & Operation 11. I/O Remote Settings

(*1) Outputs the current or the last function number of CurrProg1, CurrProg2, or CurrProg4.

Function CurrProg1 CurrProg2 CurrProg4

Main 0 0 0

Main1 1

Main2 0

Main3 1

0

1

1

0

0

0

Main4 0

Main5 1

Main6 0

Main7 1

0

0

1

1

1

1

1

1

0=OFF, 1=ON

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

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

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

(*3) It is supported by EPSON RC+ 5.0 Ver.5.4 and Firmware Ver. 1.10.*.*.

68

RC180 Rev.14

Setup & Operation 11. I/O Remote Settings

11.2 Timing Specifications

11.2.1 Design Notes for Remote Input Signals

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

Controller.

The indicated time lapses (time durations) should be referred to only as reference values since the actual timing values vary depending on the number of tasks running, as well as

CPU speed of the Controller. Check carefully and refer to the following charts for the timing interrelation when you enter an input signal.

RC180 Rev.14

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.

[Unit: msec]

11.2.2 Timing Diagram for Operation Execution Sequence

MotorsOn

Output

AtHome

Output

940

924

Depending on

HOME motion

SetMotorsOn

Input

SetMotorsOff

Input

Home

Input

11.2.3 Timing Diagram for Program Execution Sequence

Ready

Output

17

162

CurrProg1

Output

Running

Output

* Paused

Output

13

17

107

107

16

15

162

SelProg1

Input

Start

Input

Pause

Input

Continue

Input

Stop

Input

* The duration varies depending on the Quick Pause (QP) setting and the program’s operating status at the time of Pause input

69

Setup & Operation 11. I/O Remote Settings

11.2.4 Timing Diagram for Safety Door Input Sequence

Running

Output

1052

Paused

1052

Output

SafeguardOn

Output

8

500

9

MotorsOn

Output

Safety Input

Latch Input

Continue

Input

11.2.5 Timing Diagram for Emergency Stop Sequence

Running

Output

MotorsOn

Output

EStopOn

Output

7

5

920

9

Emergency Input

Reset

Input

11

11

928

70 RC180 Rev.14

Setup & Operation 12. Option Units

12. Option Units

12.1 What are Option Units?

The option units contain option boards for RC180.

Up to two units can be installed on one Controller. Up to four option boards can be installed.

The types of the option boards are as follows.

12.2 Expansion I/O Board

12.3 Fieldbus I/O Board

12.4 RS-232C Board

12.2 Expansion I/O Board

12.2.1 About Expansion I/O Board

Install an option unit in the Controller when extra inputs or outputs are desired.

Each additional expansion I/O board provides 32 inputs and 32 outputs.

CN1: 16 inputs / 16 outputs

CN2: 16 inputs / 16 outputs

The number of I/Os that can be expanded is maximum 4 boards and 128 inputs and outputs.

The input and output bit numbers are assigned as follows. (Bit number is assigned from

CN1.)

Input Bit #

0 to 23

64 to 95

96 to 127

128 to 159

160 to 191

Output Bit #

0 to 15

64 to 95

96 to 127

128 to 159

160 to 191

Applicable Hardware

STANDARD I/O

The 1 st

Expansion I/O board

The 2 nd

Expansion I/O board

The 3 rd

Expansion I/O board

The 4 th

Expansion I/O board

12.2.2 Board Configuration (Expansion I/O)

Board Appearance

CN1

Switch and Jumper Configuration

Setup the DSW1 and DSW2. CN4 is all open.

1 st

board

SW4

SW3

SW2

SW1

2

SW4

SW3

SW2

SW1 nd

board 3

SW4

SW3

SW2

SW1 rd

board

CN4

DSW2

DSW1

4 th

board

SW4

SW3

SW2

SW1

CN2

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

RC180 Rev.14 71

Setup & Operation 12. Option Units

12.2.3 Confirmation of Operation Using EPSON RC+ 5.0

When an expansion I/O board is mounted to the option unit, the Controller software automatically identifies the expansion I/O board. Therefore, no software configuration is needed.

Correct identification can be confirmed from EPSON RC+ 5.0.

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

Controller] dialog.

(2) Select the [Inputs / Outputs].

(3) Make sure that “Yes” is displayed in the Installed column.

The expansion I/O board is identified by the Controller software. Corresponding

Input and Output is available.

12.2.4 Input Circuit

Input Voltage Range : + 12 V to 24 V

±10%

ON Voltage : + 10.8 V (Min.)

OFF Voltage

Input Current

: + 5 V (Max.)

: 10 mA (TYP) at + 24 V input

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

72 RC180 Rev.14

RC180 Rev.14

Setup & Operation 12. Option Units

Protected Expansion I/O Board

Typical Input Circuit Application 1

Expansion I/O board-1

GND +DC

1 Input No.64 to 71 common

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

2 Input No.64

3 Input No.65

4 Inp ut No.66

5 Input No.67

6 Input No.68

7 Input No.69

8 Input No.70

9 Input No.71

18 Input No.72 to 79 common

19 Input No.72

20 Input No.73

Omit

Protected Expansion I/O Board

Typical Input Circuit Application 2

Expansion I/O boa rd -1

GND +DC

1 Input No.64 to 71 common

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

2 Input No.64

3 Input No.65

4 Input No.66

5 Input No.67

6 Input No.68

7 Input No.69

8 Input No.70

9 Input No.71

18 Input No.72 to 79 common

19 Input No.72

20 Input No.73

Omit

73

Setup & Operation 12. Option Units

12.2.5 Output Circuit

Rated Output Voltage

Maximum Output Current

Output Driver

: +12 V to 24 V

±10%

: TYP 100 mA/1 output

: PhotoMOS Relay

On-State Resistance (average) : 23.5 Ω or less

Two types of wiring are available for use with the nonpolar photoMOS relay in the output circuit.

Protected Expansion I/O Board

Typical Output Circuit Application 1

Expansion I/O-1

+DC

10 Output No.64

L

Load

GND

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

11 Output No.65

12 Output No.66

13 Output No.67

14 Output No.68

L

15 O utput No.69

27 Output No.70

28 Output No.71

17 Output No.64 to 71 common

29 Output No.72

30 Output No.73

Omit

33 Output No.72 to 79 common

74 RC180 Rev.14

(Same)

(Same)

Setup & Operation 12. Option Units

Protected Expansion I/O Board

Typical Output Circuit Application 2

Expansion I/O-1

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

(Same)

10 Output No.64

L

Load

GND +DC

11 Output No.65

12 Output No.66

13 O utput No.67

14 Output No.68

L

15 Output No.69

27 Output No.70

28 Output No.71

17 Output No.64 to 71 common

29 Output No.72

30 Output No.73

Om it

33 Output No.72 to 79 common

RC180 Rev.14 75

Setup & Operation 12. Option Units

12.2.6 Pin Assignments

Pin Assignment table of the 1 st

Expansion I/O board.

Connector 1 Pin Assignments

Pin

No.

Signal Name

1 Input common No.64 to 71

2 Input No.64

3 Input No.65

4 Input No.66

5 Input No.67

6 Input No.68

7 Input No.69

8 Input No.70

9 Input No.71

10 Output No.64

11 Output No.65

12 Output No.66

Pin

No.

Signal Name

18 Input common No.72 to 79

19 Input No.72

20 Input No.73

21 Input No.74

22 Input No.75

23 Input No.76

24 Input No.77

25 Input No.78

26 Input No.79

27 Output No.70

28 Output No.71

29 Output No.72

Pin

No.

34 NC

35 NC

36 NC

37 NC

38 NC

39 NC

40 NC

41 NC

42 NC

Signal Name

43 Output No.75

44 Output No.76

45 Output No.77

13 Output No.67

14 Output No.68

30 Output No.73

31 Output No.74

I/O Connector (Controller side)

46 Output No.78

47 Output No.79

16 NC

32 NC

33 Output common No.72 to 79

48 NC

49 NC

17 Output common No.64 to 71 50 NC

Connector Standard

D-sub 50 male pin

Mounting style #4 - 40

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

76 RC180 Rev.14

Setup & Operation 12. Option Units

Connector 2 Pin Ass ignments

Pin

No.

Signa l Name

Pin

No.

Signal Name

1 Input common No.80 to 87 18 Input common No.88 to 95

2 Input No.80 19 Input No.88

Pin

No.

34

35

NC

NC

Signal Name

3 Input N o.81

4 Input No.82

9

10

11

12

7

8

5

6

13

14

Input No.83

Input No.84

Input No.85

Input No.86

Input No.87

Output No.8

Output No.8

Output No.8

0

1

2

Output No.83

Output No.84

15 Output

20 Input N o.89

21 Input No.90

22 Input No.91

23 Input No.92

24 Input No.93

25 Input No.94

26 Input No.95

27 Output No.86

28 Output No.87

29 Output No.88

30 Output No.89

31 Output No.90

32 NC

36

37

38

39

40

41

42

43 Outp

44

45

46

47

NC

NC

NC

NC

NC

NC

NC

Outp

Outp ut No.91 ut No.92 ut No.93

Output No.94

Output No.95

48 NC

16

17

NC

Output comm on No.80 to 87

33 Output commo n No.88 to 95 49

50

NC

NC

Connector Standard

D 5 le pin

I/O Connector (Controlle ide)

Mounting style #4 - 40

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

RC180 Rev.14 77

Setup & Operation 12. Option Units

12.3 Fieldbus I/O Board

12.3.1 Overview of Fieldbus I/O

The Fieldbus I/O option is an option to add fiel dbus slave function (DeviceNet,

PROFIBUS-DP, PROF INET, CC-Link, EtherN et/IP) to the robot Controller.

A fieldbus is a standard of signal communications be n devices operating in a factory (sensor, a t roller, etc.) and controller (PLC or robot controller) using serial comm unications. Com pared to signal com ni ns using analog signals, a fieldbus has the follow ing features: a. Access to sign r evices and multiple data from each device using one cable. b . Precise signal transmission since there is no ne or on and D/A conversion. c.

Less wiring costs, including signal relay board costs and installation area due to several dozen (or a hundred) device s connected on o ne f ie ldbus. d. More flexible i pansion of a system b ecause multiple devices are simply added to e ut additional wiri ng. e . Slave devices can transmit self-diagnostics informati on.

Master Device

Mas ter Device

RS-232C

RS-232C

Fieldbus

78

NOTE

)

Sample Parallel Connection Sample Fieldbus Connection

Fieldbus slave function can be added to the RC180 Controller. For each fieldbus on the controller, there is one board installed. You cannot use more than one fieldbus type on the same controller.

For master device transmission, up to 256 inputs and 256 outputs are available with

Fieldbus I/O.

Response tim es for Fieldbus I/O can vary and depend on several factors, including baud rate, scan rate, number and types of devices, number of SPEL+ tasks, etc.

12.3.2 Response Speed of Fieldbus I/O

Fieldbus I/O communicates the I/O status using serial communication. I/O status exchange lag occurs according to the serial communication speed. This exchange lag is also influenced by scan cycle, amount and type of the device, and existence of communication error.

In the RC180 Controller, status of the Fieldbus I/O is updated approximately every 30 mS.

Although the fieldbus communication speed is fast, response is not available for pulses less than or equal to 30 mS.

RC180 Rev.14

Setup & Operation 12. Option Units

12.3.3 Fieldbus I/O Board Configuration

Th e Fieldbus I/O board is configured as fo llows at shipment.

Board Appearance Configuration

CN3 DSW2 DSW1 JMP1

CN 3

DSW2

DSW1

JM P1

All Open

SW4

SW3

SW2

SW1

All ON

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

Fixed as above

IRQ15

IRQ11

IRQ10

IRQ7

IRQ5

1 2

JP5

JP4

JP3

JP2

JP1

All Open

RC180 Rev.14 79

Setup & Operation 12. Option Units

12.3.4 DeviceNet

Overview of DeviceNet

DeviceNet is a fieldb us network that provides easy interconnection between control devices (PLC, PC, sensor, actuator, etc.).

DeviceNet was developed by Allen-Bradley as an open communication standard to connect various field devices (sensor, actuator, robot controller, etc.). Because of the open communication standard, DeviceNet users can easily construct a multi-vendor system with various devices developed around the world.

Master Device

DeviceNet Network

Motor Driver from Company A

Motor Driver from Company B

Intelligent I/O from Company C

Intelligent I/O from Company D

Photo Sensor from Company E

Analog Device from Company G

HMI Device from Company F

DeviceNet Communication Specifications

Item Specification

Code R12B040706

Supported Connection I/O messaging connection (Polling),

Explicit message connection

Baud Rates

DeviceNet communication protocol

125 K / 250 K / 500 K (bps)

Transfer Distance

Baud Rates

500 K (bps)

250 K (bps)

Max. Network

Length

100 m

250 m *

Drop Length

Total Drop

Line Length

6 m or under 39 m or under

6 m or under 78 m or under

Cable

Communications

Power Supply Voltage

Communication

Power Supply Current

Consumption

Mode Slave

Interface

Connection type

Explicit message connection

125 K (bps) 500 m * 6 m or under 156 m or under

5-wire cable dedicated to DeviceNet (2 wires for signal, 2 wires for power supply, 1 shield wire)

24 V DC (supplied from a connector)

Maximum 30 mA

1 DeviceNet port

Polling

Supported

Input data size

Output data size

256 bits (32 bytes)

256 bits (32 bytes)

* When thin cable is used for trunk line, the maximum network length is 100 m.

80 RC180 Rev.14

Setup & Operation 12. Option Units

DeviceNet Appearance

Status Display LED

Configure Switch

DeviceNet Connector

NS LED : Network status display

MS LED : Module status display

Refer to the following table for functions of

LED.

WARNING

LED Description of DeviceNet

LED status represents the status of the fieldbus board.

LED status

GRN

RED

OFF

NS

Communication power supply OFF

Disconnected

ON

Link OK

Online connected

Blinking Online disconnected

ON Link error

Blinking Communication time out

Board Installation of DeviceNet

MS

Device power supply OFF

Device operating

Data size error

Critical error

Error

„ Make sure that th e p i g/removing any boards or connectin g/disconnecting any cables. Inst alling/removing any boards o r connectin g/disconnecting any cables with the power ON is extremely haz equipment. ardou s and may re h alf

Set the baud rates betwe en the MAC addr ess of the devi ce and the ma ste r by setting the

DeviceNet board configu re switch.

(1) Set the MAC addres s for DeviceNet board by setting the configure switch. Make sure that the MA C ad dress is different from the other devices in the network. Refer to the following tab le for the configuration.

MAC address

0

1

2

3

62

63

(at shipment) sw3

(MSB)

Switch sw4 sw5 sw6 sw7 sw8

(LSB)

OFF OFF OFF OFF OFF OFF

OFF O FF OFF OFF OFF ON

OFF OFF OFF OFF ON OFF

OFF OFF OFF OFF ON ON

OFF OFF OFF OFF OFF OFF

ON O N ON ON ON OFF

ON O N ON ON ON ON

RC180 Rev.14 81

Setup & Operation 12. Option Units

(2 ) Set the DeviceNet baud r ate. Check the master configuration and set the same baud rate. Refer to the following table for configuration settings.

Baud Rate

125 K

250 K

500 K

Configuration prohibited

Switch sw1 sw2

OFF OFF

OFF ON

ON OFF

ON ON

Wiring (DeviceNet)

The DeviceNet connector is a 5 pin open connector. Use the connector attached to the board for wiring.

NOTE

)

T erminal name for each pin

Terminal No Terminal N ame

1 V-

2 CAN_L

3 SHELD

4 CAN_H

5 V+

Prepare the cable for D eviceNet s old in the market as a comm unication cable.

Install terminating resistors at both ends of the network.

DeviceN et Confirmation with EPSON RC+ 5.0

W hen the DeviceNet board is installed to the Controller, it is recognized automatically.

C onfirm whether EPSON RC+ 5.0

has recognized the DeviceNet board using the f ollowing procedure.

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

(4)

(2)

(3)

(3)

(3)

(2) Select [Inputs / Outputs].

(3) Make sure that the followin g are d isp layed.

Feildbus T

Field ype bus Slave ID

: DeviceNet

: (MA C ad dress depe ndin g on the s etting )

(4) Click the <Close> button.

82 RC180 Rev.14

Setup & Operation 12. Option Units

Operation

For details, refer to 12.3.9 Operatio

n (Devi ceNet, PROFIBU S-DP, EtherNet/IP,

PROFINET)

.

Electronic Inf ormatio n File (EDS file)

An ED S file is supplied for Device Net network confi guration. The file is located in the fo llowing folder in the Manual Update CD that is attached to the Robot Controller.

\EpsonRC50\Fieldb us\DeviceNet

RC180 Rev.14 83

Setup & Operation 12. Option Units

12.3.5 PROFIBUS-DP

Overview of PROFIBUS-DP

PROFIBUS DP is one of the fieldbus networks that provide easy interconnection between c ontrol devices (PLC, PC, sensor, actuator, etc.).

PR OFIBUS DP was developed as an open communication standard to connect various field devices (sensor, actuator, robot controller, etc.). Because of the open communication standard, PROFIBUS DP can easily construct multi-vendor system with vario us devices developed around the w orld.

Master Device

PROFIBUS-DP Network

Motor Driver from Company A

Motor Driver from Company B

Intelligent I/O from Company C

Intelligent I/O from Company D

Photo Sensor from Company E

Analog Device from Company G

HMI Device from

Company F

PROFIBUS DP Specifications

Item Specification board

Code R12B040707

Connection Method Hybrid

Baud Rates (bps)

(token passing procedure and master-slave communication)

9.6 K, 19.2 K, 45.45K, 93.75 K, 187.5 K, 500 K,

1.5 M, 3 M, 6 M, 12 M

Transfer Distance

Baud Rates

12 M (bps)

6 M (bps)

Cable Length

100 m

100 m

3 M (bps)

1.5 M (bps)

500 K (bps)

187.5 K (bps)

93.75 K (bps)

45.45 K (bps)

19.2 K (bps)

9.6 K (bps)

Maximum Stations 126 (including master unit and repeater)

100 m

200 m

400 m

1000 m

1200 m

1200 m

1200 m

1200 m

Data Length / Frame 244 bytes

Cable 2-wire cable dedicated to PROFIBUS (2 wires for signal)

Modes Slave

Interface 1 PROFIBUS-DP port (EN 50170)

Output

Current Capacity

Input Data Size

Output Data Size

Maximum 150 mA

256 bits (32 bytes)

256 bits (32 bytes)

84 RC180 Rev.14

Setup & Operation 12. Option Units

Appearance of PROFIBUS-DP

Status Display LED

Address Configure Switch (

×1)

Address Configure Switch (

×10)

Terminator Switch

PROFIBUS-DP Connector

ONLINE LED

: Online status display

OFFLINE LED

: Offline status display

ERROR LED

: Error status display

Refer to the following table for functions of LED.

LED Description of PROFIBUS-DP

1 Hz blinking

2 Hz blinking

4 Hz blinking

LED status represents the status of the fieldbus board.

LED status ONLINE GRN

OFF Offline

ON

Online

Data exchangeable

OFFLINE RED

Online

Offline

Data unexchangeable −

ERROR RED

Initialization error

(Mismatch with network configuration)

Initialization error

(Mismatch with user parameter)

Initial ization error

(Mo du le initialization error)

Board Installation o f PROFIB US-DP

WARNING

„ Make sure that t he p ower is turned OFF before installing/removing any boards or connecting/disco nnecting any cables. In stalling/removing any boards or connecting/disco nnecting an y cables with the power ON is extremely hazardous and may result in ele ctric shock and/or malfunction of equi pment.

Set the node address of the device using the address configuration switch of the

PROFIBUS-DP board. Set netwo rk termination ON or OFF with the termina tor switch.

NOTE

)

(1) Set the node address of th e PROFIBUS-D P board using the address configuration switch. Make sure that the node address is different from the other devices in the network. Switch on the “

×10” side for t ens digit address co nfiguratio n. Switch on the “

×1” side for units digit address configuration.

PROFIBUS-DP device,

Ge nerally, node addresses recom as sh mended to own in the ta ble. are be configured

Node address

0

1

Se

Device Name rvice unit such as PG/PC

Operation panel such as HMI

399 (-125) DP slave station

(2) Turn network ter mination ON or OFF using the terminator switch.

RC180 Rev.14 85

Setup & Operation 12. Option Units

Wiring (PROFIBUS-DP)

PROFIBUS-DP connector is standard D-sub 9 pins connector .

Terminal name for each pin

Terminal No Terminal Name

Case Shield

1 NC

2 NC

3 B

4 RTS

BUS

6 +5V

7 NC line

9 NC

NOTE

)

Prepare the cable for PRO FIBUS-DP sold in the m arket as a communication cable.

Install terminating res istors at both ends of the network.

A term inating resistor is installed in the PROFIBUS-DP bo ard. Turn the terminating

PROFIBUS-DP Confirmation with EP SON RC+ 5.0

W hen a PROFIBU S-D P board is installed to the Controller, it is recognized automatically.

C onf irm whether EPSON RC+ 5.0 has re cognized the PROFIBUS-DP board using the follow ing procedure.

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

(4)

86

(2)

(3)

(3)

(3)

(2) Select [Inputs / Outputs].

(3) Make sure that the following are d isplayed.

Fieldbus-Installed :

Fieldbus Ty pe

Fieldbus Slave ID

: PROFIBUS DP

: (depends on the address configure switch)

(4) Click the <Close> button.

RC180 Rev.14

Setup & Operation 12. Option Units

Operation

For details, refer to 12.3.9 Operation (DeviceNet, PROFIBUS-DP, EtherNet/IP,

PROFINET)

.

Electronic Inform ation File (GSD f ile)

A GSD file is supplied for PROFIBUS-DP network configuration. The file is located in the following folder in the Manual Update CD that is attached to the Robot Controller.

\EpsonRC50\Fieldbus\PROFIBUS

RC180 Rev.14 87

Setup & Operation 12. Option Units

12.3.6 CC-Link

Overview of CC-Link

CC-Link is one of fieldbus netw orks that provide easy interconnection between control de vices (PLC, PC, sensor, actuator, etc.).

CC-Link was developed as an open communication standard to connect various field devices (sensor, actuator, robot controller, etc.). Because of the open communicatio n stand ard, CC-Link can easily construc t multi-vendor system with various devices d eveloped around the world.

Master Device

CC-Link Network

Motor Driver Motor Driver from Company A from Company B

Intelligent I/O from Company C

Photo Sensor from Company E

Intelligent I/O from Company D

Analog Device from Company G

HMI Device from Company F

CC-Link Specifications

Item Specification board

Code R12B040708

Connection Method

Baud Rates (bps)

Transfer Distance

Broadcast polling

156 K, 625 K, 2.5 M, 5 M, 10 M

Baud Rates

10 M (bps)

5 M (bps)

2.5 M (bps)

625 K (bps)

156 K (bps)

Cable Length

100 m

160 m

400 m

900 m

1200 m

Maximum Device Volume 64 units

Cable Dedicated cable supporting CC-Link Ver.1.10

Modes Slave

Interface 1 CC-Link V1 port

Occupied stations

Input Data Size

Output Data Size

3 station fixed

256 bits (96 bits + 10 words)*

256 bits (96 bits + 10 words)*

* 16 bits of each system inputs and outputs are reserved. Open data size for user is as follows.

Inputs/Outputs: 80 bits

+ 10 words

88 RC180 Rev.14

Setup & Operation 12. Option Units

Appearance of CC-Link

Status Display LED

Station Configure Switch (

× 1)

Station Configure Switch (

× 10)

Baud Rate Configure Switch

CC-Link Connector

ERRL LED : Error status display

RUN LED : Offline status display

RD LED : Data reception status display

SD LED : Data transmission status display

Refer to the following table for

LED functions.

LED Description of CC-Link

LED status represents the status of the fieldbus I/O board.

LED status

OFF

ERRL RED

Normal operation

Device power supply

OFF

CRC error: station

ON

Address error

Baud

Blinking

− rate configuration error

RUN GRN

Offline

Device power supply

OFF

Normal operation

Board Configuration (CC -Link)

RD GRN

No data reception

Device power supply

OFF

Data reception

SD GRN

No data transmission

Device power supply

OFF

Data transmission

WARNING

„ Make sure that th e power is turne d OFF before

installing/removing any boards or connecting/disconnecting any ca bles. Ins talling/removing any boards or connecting/disconnecting any cables with the power ON is extremely hazardous and may result in electric shock an d/or malfunc tion of equipmen t. available with the station configure switch on the

CC-Lin k board.

Baud ra te configuration is available with baud rate configure switch on the CC-Link board.

(1) Set the statio n of the CCLink board with the station con figuration switch.

Make sure tha t the stat ion does not duplicate with t he other devices inside the network at configuration.

Switche s on the

×10 side are for tens place address value configuration. Switches on the

×1 side are for units digit a ddress value configuration. Stations from 1 to 62 are available. CC-Link board occupies three stations. Assign the configured stations +3 stations to the next node.

RC180 Rev.14 89

Setup & Operation 12. Option Units

(2 ) Set the CC-Link baud ra te. Check the master configuration and set the same baud rate. Refer to the following table for configuration.

Baud Rate

156 K

625 K

2.5 M

5 M

10 M

Configuration prohibited

Switch

0

1

2

3

4

5-9

Wiring (CC-Link)

The CC-Link connector is a 5 pin open connector. Use the connector attached to the b oard for wiring.

Terminating

Resistor

Te rminal name for each pin

Terminal No Terminal Name

1 DA

2 DB

3 DG

4 SLD

5 FG

Connect the CC-Lin k master module an d th e CC-Link board as fol lows.

Master Stati on

DA

RC170

CC-Link Board

DA

CC-Link

Module

D A

DB

DB

DB

DG

DG

DG

SLD

SLD

SLD

FG

FG

FG

Twisted-pair Cable with Shield

Twisted-pair Cable with Shield

Terminating

Resistor

NOTE

)

Prepare the cable for CC-Link Ver.1.10 sold in the market as a communication cable.

Install terminating resistors at both end of the network.

Use the terminating resistor attached to the CC-Link master station.

Make sure to disconnect the connectors only after turning OFF the power supply of the specific station.

Connect the shield wire for CC-Link to the “SLD” of each unit and ground the both end via the “FG.”

CC-Link Confirmation with EPSON RC+ 5.0

When CC-Link board is installed to the Controller, it is recognized automatically.

Confirm whether EPSON RC+ 5.0 has recognized the CC-Link board using the following procedure.

90 RC180 Rev.14

Setup & Operation 12. Option Units

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

(4)

(2)

(3)

(3)

(3)

NOTE

)

(2) Select [Input s / Outputs].

(3) Make sure that the follo

Fieldbus T ype wing are displayed.

Fieldbus-Installed :

: CC Link

(4) Cli ck the <Close> bu tton.

For CC-Link, station address cannot be confirmed. “

−1” is displayed.

Operation (CC-Link)

When CC-Link is installed, some operation differs from the other Fieldbus I/O options.

This section indicates how to operate.

Remote Input

Remote input (RX) and remote output (RY) indicates ON/OFF information. Remote data is bit data and the FROM/TO command is executed per 16 bits (1 word).

“n” in the following tables is address configured as a master station with the station configure. This is calculated by the following expression. n = (Station

− 1) × 2

Result of the calculation is in decimal number. Substitute the result to “n” after converting to hexadecimal number.

(Example)

When CC-Link board station is 1

Remote Input RXn0 to RX(n+5)F

→ RX00 to RX5F

Remote Output RYn0 to RY(n+5)F

→ RY00 to RY5F

When CC-Link board station is 4

Remote Input RXn0 to RX(n+5)F

→ RX60 to RXAF

Remote Ou tput RYn0 to RY(n+5)F

→ RY60 to RYAF

R emote Input List (3 stations occupied, Default configuration *1)

Signal direction : Remote device station (CC-Link board)

→ Master station (PLC)

Bits indicated as “NA” are left for user. Use these free for SPEL+ program.

RC180 Rev.14 91

Setup & Operation 12. Option Units

Address Signal Name

RXn0 Ready

RXn1 Start

RXn2 Pause

RXn3 Error

RXn4 EStopOn

RXn5 SafeguardOn

RXn6 SError

RXn7 Waning

RXn8 MotorOn

RXn9 Home

RXnA CurrProg1

RXnB CurrProg2

Controller Bit No

*1 512

*1 513

*1 514

*1 515

*1 516

*1 517

*1 518

*1 519

*1 520

*1 521

*1 522

*1 523

RXnC CurrProg4

RXnD AutoMode

RXnE TeachMode

RXnF ErrorCode1

RX(n+1)0 ErrorCode2

RX(n+1)1 ErrorCode4

RX(n+1)2 ErrorCode8

RX(n+1)3 ErrorCode16

RX(n+1)4 ErrorCode32

RX(n+1)5 ErrorCode64

RX(n+1)6 ErrorCode128

R X(n+1)7 ErrorCod

RX e256

(n+1)8 ErrorCode512

RX(n+1)9 ErrorCode1024

*1 524

*1 525

*1 526

*1 527

*1 528

*1 529

*1 530

*1 531

*1 532

*1 533

*1 534

*1 535

*1 536

*1 537

RX(n+1)A ErrorCode2048

RX(n+1)B ErrorCode4096

RX(n+1)C

*1

*1

538

539

ErrorCode8192 *1 540

RX(n+1)D NA

RX(n+1)E NA

RX(n+1)F NA

RX(n+2)0 NA

:

RX

:

(n+4)F NA

541

542

543

544

591

592

593

594

595

596 reservation

RX(n+5)3 System

R reservation

X(n+5)4 System

RX

RX

RX st reservation reservation

(n+5)7 System

597

598

599

R X(n+5)8 Initial data processi ng request flag *2 600

RX (n+5)9 Initial data configuration complete *2 flag

601

RX(n+5)A

RX(n+5)B Remote

RX(n+5)C

Error status flag

Ready

System reservation reservation reservation

RX(n+5)F System

*2

*2

602

603

604

605

606

607

*1 I/O assignment can be changed or invalid (NA). For details, refer to EPSON RC+

5.0 User’s Guide 10. Remote Control

.

*2 For details, refer to the CC-Link flag operation section.

92 RC180 Rev.14

Setup & Operation 12. Option Units

Re mote Outp ut List (3 station s occupied, De fault configurat ion *1)

Signal direction : Master station (PLC)

→ Remote device station (CC-Link board)

B its indi cated as “NA” are left for user. Use these free for SPEL+ program.

Add ress Signal Name

RYn0 Start

RYn1 Pause

RYn2 Reset

RYn3 SelProg1

RYn4 SelProg2

RYn5 SelProg4

RYn6 Stop

RYn7 Continue

RYn8 MotorOn

RYn9 MotorOff

RYnA Home

RYnB NA

RYnC NA

RYnD NA

RYnE NA

RYnF NA

RY(n+1)0 NA

: :

RY(n+4)F NA

*1

C

512

513 ontroller Bit No

*1

*1 514

*1 515

*1 516

*1 517

*1 520

521

522

523

524

526

527

591

592

593

594

595

596

597 reservation

RY(n+5)7 System

RY(n+5)8 reservation

Initial data processing complete flag *2

598

599

600

RY(n+5)9

RY(n+5)A

Initial data configuration request flag

E rror reset request flag reservation

*2 601

*2 602

603 reservation reservation reservation reservation

604

605

606

607

* 1 I/O assig nm ent can be changed o r invalid (NA). For det ails, refer to EPSON RC+

5.0 User ’s G uide 10. Remote Con trol

.

* 2 For deta ils, refer to the CC-Link f

lag operation

section.

RC180 Rev.14 93

Setup & Operation 12. Option Units

Remote Register

Remote register (RWr, RWw) is numeric value

“m” indicated in the following tables are master station address configured with station conf igure. Th is is calculated by the following ex pression. m = (Station

1)

× 4

Result of the calculation is in decimal number. Substitute the result to “m” after c onvertin g to hexad ecimal num ber.

( Example)

When the CC-Li nk board is 1

Rem ote Regis ter RW rm to RWrm+B

→ RWr0 to RWr

B

Rem ote Regis ter RWwm to RWwm+B

→ RWw0 to R

Ww

When the CC-Li nk board is 4

Rem ote Regis ter RWr m to RWrm +B

→ RWrC to RW r17

Rem ote Regis ter RW wm to RWwm+B W 7

Remote Register List (3 stations occupied, Default configuration *1)

S ignal di rection : R tion (PLC)

Bits indicated as “N A” a re left for user. Use these free for SPEL+ program.

Address

RWrm

:

RWrm+9

RWrm+A

RWrm+B

Signal Name

NA

:

Controller Word No Controller Bit No

38 608 to 623

NA 47 752 to 767

System reservation - -

System reservation - -

S ignal direct ion : M aster station (PLC)

Remote device station (CC-Link board)

Bits indicated as “N A” are left for user. Use these free for SPEL+ program.

Address

RWwm

:

RWwm+9

RWwm+A

RWwm+B

Signal Name

NA

: rd C ontroller Bit No

38 608 to 623

NA 47 752 to 767

System reservation - -

System reservation - -

94 RC180 Rev.14

Setup & Operation 12. Option Units

CC-Link Flag Operation

Flag operation of the remote output is describes in this section.

Initial Request Process after Power Supply

Initial request process is executed from the remote device station (CC-Link board).

After turning ON the Controller, the initial data processing request flag [RX(n+5)8] will be ON by completing the CC-Link board initialization. Se t the initial data processing complete fla g [RY(n+5)8] ON.

Initia l Data Processing

Request Flag

In itial Data Processing

C omplete Flag

Remote Ready

[RX(n+5)8]

[RY(n+5)8]

[RX(n+5)B]

ON

OFF

ON

OFF

ON

OFF

Initial Processing Request from the Master (PLC)

This is an initia l config ure request for the C C-Link board. No p roc essing is required fo r no initial data.

In itial Data C onfigur e

Request Flag

[RY (n+5)8]

Initial Data Configure

Complete Flag

[RX(n+5)8]

R emote Ready [R X(n+5)B]

ON

OFF

ON

OFF

ON

OF F

Error Flag, Error Reset Process

Error status flag [R

W hen error r eset r equest flag [RY(n+5 ] (n+5)A] turns OFF at status that enables error status clear.

Error Reset

Request Flag

[RY(n+5)A]

Error Status Flag [RX(n+5)A]

ON

OFF

ON

OFF

ON

Remote Ready [RX(n+5)B]

OFF

NOTE

When CC-Link error occurs (when error status flag is ON), the Controller status changes

) to the error status. Reset the error status of the Controller after the error reset process indicated above is completed.

When an error occurred at the Robot or the program, the error flag indicated above does not turn ON.

RC180 Rev.14 95

Setup & Operation 12. Option Units

Electronic Information File (CSP file)

A CSP file is supplied for CC-Link network configuration. The file is located in the following folder in the Manual Update CD that is attached to the Robot Controller .

\EpsonRC50\Fieldbus\CCLink

96 RC180 Rev.14

Setup & Operation 12. Option Units

12.3.7 EtherNet/IP

Overview of EtherNet/IP

EtherN et/IP is a fieldbus network that provides easy interconnection between control devic es (PLC, PC, sensor, actuator, et c.).

E therNet/IP was developed by Allen-Bradley as an open communication standard to connect various field devices (sensor, actuator, robot controller, etc.). Because of the open communication standard, EtherNet/IP users can easily construct a multi-vendor system with various devices developed around the world.

Master Device

EtherNet Network

Motor Driver

Motor Driver Intelligent I/O Intelligent I/O from Company A from Company B from Company C from Company D

Photo Sensor from Company E

Analog Device from Company G

HMI Device from Company F

EtherNet/IP Communication Specifications

Item Specification

Code R12B040719

Supported

I/O messaging connection (Cyclic), Explicit message connection

Connection

EtherNet/IP communication protocol

Baud Rates

10 M, 100 M (bps)

Transfer Distance

Standard Ethernet protocol

Cable Standard Ethernet protocol

Mode Slave

Interface

Connection type

1 EtherNet/IP port

Cyclic

Explicit message connection

Input data size

Output data size

Supported

256 bits (32 bytes)

256 bits (32 bytes)

RC180 Rev.14 97

Setup & Operation 12. Option Units

EtherNet/IP Appearance

Status Display LED

Configure Switch

EtherNet/IP Connector

MS LED : Module status display

NS LED : Network status display

LNK LED : Link status display

ACT LED : Communication packet reception or transmission status display

Refer to the following table for functions of

LEDs.

LED Description of EtherNet/IP

LED status MS NS

GRN

RED

OFF

ON

GRN/RED

Power supply OFF

Master connected (executing)

Blinking Master connected (idling)

ON Non-recoverable error

Blinking Non-recoverable error

Self-diagnosing

Power supply OFF or IP address not configured

Online operating

Waiting master connection

Wrong IP address (duplication)

Connection time out

Self-diagnosing alternate

LED status LNK

ON Linking

ACT

No communication packet reception or transmission

Communication packet reception or transmission

Board Installation of EtherNet/IP

WARNING

„ Make sur e that the p ower is turned OFF before inst alling/removing any boards or connecting/disco nne cting any cables. Installing/removing any boards or connecting/disco nne cting any c ables with the power ON is extremely hazardous and may re sul t in ele ctric shock and/or malfunction of equipment.

Set all EtherNet/IP b oard configure switc hes OFF. If all EtherNet/IP board configure sw itches are not OFF, reset error occurs.

A ll the EtherNet/IP communication configurations are set by the development software

(EPSON RC+ 5.0).

98 RC180 Rev.14

Setup & Operation 12. Option Units

Wiring (EtherNet/IP)

Use a standard Ethernet connector for wiring to the board.

CAUTION

„ You can use the general Ethernet hub o r Ethernet switch for the EtherNe t/IP.

However, be sure to a use product com plying with the industrial standa rds or noise resistant Ethernet cable (STP cab le). If you use an office use prod uct or

UTP cable, it may cause communicatio n errors and may not offer the proper performance.

EtherNet/IP Confirmation and Configuration with EPSON RC+ 5.0

When EtherNet/IP board is installed to the Controller, it is recognized automatically.

Confirm whether the EPSON RC+ 5.0 has recognized the EtherNet/IP board by the fo llowing procedure.

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

(2)

(3)

(2) Select the [Inputs / Outputs].

(3) Make sure that following is displayed.

(4) Click the “+” displayed on the left of [Input / Output] and select the [General].

(5)

(5)

(4)

RC180 Rev.14

(5) Make sure that following are displayed.

Fieldbus type : EtherNet/IP

Fieldbus station ID :

−1 (Fixed)

99

Setup & Operation 12. Option Units

(6 ) Click the “+” displayed on the left of [Input / Ou tput] and select the [EtherNet/IP].

(7)

NOTE

)

(7) Set each item to the specific value to connect the Ethernet network.

For information about the setting values, contact your network administrator.

Address Configuration is set to “DHCP/BOOTP/ARP” at shipment.

(8) When the configuration is completed, click the <Apply> button to apply the setting.

(9) Click the <Close> button.

When Address Configuration is set to “DHCP/BOOTP/ARP”, the Controller waits for

DHCP/BOOTP/ARP sever response for 30 seconds at Controller startup. When

DHCP/BOOTP/ARP does not response within a time, the Controller stops the request to the DHCP/BOOTP/ARP server and waits ARP.

Operation

For details, refer to 12.3.9 Operation (DeviceNet, PROFIBUS-DP, EtherNet/IP,

PROFINET)

.

Electronic Information File (EDS file)

An EDS file is supplied for EtherNet/IP netw ork configuration. The file is located in the following folder in the Manual Update CD that is attached to the Robot Controller.

\EpsonRC50\Fieldbus\EtherNet/IP

100 RC180 Rev.14

Setup & Operation 12. Option Units

12.3.8 PROFINET

Overview of PROFINET

PROFINET is a fieldbus network using industrial Ethernet.

PROFINET was developed as an open communication standard to connect various field devices (sensor, actuator, robot controller, etc.). Because of the open communication standard, PROFIBUS DP can easily construct multi-vendor system with various devices developed around the world.

IO Controller

Ethernet Network

Motor Driver

Motor Driver from Company A fro m Company B

IO device from Company C

Photo Sensor from Company E

IO device from Company D

Analog Device from Company G

HMI Device from Company F

PROFINET Specifications

Item Specification

Code R12B040707

Connection Method RT (Real-Time)

P IO

Device type IO device

Baud Rates (bps) 100 M bps, full duplex

Maximum segment length 100 m

Cabl e

Cycle time

RJ45 with c

2 msec onnector 100BASE-TX (Cat5)

Interface

Input Data Size

Output Data Size

RJ45 port

× 1

256 bits (32 bytes)

256 bits (32 bytes)

RC180 Rev.14 101

Setup & Operation 12. Option Units

PROFINET Appearance

Status Display LED

RJ45 Connector

MS LED

CS LED

: Module status display

: IO Controller connection status display

LNK/ACT LED : Link status /

Communication packet reception or transmission status display

Refer to the following table for functions of LEDs.

LED status

OFF

LED Description of PROFINET

LED status represents the status of the fieldbus board.

MS

Power OFF or

Device is being initialized

Offline

CS

Offline

IO controller is in RUN

Blinking - -

LNK/ACT

No link or

Power OFF

Linking

Receiving/transmitting communication packet

Blinking once Evaluati ng

Blinking once

Blinking

3 times

Blinking

4 times

Struc ture Error

- Too many (Sub

- I/O size set by is to o large.

- Structur

) Modu

IO con e mismatched les troller

(No module, wrong mo dule)

No station name has been set or

No IP address has been set

Internal er ror

Offline /

IO controller is in STOP

-

- -

-

-

-

-

Board Configuration (PROFINET)

WARNING

„ Make sure that the power is turned OFF before installing/removing any boards or connecting/disconnecting any cables. Installing/removing any boards or connecting/disconnecting any cables with the power ON is extremely hazardous and may result in electric shock and/or malfunction of equipment.

PROFINET settings such as the communication setting are all configured by the development software (EPSON RC+ 5.0). You don’t need to configure anything about

PROFINET board.

102 RC180 Rev.14

Setup & Operation 12. Option Units

Wiring (PROFINET)

PROFINET connector is

RJ45 connector.

Use cable 100 BASE-TX (STP type).

CAUTION

„ Be sure to use cables and connectors comp lying wit h the i ndustrial standards or noise resistant Ethernet cable (STP cable). If you use an office us e product or

UTP cable, it may cause communication errors and may not offer the proper performance.

PROFINET Confirmation with EPSON RC+ 5.0

When PROFINET board is installed n the c ontroller, it is recognized automatically.

Confirm that EPSON RC+ 5.0 has recognized th e board in the following procedure.

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

(2)

(3)

( 2) Select the [In puts / Outputs].

(3) Make sure that following is displayed.

(4) Click the “+” displayed on the left of [Input / Output] and select the [G eneral].

(5)

(4)

(6)

(5) Make sure that following is displayed.

Fieldbus Type : PROFINET IO

RC180 Rev.14 103

Setup & Operation 12. Option Units

( 6) Set the [MAC Add ress] according to the PROFINET IO controller that uses the

DAP mode.

Usually, select DAP Ver.2. DA P V er.1 is available for the obsolete PROFINET

IO controller.

NOTE

)

The PROFINET option does not have the alert function that is an optional function in DAP Ver.2.

(7) When the configuration is completed, click the <Apply> button and apply the settings.

( 8) Click the <Close> button.

Operation

For details, refer to 12.3.9 Operation (DeviceNet, PROFIBUS-DP, EtherNet/IP,

PROFINET)

.

Electronic Information File (GSDML file)

A GSDML file is supplied for PROFINET network configuration. The file is located in the following folder in the Manual Update CD that is attached to the Robot Controller.

\EpsonRC50\Fieldbus\PROFINET

104 RC180 Rev.14

Setup & Operation 12. Option Units

12.3.9 Operation

(DeviceNet, PROFIBUS-DP, EtherNet/IP, PROFINET)

This section indicates how to use the Fieldbus I/O option after it has been installed.

For details of CC-Link, refer to 12.3.5 CC-Link – Operation (CC-Link).

SP EL+ Fieldbus I/O Commands

All the commands for the Fieldbus I/O are the same as the standard I/O.

Bit numbers differ from standard I/O. There is no restriction for command use.

Typical I/O com mands are listed in the following table.

For command details, refer to EPSON RC+ 5.0 Online Help or SPEL

+

Language

Reference

.

Command Function

In

InW

Returns the status of the specified 8 bits input port.

Returns the status of the specified 16 bits input port.

Off

On

Out

O utW

Sw

Wait

Turns Off the specified output.

Turns On the specified output.

Simultaneously sets 8 output bits.

Simultaneously sets 16 output bi ts.

Returns the specified input port status.

Waits until the specified input condition.

Resp onse times for Fieldbus I/O can var y and depend on several factors, including baud rate, scan rate, number and types of devices, communication error, etc.

NOTE

)

Outputs Off by Emergency Stop and Reset Instruction

You can configure the controller system so that all outputs including the fieldbus outputs will be turned off when the emergency stop occurs and when a Reset instruction is executed.

For details of the configuration, refer to [Setup]-[Controller]-[Preference] in EPSON

RC+ 5.0 User's Guide 5.12.2 Controller command (Setup Menu)

.

NOTE

A comm and that was issued just before an emergency stop can be executed after the

) emergency stop condition is cleared. If the outputs from the fieldbus involve risk, check the [Outputs off during Emergency Stop] box to remove all power to output devices when an emergency stop occurs.

RC180 Rev.14 105

Setup & Operation 12. Option Units

Remote I/O Configuration

You can configure the controller system so that all I/O including the fieldbus will b e set to remote function.

I/O setup for Fieldbus I/O is the default configuration.

NOTE

)

Se tup for the Remote I/O can be chang ed by signal. Configuration with bits of standard

I/O, expansion I/O and Fieldbus I/O is available.

Input Signal Bit No.

Start 512

Pause 513

Reset 514

SelProg1 515

SelProg2 516

SelProg4 517

Stop 518

Continue 519

MotorOn 520

MotorOff 521

Home 522

Ou tput Sig nal Bit No. Output S ignal Bit No.

Ready 512

InsideBox2 NA

S afeguardOn 517 NA

Waning 519

InsideBox9 NA

Home 521

InsideBox11 NA

CurrProg2 523

InsideBox13 NA

TeachMode 526

InsidePlane1 NA

ErrorCode2 528

InsidePlane3 NA

ErrorCode8 530

InsidePlane5 NA

ErrorCode32 532

InsidePlane7 NA

ErrorCode128 534

InsidePlane9 NA

ErrorCode1024 537

InsidePlane12 NA

ErrorCode4096 539

InsidePlane14 NA

106 RC180 Rev.14

Setup & Operation 12. Option Units

Explicit Message Connection (for DeviceNet, EtherNet/IP)

Issuing an Explicit message from DeviceNet / EtherNet/IP master unit to the RC180 controller acquires a nd configures the DeviceNet / EtherNet/IP I/O area.

Supported function and Class ID configurations are as follows:

When using Assembly Object Class (Class ID = 4)

Function

Input acquisition

Output configuration

Output acquisition

4 (0

4 (04

4 (04

Class ID

4h) h) h)

Instance

100 (64h)

150 (96h)

150 (96h)

Service Code

14 (0Eh)

16 (10h)

14 (0Eh)

When using I/O Data Mapping Object Class (Class ID = 160, 161)

Fun ction Class ID Instance

Input acquisition

Output configuration

Output acquisition

160 (

161 (

161 (

A0h)

A1h)

A1h)

01 (01h)

01 (01h)

01 (01h)

Service Code

14 (0Eh)

16 (10h)

14 (0Eh)

Command response

It ca n acquire 32 bytes input/output data.

12.4 RS-232C Board

12.4.1 About the RS-232C Board

A standar d RS-232C port is no t avai lable with the Controller. An RS-232C option board m ust be ad ded.

M ount t he RS-232C board in the op tion un it to commun icate with extern al eq uipment w ith RS-232C .

T he RS-232C option accepts fo ur por ts expan sion per board . A maximum of tw o boards, e ight ports ex pansion is availab le for RS-232C board.

P ort numbers a re assigned as fo llows .

Por t No.

#1 to #4

#5 to #8

Sup

Fir

Seco ported st RS-23 nd RS-2 hardware

2C board

32C board

RC180 Rev.14 107

Setup & Operation 12. Option Units

12.4.2 Board Setup (RS-232C)

Board Appearance

CN1

CN2

CN3

CN4

CN6

JMP1

DSW2

DSW1

Switch and Jumper Configuration

Set DSW1, DSW2 and JMP1.

CN6 is all open.

1 st

board 2 nd

board

IR Q15

IRQ11

IRQ10

IRQ7

IRQ5

1 2

JP5

JP4

JP3

JP2

JP1

SW4

SW3

SW2

SW1

IRQ15

IRQ11

IRQ10

IR Q7

IRQ5

1 2

JP5

JP4

JP3

JP2

JP1

SW4

SW3

SW2

SW1

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

SW8

SW7

SW6

SW5

SW4

SW3

SW2

SW1

12.4.3 Verify with EPSON RC+ 5.0 (RS-232C)

When an RS-232C board is mounted in as option unit, the Controller software automatically identifies the RS-232C board. Therefore, no software configuration is needed. Correc t identification can be confirmed from EPSON RC+ 5.0.

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

Controller] dialog.

(2) Select the [RS-232C].

108

If no RS-232C board is identified, RS-232C will not be displayed.

If RS-232C is displayed, then the Controller software identified the RS-232C board.

Communication with external equipment is available.

RC180 Rev.14

NOTE

)

Setup & Operation 12. Option Units

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

Available communicat ion settings are as foll ows.

Item Specification

Baud Rates 110, 300, 600, 1200, 2400, 4800, 9600,

Data bit length

Stop bit length

14400, 19200, 38400, 57600, 115200

7, 8

Parity

Terminator

1, 2

Odd, even, NA

CR, LF, CRLF

Refer to EPSON RC+ 5.0 Online Help or 11. RS-232C Communications for RS-232C communication from the Robot application.

12.4.5 Communication Cable (RS-232C)

Prepare a communication cable as described in this section.

Connector Standard

RS-232C

Connector

(Controller side)

D-sub 9 male pin

Mounting style #4 - 40

Use tw isted pair cable for shielded wire.

Clam p the shield to the hood for noise prevention.

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

Pin No Signal Function Signal Direction

1 DCD Data carrier detect Input

Receive Input

3 TXD data Output

6

7

8

DSR

RTS

CTS

Signal -

Data set ready Input

Request to send

Clear to send

Output

Input

RC180 Rev.14 109

Setup & Operation 12. Option Units

110 RC180 Rev.14

Maintenance

This section contains maintenance procedures for the Robot Controller.

112

Maintenance 1. Safety Precautions on Maintenance

1. Safety Precautions on Maintenance

1.1 Safety Precautions

WARNING

WARNING

■ Only authorized personnel who have taken the safety training should be allowed to execute teaching or calibration of 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.).

The personnel who have completed the robot system-training class held by the manufacturer, dealer, or locally-incorporated company are allowed to maintain the robot system.

■ 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.

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.

■ Before performing any maintenance procedure, always make sure that the main power of the Controller is turned OFF, unplug the power supply, 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.

RC180 Rev.14

113

Maintenance 1. Safety Precautions on Maintenance

■ Do not touch the Motor Driver modules, Switching Power Supply, and

Regeneration Module directly in the Controller. The metal resistance of these 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

■ Do not shock, shake, or drop any parts during maintenance. When the parts related with data 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.

■ 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 cause improper function of the robot system and errors.

■ 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.

NOTE

)

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 4. Backup and

Restore.

1.2 Lockout / Tagout

Lockout / tagout 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 performing maintenance and repair, lockout and tagout using the following procedure.

(1) Turn OFF the POWER switch.

(2) Secure the POWER switch mounting metal hasp in the POWER switch OFF position with screws.

POWER Switch

POWER Switch

Mounting Metal Hasp

114

(3) Unplug the power supply plug of the Controller from the power supply socket.

(4) Attach a note to the POWER switch or the power supply plug to prevent any one from turning ON the robot system by mistake.

RC180-UL:

For maintenance and repair, make sure to lockout and tagout the external disconnecting means.

RC180 Rev.14

Maintenance 2. Regular Maintenance Inspection

2. Regular Maintenance Inspection

Performing regular maintenance inspection properly is essential for preventing trouble and maintaining safety. This chapter describes the schedules for maintenance inspection and procedures.

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

2.1 Schedule for Maintenance Inspection

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

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

1 month (250 h)

2 months (500 h)

3 months (750 h)

4 months (1000 h)

5 months (1250 h)

6 months (1500 h)

7 months (1750 h)

8 months (2000 h)

9 months (2250 h)

10 months (2500 h)

11 months (2750 h)

12 months (3000 h)

13 months (3250 h)

Daily inspection

Monthly inspection

Inspection Point

Quarterly inspection

Biannual inspection

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9 9

Annual inspection

RC180 Rev.14

115

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.

Clean the fan filter

Inspection Location Daily Monthly Quarterly Biannual Annual

External appearance of Controller 9 9 9 9 9

Battery

Fan filter on the side of the Controller

Front side

9 9

Ever 5 years

9 9

2.2.2 Inspection While the Controller is Turned ON

Inspection Point Inspection Location Daily Monthly Quarterly Biannual Annual

Check whether unusual sound or vibration is occurring.

Entire Controller

Make a backup of data. Project and system data

9

9 9 9

Whenever data is changed.

9

116

RC180 Rev.14

3. Controller Structure

3.1 Location of Parts

Maintenance 3. Controller Structure

(1)

(1)

(2)

[1]

AC Terminal Block

This area contains high voltage.

Turn OFF and unplug the power supply during the procedure.

(3)

[2]

[3]

[4]

Motor Driver

[1]:Axis 1

[2]:Axis 2

[3]:Axis 3

[4]:Axis 4

(1) Thumb Head screws

These are two of the four screws used to mount the front cover of the Controller.

These screws are also used to pull out the Motor Driver module and CPU board unit.

(2) Motor Driver Mounting Bracket

This is a bracket is used to secure the four motor drives. Make sure that each Motor

Driver is connected properly and then mount the bracket. Improper connection may cause not only improper function of the robot system but also safety problems.

(3) Front Side Supporting Bar

This supporting bar is used to hold the front cover open. Make sure that the supporting bar is in the proper position.

RC180 Rev.14

117

Maintenance 3. Controller Structure

Regeneration Module

Encoder I/F Board

15V Switching Power Supply Module

DPB

Fan

Be careful of the regeneration module resistor high temperature.

24V Switching Power

Supply Module

Be careful of the regeneration module resistor high temperature.

5V Switching Power

Supply Module

CPU Board

DMB

118

RC180 Rev.14

Maintenance 3. Controller Structure

3.2 Diagram of Cable Connections

For the electrical connections of the Controller, refer to the following diagram.

RC180

Motor Driver

Motor Driver

5 axis

6 axis

Resistor

AC200

-240V

Switching

Power

Supply (5V)

AC200

-240V

Switching

Power

Supply (5V)

AC200

-240V

Switching

Power

Supply (5V)

24V

*1

Motor Control Circuit

Encoder Receiving Circuit

5V

*3

Motor Power Junction Circuit

RC180 Rev.14

7-segment

Encoder I/F Board

(EIB)

Signal M/C Power

Regenerative

Resistor

Temperature

Sensor

Option Board

Option Board

119

Maintenance 3. Controller Structure

Cable Layout Drawing

For cable connections inside the Controller, refer to the following figure.

This diagram is a simplified development view inside the Controller.

The numbers indicated such as (1), (2), (3) correspond to the following cable list.

RC180

M/C POWER

Encoder I/F Board

Regeneration Board

Back Plane Board

(9)

(10)

(7)

(6)

(8)

DPB

(4)

(13)

(3)

(5)

Switching Power Supply (15V)

(11)

(1) to Noise Filter

Switching Power Supply (24V)

Switching Power Supply (5V)

(2)

(12)

(14)

Fan

Fan DMB

(15)

(18)

(17)

(20)

(21)

(19)

(16)

CPU Board

(21) (22)

ProSix

Driver Unit I/F Board

Cable

120

RC180 Rev.14

Maintenance 3. Controller Structure

RC180 Cable List

Cable

No.

Connection

(1) DPB

(2) DPB

(3) DPB

(4) DPB

(5) DPB

(6) DPB

(7) DPB

(8) DPB

(9) DPB

(10)

Regeneration

Board

(11)

Regeneration

Board

(12) DMB

(13) DMB

(14) DMB

5

4

8

5

3

34

4

2

5

5

26

4

8

Connector Pin

Quantity

5

50

Wire

Quantity

6

3

3

Connector Pin

Quantity

5

5

5

3

26<F> 25(D-SUB)

8

4

6

3

2

2

Connection Note

Switching Power Supply (5V)

Switching Power Supply (24V)

Switching Power Supply (24V)

DMB

ProSix Driver Unit I/F Board

Regeneration Board

2

− Resistance

34<F> 34

4

4

Encoder I/F Board

Switching Power Supply (15V)

2

8

5

5

2

4

(17) CPU 3

(18) CPU 3

(19) CPU 2

(20) CPU Board 80

50

<F> Flat cable

*1 When connected to ProSix Driver unit

*3 When connected to Option unit

34<F>

16<F>

34

16

4

4

3

3

2

80<F> 80

16 4,4,4,4

16

14

4,4,4,4

4,4,8

Switching Power Supply (15V)

EMERGENCY

ProSix Driver Unit I/F Board

DPB

Encoder I/F Board

Switching Power Supply (5V)

*1

*1

Fan

Fan

Temperature Sensor

Back Plane Board

DMB

*3

DMB

ProSix Driver Unit I/F Board

*1

RC180 Rev.14

121

Maintenance 3. Controller Structure

3.3 Connector Pin Assignment

Pin assignments differ depending on the manipulator type.

The following tables show the pin assignments for the M/C power connector and M/C signal connector for E2 series and PS series. For EMERGENCY and TP/OP connectors, refer to Setup & Operation.

3.3.1 M/C Power Connector

E2 / G / RS series

E D C B A

1W 1V 1U

2W 2V 2U

3W 3V 3U

4W 4V 4U

FG FG

7

8

9

10

4

5

6

1

2

3

PS series

E D C B A

1W

2W

3W

4W

5W

1V

2V

3V

4V

5V

1U

1

2U 2

3U 3

3U

4

5U

5

6W 6V 6U

6

7

FG5 FG4 FG3 FG2 FG1

FG6

8

BR3 BR2

9

GND GND BR6 BR5 BR4

10

C3 / S5 series

E D C B A

1W 1V 1U

2W 2V 2U

3W 3V 3U

4W 4V 4U

5W 5V 5U

6W 6V 6U

FG5 FG4 FG3 FG2 FG1

FG6 BR3 BR1

BR6 BR4

9

10

7

8

5

6

3

4

1

2

122

RC180 Rev.14

Maintenance 3. Controller Structure

3.3.2 M/C Signal Connector

E2 PS G / RS C3 / S5 E2 PS G / RS C3 / S5

1 ENC_GND - - - 26 ENC_GND

2 4A+ 1S+ 1S+ 1S+ 27

- ENC_GND ENC_GND

4A- 1S- 1S- 1S-

3 4B+ 2S+ 2S+ 2S+ 28

4 4Z+ 3S+ 3S+ 3S+ 29

4B- 2S- 2S- 2S-

4Z- 3S- 3S- 3S-

5 ENC_5V

6 ENC_GND

- ENC_5V ENC_5V 30 ENC_5V

- ENC_GND ENC_GND 31 ENC_GND

7 3A+ 4S+ 4S+ 4S+ 32

8 3B+ 5S+ - 5S+ 33

-

-

-

-

EMC_PWR

ENC_GND

3A- 4S- 4S- 4S-

3B- 5S- - 5S-

9 3Z+ 6S+ -

10 ENC_5V - ENC_5V

11 ENC_GND

12 2A+

-

- -

6S+ 34

ENC_5V

ENC_GND ENC_GND

35

- 37

3Z- 6S- - 6S-

ENC_5V

36 ENC_GND

-

-

-

-

ENC_5V

ENC_GND

2A- - - -

13 2B+

14 2Z+

15 ENC_5V

16 ENC_GND

-

-

-

-

-

-

- 38

- 39

2B- - -

2Z- - -

ENC_5V ENC_5V 40 ENC_5V

ENC_GND ENC_GND 41 ENC_GND

-

-

-

-

-

-

-

-

17 1A+

18 1B+

19 1Z+

20 ENC_5V

-

-

-

-

- -

24V ENC_5V

- 42

- 43

1A- - - -

1B- - - -

- 44 1Z- - - -

ENC_5V 45 ENC_5V 24V - -

21 - - - - 46

22 MPOWER MPOWER MPOWER MPOWER 47

23 EMB_J3

24 24V

-

-

EMB_J3

-

- 48

- 49

- - - -

- - - -

EMB_J3 - -

24V 24V 24V

-

24V

- 24VGND 50 24VGND 24VGND 24VGND 24VGND 25 24VGND 24VGND

RC180 Rev.14

123

Maintenance 4. Backup and Restore

4. Backup and Restore

4.1 What is the Backup Controller Function?

The controller configuration set by EPSON RC+ 5.0 can be stored with the “Backup

Controller” function.

NOTE

)

The Controller settings can be restored easily using the data previously stored with

“Backup Controller” after a configuration mistake or Controller problem.

Be sure to execute “Backup Controller” before changing the Controller setup, before maintenance, or after teaching.

For some problems, backup may not be available before maintenance has to be performed.

Be sure to backup the data after making changes, before problems occur.

“Controller Status Storage” is one of the RC180 functions. It saves the Controller setup data the same as with “Backup Controller,” and additional data such as the Controller status.

There data can be used as the backup data at restoring.

The methods for “Controller Status Storage” are as follows:

A : “Controller status storage to USB memory”

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

B : “Export Controller Status function” in EPSON RC+ 5.0.

For details, refer to EPSON RC+ 5.0 User’s Guide 5.9.9 Import Command (Project

Menu).

4.2 Backup Data Types

The table below shows the files created with “Backup Controller”.

File Name

Backup.txt

Information file for restore

Overview

File including information for restoring the Controller.

CurrentMnp01.PRM Robot parameters Stores information such as TlSet.

InitFileSrc.txt

MCSys01.MCD

All the files related to Project *

Initial configuration

Robot configuration Stores connected Robot information.

Project related

Stores various Controller parameters.

All the project files transferred to the

Controller. Includes program files when

EPSON RC+ 5.0 is configured to transfer source code to the Controller.

GlobalPreserves.dat

*

Global Preserve variables

Saves values of Global Preserve variables.

* If the version of the Controller firmware is Ver.1.0.*.*, project related data and

GlobalPreserves.dat are not stored.

124

RC180 Rev.14

Maintenance 4. Backup and Restore

4.3 Backup

Backup the Controller status from the Teach Pendant (Option) or EPSON RC+ 5.0.

4.3.1 Backup from EPSON RC+ 5.0

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

(2) Click the <Backup Controller…> button to display the [Browse For Folder] dialog.

(3) Specify the folder to save the backup data. Create a new folder if desired.

(4) Click the <OK> button. A folder is created in the specified folder containing the backup data with a name in the following format.

B_ serial number_date status was saved

→ Example: B_12345_200608074410

(5) The following message appears when backup is completed.

CAUTION

(6) Click the <OK> button to complete the backup.

■ Do not edit the backup files. Otherwise, operation of the robot system after data restoration to the Controller is not assured.

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Maintenance 4. Backup and Restore

4.3.2 Backup from the Teach Pendant TP1 (Option)

Backs up system files in the Controller to USB memory. (Only TP1. TP2 does not support this function.)

(1) Insert the USB memory into the Controller.

(2) In the [Programming] screen, move the cursor to [System Backup…], and press the

<OK> key. The following screen appears.

Enter the file name.

(3) Press the <Enter> key. The following screen appears.

<OK> When the <OK> key is pressed without specifying a folder, the backup files are stored in a subfolder of the USB memory root folder.

(4) Press the <F2> key. The following screen appears.

Specify the folder to save the backup data.

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(5) Press the <OK> key. The following screen appears.

(6) Press the <OK> key to execute the system backup.

When a file of the same name already exists, the following screen appears.

<F1> Overwrites the file.

<F2>

Moves to the [Programming] screen.

(7) After execution has completed, the following screen appears.

CAUTION

■ Do not edit the backup files. Otherwise, operation of the robot system after data restoration to the Controller is not assured.

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4.4 Restore

Restore the Controller status from the Teach Pendant (Option) or EPSON RC+ 5.0.

CAUTION

4.4.1 Restore from EPSON RC+ 5.0

■ Make sure that the data used for restore was saved previously for same

Controller.

■ Do not edit the backup files. Otherwise, operation of the robot system after data restoration to the Controller is not assured.

(1) Select the EPSON RC+ 5.0 menu-[Tools]-[Controller] to display the [Controller

Tools] dialog.

(2) Click the <Restore Controller…> button to display the [Browse For Folder] dialog.

128

NOTE

)

(3) Specify the folder that contains the backup data. Backup data folders are named using the following format:

B_serial number_date status was saved

→ Example: B_12345_200608074410

Data saved with the Controller status storage function can also be specified for restore.

Specify the following folder.

S_serial number_data status was saved

→ Example: S_12345_200608074410

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Maintenance 4. Backup and Restore

(4) Click the <OK> button to display the dialog to select the restore data.

NOTE

)

Robot name, serial #, calibration

This checkbox allows you to restore the robot name, robot serial number, Hofs data, and CalPls data. Make sure that the correct Hofs data is restored. If the wrong

Hofs data is restored, the robot may move to wrong positions.

The default setting is unchecked.

Project

This checkbox allows you to restore the files related to projects.

The default is unchecked.

When a project is restored, the values of Global Preserve variables are loaded.

For details about Global Preserve variable backup, refer to EPSON RC+ 5.0 User’s

Guide 5.10.10 Display Variables Command (Run Menu)

.

If the version of the Controller firmware is Ver.1.0.*.*, or the version of EPSON RC+

5.0 Ver.5.0.*, this dialog does not appear. Robot name, serial number, and calibration data is always restored.

The project is not restored.

NOTE

)

(5) Click the <OK> button to restore the system information.

Restore the system configuration saved using Backup Controller only for the same system.

When different system information is restored, the following warning message appears.

CAUTION

Click the <No> button (do not restore data) except for special situations such as controller replacement.

4.4.2 Restore from Teach Pendant TP1 (Option)

■ Make sure that the data used for restore was saved previously for same

Controller.

■ Do not edit the backup files. Otherwise, operation of the robot system after data restoration to the Controller is not assured.

Restores system files backed up in USB memory to the Controller. (Only TP1. TP2 does not support this function.)

(1) Insert the USB memory into the Controller.

(2) In the [Program Mode] screen, move the cursor to [7 System Restore...], and press the <OK> key.

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Maintenance 4. Backup and Restore

(3) The following screen appears.

When you restore the robot name, serial number, and the calibration data with the basic

Controller settings, move the cursor to [Robot name, serial #, calibration] and press the

<

→> key.

When you restore the project with the basic Controller settings, move the cursor to

[Project] and press the <

→> key.

(4) Press the <OK> key

(5) The following screen appears. Press the <OK> key.

(6) The following screen appears. Move the cursor to the desired folder.

Press the <Enter> key.

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(7) The following screen appears. Press the <F1> key to start the restore.

When the Controller serial number does not match the serial number of the selected

Controller setting data, the following screen appears. To continue, press the <F1> key.

When the Controller system software version does not match the version of the selected Controller setting data, the following screen appears. To continue, press the <F1> key.

RC180 Rev.14

(8) After execution is completed, the following screen appears.

Press the <OK> key and the Controller reboots.

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Maintenance 5. Firmware Update

5. Firmware Update

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

5.1 Updating Firmware

Firmware (software stored in non-volatile memory) and data files necessary to control the

Controller and the Robot are preinstalled in the Controller. Controller configuration set from EPSON RC+ 5.0 is always saved in the Controller.

Controller firmware is supplied by CD-ROM as needed. Please contact us for information.

You must use a PC running EPSON RC+ 5.0 connected to a Controller with USB to update the Controller firmware. Firmware cannot be updated with an Ethernet connection.

5.2 Firmware Upgrade Procedure

The firmware upgrade procedure is described as follows:

(1) Connect the development PC and the Controller with a USB cable (the firmware cannot be changed with an Ethernet connection).

(2) Turn ON the Controller. (Do not start the development software EPSON RC+ 5.0 until the firmware upgrade is completed.)

(3) Insert the “firmware CD-ROM” in the development PC CD-ROM drive.

(4) Execute “Ctrlsetup.exe”. The following dialog appears.

(5) Select the <Upgrade> option button and click the <Next> button.

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(6) Make sure that the development PC is connected to the Controller with a USB cable and Click the <Next> button.

(7) Check the current firmware version and the new firmware version and click the

<Install> button.

NOTE

)

(8) The firmware upgrade starts. It takes several minutes to complete.

Do not unplug the USB cable during transfer or turn OFF the Controller or the development PC.

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Maintenance 5. Firmware Update

(9) Continuous data file transfer starts.

(10) The following dialog appears when transfer has completed. Click the <Next> button to reboot the Controller.

(11) The following dialog appears after the Controller reboot. Click the <Finish> button.

The firmware upgrade is complete.

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5.3 Controller Recovery

NOTE

)

If the Controller becomes inoperable, use the procedures described in this section to recover.

Controller Backup is recommended for easy recovery of the Controller operation. For details of Controller Backup, refer to Maintenance 4. Backup and Restore.

The following two conditions describe the Controller error status after turning on the Controller.

Condition A The Controller automatically changes to Recovery mode and the seven-segment LED blinks . You are able to communicate with the development PC though the Controller does not operate properly.

Condition B The Controller seven-segment LED does not blink.

Cannot communicate with the Controller using the development PC.

Countermeasure for the error status is as follows.

Condition A Follow the Firmware Initialization Procedure in section 5.4 to initialize the firmware.

Condition B Execute the following steps:

(1) Turn OFF the Controller.

(2) Push the trigger button located on the front side of the Controller and while holding the button in, turn ON the Controller. Continue to hold in the trigger button for 30 seconds. This will cause the

Controller to start in Recovery mode.

(3) Make sure that the seven-segment LED blinks .

(4) Follow the procedure in 5.4 Firmware Initialization Procedure from step (3) to initialize the firmware.

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5.4 Firmware Initialization Procedure

The firmware initialization procedure described in this section.

(1) Connect the development PC to the Controller with a USB cable (the firmware cannot be changed with an Ethernet connection).

(2) Turn ON the Controller. Do not start the development software EPSON RC+ 5.0 until firmware initialization is complete.

(3) Insert the “firmware CD-ROM” in the development PC CD-ROM drive.

(4) Execute “Ctrlsetup.exe”.

(5) Select the <Initialize> option button and click the <Next> button.

(6) Make sure that the development PC is connected to the Controller with a USB cable and Click the <Next> button.

(7) Check the version information and click the <Install> button.

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Maintenance 5. Firmware Update

NOTE

)

(8) Firmware and data file transfer starts. It takes several minutes to complete.

Do not unplug the USB cable during transfer or turn OFF the Controller or the development PC.

(9) The following dialog appears when transfer is completed. Click the <Next> button to reboot the Controller.

(10) The following dialog appears after the Controller reboot. Click the <Finish> button.

The firmware upgrade is completed.

Start EPSON RC+ 5.0 and restore the Controller settings.

For details of restoring the operating system, refer to Maintenance 4. Backup and

Restore

.

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Maintenance 6. Maintenance Parts Replacement Procedures

6. Maintenance Parts Replacement Procedures

WARNING

NOTE

)

■ 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 is not discharged completely is extremely hazardous and may result in electric shock and/or cause serious safety problems.

■ When opening or closing the front side, make sure that the 200 V power supply for the Controller is OFF. Performing procedure to the power supply terminal block inside the Controller while the power supply is ON is extremely hazardous and may result in electric shock and/or cause serious safety problems.

- Be careful not to damage cables. Be sure not to drop any screws into the Controller.

- A spacer is used with each thumb head screw on controllers with serial number 01001 or later. Do not remove the spacer.

Installing the front cover using a thumb head screw without a spacer may result in a cable being damaged and/or malfunction of the Controller.

- Installing the front cover using the wrong screws may result in a cable being damaged and/or malfunction of the Controller.

138

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Maintenance 6. Maintenance Parts Replacement Procedures

6.1 Fan and Fan Filter

Inspect the fan filter periodically and clean it when needed. The temperature inside the

Controller may get too high and the Controller may not operate properly if the filter is not kept clean.

For the inspection schedule of the fan filter, refer to Maintenance 2. Regular Maintenance

Inspection.

Fan Filter

Remove

6.1.1 Cleaning and Replacing the Fan Filter

(1) Turn OFF the Controller.

(2) Pull out the two plastic fasteners indicated in the photo.

Inlet Plate

Plastic Fasteners

(3) Remove the fan filter.

Vacuum off the dust when cleaning the filter.

Fan Filter

Fan Filter

Mount

(1) Mount the fan filter.

(2) Insert the two flared parts of the inlet plate into the opening of the Controller in the direction shown by arrow (a).

Fan Filter

(b)

(3) Push the two plastic fasteners in the direction shown by arrow (b) until they make a clicking sound to secure the inlet plate.

Make sure that the plate is mounted properly.

Flared Parts

(a)

(4) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.1.2 Replacing the Fan Unit

Fan Unit

Remove

(1) Turn OFF the Controller.

Remove the Option Units if they are mounted.

Refer : Procedure (1) to (4) in Maintenance 6.7.1 Remove Option Unit 1

Maintenance 6.7.5 Remove Option Unit 1, 2

(2) Pull out the two plastic fasteners and remove the inlet plate.

(3) Remove the four screws on the fan unit.

NOTE

)

(4) Remove the fan unit.

The fan cable is connected to the fan unit. Be sure to remove it slowly.

(5) Pull out the two fan cable connectors from the CPU board to the direction shown by the arrow.

Fan Unit

NOTE

)

(6) Remove the fan filter from the fan unit.

When the Option Unit is mounted, the fan filter is not used.

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Maintenance 6. Maintenance Parts Replacement Procedures

Fan Unit

Mount

(1) Mount a new fan filter in the fan unit.

NOTE

)

When an Option Unit is mounted, no fan filter is necessary.

(2) Connect the two fan cable connectors to the CPU board.

Refer : Maintenance 3.2 Diagram of Cable Connections

- Cable Layout Drawing

(3) Hold down the fan cable protection tube as shown in the photo and install the fan unit to the Controller.

NOTE

)

Be sure to keep the Controller cable from being trapped between the DPB and the fan.

Front Side

(4) Secure the fan unit to the main chassis with four screws.

(5) Mount the Option units if they were mounted before.

Refer : Maintenance 6.7.2 Mount Option Unit 1.

(6) Insert the two flared parts of the inlet plate into the opening of the Controller in the direction shown by arrow (a).

Fan Filer

(b)

(7) Push in the two plastic fasteners in the direction shown by arrow (b) until they make a clicking sound to mount the inlet plate.

Make sure that the plate is mounted properly.

Flared Parts

(a)

(8) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.1.3 Cleaning and Replacing the Option Unit Fan Filter

(1) Turn OFF the Controller. Option Unit

Fan Filter

Remove

(2) Remove the mounting screw for each fan filter located on the top and the bottom of the Option Unit.

NOTE

)

Two fan filters are mounted on the

Option Unit. Be sure to replace both at the same time.

Fan Filters

Screws

Clean the fan filter when it is necessary.

Option Unit

Fan Filter

Mount

(1) Insert the fan filters into the Option Unit and secure each of them with a screw.

(2) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.2 Battery

■ Use meticulous care when handling the lithium battery. Improper handling of the lithium battery as mentioned below is extremely hazardous, may result in heat generation, leakage, explosion, or inflammation, and may cause serious safety problems.

Battery Charge

Disassembly

Incorrect Installation

Exposing to Fire

Forced Discharge

Deformation by Pressure

Short-circuit (Polarity; Positive/Negative)

Heating (85

°C or more)

Soldering the terminal of the lithium battery directly

CAUTION

Battery

Removal

■ Be sure to use the battery supplied as maintenance part from EPSON (Refer to

9. Maintenance Parts List).

■ When disposing of the battery, consult with the professional disposal services or comply with the local regulation.

Spent battery or not, make sure the battery terminal is insulated. If the terminal contacts with the other metals, it may short and result in heat generation, leakage, explosion, or inflammation.

NOTE

Before starting battery replacement, turn on the controller for approximately one

) minute. Perform the replacement within 10 minutes to prevent data loss.

(1) Backup the Controller data.

Refer to Maintenance 4. Backup and Restore.

(2) Turn OFF the Controller.

(3) Remove the screw for the battery mounting plate.

NOTE

)

(4) Pull out the battery assembly.

The lithium battery cable is connected to the main chassis. Be sure to remove it slowly.

(5) Disconnect the relay connector.

Relay Connector

RC180 Rev.14

(6) Cut the cable tie to remove the lithium battery.

Cable Tie

143

Maintenance 6. Maintenance Parts Replacement Procedures

Battery

Installation

(1) Place a new lithium battery in position and secure it with the attached cable tie.

Position the cable tie as show in the photo.

If it is difficult to insert the lithium battery to the Controller, adjust the cable tie position.

NOTE

)

(2) Connect the relay connector.

(3) Insert the lithium battery assembly into the Controller.

Be sure to prevent the cable and the connector from being trapped.

Push the relay connector to the left when inserting the lithium battery. If the connecter is behind the lithium battery, the lithium battery may not be inserted.

(4) Mount the plate to the Controller with a screw.

(5) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.3 Motor Driver

6.3.1 Part Names

Main Circuit Connector

Input/ Output Signal Connector

Heat Sink

Signature Plate

50W, 100W, 200W, 400W

750W (With cable for dynamic brake resistor)

The wattage of the motor driver can be determined by the type code indicated on the signature plate. The wattage of the installed motor driver corresponds with the wattage of the driving motor.

Type Wattage

JUSP-SU021A*

50 W

JUSP-SU028A*

JUSP-SU065A*

JUSP-SU085A*

100 W

200 W

400 W

JUSP-SU169A*

750 W

* The asterisk indicates one alphanumeric character.

6.3.2 Replacing the Motor Driver (Axis 1 to 4)

WARNING

Motor Driver

(Axis 1 to 4)

Remove

■ Be sure to record the type and the power rating (wattage) setting of the current

Motor Driver to set the correct power rating (wattage) when replacing the Motor

Driver.

Using a Motor Driver with improper power rating (wattage) in the Controller will cause improper function of the robot system.

(1) Turn OFF the Controller and unplug the power connector.

(2) Disconnect the following cables from the front side of the Controller.

M/C Power Cable

M/C Signal Cable

EMERGENCY Cable

Front Side

Thumb Head

Screws

NOTE

)

(3) Remove the four screws shown in the photo.

The thumb head screws are used to pull out the Motor Driver.

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145

Maintenance 6. Maintenance Parts Replacement Procedures

(4) Loosen the two screws on the side of the front side.

(5) Open the front cover and hold it open.

Motor Driver

1: Axis 1

2: Axis 2

3: Axis 3

4: Axis 4

NOTE

)

(6) Open the clamp for the front cover support bar.

Push the latch A shown in the photo first and then open the clamp.

A

(7) Insert the top of the support bar into the support hole as shown without moving the base point.

3

4

1

2

Front Cover

Support Bar

Base Point

Support Hole

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Maintenance 6. Maintenance Parts Replacement Procedures

(8) Remove the five screws from the Motor Driver mounting bracket.

Motor Driver

Mounting

Bracket

Connected to the G10 or G20 series manipulator

Refer to Remove step (9) and remove the connector.

Connected to the G1, G3, G6, E2, RS, PS, C3 or S5 series manipulator

Go on to Remove step (10).

(9) When replacing the first or the second motor driver, compress both ends of the connector connected to the driver to pull out the connector.

(Remove the connector connected to the replacing motor deriver.)

1. Compress

Connector

2. Pull out

(10) Secure the two thumb head screws removed in step (3) to the Motor Driver heat sink.

Pull out the Motor Driver by pulling the two thumb head screws together evenly.

NOTE

)

When using the G10 or G20 series manipulator, a cable and a connector are connected to the first and the second motor driver.

When removing the motor driver, make sure to keep the connector from being stuck.

CAUTION

■ Be careful not to cut your fingers.

The Motor Driver connector may be connected tightly. The connector may be disconnected suddenly by a strong pull and may cause your fingers to be cut by the Motor Driver heat sink.

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Maintenance 6. Maintenance Parts Replacement Procedures

Motor Driver

(Axis 1 to 4)

Connected to the G10 or G20 series manipulator

Start from Mount step (1).

Mount

Connected to the G1, G3, G6, E2, RS, PS, C3 or S5 series manipulator

Start from Mount step (3).

(1) When replacing the first or the second motor driver, insert the connector connected to the motor driver carefully along the guide rail through the rear side of the intermediate plate

Cement

Resistance Connector

Driver

Connector

(2) Connect the connector connected to the replacing first or second motor driver to the cement resistance connector.

NOTE

)

There are two cement resistance connectors. The connector for the motor driver can be connected to either one of them. Connect to the resistance connector in the easier position.

(3) Insert the Motor Driver along the guide rails until the surface height differences of the Motor Driver comes to 5 mm or less.

Top Surface of

Motor Driver

5mm or less

(4) Push the Motor Driver securely into the two Motor Driver connectors.

Intermediate Plate

148

NOTE

)

(5) Secure the Motor Driver mounting bracket with five screws.

(6) Hold the front cover and put the front cover support bar back to the normal position.

(7) Secure the front cover support bar with the clamp.

Push latch A as shown in the photo first and open up the clamp.

A

(8) Secure the two screws on the side of the front cover.

NOTE

)

(9) Close the front cover and secure it with four screws.

Make sure to keep cables from becoming trapped or damaged.

RC180 Rev.14

Maintenance 6. Maintenance Parts Replacement Procedures

(10) Connect the following cables if they were previously connected to the front of the

Controller.

M/C Power Cable

M/C Signal Cable

EMERGENCY Cable

(11) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.3.3 Replacing the Motor Driver (Axis 5 and 6)

(1) Turn OFF the Controller and unplug the power connector. Motor Driver

(Axis 5 and 6)

Remove

(2) Open the front cover.

Refer : Maintenance 6.3.2 Replacing Motor Driver (Axis 1 to 4)

Removing procedure from (2) to (7)

(3) Remove the four screws shown to remove the top cover of the ProSix

Driver Unit.

ProSix

Driver Unit

(4) Remove two screws to remove the

Motor Driver mounting bracket.

Motor Driver

5: Axis 5

6: Axis 6

Motor Driver

Mounting

Bracket

5

6

(5) Secure the two thumb head screws removed in step (2) to the Motor Driver heat sink as shown.

(6) Pull out the Motor Driver by pulling the two thumb head screws together evenly.

CAUTION

■ Be careful not to cut your fingers.

The Motor Driver connector may be connected tightly. The connector may be disconnected suddenly by a strong pull and may cause your finger to be cut by the Motor Driver heat sink.

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Maintenance 6. Maintenance Parts Replacement Procedures

Motor Driver

(Axis 5 and 6)

Mount

(1) Insert the Motor Driver along the guide rails until the surface height differences of the Motor Driver comes to 5 mm or less.

Top Surface of

Motor Drive

(2) Push the Motor Driver securely into the two Motor Driver connectors.

A

5mm or less

(3) Secure the Motor Driver mounting bracket with two screws.

(4) Secure the top cover of the ProSix Driver Unit with four screws.

(5) Close the front side.

Refer : Maintenance 6.3.2 Replacing Motor Driver (Axis 1 to 4)

Mounting procedure from (5) to (9)

(6) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.4 CPU Board Unit

NOTE

)

The controller differs by the using manipulator. Different procedures are instructed for each controller as follows. Follow the corresponding procedure.

Connected to the PS, C3, or S5 series manipulator

Connected to the E2 , G or RS series manipulator

Remove the Option Units if they are mounted.

Refer : Maintenance 6.7.1 Remove Option Unit 1

Maintenance 6.7.5 Remove Option Unit 1, 2

CPU Board Unit (1) Turn OFF the Controller and unplug the power connector.

Remove

(2) Disconnect the cables connected to the CPU board.

USB PC LAN USB memory TP/OP I/O

(3) Remove four screws on the front cover and three screws on the backside shown in the photo.

Front Cover

Back Side

Thumb Head

Screws

Connected to the PS, C3, or S5 series manipulator

Perform steps (4) to (6) to remove the ProSix Driver Unit.

Connected to the E2, G or RS series manipulator

Go on to step (7).

(4) Remove the screw on the top and bottom to remove the two covers.

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Maintenance 6. Maintenance Parts Replacement Procedures

(5) Remove two screws on each cover.

NOTE

)

(6) Slide the ProSix Driver Unit approximately 20 mm in direction (A) and then slowly slide it approximately 10 mm in direction (B).

The ProSix Driver Unit cable is connected to the main chassis. Be sure to remove it slowly.

The DMB of the ProSix Driver Unit is connected to the board connector.

Be sure to slide the ProSix Driver Unit straight out in direction (A) as shown.

(7) Remove the screws on both sides of the

CPU board unit.

Side

(A)

(B)

(8) Install the two thumb head screws removed in step (3) in the CPU board unit.

NOTE

)

(9) Hold the thumb head screws and pull the

CPU board unit straight out.

The CPU board unit cable is connected to the main chassis. Be sure to remove slowly.

RC180 Rev.14

(10) Disconnect the four connectors connected to the CPU board.

Refer : Maintenance 3.2 Diagram of Cable Connections

- Cable Layout Drawing

153

Maintenance 6. Maintenance Parts Replacement Procedures

CPU Board Unit (1) Connect the four CPU board connectors.

Mount Refer : Maintenance 3.2 Diagram of Cable Connections

- Cable Layout Drawing

NOTE

)

(2) Carefully insert the CPU board unit by pushing it straight in.

Make sure that connector CN2 of the

CPU Board and the DMB connector

(CPU IF) are connected when inserting the Unit.

NOTE

)

Be sure to keep the cable from being trapped or damaged.

(3) Mount the screw on each side of the CPU board.

Connected to the PS, C3, or S5 series manipulator

Perform steps (4) to (6) to secure the ProSix Driver Unit.

Connected to the E2, G or RS series manipulator

Move on to step (7).

(4) Insert the ProSix Driver Unit into the position.

Refer to the photo and be sure to position the mounting bracket properly as shown.

ProSix

Driver Unit side

(5) Secure the ProSix Driver Unit with two screws on the top and bottom.

(6) Secure the two covers with a screw of the top and bottom.

(7) Secure each cover with the screws.

(Front cover : 4 screws, Backside : 3 screws)

(8) Connect the following cables to the CPU board.

USB PC LAN USB memory TP/OP I/O

(9) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.5 CF (Compact Flash)

CF Remove (1) Turn OFF the Controller and unplug the power connector.

(2) Remove the CPU board unit.

Refer : Maintenance 6.4 CPU Board Unit

(3) Pull out the CF in the direction shown by the arrow.

ETX

Module

CF

CF Mount (1) Insert the new CF along the guide rail.

NOTE

)

Insert the CF until the CF is approximately 3 mm out from the ETX module.

(2) Mount the CPU board unit.

Refer : Maintenance 6.4 CPU Board Unit

(3) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

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Maintenance 6. Maintenance Parts Replacement Procedures

6.6 Fuse

Fuse

Remove

NOTE

)

The fuse is not used for RC180-UL.

(1) Turn OFF the Controller and unplug the power connector.

(2) Remove the Option Unit when it is mounted.

Refer : Maintenance 6.7.2 Remove Option Unit 1

Maintenance 6.7.5 Remove Option Unit 1, 2

(3) Remove the fan unit

Refer : Maintenance 6.1.2 Replacing Fan Unit

(4) Remove the Motor Drive Module.

Refer : Maintenance 6.3.2 Replacing Motor Driver (Axis 1 to4)

(5) Remove four screws on the intermediate plate as shown.

Intermediate

Plate

NOTE

)

(6) Remove the FG mounting screws

(E2 / G / RS: 2 screws, PS / C3 / S5: 3 screws) and remove the plate.

Be sure to remove the intermediate plate slowly.

The cables are connected to the main chassis.

PS, C3, S5

(3 screws)

Intermediate

Plate

WARNING

■ Before disconnecting the DPB cable connector, always make sure that the power supply of the Controller is unplugged. Performing this procedure while the power supply is connected is extremely hazardous and may result in electric shock and/or cause serious safety problems.

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RC180 Rev.14

Maintenance 6. Maintenance Parts Replacement Procedures

(7) Pull out the DPB cable connector (CN1) and remove the intermediate plate.

Fuse

CN1

NOTE

)

(8) Pull out the fuse in direction of the arrow.

Pull the wires to the side to allow clearance for pulling out the fuse.

Fuse

Mount

(1) Hold the intermediate plate to connect the DPB cable connector (CN1).

(2) Mount the intermediate plate to the Controller and secure the four mounting screws and the FG mounting screws (E2 / G / RS : 2 screws, PS / C3 / S5: 3 screws) removed in steps (5) and (6).

NOTE

)

Be sure to keep the cable from being trapped or damaged.

(3) Mount the Motor Driver Module.

Refer : Maintenance 6.3.2 Replacing Motor

(4) Mount the fan unit.

Refer : Maintenance 6.1.2 Replacing Fan Unit

(5) Mount the Option Unit when it was installed.

Refer : Maintenance 6.7.2 Mount Option Unit 1

Maintenance 6.7.6 Mount Option Unit 1, 2

(6) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

RC180 Rev.14

157

Maintenance 6. Maintenance Parts Replacement Procedures

6.7 Option Unit

This section contains instructions for removing and installing the two Option Units.

Option Unit 1 and Option Unit 2 are shown in the following figure.

Option Unit 2

Option Unit 1

RC180

6.7.1 Remove Option Unit 1

(1) Turn OFF the Controller and unplug the power connector.

(2) Disconnect the cables connected to the Option Unit board.

(3) Remove two screws on the backside and remove the cover.

NOTE

)

(4) Pull out the flat cable connector connected on the backside.

Compress both ends of the connector to pull out the connector.

(5) Remove the screws (two screws each on front side and backside) and remove Option Unit 1 in the direction shown by the arrow.

158

RC180 Rev.14

Maintenance 6. Maintenance Parts Replacement Procedures

6.7.2 Mount Option Unit 1

(1) Secure Option Unit 1 with two screws each on front side and backside.

(2) Connect the flat cable connector to the backside of Option Unit 1.

Option Unit 1

Back of Controller

Main Chassis

Connecting Connector

(3) Secure the backside cover to Option Unit 1 with two screws.

Orient the cover so that there is no gap when mounted.

(4) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

6.7.3 Remove Option Unit 2

(1) Turn OFF the Controller and unplug the power connector.

(2) Disconnect the cables connected to the Option Unit board.

(3) Remove two screws on each unit from the backside of Option Units 1 and 2 to remove the covers.

NOTE

)

(4) Pull out the flat cable connector connected on the backside of Option Units 1 and 2.

Compress both ends of the connector to pull out the connector.

RC180 Rev.14

159

Maintenance 6. Maintenance Parts Replacement Procedures

(5) Secure a backside cover to Option Unit 1 with two screws.

Orient the cover so that there is no gap when mounted.

NOTE

)

Be sure to keep the cable from being trapped or damaged.

(6) Remove two screws each on the front side and backside and remove

Option Unit 2 in the direction shown by the arrow.

When replacing Option Unit 2.

The removal procedure is complete.

When Option Unit 2 in not used.

Perform steps (7) to (9).

(7) Remove four screws and remove the

Option Unit mounting bracket from the

Option Unit 1.

オプションユニット

取付金具

Brackets

(8) Remove the Option Unit 2 filter units (two places).

Refer : Maintenance 6.1.3 Cleaning and Replacing Fan Filter

(9) Mount the fan filters (two places) to

Option Unit 1.

Mounted

Filter Units

160

RC180 Rev.14

Maintenance 6. Maintenance Parts Replacement Procedures

NOTE

)

6.7.4 Mount Option Unit 2

When adding Option Unit 2

Perform steps (1) to (8).

When replacing Option Unit 2

Perform steps (3) to (7).

(1) Remove the fan filters (two places) of Option Unit 1 and mount Option Unit 2.

Refer : Maintenance 6.1.3 Cleaning and Replacing Fan Filter

(2) Secure the Option Unit mounting

Top (DPB) Side brackets to Option Unit 1 with four screws.

The shape of the mounting bracket for the top (DPB) and bottom (CPU board) side are different. Be sure to mount them properly.

Bottom (CPU Board) Side

(3) Secure Option Unit 2 with two screws each on front and backside.

(4) Remove two screws to remove the backside cover of the Option Unit 1.

(5) Connect the flat cable connectors (two places) to the backside of Option Units 1 and 2.

Option Unit 2

Option Unit 1

Back of Controller

Main Part

(6) Secure the covers to the backside of

Option Units 1 and 2 with two screws for each.

Orient the cover so that there is no gap when mounted.

Connecting Connector

RC180 Rev.14

(7) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

161

162

Maintenance 6. Maintenance Parts Replacement Procedures

6.7.5 Remove Option Units 1 & 2

(1) Turn OFF the Controller and unplug the power connector.

(2) Disconnect the cables connected to the Option Unit boards.

(3) Remove two screws from the backside of Option

Unit 1 to remove the cover.

NOTE

)

(4) Pull out the flat cable connector connected on the backside.

Compress both ends of the connector to pull out the connector.

(5) Remove the screws (two screws each on front side and backside) and remove

Option Units 1 and 2 in direction shown by the arrow.

RC180 Rev.14

Maintenance 6. Maintenance Parts Replacement Procedures

6.7.6 Mount Option Units 1 & 2

(1) Secure Option Units 1 and 2 with two screws each on front and backside.

(2) Connect the flat cable connector to the backside of Option Unit 1.

Option Unit 1

Back of Controller

Main Chassis

Connecting Connector

(3) Secure the backside covers of Option Unit 1 with two screws for each.

(4) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

RC180 Rev.14

163

Maintenance 6. Maintenance Parts Replacement Procedures

6.7.7 Replacing or Adding an Option Board

Remove (1) Turn OFF the Controller and unplug the power connector.

(2) Disconnect the cables connected to the Option Unit board.

(3) Remove two screws and pull out the

Option board.

Mount

Add

(1) Configure the Option board switches.

Refer : Maintenance 12. Option Unit

(2) Insert an Option board into the Option Unit along the guide rail and secure with two screws.

(3) Connect the cables to the Option board.

(4) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly without any vibration or abnormal noise.

(1) Turn OFF the Controller and unplug the power connector.

(2) Remove two screws to remove the cover.

(3) Insert an Option board into the Option Unit along the guide rail and secure with two screws.

(4) Plug in the power connector. Turn ON the Controller and make sure that the

Controller starts properly.

164

RC180 Rev.14

Maintenance 7. Verifying Robot System Operation

7. Verifying Robot System Operation

When maintenance has been performed for either the Manipulator or the Controller, including replacing any parts in those units, items must be checked according to the procedures in this section to ensure proper operation.

(1) Connect all the necessary cables for the system.

WARNING

■ When verifying the robot system operation, prepare for failures with initial settings or wiring. If the Manipulator operates abnormally because of incorrect initial settings or wiring, press the Emergency Stop switch immediately to stop the Manipulator.

Verify the robot system operation in the restricted mode (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.

CAUTION

■ 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. The Controller will boot up. During this process, watch and monitor the LED status as described in the following list:

From power-on to boot While running

LED for current operation mode

(TEACH, AUTO, PROGRAM) turns ON.

READY (Normal)

7 segment All lights out

Emergency Stop

Safeguard

Four digits Error

For details of the display, refer to Maintenance 2.3 LED and Seven-segment LED.

For error number, refer to Maintenance 8.1 Error Code Table.

(3) Execute MOTOR ON and check the following:

- No error is displayed.

- There is servo excitation and the Manipulator operates normally.

(4) Execute various motion commands (such as JUMP, etc.). The Manipulator must operate accordingly and normally without vibration or unusual sounds.

RC180 Rev.14

165

Maintenance 8. Trouble Shooting

8. Troubleshooting

8.1 Error Code Table

There are 14 types of errors as follows:

8.1.1 Events

8.1.2 Warnings

8.1.6 PC

8.1.7 Interpreter

8.1.8 Parser

8.1.10 Servo

8.1.11 Points

8.1.12 Fieldbus

8.1.13 Vision

8.1.14 Simulator

8.1.16 Hardware

166

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.1 Events

No. Message Remedy

1

2

Controller control program started.

Termination due to low voltage of the power supply.

3 Controller control program has completed.

Stores this log when the controller is rebooted from EPSON RC+ 5.0 or TP1.

4

5

6

Preserve variables save area has been cleaned.

Function Main started.

Function Main started. Later same logs are skipped.

Serial number has been saved.

System backup has been executed.

7

8

9 System restore has been executed.

10 Robot parameters have been initialized.

11

12

13

14

15

16

Offset pulse value between the encoder origin and the home sensor (HOFS) is changed. Additional data is J1 value.

Offset pulse value between the encoder origin and the home sensor (HOFS) is changed. Additional data is J2 value.

Offset pulse value between the encoder origin and the home sensor (HOFS) is changed. Additional data is J3 value.

Offset pulse value between the encoder origin and the home sensor (HOFS) is changed. Additional data is J4 value.

Offset pulse value between the encoder origin and the home sensor (HOFS) is changed. Additional data is J5 value.

Offset pulse value between the encoder origin and the home sensor (HOFS) is changed. Additional data is J6 value.

17 Move to the message saving mode.

18

Conversion of Robot Parameter file has been executed.

100 Device connected to Controller.

Skip the log "Function Main started." to prevent system history space run out.

101 Console device has changed.

Note 1

J1 value after change

J2 value after change

J3 value after change

J4 value after change

J5 value after change

J6 value after change

21:PC

22:Remote

23:OP1

102 Display device has changed.

103 Working mode has changed.

110

111

120

Controller firmware has been installed.

IP address has been restored.

PC connected to the Controller.

121 TP connected to the Controller.

122 OP connected to the Controller.

123 PC disconnected from the Controller.

124 TP disconnected from the Controller.

125 OP disconnected from the Controller.

126 Working mode changed to AUTO.

127 Working mode changed to Program.

May store this log when the controller firmware is installed.

1:Setup

2:Initialize

3:Upgrade

4:Recover

1:Ethernet

2:USB

Note 2

J3 value before change

J4 value before change

J5 value before change

J6 value before change

J1 value before change

J2 value before change

RC180 Rev.14

167

Maintenance 8. Trouble Shooting

No. Message

128 Working mode changed to Teach.

129

130

131

Remote Ethernet connected to the

Controller.

Remote Ethernet disconnected from the

Controller.

Remote RS232 connected to the

Controller.

132

Remote RS232 disconnected from the

Controller.

Remedy Note 1

LogoutStatus

0:Nomal

1:Abnormal

(Timeout)

Note 2

168

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.2 Warnings

No. Message Remedy Note 1

501

502

511

512

513

514

515

516

Trace history is active.

Memory has been initialized.

Battery voltage of the CPU board backup is lower than the allowed voltage. Replace the CPU board battery.

5V input voltage for the CPU board is lower than the allowed voltage.

24 V input voltage for the motor brake, encoder and fan is lower than the specified voltage.

Internal temperature of the Controller is higher than the allowed temperature.

Rotating speed of the controller fan is below the allowed speed. (FAN1)

Rotating speed of the controller fan is below the allowed speed. (FAN2)

Effects system performance if trace history is active.

When this error occurs, the value of the

Global Preserve variable will be initialized.

Replace the CPU board battery.

Replace the CPU board.

Replace the CPU board battery

Current immediately. Keep the power to the controller ON as far as possible until you replace the battery. value

If normal voltage is not generated by a 5V power supply alone, replace the power supply.

Current value

If normal voltage is not generated by a

24V power supply alone, replace the power supply.

Stop the controller as soon as possible and check whether the ambient temperature of the controller is not high.

Check whether the filter is not clogged up.

Check whether the filter is not clogged up.

If the warning is not cleared after the controller is rebooted, replace the fan.

Check whether the filter is not clogged up.

If the warning is not cleared after the controller is rebooted, replace the fan.

Current value

Current value

Current value

Current value

517

700

Internal temperature of the Controller is higher than the allowed temperature.

Motor driver type does not match the current robot model. Check the robot model. Replace the motor driver.

736

737

Encoder has been reset. Reboot the controller.

Low voltage from the encoder battery.

Replace the battery with the controller ON.

752

Servo alarm D.

Check the robot model.

Reboot the controller.

Replace the battery for the robot with the controller ON.

Note 2

Boundary value

Boundary value

Boundary value

Boundary value

Boundary value

Boundary value

RC180 Rev.14

169

Maintenance 8. Trouble Shooting

8.1.3 Controller Main

No. Message Remedy

1001

Operation Failure.

Command parameter is invalid.

1002

Requested data cannot be accessed.

The data is not set up or the range is invalid.

1003 The password is invalid

1004

1005

Check whether the target I/O, variables, and tasks exist.

Cannot execute with invalid serial number.

Enter the correct password.

Cannot execute with unsupported version.

Use the correct version file.

Use the backup data for the same controller to restore the controller configuration.

1006

1020

Cannot execute with invalid Robot model.

Cannot execute in recovery mode.

Use the backup data for the same controller to restore the controller configuration.

Boot the controller as normal.

1021

Cannot execute due to controller initialization failure.

Restore the controller configuration.

1022

1023

Cannot execute without the project being open.

Cannot execute while the project is open.

1024 Cannot activate from remote.

1025

Open a project.

Rebuild the project.

Enable the remote input.

Execution in Teach mode is Change to the AUTO mode. prohibited.

1026

Cannot execute in Teach mode except from TP.

1027 Cannot execute in Auto mode.

Change to the AUTO mode.

1028

Cannot execute in Auto mode except from the main console.

1029 Cannot execute from OP.

1030

1031

Change to the Program mode.

Change to the Program mode.

Does not allow Operation mode to be changed.

Enable the OP input.

Change to the Auto mode with a console in the Program mode.

Cannot execute while tasks are Stop the task and then execute. executing.

1032

1033

1034

1035

1036

1037

1040

1041

Cannot execute while the maximum number of tasks are executing.

Cannot execute during asynchronous motion command.

Stop the task and then execute.

Execute after the motion ends.

Asynchronous command stopped The asynchronous command already during operation. stopped when the controller received a stop command.

Cannot execute in Remote enable except from the Remote.

Cannot execute in OP enable except from the OP.

Cannot execute in Remote Ethernet enable except from the Remote

Ethernet.

Cannot execute in Remote RS232C enable except from the Remote

RS232C.

Cannot execute during Emergency

Stop status.

Cancel the Emergency Stop status.

Note 1 Note 2

170

RC180 Rev.14

Maintenance 8. Trouble Shooting

No. Message Remedy

1042

Cannot execute while the safeguard is open.

Close the safeguard.

1043

Cannot execute during error condition.

Cancel the error condition.

1044

1045

Cannot execute when the remote pause input is ON.

Input waiting condition is the only available condition to input.

Change the remote pause input to OFF.

The controller received an input while it was not in the Input waiting condition.

1046 Cannot execute during file transfer.

1047

Cannot cancel the command executed from other devices.

1048

1049

Cannot execute after low voltage was detected.

Other devices are in program mode.

Execute after the file transmission.

Cancel the motion command from the device the command was issued from.

1050 Password is too long.

1051 Export Controller Status failed.

1052 Export Controller Status busy.

1100

File failure. Cannot access the file.

1102

File failure. Read and write failure of the registry

1103 File is not found.

1104 Project file was not found.

1105 Object file was not found.

1106 Point files were not found.

1107

The program is using a feature that is not supported by the current controller firmware version.

1108

1109

One or more source files are updated.

Please build the project.

Not enough storage capacity.

Check whether the file exists.

Rebuild the project.

Rebuild the project.

Rebuild the project.

Rebuild the project.

Increase free space of the USB memory.

1110 File is not found.

1120

File failure. Setting file is corrupt.

1121

File failure. Project file is corrupt.

1122

File failure. Point file is corrupt.

Restore the controller configuration.

Rebuild the project.

Rebuild the project.

1123

File failure. I/O label file is corrupt. Rebuild the project.

1124

File failure. User error file is corrupt. Rebuild the project.

1125

1126

File failure. Error message file is corrupt.

File failure. Software option information is corrupt.

1127 File failure. Vision file is corrupt.

1128

File failure. Backup information file is corrupt.

Rebuild the project.

1130

Error message failure. No item is found in the error history.

1131

1132

1133

Cannot access the USB memory.

File failure. Failed to copy the file.

File failure. Failed to delete the file.

Insert the USB memory properly. When this error still occurs after the USB memory is inserted properly, the memory may be unrecognizable to controller. Insert another memory to check the operation.

Note 1 Note 2

RC180 Rev.14

171

Maintenance 8. Trouble Shooting

No. Message Remedy

1140

1141

1142

File failure. Failed to open the object file.

File failure. Failed to open the project file.

File failure. Failed to read the project file.

1143

File failure. Failed to open the condition save file.

1144

File failure. Failed to write the condition save file.

1150

File failure. Error history is invalid.

1151

1152

1153

1155

1156

1157

1158

1160

1161

1162

1163

1165

1166

1167

1168

1170

1171

1172

1173

1175

1176

1177

File failure. Failed to map the error history.

File failure. Failed to open the error history file.

File failure. Failed to write the error history file.

File failure. Failed to open the settings file.

File failure. Failed to save the settings file.

File failure. Failed to read the settings file.

File failure. Failed to write the settings file.

MCD failure. Failed to open the MCD file.

MCD failure. Failed to read the MCD file.

MCD failure. Failed to write the MCD file.

MCD failure. Failed to save the MCD file.

MPD failure. Failed to open the MPD file.

MPD failure. Failed to read the MPD file.

MPD failure. Failed to write the MPD file.

MPD failure. Failed to save the MPD file.

MPL failure. Failed to open the MPL file.

MPL failure. Failed to read the MPL file.

MPL failure. Failed to write the MPL file.

MPL failure. Failed to save the MPL file.

MAL failure. Failed to open the MAL file.

MAL failure. Failed to read the MAL file.

MAL failure. Failed to write the MAL file.

Restore the controller configuration.

Restore the controller configuration.

Restore the controller configuration.

Restore the controller configuration.

Restore the controller configuration.

Restore the controller configuration.

Restore the controller configuration.

Restore the controller configuration.

172

Note 1 Note 2

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

1178

1180

1181

1185

1186

1187

Message

MAL failure. Failed to save the MAL file.

MTR failure. Failed to create the MTR file.

PRM failure. Failed to replace the

PRM file.

File failure. Failed to open the backup information file.

File failure. Failed to read the backup information file.

File failure. Failed to write the backup information file.

Remedy

1188

File failure. Failed to save the backup information file.

1189

The backup data was created by an old version.

1190

The backup data was created by a newer version.

1191 There is no project in the backup data.

Cannot restore the controller configuration in the specified procedure for using old backup data. Check the backup data.

1200

1201

1501

Compile failure. Check the compile message.

This error occurs during compilation from TP. Correct where the error occurred.

Link failure. Check the link message. This error occurs during compilation from TP. Correct where the error occurred.

Command did not complete in time. Execute the command again after a while. Check the connection between the PC and controller.

1502

Re-establish communication.

1503 Disconnection while executing a task.

1510 Out of IP Address range.

1550

1551

Communication failure. Ethernet initialization error.

Communication failure. USB initialization error.

1552

Communication failure. Controller internal communication error.

1553

1555

Communication failure. Invalid data is detected.

Ethernet transmission error.

1556

1557

1558

1901

Ethernet reception error.

USB transmission error.

USB reception error.

Unsupported. Unsupported command was attempted.

Check the connection between the PC and controller.

Check the connection between the PC and controller.

Check the connection between the PC and controller.

Check the connection between the PC and controller.

Note 1 Note 2

RC180 Rev.14

173

Maintenance 8. Trouble Shooting

No. Message

1902

Unsupported. Unsupported parameter was specified.

1903

System error.

Remedy Note 1 Note 2

174

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.4 Operator Panel

No.

1600

1603

1604

1605

1606

1607

1608

1609

Message Remedy

Initialization failure. Failed to initialize OP.

Timeout error occurred during Check whether the cable is firmly communication with OP. connected.

Replace the cable. communication with OP. connected.

Replace the cable.

Framing error occurred during Check whether the cable is firmly communication with OP. connected.

Replace the cable.

Overrun error occurred during Check whether the cable is firmly communication with OP. connected.

Replace the cable.

Checksum error occurred during Check whether the cable is firmly communication with OP. connected.

Replace the cable. communication with OP.

OP cannot be connected. connected.

Replace the cable.

Upgrade the controller software.

Upgrade the OP firmware.

Note 1 Note 2

RC180 Rev.14

175

Maintenance 8. Trouble Shooting

8.1.5 Teach Pendant

No.

1700

1701

1702

1703

Message

Initialization failure. Failed to initialize TP.

Initialization failure. Failed to initialize TP.

Initialization failure. Failed to initialize TP.

File failure. Failed to read the screen data file.

1704

Failed to read the setting file.

1706

Failed to open the TP port.

1708

Failed to read the key table for TP.

1709

Failed to change the language.

1710

Failed to make the screen.

Remedy Note 1 Note 2

176

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.6 PC

No.

1800

1802

1803

1804

1805

1806

1807

Message

The controller is already connected to a PC.

The command was attempted without being connected to a controller.

Failed to read or write the file on the

PC.

Initialization failure. Failed to allocate memory on the PC.

Connection failure. Check the controller startup and connection of the communication cable.

Timeout during connection via

Ethernet.

Timeout during connection via USB.

Remedy

Only one PC can be connected to the controller.

Note 1 Note 2

1808

USB driver is not installed. Failed to install EPSON RC+ 5.0.

Install EPSON RC+ 5.0 again.

RC180 Rev.14

177

Maintenance 8. Trouble Shooting

8.1.7 Interpreter

No.

2000

2001

2002

2003

2004

2005

Message

Unsupported. Unsupported command was attempted.

Remedy

Rebuild the project.

Unsupported. Unsupported motion Rebuild the project. command was attempted.

Unsupported. Unsupported conveyer command was attempted.

Rebuild the project.

Unsupported. Unsupported Function argument was specified.

Rebuild the project.

Unsupported. Unsupported Function return value was specified.

Rebuild the project.

Unsupported. Unsupported condition was specified.

Rebuild the project.

2006

2012 command was specified.

2007

Unsupported condition was specified.

2008

Unsupported.

Unknown error number.

2009

2010

Unsupported.

Invalid Task number.

Object file error. Build the project. Out of internal code range.

Rebuild the project.

2011

Object file error. Build the project.

Function argument error.

Rebuild the project.

Object file error. Build the project.

Command argument error.

Rebuild the project.

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022

Object file error. Build the project.

Cannot process the code.

Rebuild the project.

Object file error. Build the project.

Cannot process the variable type code.

Rebuild the project.

Object file error. Build the project.

Cannot process the string type code.

Rebuild the project.

Object file error. Build the project.

Cannot process the variable category code.

Object file error. Build the project.

Cannot process because of improper code.

Object file error. Build the project.

Failed to calculate the variable size.

Rebuild the project.

Rebuild the project.

Rebuild the project.

Object file error.

Cannot process the variable wait. Build the project.

Stack table number exceeded. Function call or local variable is out of range.

Rebuild the project.

Stack area size exceeded. Stack error.

Function call or local variable is out of range.

Stack failure. Required data not found on the stack.

Check whether no function is called infinitely. Reduce the Call function depth.

If using many local variables, especially

String type, replace them to global variables.

Rebuild the project.

Note 1

178

Note 2

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

2023

2024

2030

2031

Message

Stack failure. Unexpected tag found on the stack.

Stack area size exceeded. Local variable is out of range.

Remedy

Rebuild the project.

System failure. Drive unit quantity is beyond the maximum count.

Restore the controller configuration.

System failure. Robot number is beyond the maximum count.

Restore the controller configuration.

Note 1 Note 2

2032 compliance error.

2033

System failure. Too many errors.

2040

Thread failure. Failed to create the thread.

Remedy the errors occurring frequently.

2041

2042

Thread failure. Thread creation timeout.

Thread failure. Thread termination timeout.

2043

2044

2045

Thread failure. Thread termination timeout.

Thread failure. Daemon process timeout.

Thread failure. Task continuance wait timeout.

2046

Thread failure. Task stop wait timeout.

2047

2050

Thread failure. Task startup wait timeout.

Object file operation failure. Object file size is beyond the allowable size.

Rebuild the project.

2051

2052

2053

Object file operation failure. Cannot delete the object file during execution.

Object file operation failure. Cannot allocate the memory for the object file.

Object file update. Updating the object file.

Reboot the controller.

Reboot the controller.

Perform the same processing after a while. Rebuild the project.

2054 Synchronize the project. Function ID failure.

Rebuild the project.

2055 Synchronize the project. Local variable

ID failure.

Rebuild the project.

2056 Synchronize the project. Global Rebuild the project. variable ID failure.

2057

2058

2059

Synchronize the project. Global Rebuild the project.

Preserve variable ID failure.

Object file operation failure. Failed to calculate the variable size.

Synchronize the files of the project.

Rebuild the project.

Exceed the global variable area.

Cannot assign the Global variable area.

Reduce the number of Global variables to be used.

2070

SRAM failure. SRAM is not mapped. Replace the CPU board.

RC180 Rev.14

179

Maintenance 8. Trouble Shooting

No. Message

2071

Remedy

SRAM failure. Cannot delete when

Global Preserve variable is in use.

Perform the same processing after a while. Rebuild the project.

2072

2073

2074

2100

2101

2102

2103

2104

2105

2106

2107

2108

Note 1

Exceed the backup variable area.

Cannot assign the Global Preserve variable area.

Reduce the number of Global Preserve variables to be used.

SRAM failure. Failed to clear the

Global Preserve variable area.

Rebuild the project.

Reboot the controller. SRAM failure. Failed to clean up the

Global Preserve variable save area.

Initialization failure. Failed to open the initialization file.

Restore the controller configuration.

Initialization failure. Duplicated initialization.

Initialization failure. Failed to initialize

MNG.

Initialization failure. Failed to create an event.

Initialization failure. Failed to setup a priority.

Initialization failure. Failed to setup the stack size.

Initialization failure. Failed to setup an interrupt process.

Initialization failure. Failed to start an interrupt process.

Initialization failure. Failed to stop an interrupt process.

Maximum size

Note 2

The size you attempted to use

2109

2110

2111 terminate MNG.

Initialization failure. Failed to allocate memory.

Initialization failure. Failed to initialize motion.

Reboot the controller.

Restore the controller configuration.

2112

2113

2114

2115

2116

2117

2118

2119

2120 terminate motion.

Initialization failure. Failed to map

SRAM.

Initialization failure. Failed to register

SRAM.

Replace the CPU board.

Replace the CPU board.

Initialization failure. Fieldbus board is beyond the maximum count.

Initialization failure. Failed to initialize fieldbus.

Initialization failure. Failed to terminate fieldbus.

Initialization failure. Failed to open motion.

Initialization failure.

Failed to initialize conveyor tracking.

Initialization failure. Failed to allocate the system area.

Restore the controller configuration.

Make sure the settings of conveyor and encoder are correct.

Reboot the controller.

180

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

2121

2122

Message

Initialization failure. Failed to allocate the object file area.

Initialization failure. Failed to allocate the robot area.

Remedy

Reboot the controller.

Reboot the controller.

2123

2135

2136

2137

2150

Initialization failure.

Failed to create event.

Reboot the controller.

2130

MCD failure. Failed to open the MCD file.

Restore the controller configuration.

2131

2132

MCD failure. Failed to map the MCD file.

PRM failure. PRM file cannot be found.

Restore the controller configuration.

Restore the controller configuration.

2133

PRM failure. Failed to map the PRM file.

Restore the controller configuration.

2134

PRM failure. PRM file contents error. Restore the controller configuration.

PRM failure. Failed to convert the

PRM file.

PRM failure. Failed to convert the

PRM file.

PRM failure. Failed to convert the

PRM file.

Operation failure. Task number cannot be found.

2151

Operation failure. Executing the task.

2152

Operation failure. Object code size failure.

2153

Operation failure. Jog parameter failure.

2154

Operation failure. Executing jog.

2155

Operation failure. Cannot execute the jog function.

2156

2157

2158

2159

2160

2161

2162

2163

2164

2165

Operation failure. Jog data is not configured.

Operation failure. Failed to change the jog parameter.

Operation failure. Failed to allocate the area for the break point.

Operation failure. Break point number is beyond the allowable setup count.

Operation failure. Failed to allocate the function ID.

Operation failure. Failed to allocate the local variable address.

Operation failure. Not enough buffer to store the local variable.

Operation failure. Value change is available only when the task is halted.

Operation failure. Failed to allocate the global variable address.

Operation failure. Not enough buffer to store the global variable.

Note 1 Note 2

RC180 Rev.14

181

Maintenance 8. Trouble Shooting

No. Message

2166

Operation failure. Failed to obtain the

Global Preserve variable address.

Remedy

2167

2168

2169

2170

2171

2172

Operation failure. Not enough buffer to store the Global Preserve variable.

Operation failure. SRAM is not mapped.

Operation failure. Cannot clear the

Global Preserve variable when loading the object file.

Operation failure. Not enough buffer to store the string.

Operation failure. Cannot start the task after low voltage was detected.

Operation failure. Duplicated remote

I/O configuration.

2173

2174

2175

Remote setup error. Cannot assign non-existing input number to remote function.

Remote setup error. Cannot assign non-existing output number to remote function.

Operation failure. Remote function is not configured.

2176

Operation failure. Event wait error.

2177

2178

2179

2180

2190

2191

2192

2193

Operation failure. System backup failed.

Operation failure. System restore failed.

Remote setup error. Cannot assign same input number to some remote functions.

Remote setup error. Cannot assign same output number to some remote functions.

Cannot calculate because it was queue data.

Cannot execute AbortMotion because robot is not runnning from a task.

Check the program.

If you don’t operate the robot from a program, you cannot use AbortMotion.

Cannot execute AbortMotion because robot task is already finished.

Cannot execute Recover without motion because AbortMotion was not executed.

Execute AbortMotion in advance to execute Recover WithoutMove.

2194

2195

2196

2200

Conveyor setting error.

Conveyor setting error.

Conveyor number is out of range.

Robot in use. Cannot execute the motion command when other tasks are using the robot.

Make sure the settings of conveyor and encoder are correct.

Make sure the settings of conveyor and encoder are correct.

Make sure the settings of conveyor and encoder are correct.

The motion command for the robot cannot be simultaneously executed from more than one task. Review the program.

Note 1 Note 2

182

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

2201

2202

2203

2204

2205

2206

2207

2208

2209

Message

Robot does not exist.

Motion control module status failure.

Unknown error was returned.

Cannot clear local number ' 0 '.

Remedy

Check whether the robot setting is performed properly. Restore the controller configuration.

The Local number 0 cannot be cleared.

Review the program.

Cannot clear an arm while in use.

Cannot clear arm number ' 0 '.

Note 1

The Arm cannot be cleared while it is in use. Check whether the Arm is not used.

The Arm number 0 cannot be cleared.

Review the program.

The Arm number you attempted to clear

Note 2

Cannot clear a tool while in use.

Cannot clear tool number ' 0 '.

Cannot clear ECP ' 0 '.

Cannot clear an ECP while in use.

The Tool cannot be cleared while it is in use. Check whether the Tool is not used.

The Tool number 0 cannot be cleared.

Review the program.

The Tool number you attempted to clear

The ECP number 0 cannot be cleared.

Review the program.

The ECP cannot be cleared while it is in use. Check whether the ECP is not used.

The ECP number you attempted to clear

2210

Cannot specify ' 0 ' as the local number.

2216 Box number is out of range.

2217 Box number is not defined.

2218

2219

2220

Plane number is out of range.

Plane number is not defined.

PRM failure. No PRM file data is found.

The command processing the Local cannot specify the Local number 0.

Review the program.

Reboot the controller. Restore the controller configuration.

2221

PRM failure. Failed to flash the PRM file.

Local number is not defined.

Reboot the controller. Restore the controller configuration.

2222

2223

Local number is out of range.

Check the Local setting. Review the program.

The specified

Local number

Available Local number is from 1 to 15.

Review the program.

The specified

Local number

2224

2226

2227

2228

Unsupported. MCOFS is not defined

2225

CalPls is not defined.

Arm number is out of range.

Arm number is not defined.

Check the CalPls setting.

Available Arm number is from 0 to 3.

Depending on commands, the Arm number 0 is not available. Review the program.

The specified

Arm number

Check the Arm setting. Review the program.

The specified

Arm number

Pulse for the home position is not defined.

Check the HomeSet setting.

RC180 Rev.14

183

Maintenance 8. Trouble Shooting

No.

2229

2230

2231

2232

2233

2234

2235

2236

2240

Message

Tool number is out of range.

Tool number is not defined.

Remedy Note 1

Available Tool number is from 0 to 3.

Depending on commands, the Tool number 0 is not available. Review the program.

The specified

Tool number

Check the Tool setting. Review the program.

The specified

Tool number

Note 2

ECP number is out of range.

ECP number is not defined.

Available Tool number is from 0 to 15.

Depending on commands, the Tool number 0 is not available. Review the program.

Check the ECP setting. Review the program.

The specified

ECP number

The specified

ECP number

Axis to reset the encoder was not specified.

Cannot reset the encoder with motor in the on state.

XYLIM is not defined.

Be sure to specify the axis for encoder reset.

Turn the motor power OFF before reset.

PRM failure. Failed to set up the PRM file contents to the motion control status module.

Array subscript is out of user defined range. Cannot access or update beyond array bounds.

Check the XYLim setting. Review the program.

Reboot the controller. Restore the controller configuration.

Check the array subscript. Review the program.

The dimensions exceeding the definition

The specified subscript

2241

Dimensions of array do not match the declaration.

2242

Zero '0' was used as a divisor.

2243

2244

2245

2246

Check the array's dimensions. Review the program.

Review the program.

Variable overflow. Specified variable was beyond the maximum allowed value.

Variable underflow. Specified variable was below the minimum allowed value.

Cannot execute this command with a floating point number.

Check the variable type and calculation result. Review the program.

Check the variable type and calculation result. Review the program.

This command cannot be executed for

Real or Double type. Review the program.

Cannot calculate the specified value using the Tan function.

Check the specified value. Review the program.

The specified value

2247

Specified array subscript is less than ' 0

'.

Check the specified value. Review the program.

The specified value

2248

2249

2250

2251

2252

Array failure. Redim can only be executed for an array variable.

You attempted to redimension the variable that is not array. Rebuild the project.

Array failure. Cannot specify Preserve for other than a single dimension array.

Other than a single dimension array was specified as Preserve for Redim.

Rebuild the project.

Array failure. Failed to calculate the size of the variable area.

Cannot allocate enough memory for

Redim statement.

Cannot allocate enough memory for

ByRef.

Rebuild the project.

Reduce the number of subscripts to be specified for Redim. Perform Redim modestly.

Reduce the number of array's subscripts to be seen by ByRef.

184

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

2253

2254

2255

2256

2260

2261

2262

2263

2264

2265

2266

2267

2268

2269

2270

2271

2272

2273

2274

Message Remedy

Cannot compare characters with Check whether the string type and the values. numeric data type are not compared.

Review the program.

Specified data is beyond the array bounds. Cannot refer or update beyond the array bounds.

Check the number of array's subscripts and data. Review the program.

Note 1

The number of array subscripts

Variable overflow or underflow. The value that exceeds the range of

Specified variable is out of value range.

Double type is specified. Review the program.

Specified array subscript is beyond the maximum allowed range.

Reduce the number of subscripts to be specified. For available subscripts, see the online help.

Task number is out of the available range.

For available task number, see the online help. Review the program.

The specified task number

Note 2

The number of data to be referred or updated

Specified task number does not exist.

Robot number is out of the available range.

Review the program.

The specified task number

The available Robot number is 1.

The specified

Review the program. robot number

Output number is out of the available range. The Port No. or the Device No. is out of the available range.

Command argument is out of the available range. Check the validation.

Added data 1: Passed value. Added data 2: argument order.

Joint number is out of the available range.

For available output number, see the online help. Review the program.

For available range of argument, see the online help. Review the program.

The specified output number

The specified What number value argument?

Available Joint number is from 1 to 6.

Review the program.

The specified joint number

Wait time is out of available range. Available wait time is from 0 to

2147483. Review the program.

The specified wait time

Timer number is out of available range.

Available timer number is from 0 to 15.

Review the program.

The specified timer number

Trap number is out of available range. Available trap number is from 1 to 4.

Review the program.

The specified trap number

Language ID is out of available range. For available language ID, see the online help. Review the program.

The specified language ID

Specified D parameter value at the parallel process is out of available range.

Available D parameter value is from 0 to

100. Review the program.

The specified D parameter value

Arch number is out of available range. Available arch number is from 0 to 7.

Review the program.

The specified arch number

Device No. is out of available range. The specified number representing a control device or display device is out of available range. For available device number, see the online help. Review the program.

Output data is out of available range. Available output data value is from 0 to

255. Review the program.

The specified device number

Output data

What number byte data is out of range?

Asin argument is out of available range. Range is from -1 to 1.

Review the program.

RC180 Rev.14

185

Maintenance 8. Trouble Shooting

No. Message

2275

Remedy

Acos argument is out of available range. Range is from -1 to 1.

Review the program.

Note 1 Note 2

2276

Sqr argument is out of available range. Review the program.

2277

2278

2280

2281

2282

2283

2290

2291

2292

2293

2294

2295

2296

2297

2298

2299

2300

2301

Randomize argument is out of Review the program. available range.

Sin, Cos, Tan argument is out of available range.

Review the program.

Timeout period set by the TMOut statement expired before the wait condition was completed in the WAIT statement.

Investigate the cause of timeout.

Check whether the set timeout period is proper.

Timeout period

Timeout period set by TMOut Investigate the cause of timeout. statement in WaitSig statement or

SyncLock statement expired.

Check whether the set timeout period is proper.

Signal number

Timeout period set by TMOut Investigate the cause of timeout. statement in WaitNet statement Check whether the set timeout period is expired. proper.

Port number

Reboot the controller. Timeout. Timeout at display device setting.

Cannot execute a motion command. Cannot execut the motion command after using the user function in the motion command. Review the program.

Cannot execute the OnErr command. Cannot execute OnErr in the motion command when using user function in the motion command. Review the program.

Timeout period

Timeout period

Cannot execute an I/O command while the safeguard is open. Need Forced.

Cannot execute an I/O command during emergency stop condition. Need

Forced.

Cannot execute an I/O command when an error has been detected. Need

Forced.

Cannot execute this command from a

NoEmgAbort Task.

One or more source files are updated.

Please build the project.

Cannot execute an I/O command in

TEACH mode without the Forced parameter.

Rebuild the project.

Cannot continue execution in Trap

SGClose process.

Cannot execute this command. Need the setting.

Robot in use. Cannot execute the motion command when other task is using the robot.

Cannot execute the motion command when the Enable Switch is OFF.

You cannot execute Cont and Recover statements with processing task of Trap

SGClose.

Enable the [enable the advance taskcontrol commands] from RC+ to execute the command.

The motion command for the robot cannot be simultaneously executed from more than one task. Review the program.

Task number that is using the robot

186

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

2302

2303

2304

2305

2306

2307

2308

2309

2310

2311

2312

Message

Cannot execute a Call statement in a

Trap Call process.

Remedy

Another function cannot be called from the function called by Trap Call.

Review the program.

Review the program. Cannot execute a Call statement in a parallel process.

Cannot execute an Xqt statement in a parallel process.

Cannot execute a Call statement from the command window.

Cannot execute an Xqt statement from the task started by Trap Xqt.

Review the program.

Review the program.

Cannot execute this command while tasks are executing.

Cannot turn on the motor because of a critical error.

Cannot execute a motion command while the safeguard is open.

Check whether all tasks are completed.

Find the previously occurring error in the error history and resolve its cause.

Then, reboot the controller.

Check the safeguard status.

Cannot execute a motion command while waiting for continue.

Execute the Continue or Stop and then execute the motion command.

Cannot execute a motion command during the continue process.

Wait until the Continue is complete and then execute the motion command.

Cannot execute a task during Check the emergency stop status. emergency stop condition.

Note 1 Note 2

2313

2314 safeguard.

Cannot continue execution while the safeguard is open.

2315

Duplicate execution continue.

2316

Cannot continue execution after an error has been detected.

Check the safeguard status.

Wait until the Continue is completed.

Check the error status.

2317

2318

2319

2320

Cannot execute the task when an error has been detected.

Reset the error by Reset and then execute the task.

Cannot execute a motion command when an error has been detected.

Cannot execute an I/O command during emergency stop condition.

Function failure. Argument type does not match.

Rebuild the project.

Rebuild the project.

2321

2322

2323

Function failure. Return value does not match to the function.

Function failure. ByRef type does not match.

Function failure. Failed to process the

ByRef parameter.

Rebuild the project.

Rebuild the project.

2324

2325

Function failure. Dimension of the

ByRef parameter does not match.

Rebuild the project.

Function failure. Cannot use ByRef in an Xqt statement.

Rebuild the project.

2326

Cannot execute a Dll Call statement from the command window.

-

2327 Failed to execute a Dll Call.

RC180 Rev.14

-

187

Maintenance 8. Trouble Shooting

No. Message

2328

2329

2330

2331

Cannot execute the task before connect with RC+.

Cannot execute a Eval statement in a

Trap Call process.

Trap failure. Cannot use the argument in Trap Call or Xqt statement.

Remedy

You need to connect with RC+ before executing the task.

Check the program.

Check the program.

Trap failure. Failed to process Trap

Goto statement.

Rebuild the project.

Note 1 Note 2

2332

Trap failure. Failed to process Trap

Goto statement.

Rebuild the project.

2333

Trap failure. Trap is already in process. Rebuild the project.

2334

2335

2336

2337

2340

2341

2342

Cannot execute a Eval statement in a

Trap Finsh and Trap Abort process.

Cannot continue execution and Reset

Error in TEACH mode.

Check the program.

Check the program.

Cannot use Here statement with a parallel process.

Go Here :Z(0) ! D10; MemOn(1) ! is not executable.

Change the program to:

P999 = Here

Go P999 Here :Z(0) ! D10; MemOn(1) !

Cannot execute except from the event handler function of GUI Builder

Check the program.

Value allocated in InBCD function is an invalid BCD value.

Review the program.

Specified value in the OpBCD Review the program. statement is an invalid BCD value.

Cannot change the status for output bit configured as remote output.

Check the remote I/O setting.

2343

2344

2345

2346

2347

2348

2349

2350

2351

Tens digit

The specified value

Units digit

I/O number

Output time for asynchronous output commanded by On or Off statement is out of the available range.

I/O input/output bit number is out of available range or the board is not installed.

I/O input/output byte number is out of available range or the board is not installed.

I/O input/output word No. is out of available range or the board is not installed.

Review the program.

Review the program.

Check whether the expansion I/O board and Fieldbus I/O board are correctly detected.

Review the program.

Check whether the expansion I/O board and Fieldbus I/O board are correctly detected.

Review the program.

Check whether the expansion I/O board and Fieldbus I/O board are correctly detected.

Review the program. Memory I/O bit number is out of available range.

Memory I/O byte number is out of available range.

Memory I/O word number is out of available range.

Command allowed only when virtual

I/O mode is active.

Cannot change the status for CC-Link system area.

Review the program.

Review the program.

The command can be executed only for virtual I/O mode.

The specified time

Bit number

Byte number

Word number

Bit number

Byte number

Word number

1: bit, 2: byte,

3: word

188

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

2352

2360

2361

2362

2363

2364

2365

2370

2371

2372

2373

2374

2380

2381

2382

2383

2384

2385

2386

2400

2401

2402

2403

2404

2405

2406

Message Remedy

Remote setup error. Cannot assign

CC-Link system area to remote function.

File failure. Failed to open the configuration file.

Restore the controller configuration.

File failure. Failed to close the configuration file.

Restore the controller configuration.

File failure. Failed to open the key of the configuration file.

Restore the controller configuration.

File failure. Failed to obtain the string from the configuration file.

File failure. Failed to write in the configuration file.

Restore the controller configuration.

Restore the controller configuration.

File failure. Failed to update the configuration file.

Restore the controller configuration.

Note 1

The string combination exceeds the maximum string length.

String length is out of range.

Invalid character is specified after the ampersand in the Val function.

The maximum string length is 255.

Combined

Review the program. string length

The maximum string length is 255.

The specified

Review the program. length

Review the program.

Illegal string specified for the Val function.

String Failure. Invalid character code in the string.

Review the program.

Review the program.

Cannot use ' 0 ' for Step value in

For...Next.

Check the Step value.

Relation between For...Next and Review the program.

GoSub is invalid. Going in or out of a

For...Next using a Goto statement.

Cannot execute Return while executing

OnErr.

Return was used without GoSub.

Review the program.

Review the program.

Review the program.

Case or Send was used without Select.

Review the program.

Review the program.

Cannot execute EResume while Review the program. executing GoSub.

EResume was used without OnErr.

Review the program.

Review the program.

Curve failure. Failed to open the Curve file.

Curve failure. Failed to allocate the header data of the curve file.

Reboot the controller.

Create a Curve file again.

Reboot the controller.

Create a Curve file again.

Curve failure. Failed to write the curve file.

Curve failure. Failed to open the curve file.

Curve failure. Failed to update the curve file.

Curve failure. Failed to read the curve file.

Curve failure. Curve file is corrupt.

Reboot the controller.

Create a Curve file again.

Reboot the controller.

Create a Curve file again.

Reboot the controller.

Create a Curve file again.

Reboot the controller.

Create a Curve file again.

Reboot the controller.

Create a Curve file again.

Note 2

RC180 Rev.14

189

Maintenance 8. Trouble Shooting

No. Message

2407

2408

Curve failure. Specified a file other than the curve file.

Curve failure. Version of the curve file is invalid.

Remedy

Reboot the controller.

Create a Curve file again.

Reboot the controller.

Create a Curve file again.

Note 1

2409

2410

2411

2412

2413

2414

2415

2416

2417

Curve failure. Robot number in the curve file is invalid.

Reboot the controller.

Create a Curve file again.

Curve failure. Cannot allocate enough memory for the CVMove statement.

Reboot the controller.

Specified point data in the Curve statement is beyond the maximum count.

Specified number of output commands in the Curve statement is beyond the maximum count.

The maximum number of points specified in the Curve statement is 200.

Review the program.

The maximum number of output commands specified in the Curve statement is 16. Review the program.

Reboot the controller. Curve failure. Specified internal code is beyond the allowable size in Curve statement.

Specified continue point data P(:) is beyond the maximum count.

Curve failure. Cannot create the curve file.

Curve file does not exist.

Curve failure. Output command is specified before the point data.

The maximum number of points

Start point specified continuously is 200. Review the program.

Reboot the controller.

Create a Curve file again.

Check whether the specified Curve file name is correct.

Check whether no output command is specified before the point data.

2418

Curve file name is too long.

2419

Curve failure. Curve file path is too long.

2420 Curve file name is invalid.

2430

Error message failure. Error message file does not exist.

2431

Error message failure. Failed to open the error message file.

2432

2433

2434

2435

Error message failure. Failed to obtain the header data of the error message file.

Error message failure. Error message file is corrupted.

Error message failure. Specified a file other than the error message file.

Error message failure. Version of the error message file is invalid.

2440

2441

File Error.

File number is used.

File Error.

Failed to open the file.

2442

2443

File Error.

The file is not open.

File Error. The file number is being used by another task.

2444 File Error. Failed to close the file.

Check whether the specified Curve file name is correct. The maximum string length of the file name is 32.

Check whether the specified Curve file name is correct.

Reboot the controller.

Reboot the controller.

Reboot the controller.

Reboot the controller.

Reboot the controller.

Reboot the controller.

Check the file number.

Make sure the file exists and you specified the file correctly.

Open the file in advance.

Check the program.

190

Note 2

End point

RC180 Rev.14

Maintenance 8. Trouble Shooting

No. Message

2445 File Error. File seek failed.

2446

File Error.

All file numbers are being used.

2447

File Error.

No read permision.

Remedy

Use ROpen or UOpen that has read access to the file.

2448

2449

2450

File Error.

No write permision.

File Error.

No binary permision.

File Error.

Failed to access the file.

Use WOpen or UOpen that has write access to the file.

Use BOpen that has binary access to the file.

2451 File Error. Failed to write the file.

2452 File Error. Failed to read the file.

2453

File Error.

Cannot execute the commnad for current disk.

2454 File Error. Invalid disk.

The specified command is not available in the current disk (ChDisk).

2455 File Error. Invalid drive.

2456 File Error. Invalid folder.

2460

Database Error.

The database number is already being used.

2461

Database Error.

The database is not open.

2462

2470

2471

Database Error.

The database number is being used by another task.

Windows Communication Error.

Invalid status.

Windows Communication Error.

Invalid answer.

Note 1

2472

Windows Communication Error.

Already initialized.

2473 Windows Communication Error. Busy.

2474

Windows Communication Error. No request.

2475

2476

Windows Communication Error. Data buffer overflow.

Windows Communication Error.

Failed to wait for event.

2477

2478

2500

2501

2502

2503

Invalid folder.

Windows Communication Error.

Invalid error code.

Specified event condition for Wait is beyond the maximum count.

Specified bit number in the Ctr function was not setup with a CTReset statement.

Task number is beyond the maximum count to execute.

Cannot execute Xqt when the specified task number is already executing.

The maximum number of event conditions is 8. Review the program.

Review the program.

The specified

The available number of the tasks that can be executed simultaneously is 16.

Review the program.

Review the program. bit number

The specified task number

Note 2

RC180 Rev.14

191

Maintenance 8. Trouble Shooting

No. Message

2504

2505

2506

2507

2508

2509

Task failure. Specified manipulator is already executing a parallel process.

OnErr failure. Failed to process the

OnErr statement.

Remedy

Rebuild the project.

Not enough data for Input statement variable assignment.

All counters are in use and cannot setup a new counter with CTReset.

Check the content of communication data. Review the program.

Specified variable for the Input For OP, only one variable can be statement is beyond the maximum count. specified. For other devices, up to 32 variables can be specified.

The available number of the counters that can be set simultaneously is 16.

Review the program.

OnErr failure. Failed to process the

OnErr statement.

Rebuild the project.

Rebuild the project.

Note 1

2510

2511

2512

2513

2514

2515

2516

2517

2518

2519

Specified I/O label is not defined. The specified I/O label is not registered.

Check the I/O label file.

SyncUnlock statement is used without executing a previous SyncLock

Review the program. statement. Review the program.

Signal number

SyncLock statement was already The SyncLock statement cannot be executed. executed for the second time in a row.

Review the program.

Specified point label is not defined. The specified point label is not registered. Check the point file.

Signal number

Failed to obtain the motor on time of the robot.

Failed to configure the date or the time.

Failed to obtain the debug data or to initialize.

Failed to convert into date or time.

Reboot the controller.

Check whether a date and time is set correctly.

Reboot the controller.

Larger number was specified for the start point data than the end point data.

Specified the format for FmtStr$ can not understand.

Check the time set on the controller.

Reboot the controller.

Specify a larger number for the end point data than that for the start point data.

Check the format.

Start point

2520 Point file name is too long.

2521

Point failure. Point file path is too long.

2522 Point file name is invalid.

2523

2524

The continue process was already executed.

Cannot execute Xqt when the specified trap number is already executing.

Check whether the specified point file name is correct. The maximum string length of the file name is 32.

Check whether the specified point file name is correct.

Note 2

End point

2525 Password is invalid.

2526

No wait terms.

2527

2528

Too many variables used for global valiable wait.

The variables cannot use global valiable wait.

Check whether a password is set correctly.

192

RC180 Rev.14

Maintenance 8. Trouble Shooting

No. Message Remedy

2529

Cannot use Byref if the variables used for global variable wait.

2530 Too many point files.

2531

The point file is used by another robot.

2532

Cannot calculate the point position because there is undefined data.

2533

Error on INP or OUTP.

2534

No main function to start on Restart statement.

Without executing main function,

Restart is called.

2539

2900

2901

2902

Failed to open as server to the Ethernet port.

Failed to open as client to the Ethernet port.

Failed to read from the Ethernet port.

Check whether a password is set correctly.

Check whether the Ethernet port is set properly. Check whether the Ethernet cable is connected properly.

Check whether the Ethernet port is set properly. Check whether the Ethernet cable is connected properly.

Check whether the port of communication recipient is not close.

2909

Note 1

2904 Invalid IP Address was specified.

2905

Ethernet failure. No specification of

Server/Client.

2906

2907

2908

Ethernet port was not configured.

Ethernet pot was already in use by another task.

Cannot change the port parameters while the Ethernet port is open.

Check whether the Ethernet port is set properly.

A single port cannot be used by more than one task.

The port parameters cannot be changed while the port is open.

Port number

Port number

Port number

Ethernet port is not open. To use the Ethernet port, execute the

OpenNet statement.

Port number

2910

Timeout reading from an Ethernet port.

Check the communication.

2911

Failed to read from an Ethernet port. Check the communication.

2912

2913

2914

Ethernet port was already open by another task.

Failed to write to the Ethernet port.

A single port cannot be used by more than one task.

Check whether the Ethernet port is set properly. Check whether the Ethernet cable is connected properly.

Ethernet port connection was not completed. communication recipient is open.

Timeout value

Port number

Port number

2915

Data received from the Ethernet port is beyond the limit of one line.

The maximum length of a line is 255 bytes.

The number of bytes in a received line

Note 2

2920

2921

2926

2927

2928

RS-232C failure. RS-232C port Check whether the RS-232C board is process error. correctly detected.

RS-232C failure. Uncommon error.

RS-232C port read process error.

The RS-232C port hardware is not installed.

Check whether the RS-232C board is correctly detected.

Port number

RS-232C port is already open by another task.

Cannot change the port parameters while the RS-232C port is open.

A single port cannot be used by more than one task.

The port parameters cannot be changed while the port is open.

Port number

Port number

RC180 Rev.14

193

Maintenance 8. Trouble Shooting

No.

2929

Message

RS-232C port is not open.

Remedy

To use the RS-232C port, execute the

OpenCom statement.

Note 1

Port number

2930

Timeout reading from the RS-232C port.

Check the communication.

2931

Failed to read from the RS-232C port. Check the communication.

2932

RS-232C port is already open by another task.

2933

Failed to write to the RS-232C port.

A single port cannot be used by more than one task.

Check the communication.

2934

2935

RS-232C port connection not completed.

Data received from the RS-232C port is beyond the limit of one line.

The maximum length of a line is 255 bytes.

2937

2950

2951

2952

2953

2954

2955

Timeout value

Port number

Port number

Cannot execute while Remote

RS-232C are useing.

Daemon failure. Failed to create the daemon thread.

Daemon failure. Timeout while creating the daemon thread.

TEACH/AUTO switching key input signal failure was detected.

Set the TP key switch to TEACH or

AUTO properly. Check whether the

TP is connected properly.

ENABLE key input signal failure was detected.

Relay weld was detected.

Check whether the TP is connected properly.

Overcurrent probably occurred due to short-circuit failure. Investigate the cause of the problem and take necessary measures and then replace the DPB.

Temperature of regeneration resistor Check whether the filter is not clogged was higher than the specified up and the fan does not stop. temperature. If there is no problem on the filter and fan, replace the regenerative module.

The number of bytes in a received line

Note 2

2970 MNG failure. Area allocate error.

2971 MNG failure. Real time check error.

2972 MNG failure. Standard priority error.

2973 MNG failure. Boost priority error.

2974 MNG failure. Down priority error.

2975 MNG failure. Event wait error.

2976 MNG failure. Map close error.

2977 MNG failure. Area free error.

2978 MNG failure. AddIOMem error.

2979 MNG failure. AddInPort error.

2980 MNG failure. AddOutPort error.

2981 MNG failure. AddInMemPort error.

2982 MNG failure. AddOutMemPort error.

2983 MNG failure. IntervalOutBit error.

2984 MNG failure. CtrReset error.

194

RC180 Rev.14

No.

2998

2999

Message

AbortMotion attempted when robot was not moving

AbortMotion attempted when robot was moving

Remedy

See Help for AbortMotion.

See Help for AbortMotion.

Maintenance 8. Trouble Shooting

Note 1 Note 2

RC180 Rev.14

195

Maintenance 8. Trouble Shooting

8.1.8 Parser

No.

3000

Message

OBJ file size is large. TP1 may not be able to build this project.

3050 Main function is not defined.

3051 Function does not exist.

3052 Variable does not exist.

3100 Syntax error.

3101

Parameter count error.

Remedy

Declare a Main function.

Declare an unresolved function.

Declare an unresolved variable.

Correct the syntax error.

The number of parameters is excess or deficiency. Correct the parameters.

3102

File name length is beyond the maximum allowed.

3103 Duplicate function definition.

Shorten the file name.

Change the function name.

3104 Duplicate variable definition ‘ ** ’.

3105

Global and Global Preserve variables cannot be defined inside a function block.

Change the variable name.

Declare the Global and Global Preserve variables outside the function block.

3106

An undefined function was specified. Specify a valid function name.

3107

3108

Both While and Until for Do...Loop was specified.

Specified line number or label ‘ ** ’ does not exist.

The While/Until statement is specified for both Do statement and Loop statement. Delete either While/Until statement.

Set the line label.

3109

The direct numerical specification overflows. Reduce the numeric value.

3110

3111

3112

3114

3115

3116

An undefined variable was specified

‘ ** ’.

Specified variable is not an array variable.

Cannot change the dimensions of the array variable.

Specified Next variable does not match the specified For variable.

Correct the variable name.

Cannot use a point expression in the first argument.

There is an undefined variable.

Declare the variable.

Specify the array variable.

Specify a single point for the point flag setting. Do not specify a point expression.

Array number of dimensions does not match the declaration.

Check the number of array dimensions.

3117

File cannot be found.

3118

3119

3120

3121

Corresponding EndIf cannot be found. The number of EndIf statements is not enough. Add the EndIf.

Corresponding Loop cannot be found. The number of Loop statements is not enough. Add the Loop.

Corresponding Next cannot be found. The number of Next statements is not enough. Add the Next.

Corresponding Send cannot be found. The number of Send statements is not enough. Add the Send.

3123

On/Off statements are beyond the maximum count.

An upper limit is set on the number of

On/Off statements. Check the upper limit and correct the program.

3124

Point number is beyond the maximum count.

An upper limit is set on the available number of points. Check the upper limit and correct the program.

196

Note 1 Note 2

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

3125

3126

3127

3128

Message

Corresponding If cannot be found.

Remedy

The number of EndIf statements is too many. Delete the unnecessary EndIf.

Corresponding Do cannot be found. The number of Loop statements is too many. Delete the unnecessary Loop.

Corresponding Select cannot be found.

The number of Send statements is too many. Delete the unnecessary Send.

Corresponding For cannot be found. The number of Next statements is too many. Delete the unnecessary Next.

3129

'_' cannot be used as the first character of an identifier.

Change the first character of the identifier to an alphabetic character.

3130

Cannot specify Rot parameter.

3131

Cannot specify Ecp parameter.

3132

Cannot specify Arch parameter.

3133

Cannot specify LimZ parameter.

3134

Cannot specify Sense parameter.

3135

Invalid parameter is specified.

3136

Cannot use #include.

3137

3138

3139

Cannot specify the array variable subscript.

ByRef was not specified on Function declaration.

The array variable subscript cannot be specified.

Cannot execute the Xqt statement for a The Xqt statement cannot be executed function that needs a ByRef for a function needing a ByRef parameter. parameter. Delete the ByRef parameter.

3140

Cannot execute the Redim statement for a ByRef variable.

3141

OBJ file is corrupt.

3142

OBJ file size is beyond the available size after compiling.

The compilation result exceeds the limit value. Divide the program.

3143

Ident length is beyond the available size.

3144

' ** ' already used for a function name.

3145

3146

3147

' ** ' already used for a Global

Preserve variable.

' ** ' already used for a Global variable.

' ** ' already used for a Module variable.

3148

' ** ' already used for a Local variable.

3149

' ** ' already used for an I/O label.

3150

' ** ' already used for a User Error label.

Cannot use a function parameter.

3151

3152

Over elements value.

3153

Parameter type mismatch.

Argument cannot be specified for the function that is executed by the Trap statement.

3154

' ** ' is not Input Bit label.

3155

' ** ' is not Input Byte label.

3156

' ** ' is not Input Word label.

RC180 Rev.14

Note 1 Note 2

197

Maintenance 8. Trouble Shooting

No. Message

3157

' ** ' is not Output Bit label.

3158

' ** ' is not Output Byte label.

3159

' ** ' is not Output Word label.

3160

' ** ' is not Memory Bit label.

3161

' ** ' is not Memory Byte label.

3162

' ** ' is not Memory Word label.

3163

Too many function arguments.

3164

Cannot compare Boolean value.

3165

3166

Cannot use Boolean value in the expression.

Cannot compare between Boolean and expression.

3167

3168

Cannot store Boolean value to the numeric variable.

Cannot store numeric value to the

Boolean variable.

3169

Undefined I/O label was specified.

3170

3171

3172

Invalid condition expression was specified.

Cannot compare between numeric value and string.

Cannot use keyword for the variable name.

3172 ' ** ' already used for a line label.

3173 Duplicate line number or label (**).

3175 Undefined Point label was specified.

3176 An undefined variable was specified.

3177 ' ** ' already used for a Point label.

3178 Cannot use the result number.

3179

3180

String literal is beyond the available length.

Cannot change a calibration property value with the VSet command.

3181

Array variable should be used with

ByRef.

3182 Subscription was not specified.

3187 Invalid Point flag value was specified.

3200 Value is missing.

3201 Expected ' , '.

3202 Expected ' ( '.

3203 Expected ' ) '.

3204 Identifier is missing.

3205 Point is not specified.

3206

Event condition expression is missing.

3207

Formula is missing.

3208

String formula is missing.

3209

Point formula is missing.

3210

Line label was not specified.

3211

Variable was not specified.

3212

Corresponding Fend cannot be found.

3213

Expected ' : '.

3214

True/False was not specified.

198

Remedy Note 1

RC180 Rev.14

Note 2

No. Message

3215

On/Off was not specified.

3216

High/Low was not specified.

3217

Input bit label was not specified.

3218

Input byte label was not specified.

3219

Input word label was not specified.

3220

Output bit label was not specified.

3221

Output byte label was not specified.

3222

Output word label was not specified.

3223

Memory bit label was not specified.

3224

Memory byte label was not specified.

3225

Memory word label was not specified.

3226

User error label was not specified.

3227

Function name was not specified.

3228

Variable type was not specified.

3229

Invalid Trap statement parameter.

Use Goto, Call, or Xqt.

3230

Expected For/Do/Function.

3231

Above/Below was not specified.

3232

Righty/lefty was not specified.

3233

NoFlip/Flip was specified.

3234

Port number was not specified.

3235

String type variable was not specified.

3236

RS-232C port number was not specified.

3237

3238

Network communication port number was not specified.

Communication speed was not specified.

3239

Data bit number was not specified.

3240

Stop bit number was not specified.

3241

Parity was not specified.

3242

Terminator was not specified.

3243

Hardware flow was not specified.

3244

Software flow was not specified.

3245

None was not specified.

3246

3247

Parameter ' O ' or ' C ' was not specified.

NumAxes parameter was not specified.

3248

J4Flag value (0-1) was not specified.

3249

J6Flag value (0-127) was not specified.

3250

Array variable was not specified.

3251

String Array variable was not specified.

3252

Device ID was not specified.

3253

I/O type was not specified.

3254

I/O bit width was not specified.

3256

Variable type was not specified.

RC180 Rev.14

Remedy

Maintenance 8. Trouble Shooting

Note 2

199

Note 1

Maintenance 8. Trouble Shooting

No. Message Remedy

3257

3258

3259

Condition expression does not return

Boolean value.

RS232C port number was not specified.

Network communication port number was not specified.

3260

Language ID was not specified.

3261

Expected '.'.

3262

3263

3264

3265

3266

Vision Sequence Name was not specified.

Vision Sequence Name or Calibration

Name was not specified.

Vision Property Name or Result Name was not specified.

Vision Property Name, Result Name or Object Name was not specified.

Vision Calibration Property Name was not specified.

3267

Task type was not specified.

3255

3300

3301

ByRef was not specified. Although the ByRef is specified in the function declaration, no ByRef is specified for calling.

External definition symbol was included. (Not in use)

Version of linked OBJ file does not match.

Not all project files are complied in the same version. Perform the rebuild.

3302

3303

3304

3305

Linked OBJ file does not match the compiled I/O label.

The project configuration has been changed. Perform the rebuild.

Linked OBJ file does not match the compiled user error label.

The project configuration has been changed. Perform the rebuild.

Linked OBJ file does not match the compiled compile option.

The project configuration has been changed. Perform the rebuild.

Linked OBJ file does not match the compiled link option.

The project configuration has been changed. Perform the rebuild.

3306

3307

3308

Linked OBJ file does not match the compiled SPEL option.

The project configuration has been changed. Perform the rebuild.

Duplicate function.

Duplicate global preserve variable.

The same function name is used for more than one file.

The same global preserve variable name is used for more than one file.

3309

Duplicate global variable. The same global variable name is used for more than one file.

3310

Duplicate module variable. The same module variable name is used for more than one file.

3311

File cannot be found.

3312

OBJ file is corrupt.

3313

The specified file name includes character(s) that cannot be used.

3314

Cannot open the file. The file is used for other application.

Quit the other application.

Note 1 Note 2

200

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

3315

3316

3317

3318

3319

Message

' ** ' is already used for the function name.

' ** ' is already used for the global preserve variable.

' ** ' is already used for the global variable.

' ** ' is already used for the module variable.

Dimension of the array variable does not match the declaration.

Remedy

3320

Return value type of the function does not match the declaration.

3321

' ** ' is already used with function name.

3322

3323

' ** ' is already used with Global

Preserve name.

' ** ' is already used with Global name.

3324

' ** 'is already used with Module name.

3325

' ** ' is already used with Local name.

3326

3327

The number of parameters does not match the declaration.

ByRef was not specified on Function declaration on parameter **.

3328

ByRef was not specified on parameter

**.

3329

Parameter ** type mismatch.

3330

3331

3332

3500

Linked OBJ file does not match the compiled Vision Project.

OBJ file size is beyond the available size after linking.

Variable '%s' is redefined.

The OBJ file size exceeds the limit value. Reduce the program.

Variable '%s' is redefined with the different variable type. Review the definition.

Duplicate macro in #define statement.

Another macro with the same name has been defined. Change the macro name.

3501

Macro name was not specified.

3502

Include file name cannot be found.

3503

Specified include file is not in the project.

The include file that is not registered in the project configuration is specified.

Add the include file to the project configuration.

3504

Parameter of the macro function does not match to the declared.

Macro has a circular reference.

3505

The macro has a circular reference.

Correct the circular reference.

3506

3507

#define, #ifdef, #ifndef, #else, #endif,

#undef and variable declaration statements are only valid in an include file.

Over #ifdef or #ifndef nesting level. Reduce the nesting level to under the limited value.

Note 1 Note 2

RC180 Rev.14

201

Maintenance 8. Trouble Shooting

No. Message Remedy

3508

Cannot find corresponding #ifdef or

#ifndef.

3509

No #endif found for #ifdef or #ifndef.

3510

Cannot obtain the macro buffer.

3550

Parameter for the macro function was not specified.

The macro declared as a macro function is called without argument.

3800

Compile process aborted.

3801

Link process aborted.

3802

Compile process aborted. Compile errors reached the maximum count.

3803

Link process aborted. Link errors reached the maximum count.

3804

3805

3806

Specified command cannot be executed from the Command window.

Specified command can only be executed from the Command window.

Specified function cannot be executed from the Command window.

3810

3811

The number of point file is beyond the limit.

The number of points is beyond the limit.

3850 File not found.

3900

Uncommon error. Cannot obtain the internal communication buffer.

There are too many point files.

Reduce some point files that are registered to project.

There are too many points defined by registered point files.

Reduce some points.

3910

Undefined command was specified.

3911

Cannot enter the file name in the file name buffer.

3912

Cannot obtain the internal buffer.

3913

Cannot set priority.

Note 1 Note 2

202

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.9 Motor Control

No.

4001

4002

Message Remedy

Arm reached the limit of motion range.

Check the point to move, current point, and Range setting.

Specified value is out of allowable range.

Review the setting parameters.

Note 1 Note 2 causing the error

4003

4004

Communication error within the Initialize the controller firmware. motion control module. Replace the controller.

Motion device driver failure. Event waiting error within the motion control module.

Reboot the controller.

Initialize the controller firmware.

Replace the controller.

4005

4006

4007

4008

4009

4010

4011

4013

4016

4018

4021

4022

4023

4024

4025

Current point position is above the specified LimZ value.

Target point position is above the specified LimZ value.

Coordinates conversion error. The end/mid point is out of the motion area. Jogging to the out of the motion area.

Current point position or specified

LimZ value is out of motion range.

Lower the Z axis. Increase the specified LimZ value.

Lower the Z coordinate position of the target point. Increase the specified

LimZ value.

Check whether the coordinate out of the motion range is not specified.

Change the specified LimZ value.

Motion device driver failure.

Timeout error within motion control module.

Reboot the controller.

Initialize the controller firmware.

Replace the controller.

Specified Local coordinate was not defined.

Arm reached the limit of XY motion range specified by XYLim statement.

Define the Local coordinate system.

Check the area limited by the XYLim statement.

Motion control module internal calculation error.

SFree statement was attempted for prohibited joint(s).

Due to robot mechanistic limitation, setting some joint(s) to servo free status is prohibited. Check the robot specifications.

Communication error within the Reboot the controller. motion control module. Check sum error.

Initialize the controller firmware.

Replace the controller.

Point positions used to define the

Local are too close.

Point coordinate data used to define the Local is invalid.

Cannot execute when the motor is in the off state.

Cannot complete the arm positioning using the current Fine specification.

Cannot execute a motion command during emergency stop condition.

Set the distance between points more than 1μm.

Match the coordinate data for the points to be specified.

Turn the motor power ON and then execute.

Check whether the robot does not generate vibration or all parts and screws are secured firmly. Increase the Fine setting value.

Clear the emergency stop condition and execute the motion command.

RC180 Rev.14

203

Maintenance 8. Trouble Shooting

No. Message

4026

Remedy

Communication error within the Reboot the controller. motion control module. Servo I/F failure.

Initialize the controller firmware.

Replace the controller.

4028

Communication error within the Reboot the controller. motion control module. Device driver status failure.

Initialize the controller firmware.

Replace the controller.

4030

4031

4032

4034

4035

4036

4037

4038

4039

4041

4042

4043

4044

4045

4046

4047

4048

Buffer for the average torque Shorten the time interval from Atclr to calculation has overflowed. Shorten the time interval from Atclr to Atrq.

Atrq less than about two minutes.

Cannot execute a motion command when the motor is in the off state.

Turn the motor power ON and then execute the motion command.

Cannot execute a motion command when one or more joints are in SFree state.

Specified command is not supported for this manipulator model.

Set all joints to the SLock state and execute the motion command.

Use the Jump3 and Jump3CP statements.

Only the tool orientation was Set a move distance between points. attempted to be changed by the CP statement.

Use the ROT modifier, SpeedR statement, and AccelR statement.

Rotation speed of tool orientation by the CP statement is too fast.

Decrease the setting values for the

SpeedS and AccelS statements. Use the ROT modifier, SpeedR statement, and AccelR statement.

The point attribute of the current and target point positions differ for

Match the point attribute. executing a CP control command.

Two point positions are too close to execute the Arc statement.

Set the distance between points more than 1μm.

Use the Move statement. Three point positions specified by the

Arc statement are on a straight line.

Motion command was attempted to the prohibited area at the backside of the robot.

Motion device driver failure. Cannot detect the circular format interruption.

Check the robot motion range.

Reboot the controller.

Initialize the controller firmware.

Replace the controller.

Specified command is not supported for this manipulator model or this joint type.

Curve failure. Specified curve form is not supported.

Create a Curve file again with the Curve statement.

Curve failure. Specified mode is not supported.

Curve failure. Specified coordinate number is out of the allowable range.

Specify the Curve mode properly.

Create a Curve file again with the Curve statement.

The number of the available coordinate axes is 2, 3, 4, and 6. Create a Curve file again with the Curve statement.

Curve failure. Point data was not specified.

Create a Curve file again with the Curve statement.

Curve failure. Parallel process was specified before the point designation.

Create a Curve file again with the Curve statement.

Note 1 Note 2

204

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

4049

4050

4051

4052

4053

4054

4055

4056

4059

4060

4061

4062

4063

4064

4065

4066

Message

Curve failure. Number of parallel processes is out of the allowable range.

Curve failure. Number of points is out of the allowable range.

Remedy

Create a Curve file again with the Curve statement.

The number of available point numbers differs according to the curve form.

Check the number of points again.

Curve failure. Local attribute and the point attribute of all specified points do not match.

Curve failure. Not enough memory to format the curve file.

Match the local and point flag for all the specified points.

Curve failure. Failed to format the curve file.

Curve failure. Curve file error

Review the point data. Check whether adjacent two points do not overlap on the specified point line.

The Curve file is broken. Create a

Curve file again with the Curve statement.

Review the point data. Curve failure. No distance for curve file movement.

Curve failure. Point positions for the

Curve statement are too close.

Set the distance between two points adjacent to the specified point more than

0.001 mm.

Executed encoder reset command while the motor is in the on state.

Turn the motor power OFF.

Turn the motor power OFF. Executed an invalid command while the motor is in the on state.

Specified parameter is in use. You attempted to clear the currently specified Arm and Tool.

Select other Arm and Tool and execute.

Orientation variation is over 360 degrees.

You attempted to rotate the joint #J6 more than 360 degrees with a CP motion command.

Orientation variation of adjacent point is over 90 degrees.

On the specified point line by the Curve statement, set the orientation variation of

U, V, and W coordinate values between two adjacent points to under 90 degrees.

Cannot execute the orientation On the specified point line, a curve correction automatically. cannot be created by automatic orientation correction.

Change the specified point line so that the joint #J6 orientation variation decreases.

Attempt to revolve J6 one rotation with the same orientation in CP statement.

You attempted to rotate the joint #J6 more than 360 degrees with a CP motion command. You attempted to revolve the joint 6 one rotation with the same as motion start orientation.

Change the target point so that the joint

#J6 revolves less than one rotation.

Motion command was attempted in the prohibited area depended on joint combination.

You attempted to move the joints to the robot's interference limited area.

Note 1 Note 2

RC180 Rev.14

205

Maintenance 8. Trouble Shooting

No. Message

4068

4069

4070

4071

Delete the ROT from the CP motion command.

Remedy

ROT modifier parameter was specified for the CP motion command without orientation rotation.

Specified ECP without selecting ECP in CP statement.

Specified ECP number does not match the ECP number used in curve file creation.

Attempted motion command during electronic brake lock condition.

Specify a valid ECP.

Specify a valid ECP.

4072

Initialization failure. Hardware monitor was not initialized.

4074

Motor type does not match the current robot setting.

4075

ECP Option is not active.

4076

4077

4080

4099

4100

Check whether the specified robot model is connected.

Enable the ECP option.

Point positions used to define the

Plane are too close.

Point coordinate data used to define the Plane is invalid.

Set the distance between points more than 1 μm.

Match the coordinate data for the points to be specified.

Cannot execute when the Enable

Switch is OFF.

Servo error was detected during operation.

Turn the Enable Switch ON and then execute.

Communication error in motion Reboot the controller. control module. Cannot calculate the current point or pulse.

Initialize the controller firmware.

Replace the controller.

4101

4103

4150

4151

4152

Communication error in the motion control module. Cannot calculate the current point or pulse.

Reboot the controller.

Initialize the controller firmware.

Replace the controller.

Initialization failure. Motion control module initialization error.

Redundant input signal failure of the emergency stop.

Redundant input signal failure of the safeguard.

Relay welding error of the main circuit.

Reboot the controller.

Initialize the controller firmware.

Replace the controller.

The input status of the redundant emergency stop input continuously differs for more than two seconds.

Check whether no disconnection, earth fault, or short-circuit of the emergency stop input signal exits. Then reboot the controller.

The input status of the redundant emergency stop input continuously differs for more than two seconds.

Check whether no disconnection, earth fault, or short-circuit of the emergency stop input signal exits. Then reboot the controller.

A relay welding error was detected due to power system over current.

Replace the controller.

Replace the robot.

Note 1 Note 2

206

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

4153

4154

4180

4181

4182

4183

4184

4185

4186

4187

4188

4189

4191

4192

4210

4211

4212

4213

Message Remedy

Redundant input signal failure of the enable switch.

Temperature of regeneration resistor was higher than the specified temperature.

Manipulator initialization failure.

Specified manipulator was is not found.

Manipulator initialization failure.

Specified manipulator was in use by another task.

Manipulator initialization failure.

Manipulator name is too long.

Manipulator initialization failure.

Manipulator data version error.

Manipulator initialization failure.

Duplication of single axis joint is assigned.

The input status of the redundant enable signal differs continuously for more than two seconds.

Check the TP connector connection.

Replace the TP.

Replace the controller.

Manipulator initialization failure.

Specified axis is in use by the other manipulator.

Manipulator initialization failure.

Necessary hardware resource is not defined.

Manipulator initialization failure.

Communication error with the module : VSRCMNPK.

Manipulator initialization failure. Joint angle interference matrix is invalid.

Manipulator initialization failure.

Communication error with the module : VSRCMC.

Manipulator initialization failure.

Physical-logical pulse transformation matrix is invalid.

Manipulator initialization failure.

Communication error with the servo module.

RAS circuit detected the servo system malfunction. Reboot the controller.

Measure the noise. Replace the controller.

Servo CPU internal RAM failure.

Reboot the controller. Measure the noise. Replace the DMB.

RAM for the main and servo CPU communication failure. Reboot the controller. Measure the noise. Replace the DMB.

Servo CPU internal RAM failure.

Reboot the controller. Measure the noise. Replace the DMB.

Note 1 Note 2

RC180 Rev.14

207

Maintenance 8. Trouble Shooting

No. Message

4233

Remedy

4214

4215

4216

4217

Communication of the main and servo

CPU failure. Reboot the controller.

Measure the noise. Replace the DMB.

4218 Servo long time command overrun.

4219

Servo long time command check sum error.

4220

System watchdog timer detected the failure. Reboot the controller. Measure the noise. Replace the DMB.

4221 Drive unit check failure.

4222

RAM failure of the servo CPU.

Reboot the controller. Measure the noise. Replace the DMB.

4223

4224

4225

4230

4232

Initialization communication of main

CPU and servo CPU failure. Reboot the Controller. Measure the noise.

Replace DMB.

Initialization communication of the main and servo CPU failure. Reboot the controller. Noise measure. Replace the DMB.

Communication of the main and servo

CPU failure. Reboot the controller.

Measure the noise. Replace the DMB.

Failure of duplicate circuit of the emergency stop or the safeguard.

Check the wiring.

Low voltage of the main circuit power supply is detected. Check the power supply voltage. Reboot the controller.

Control relay contact of the main circuit power supply is welded.

Replace the DPB.

Servo real time status failure. Check sum error.

A data checksum error was detected in the controller.

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency, D-I/O, and

Expansion I/O connectors)

Replace the controller.

Servo real time status failure. Free running counter error with the servo.

A free running counter error was detected in the controller.

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency, D-I/O, and

Expansion I/O connectors)

Replace the controller.

Servo real time status failure. A communication error was detected in

Communication error with the servo

CPU. the controller.

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency, D-I/O, and

Expansion I/O connectors)

Replace the controller.

Note 1 Note 2

208

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

4240

4241

4242

4243

4250

Message

Irregular motion control interruption was detected. Interruption duplicate.

Over speed during low power mode was detected.

Improper acceleration reference was generated.

Improper speed reference is generated in the high power mode.

Arm reached the limit of motion range during the operation.

Remedy

An interruption error was detected in the controller.

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency, D-I/O, and

Expansion I/O connectors)

Replace the controller.

The robot over speed was detected during low power mode.

Check the robot mechanism.

(Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check whether the robot does not interfere with peripheral equipment.

(Collision, contact)

Replace the motor driver.

Replace the motor. (Motor and encoder failure)

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency, D-I/O, and

Expansion I/O connectors)

You attempted to operate the robot with the acceleration reference exceeding the specified value.

For a CP motion, decrease the AccelS value.

The robot over speed was detected during high power mode.

Check the robot mechanism.

(Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check whether the robot does not interfere with peripheral equipment.

(Collision, contact)

Replace the motor driver.

Replace the motor. (Motor and encoder failure)

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency, D-I/O, and

Expansion I/O connectors)

Check whether a CP motion trajectory is within the motion range.

Note 1

4251

4252

4267

4268

Arm reached the limit of XY motion range specified by XYLim during the operation.

Coordinate conversion error occurred during the operation.

Check the XYLim setting.

Check whether a CP motion trajectory is within the motion range.

Attempt to exceed the J4Flag attribute without indication.

Attempt to exceed the J6Flag attribute without indication.

You attempted to exceed the J4Flag attribute during motion without the

J4Flag indication.

Change the J4Flag for the target point.

You attempted to exceed the J6Flag attribute during motion without the

J6Flag indication.

Change the J6Flag for the target point.

RC180 Rev.14

Note 2

209

Maintenance 8. Trouble Shooting

No. Message

Attempt to exceed the particular wrist

Remedy

You attempted to exceed the particular

Note 1

4269 indication.

Attempt to exceed the particular arm without the Wrist indication.

Change the Wrist attribute for the target point.

Change the target point to avoid a particular wrist orientation.

You attempted to exceed the particular

4270 indication.

Attempt to exceed the particular elbow without the Hand indication.

Change the Hand attribute for the target point.

Change the target point to avoid a particular hand orientation.

You attempted to exceed the particular

4271

4272 indication.

Specified point flag is invalid. motion without the Elbow indication.

Change the Elbow attribute for the target point.

Change the target point to avoid a particular elbow orientation.

For a CP motion command, the arm form at the target point is different from the point flag specified with the target point.

Change the point flag for the target point.

Note 2

210

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.10 Servo

No.

5000

Message

Servo control gate array failure. Check the DMB.

Remedy

Check the short-circuit and improper connection of the peripheral equipment wiring. (Emergency and I/O connectors)

Replace the DMB.

Replace the additional axis unit.

Note 1 Note 2

5001

Disconnection of the parallel encoder Check the M/C cable signal. signal. Check the signal cable Check the robot signal wiring. (Missing connection or the robot internal wiring. pin, disconnection, short-circuit)

Replace the motor.

Replace the DMB.

Check the connector connection in the controller. (Loosening, connecting to the serial encoder terminal on the DMB)

Check the model setting.

Check the peripheral equipment wiring.

(Emergency and I/O)

5002

5003

5004

5005

5006

5007

5008

5009

5010

Motor driver is not installed. Install the motor driver. Check the DMB or the motor driver.

Initialization communication failure of incremental encoder. Check the signal cable connection and the robot setting.

Check whether the motor driver is mounted.

Check the model setting and hardware setting.

Replace the motor driver.

Replace the DMB.

Check the model setting.

Replace the motor.

Replace the DMB.

Initialization failure of absolute Check the model setting. encoder. Check the signal cable connection or the robot setting.

Replace the motor.

Replace the DMB.

Encoder division setting failure. Check the model setting.

Check the robot setting.

Data failure during absolute encoder initialization. Check the signal cable connection, the controller, or the motor.

Replace the motor.

Replace the DMB.

Check the noise countermeasures.

Absolute encoder multi-turn is beyond the maximum range. Reset the Replace the motor. encoder.

Reset the encoder.

Position is out of the range. Reset the encoder.

Reset the encoder.

Replace the DMB.

Replace the motor.

No response from the serial encoder.

Check the signal cable connection, the motor, the DMB, or the encoder IF board.

Serial encoder initialization failure.

Reboot the controller. Check the motor, the DMB, or the encoder IF board.

Check the model setting. (Improperly setting of the parallel encoder model)

Check the signal cable connection.

Replace the DMB and encoder I/F board.

Check the robot configuration.

Check the signal cable connection.

Replace the DMB and encoder I/F board.

RC180 Rev.14

211

Maintenance 8. Trouble Shooting

No. Message

5011

5012

5013

5015

5016

5017

Remedy

Serial encoder communication failure.

Reboot the controller. Check the motor, the DMB, or the encoder IF board.

Servo CPU watchdog timer failure.

Reboot the controller. Check the motor or the DMB.

Check the robot configuration.

Check the signal cable connection.

Replace the DMB and encoder I/F board.

Replace the DMB.

Check the noise countermeasures.

Current control circuit WDT failure.

Reboot the controller. Check the controller.

Check the power cable connection.

Check the 15V power supply and cable connection.

Replace the DMB.

Check the noise countermeasures.

Encoder is reset. Reboot the Reboot the controller. controller.

Power supply failure of the absolute encoder. Replace the battery. Check the robot internal wiring.

Reset the encoder.

Check the signal cable connection.

Backup data failure of the absolute encoder. Reset the encoder.

Reset the encoder.

Check the signal cable connection.

5018

Absolute encoder battery alarm. Replace the battery.

Check the signal cable connection.

5019

5020

5021

5032

Position failure of the absolute Reset the encoder. encoder. Reset the encoder. Replace the motor.

Replace the motor.

Reboot the controller. Speed is too high at controller power

ON. Stop the robot and reboot the controller.

Absolute encoder overheat.

Servo alarm A.

Lower the motion duty.

Wait until the temperature of the encoder decreases.

5040

Motor torque output failure in high power state. Check the power cable connection, the robot, the driver or the motor.

Specify the Weight/Inertia setting.

Check the load.

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Note 1 Note 2

212

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

5041

5042

5043

Message

Motor torque output failure in low power state. Check the power cable connection, robot, brake, driver, or motor.

Remedy

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Note 1

Position error overflow in high power Specify the Weight/Inertia setting. state. Check the power cable Check the load. connection, the robot, the driver and the motor.

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Position error overflow in low power Check the robot. (Smoothness, backlash, state. Check the power cable non-smooth motion, loose belt tension, connection, robot, brake, driver, or motor. brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Note 2

RC180 Rev.14

213

Maintenance 8. Trouble Shooting

No. Message

5044

5045

Remedy

Speed error overflow in high power Specify the Weight/Inertia setting. state. Check the power cable Check the load. connection, robot, brake, driver, or motor.

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Speed error overflow in low power Check the robot. (Smoothness, backlash, state. Check the power cable non-smooth motion, loose belt tension, connection, robot, brake, drive, or motor. brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Note 1

5046

Over speed in high power state.

Reduce SpeedS. Check the signal cable connection, robot, brake, driver or motor.

Reduce SpeedS of the CP motion.

Change the orientation of the CP motion.

Specify the Weight/Inertia setting.

Check the load.

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Note 2

214

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

5047

5048

5049

5050

5051

5054

5055

Message Remedy

Over speed in low power state.

Check the signal cable connection, robot, brake, driver, or motor.

Over voltage of the main power circuit. Check the main power voltage or the regeneration module.

Check the motion in high power state.

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Specify the Weight/Inertia setting.

Check the load.

Check the robot. (Smoothness, backlash, non-smooth motion, loose belt tension, brake)

Check the interference with the peripheral equipment. (Collision, contact)

Check the model setting.

Check the power cable connection.

Check the robot power wiring. (Missing pin, disconnection, short-circuit)

Check the power supply voltage. (Low power supply voltage)

Replace the motor driver.

Replace the DMB.

Replace the motor.

Over current of the motor driver.

Check the power cable connection or the robot internal wiring.

Over speed during torque control.

Check the work motion speed range.

Check the short-circuit and earth fault of the power line.

Replace the motor driver.

Replace the DMB.

Check the motion speed during torque control.

15V PWM drive power supply failure.

Reboot the controller. Replace the

15V power supply.

Overload of the motor. Decrease the motion duty and the Accel.

Check the 15V power supply and cable connection.

Replace the motor driver.

Replace the DMB.

Lower the motion duty.

Check the Weight/Inertia setting.

Check the robot. (Backlash, large load, loose belt tension, brake)

Note 1

Overload of the motor. Decrease the operation duty and the Accel.

Lower the motion duty.

Check the Weight/Inertia setting.

Check the robot. (Backlash, large load, loose belt tension, brake)

5072

Servo alarm B.

Note 2

RC180 Rev.14

215

Maintenance 8. Trouble Shooting

No. Message

5080

Motor is overloaded. Decrease the duty and the Accel.

Remedy

Lower the motion duty.

Check the Weight/Inertia setting.

Check the robot. (Backlash, large load, loose belt tension, brake)

Note 1

5098

5099

High temperature of the encoder. Wait until the temperature of the encoder

Decrease the duty. Check the decreases. reduction gear unit of the robot. Lower the motion duty.

Check the Weight/Inertia setting.

Check the robot. (Backlash, large load, loose belt tension, brake)

High temperature of the motor driver.

Clean the controller fan filter. Check the ambient temperature. Decrease the duty.

Clean the cooling fan filter.

Lower the motion duty.

Check the Weight/Inertia setting.

Lower the ambient temperature.

5112

Servo alarm C.

Note 2

216

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.11 Points

No. Message

7003

The specified robot cannot be found.

7004

Duplicate allocation of the point data area.

7006

7007

Remedy

Specified point number cannot be found. Specify a valid point number.

Check the specified point number.

Specified point number was not defined. Specify a teach point number.

Check whether point data is registered in the specified point.

Perform the teaching.

7010

7011

7012

7013

Cannot allocate the memory area for the pallet definition.

Cannot free the memory area for the pallet definition.

Specified pallet number cannot be found. Specify a valid pallet number.

Check the pallet number.

Specified pallet is not defined. Specify a defined pallet or define the pallet.

Check whether the specified pallet is defined by the Pallet statement.

Declare the pallet.

7014

7015

Specified division number is beyond the pallet division number definition.

Specify a valid division.

Specified coordinate axis number does not exist.

Check the specified division number.

7016

Specified arm orientation number does not exist.

7017

Cannot allocate the required memory.

Check the specified point label.

7018

Specified point label cannot be found.

Specify a valid point label.

7019

7021

7022

7023

7024

7026

Parameter setup in the initialization file is invalid.

Duplicate point label. Specified label name is already registered. Change the label name.

Specified local coordinate system is not defined. Specify a valid local coordinate system number.

Specified string is not in the correct format.

Change the point label.

Check the specified local number.

Define the Local coordinate system.

Point data memory area for the specified robot is not allocated.

Cannot open the point file. Specify a valid point file name.

Check the point file name.

Check whether the point file specified for the project exists.

Note 1 Note 2

7027

7028

7029

Cannot read the point data from the point file.

Point area is allocated beyond the available point number.

Create the point file again.

Specified point file name is not correct. Specify a valid point file name.

Check the file extension.

RC180 Rev.14

217

Maintenance 8. Trouble Shooting

No. Message

7030

7031

7032

Specified point label is beyond the maximum length. Specify a valid point label.

Description for the specified point is beyond the maximum length. Specify a valid description.

Point file is corrupted. Check sum error.

7033

Specified point file cannot be found.

Specify a valid point file name.

7034

Cannot save the point file.

7035

Cannot save the point file.

7036

Cannot save the point file.

7037

Cannot save the point file.

7038

Cannot save the point file.

7039

Cannot save the point file.

7040

7041

The point label is not correct. Specify a valid point point label.

The point label is not correct. Specify a valid point point label.

Remedy

Change the point label.

Change the comment.

Create the point file again.

Note 1 Note 2

218

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.12 Fieldbus

No. Message

Communication error occur during transform.

7101

7103

Timeout error occurs during transform.

Remedy

The module is broken or the controller software is damaged. Restore the controller firmware.

(If Code 1 is 1, 2, 3, 4, or 10)

A communication data error was detected during communication. The communication cable has a problem.

Check the communication cable and its related units. (If Code 1 is 11 or 12)

The module is broken or the controller software is damaged. Restore the controller firmware.

(If Code 1 is 13, 14, or 15)

The module is broken or the controller software is damaged. Restore the controller firmware.

(If Code 1 is 1, 2, or 3)

A communication data error was detected during communication. The communication cable has a problem.

Check the communication cable and its related units. (If Code 1 is 4)

Note 1 Note 2

RC180 Rev.14

219

Maintenance 8. Trouble Shooting

8.1.13 Vision

No.

7300

7302

7303

7304

7305

7306

7307

7308

Message Remedy

Vision Communication. Server mode not supported.

Vision Communication. Failed to read from the camera.

Vision Communication. Read data overflow.

Check the connection with the camera.

Vision Communication. Failed to open the Ethernet port.

Vision Communication. Invalid IP address of camera.

Vision Communication. Failed to send to the camera.

Rebuild the project. Check the camera configuration.

Vision Communication. No specification of Server/Client.

Check the connection with the camera.

Vision Communication. Camera version is old.

7321 setting has not been set.

7322 Vision Communication. Read timeout. configuration.

7323

7324

Vision Communication. Read invalid data.

Vision Communication. Failed to send to the camera.

Check the connection with the camera.

Check the connection with the camera.

7325

7326

7327

Vision Communication. Connection is not completed.

Vision Communication. Read data is too long.

Vision Communication. Undefined vision sequence.

Check the connection with the camera.

7328

7329

7330

7341

7342

7343

7344

7345

7346 setting has not been set.

Vision Communication. Vis file is not found.

Vision Communication. Failed to allocate memory. configuration.

Rebuild the project. Check the camera configuration.

Vision Communication. Out of max camera number.

Vision Communication. Invalid camera number.

Vision Communication. VSet parameter is too long.

Vision Communication: Too many parameters for VGet.

Vision Communication. Not enough data for VGet statement variable assignment.

Vision Communication. Cannot execute a Vision statement from the command window.

7500 CV1. Out of memory.

7501 CV1. Project does not exist.

7502 CV1. Project has not been set.

7503

CV1. Vision property or result not supported.

220

Note 1 Note 2

RC180 Rev.14

No. Message

7504 CV1. Cannot open project file.

7505 Undefined vision sequence.

7506 Undefined vision object.

7507 CV1. Critical error.

7508 CV1. Invalid command.

7509 Invalid vision property value.

7510 Invalid vision property.

7511 Vision model not trained.

7512 Undefined vision calibration.

7513 Vision model object not Self.

7514 Invalid vision result.

7515 Vision object not found.

7516 No vision calibration.

7517 Incomplete vision calibration.

7518 CV1. Cannot connect with camera.

7819 CV1. Communication error.

Remedy

Maintenance 8. Trouble Shooting

Note 1 Note 2

RC180 Rev.14

221

Maintenance 8. Trouble Shooting

8.1.14 Simulator

No. Message Remedy

Reboot RC+.

7751

7752

7754

7755

7756

7757

7758

7759

7760

Failed to save the objects.

Failed to load the objects.

7753 Failed to mapping of memory.

The virtual controller already exists.

Reboot RC+.

Reboot RC+.

Reboot RC+.

Name of the virtual controller may be duplicated. Check the virtual controller name.

Failed to create the virtual controller connection information.

Reboot RC+.

The copy source of the virtual controller does not exist.

Check the virtual controller name.

The copy destination of the virtual controller already exists.

Name of the virtual controller may be duplicated. Check the virtual controller name.

Failed to copy the virtual controller connection information.

Failed to delete the virtual controller connection information.

Reboot RC+.

Reboot RC+.

Failed to delete the controller connection information.

Reboot RC+.

7761

7762

Failed to rename the controller connection information.

Check the virtual controller name.

The rename source of the virtual controller does not exist.

Check the virtual controller name.

7763

The rename destination of the virtual controller already exists.

Check the virtual controller name.

7764 Invalid Robot number. Reboot RC+.

7765 Failed to read the Robot definition file. Check whether the definition file exists.

7766 Failed to copy the layout objects. Reboot RC+

7767 Failed to cut the layout objects.

7768 Failed to paste the layout objects.

Reboot RC+

Reboot RC+

7769 Failed to remove the Robot.

7770

Reboot RC+

Cannot execute with unsupported version.

Update RC+ to the latest version

Note 1 Note 2

222

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.1.15 GUI Builder

No. Message

7600

Cannot execute a GUI Builder statement from the command window.

7602 GSet parameter is too long.

7603 Too many parameters for GGet.

7604

Not enough data for GGet statement variable assignment.

7610

7611

7612

7613

The event task cannot be executed.

System in pause state and

EventTaskType is Normal.

The event task cannot be executed.

Safeguard is open and EventTaskType is Normal.

The event task cannot be executed.

Estop is active and EventTaskType is not NoEmgAbort.

The event task cannot be executed.

System in error state and

EventTaskType is not NoEmgAbort. in the program.

-

-

Remedy

GUI Builder commands are only available

Note 1 Note 2

-

Specify NoEmgAbort for EventTaskType.

Specify NoEmgAbort for EventTaskType.

Specify NoEmgAbort for EventTaskType.

Specify NoEmgAbort for EventTaskType.

7653 The specified form is already open.

7654 Event function does not exist.

-

-

-

-

Create the event function.

RC180 Rev.14

223

Maintenance 8. Trouble Shooting

8.1.16 Hardware

No.

9001

Message Remedy

Emergency stop circuit failure was detected.

Disconnection or other failure was found in one of the redundant inputs.

Check whether no disconnection, earth fault, or short-circuit of the emergency stop input signal exits. Then reboot the controller.

Note 1 Note 2

9002

9011

9012

Safeguard circuit failure was detected.

Disconnection or other failure was found in one of the redundant inputs.

Check whether no disconnection, earth fault, or short-circuit of the safeguard input signal exits.

Then reboot the controller.

Battery voltage of the CPU board backup is lower than the specified voltage. Replace the

CPU board battery.

5V input voltage for CPU board is lower than the specified voltage.

9013

24 V input voltage for the motor brake, encoder and fan is lower than the specified voltage.

9014

9015

9016

Internal temperature of the Controller is higher than the specified temperature.

Rotating speed of the controller fan is below the allowed speed. (FAN1)

Rotating speed of the controller fan is below the allowed speed. (FAN2)

Stop the controller as soon as possible and check whether the ambient temperature of the controller is not high.

Check whether the filter is not clogged up.

Check whether the filter is not clogged up. If the warning is not cleared after the controller is rebooted, replace the fan.

Check whether the filter is not clogged up. If the warning is not cleared after the controller is rebooted, replace the fan.

9017

9100

Internal temperature of the Controller is higher than the specified temperature.

Initialization failure.

Failed to allocate memory.

9101 Message queue has become full.

9233

9234

9610

9611

Reboot the controller.

The Fieldbus I/O driver is in an abnormal state.

The module is broken or the controller software is damaged. Restore the controller firmware.

The module is broken or the controller software is damaged. Restore the controller firmware.

RAS circuit detected a servo system malfunction. Reboot the controller. Check for noise. Replace the controller.

Check the noise countermeasures.

Replace the DMB.

Servo CPU internal RAM failure. Reboot the controller. Check for noise. Replace the

DMB.

Check the noise countermeasures.

Replace the DMB.

RAM for the main and servo CPU Check the noise countermeasures.

Current value

Current value

Current value

9612

9613

9614 controller. Check for noise. Replace the

DMB.

Servo CPU internal RAM failure. Reboot the controller. Check for noise. Replace the

DMB.

Check the noise countermeasures.

Replace the DMB.

Initialization communication of main CPU and servo CPU failure. Reboot the Replace the DMB.

Controller. Check for noise. Replace DMB.

Check the noise countermeasures.

Boundary value

Boundary value

Boundary value

224

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

9615

9616

9617

9618

9619

9620

9621

9622

9623

9624

9625

9630

9632

9633

9640

9700

Message

Initialization communication of the main and servo CPU failure. Reboot the controller.

Check for noise. Replace the DMB.

Remedy

Check the noise countermeasures.

Replace the DMB.

Communication of the main and servo CPU failure. Reboot the controller. Check for noise. Replace the DMB.

Communication of the main and servo CPU failure. Reboot the controller. Check for noise. Replace the DMB.

Check the noise countermeasures.

Replace the DMB.

Check the noise countermeasures.

Replace the DMB.

Servo long time command overrun. Check the noise countermeasures.

Replace the DMB.

Servo long time command check sum error. Check the noise countermeasures.

Replace the DMB.

System watchdog timer detected a failure.

Reboot the controller. Check for noise.

Replace the DMB.

Drive unit check failure.

Check the noise countermeasures.

Replace the DMB.

Check the noise countermeasures.

Replace the DMB.

Check the noise countermeasures.

Replace the DMB.

RAM failure of the servo CPU. Reboot the controller. Check for noise. Replace the

DMB.

Failure of the redundant circuitry for the emergency stop or the safeguard. Check the wiring.

Low voltage of the main circuit power supply was detected. Check the power supply voltage. Reboot the controller.

Check the noise countermeasures.

Replace the DMB.

Check the noise countermeasures.

Replace the DMB.

Control relay contact of the main circuit power supply is welded closed. Replace the

DPB.

Servo real time status failure. Check sum error.

Replace the DMB.

Servo real time status failure. Servo free running counter error

Servo real time status failure. Servo CPU communication error.

Irregular motion control interruption was detected. Interruption duplicate.

Servo control gate array failure. Check the

DMB.

Reboot the controller.

Replace the DMB.

Check the noise countermeasures.

Reboot the controller.

Replace the DMB.

Check the noise countermeasures.

Reboot the controller.

Replace the DMB.

Check the noise countermeasures.

Reboot the controller.

Replace the DMB.

Check the noise countermeasures.

Check the short-circuit and improper connection of the peripheral equipment wiring.

(Emergency and I/O connectors)

Replace the DMB.

Replace the additional axis unit.

Note 1 Note 2

RC180 Rev.14

225

Maintenance 8. Trouble Shooting

No. Message

9701

9702

Disconnection of the parallel encoder signal.

Check the signal cable connection or the robot internal wiring.

Motor driver is not installed. Install the motor driver. Check the DMB or the motor driver.

Remedy

Check the M/C cable signal.

Check the robot signal wiring. (Missing pin, disconnection, short-circuit)

Replace the motor. (Encoder failure)

Replace the DMB. (Detection circuit failure)

Check the connector connection in the controller. (Loosening, connecting to the serial encoder terminal on the DMB)

Check the model setting. (Improperly setting of the parallel encoder)

Check the peripheral equipment wiring.

(Emergency and I/O)

Check whether the motor driver is mounted.

Check the model setting and hardware setting.

Replace the motor driver.

Replace the DMB.

Note 1 Note 2

9703

9704

9705

9706

9707

9708

9709

9710

9711

9712

9713

9715

9716

9717

Initialization communication failure of Check the model setting. incremental encoder. Check the signal cable connection and the robot setting.

Replace the motor. (Encoder failure)

Replace the DMB.

Initialization failure of absolute encoder.

Check the signal cable connection or the robot setting.

Encoder division setting failure. Check the robot setting.

Check the model setting.

Replace the motor. (Encoder failure)

Replace the DMB.

Check the model setting.

Data failure at the absolute encoder Replace the motor. (Encoder failure) initialization. Check the signal cable Replace the DMB. connection, the controller, or the motor. Check the noise countermeasures.

Absolute encoder multi-turn is beyond the maximum range. Reset the encoder.

Position is out of the range. Reset the encoder.

Reset the encoder.

Replace the motor. (Encoder failure)

Reset the encoder.

Replace the DMB.

Replace the motor. (Encoder failure)

No response from the serial encoder. Check the signal cable connection, the motor, the

DMB, or the encoder IF board.

Serial encoder initialization failure. Reboot the controller. Check the motor, the DMB, or the encoder IF board.

Check the model setting. (Improperly setting of the parallel encoder model)

Check the signal cable connection.

Replace the DMB and encoder I/F board.

Check the robot configuration.

Check the signal cable.

Replace the DMB and encoder I/F board.

Serial encoder communication failure. Check the robot configuration.

Reboot the controller. Check the motor, the

DMB, or the encoder IF board.

Check the signal cable.

Replace the DMB and encoder I/F board.

Servo CPU watchdog timer failure. Reboot the controller. Check the motor or the DMB.

Replace the DMB.

Check the noise countermeasures.

Current control circuit WDT failure. Reboot the controller. Check the controller.

Encoder is reset. Reboot the controller.

Power supply failure of the absolute encoder.

Replace the battery to a new one. Check the robot internal wiring.

Backup data failure of the absolute encoder.

Reset the encoder.

Check the power cable connection.

Check the 15V power supply and cable connection.

Replace the DMB.

Check the noise countermeasures.

Reboot the controller.

Reset the encoder.

Check the signal cable connection.

Reset the encoder.

Check the signal cable connection.

226

RC180 Rev.14

Maintenance 8. Trouble Shooting

No.

9718

9719

9720

9721

9732

Message

Absolute encoder battery alarm.

Position failure of the absolute encoder.

Reset the encoder. Replace the motor.

Speed is too high at controller power ON.

Stop the robot and reboot the controller.

Remedy

Replace the battery.

Check the signal cable connection.

Reset the encoder.

Replace the motor. (Encoder failure)

Reboot the controller.

Absolute encoder over heat.

Servo alarm A.

Lower the motion duty.

Wait until the temperature of the encoder decreases.

Note 1 Note 2

RC180 Rev.14

227

Maintenance 8. Trouble Shooting

8.2 Cannot Connect the Development PC and the Controller using the USB cable

CAUTION

„ Do not connect the USB cable to a PC or a Controller without installing Program

Development Software EPSON RC+ 5.0 to the PC.

You must install EPSON RC+ 5.0 to control the Controller.

If the USB cable is connected to a PC or a Controller without installing Program

Development Software EPSON RC+ 5.0, the [Add New Hardware] wizard appears. Click the <Cancel> button to close the [Add New Hardware] wizard.

If the following error message appears when connecting the development PC and

Controller with the USB cable and connecting the Controller to EPSON RC+ 5.0,

Windows may not recognize the Controller properly. Refer to 8.2.1 Confirmation Using

Windows Device Manager to check the connection of the Controller.

8.2.1 Confirmation Using Windows Device Manager

(1) Make sure that the development PC and the Controller is connected to the USB cable.

NOTE

)

When checking the Controller connection using the Windows device manager, the development PC and the Controller must be connected with the USB cable.

(2) Click Windows-[Control Panel]-<Performance and Maintenance>.

228

RC180 Rev.14

Maintenance 8. Trouble Shooting

(3) The [Performance and Maintenance] dialog appears.

Click the <System> icon.

(4) The [System Properties] dialog appears.

Select the [Hardware] tab and click the <Device Manager> button.

RC180 Rev.14

(5) The [Device Manager] dialog appears.

Click <Universal Serial Bus controllers> and make sure that “EPSON Robot

Controller RC170 (or RC180)” is registered.

229

Maintenance 8. Trouble Shooting

NOTE

)

When “EPSON Robot Controller RC170 (or RC180)” is registered and located under

“Universal Serial Bus controllers” in step (5), the development PC and the Controller connect properly.

If the following error message appears, please contact EPSON.

“Cannot connect to controller.

!! Error: 1805, Connection failure, check the controller startup and connection of the communication cable.”

If “EPSON Robot Controller RC170 (or RC180)” is not located under “Universal Serial

Bus controllers” but located under “Other devices” in step (5), refer to 8.2.2 When

recognized under “Other devices” in Windows Device Manager.

230

RC180 Rev.14

Maintenance 8. Trouble Shooting

8.2.2 When recognized under “Other devices” in Windows Device Manager

If “EPSON Robot Controller RC170 (or RC180)” is recognized under “Other devices” in the Windows device manager as shown in the following dialog, delete “EPSON Robot

Controller RC170 (or RC180)” from the device manager and connect the USB cable again to correct the problem.

(1) Select and right click “EPSON Robot Controller RC170 (or RC180)” in the [Device

Manager] dialog.

(2) Select [Uninstall].

(3) The [Confirm Device Removal] dialog appears.

Click the <OK> button.

(4) Remove the USB cable and connect the USB cable again. The following message appears at the right bottom of the Windows screen.

(5) When the Controller is installed automatically and the following message appears, the communication is available.

NOTE

)

RC180 Rev.14

If the problem is not corrected, please contact EPSON.

231

Maintenance 9. Maintenance Parts List

9. Maintenance Parts List

Part Name

Fan Unit

Fan Filter For Base Unit

For Option Unit

Code Note

R13B060501

R13B060502

R13B060503

2 unit per set

Motor Driver

Fuse

CPU Unit

CF (Compact Flash)

TP/OP Bypass Plug

Controller Mounting

Metal Hasp

Expansion I/O Board

RS-232C Board

DeviceNet Board

PROFIBUS-DP Board

CC-Link Board

EtherNet/IP Board

PROFINET board

CR17335SE

(FDK)

50 W

100 W

R13B070101

R13B070102

200 W

400 W

750 W

R13B070103

R13B070104

R13B070105

R13B060401

For DPB

S/N: 10000 or below

R13B040004

S/N: 10001 or later

R13B040009

S/N: 10000 or below

R13B110601

S/N: 10001 or later

R13B110608

S

L

R13B060705

R13B071302

R13B071303

R12B040301

Option

R12B040705

Option

R12B040706

Option

R12B040707

Option

R12B040708

Option

R12B040719

Option

R12B040728

Option

232

RC180 Rev.14

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