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ROBOT CONTROLLER
RC180
Rev.17
EM164C3205F

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  • Page 1

    ROBOT CONTROLLER RC180 Rev.17 EM164C3205F...

  • Page 3

    ROBOT CONTROLLER RC180 Rev.17 Copyright © 2006-2016 SEIKO EPSON CORPORATION. All rights reserved. RC180 Rev.17...

  • Page 4

    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. RC180 Rev.17...

  • Page 5

    No part of this manual may be copied or reproduced without authorization. The contents of this manual are subject to change without notice. Please notify us if you should find any errors in this manual or if you have any comments regarding its contents. MANUFACTURER RC180 Rev.17...

  • Page 6

    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...

  • Page 7: Table Of Contents

    Connecting Manipulator to Controller ......... 30 3.5 Noise Countermeasures ................. 32 4. Operation Mode (TEACH/AUTO) 4.1 Overview ....................33 4.2 Switch Operation Mode ................33 4.3 Program Mode (AUTO) ................34 4.3.1 What is Program Mode (AUTO)? ..........34 RC180 Rev.17...

  • Page 8

    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 6.3.4 Transfer with E-mail ..............43 6.4 Details of Data ..................44 7. LAN (Ethernet Communication) Port 7.1 About LAN (Ethernet Communication) Port ...........

  • Page 9

    12.2 Expansion I/O Board ................72 12.2.1 About Expansion I/O Board ............72 12.2.2 Board Configuration (Expansion I/O) ........72 12.2.3 Confirmation with EPSON RC+5.0 ........... 73 12.2.4 Input Circuit ................73 12.2.5 Output Circuit ................75 12.2.6 Pin Assignments ............... 77 12.3 Fieldbus I/O Board ..................

  • Page 10

    12.4 RS-232C Board ..................109 12.4.1 About RS-232C Board ............109 12.4.2 Board Setup (RS-232C) ............110 12.4.3 Verify with EPSON RC+5.0 (RS-232C) ........110 12.4.4 RS-232C Software Communication Setup (RS-232C) ... 111 12.4.5 Communication Cable (RS-232C) .......... 111 Maintenance 1.

  • Page 11

    Table of Contents 4.4 Restore ....................130 4.4.1 Restore from EPSON RC+5.0 ..........130 4.4.2 Restore from Teach Pendant (Option) ........132 5. Firmware Update 5.1 Updating Firmware ................135 5.2 Firmware Upgrading Procedure ............135 5.3 Controller Recovery ................138 5.4 Firmware Initialization Procedure ............

  • Page 12

    Table of Contents 8.2.2 When recognized under “Other devices” in Windows Device Manager ............ 246 9. Maintenance Parts List Appendix. Alarm RC180 Rev.17...

  • Page 13

    Safety This section contains information for safety of the Robot System.

  • Page 15: Safety

    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.

  • Page 16: Safety Precautions

     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.) RC180 Rev.17...

  • Page 17

    - 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.17...

  • Page 18

     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 WARNING inside the Controller. RC180 Rev.17...

  • Page 19: Setup & Operation

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

  • Page 21: Specifications

    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.)

  • Page 22: Standard Specifications

    Setup & Operation 1. Specifications 1.2 Standard Specifications Item Specification Robot Controller RC180 Model (UL specification: RC180-UL) 32 bits Ultra Low Voltage Processor Controllable axes Up to six (6) connectable AC servo motors Programming language and EPSON RC+ 5.0 Robot control...

  • Page 23

    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.17...

  • Page 24: Outer Dimensions

    Setup & Operation 1. Specifications 1.3 Outer Dimensions Dimension of RC180-UL is the same as RC180. Base Unit (Four-axis robot construction) 130.5 170.5 Base Unit + ProSix Driver Unit (Six-axis robot construction) 130.5 170.5 RC180: Base Unit + Option Unit 130.5...

  • Page 25: Part Names And Functions

    (1)-1 (11) (10) (14) (15) (13) (12)-1 (12)-2 (1)-2 (16) (17) (18) (19) (20) (21) (22) (23) (24) RC180-UL (4) (5) (1)-2 (1)-1 (11) (10) (15) (12)-1 (12)-2 (1)-2 (16) (17) (18) (19) (20) (21) (22) (23) (24) RC180 Rev.17...

  • Page 26: Functions

    Connect the dedicated power cable attached to the Manipulator. (8) Connection Check label MANIPULATOR The details of the Manipulator to be connected are recorded on G6-551S 00002 the label as shown in the right. The label indicates the Manipulator model and Manipulator serial number. RC180 Rev.17...

  • Page 27

    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.

  • Page 28

    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.

  • Page 29: Led And Seven-segment Led

    *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.17...

  • Page 30: Particular Status Display

    Refer to Maintenance 4. Backup and Restore. AC power supply drop is detected and software shut down. Software shut down is specified from the EPSON RC+ 5.0 (software) or the Teach Pendant (option). *1 When the Initialize Error occurs, reboot the Controller. If the Initialize Error is displayed again after the Controller is rebooted, please contact the supplier of your region.

  • Page 31

    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.17...

  • Page 32

    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. RC180 Rev.17...

  • Page 33: Installation

    - 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.17...

  • Page 34: Installation

    Fixture S: Used in I The length from the edge of fixture L differs by the side. Refer to the following figure NOTE  and mount the side with shorter distance from the edge to the screw hole on the Upper side. RC180 Rev.17...

  • Page 35

    100 mm 100 mm 100 mm Air flow of the Controller Fan 100 mm Excluding the installation side such as base table RC180 Rev.17...

  • Page 36: Install Inside The Cabinet

    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 Air Filter RC180 Rev.17...

  • Page 37: Power Supply

    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.17...

  • Page 38: Ac Power Cable

    To Controller M4 Ring solderless terminal (RC180-UL: M5 Ring solderless terminal) The AC plug in not attached to the AC power cable delivered at shipment. Refer to the wire connection specification and attach a proper plug to the cable that is suitable for the factory power supply.

  • Page 39: Cable Connection

    Connect by (5) or (7) (6) USB Memory (7) LAN (Ethernet Communication) (8) I/O Connector Input/Output Device (9) TP Cable B Teach Pendant Operator Teach (10) OP Cable (9) TP Cable A Panel Pendant FieldBus Option Unit Expansion I/O RS-232C RC180 Rev.17...

  • Page 40

    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. RC180 Rev.17...

  • Page 41

    TP cable A : Circular connector TP cable B : D-sub 25pin For details, refer to the Setup & Operation 8.TP/OP Port. (10) OP cable Connect the option Operator Panel. For details, refer to the Setup & Operation 8.TP/OP Port. RC180 Rev.17...

  • Page 42: Connecting Manipulator To Controller

    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 NOTE  Manipulator. G series G series Manipulator (the figure is G6-553S) RC180 Controller M/C Power Cable M/C Signal Cable RC180 Rev.17...

  • Page 43

    Setup & Operation 3. Installation RS series RC180 Controller M/C Signal Cable M/C Power Cable RS series Manipulator (the figure is RS3-351S) C3 series and C3 series Manipulator RC180 Controller M/C Power Cable M/C Signal Cable S5 series S5 series Manipulator...

  • Page 44: Noise Countermeasures

    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. RC180 Rev.17...

  • Page 45: Operation Mode (teach/auto)

    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.17...

  • Page 46: Program Mode (auto)

    Procedures for switching to the Program mode are the followings. 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.

  • Page 47: Auto Mode (auto)

    Auto mode (AUTO) is for automatic operation of the Robot system. Procedures for switching to the Auto mode (AUTO) are the followings. A : Set the start mode of the EPSON RC+ 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.

  • Page 48: Setup From Control Device

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

  • Page 49: Development Pc Connection Port

    For other details of development PC and Controller connection, refer to EPSON RC+ 5.0  User’s Guide 5.12.1 PC to Controller Communications Command. For RC180, be sure to install the EPSON RC+ 5.0 to the development PC first, then NOTE ...

  • Page 50: Precaution

    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.)

  • Page 51: Disconnection Of Development Pc And Controller

    EPSON RC+ 5.0. 5.4 Disconnection of Development PC and Controller 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.

  • Page 52: Memory Port

    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.

  • Page 53: Controller Status Storage Function

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

  • Page 54: Load Data With Epson Rc+ 5.0

    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.

  • Page 55: Transfer With E-mail

    (3) Send all the folders by e-mail. NOTE  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.17...

  • Page 56: Details Of Data

    VXDWORK.bin All files related to Project When [Include project files when status project except exported] check box is checked in EPSON ProjectName.obj *2 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.

  • Page 57: Lan (ethernet Communication) Port

    Setup & Operation 7. LAN (Ethernet Communication) Port 7. LAN (Ethernet Communication) Port - Refer to EPSON RC+ 5.0 User’s Guide 5.12.1 PC to Controller Communications NOTE  Command (Setup Menu) for other details for the development PC and Controller connection.

  • Page 58: Ip Address

    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. RC180 Rev.17...

  • Page 59

    When the Controller and the development PC are connected via the Ethernet, the NOTE  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.17...

  • Page 60: Connection Of Development Pc And Controller With Ethernet

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

  • Page 61: Disconnection Of Development Pc And Controller With Ethernet

    <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 with Ethernet Disconnection of the development PC and the Controller is shown below.

  • Page 62: Tp/op Port

    Operator Panel, both Operator Panel and Teach Pendant are available. (Connection D) NOTE 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.

  • Page 63: Teach Pendant Connection

    RC90/RC180 Option Teach Pendant TP2. 8.3 Operator Panel Connection 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.

  • Page 64: Emergency

    Setup & Operation 9. EMERGENCY 9. EMERGENCY NOTE The details of safety requirements for this section are described in EPSON RC+ 5.0 User’s  Guide 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.

  • Page 65: Safety Door Switch And Latch Release Switch

    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.17...

  • Page 66: Latch Release Switch

    The latch release input also functions to acknowledge the change of to TEACH mode. NOTE  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. RC180 Rev.17...

  • Page 67: Emergency Stop Switch Connection

    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.17...

  • Page 68: Pin Assignments

    +24 V ±10% Latch Release rated input voltage range 18-19 pin Latch Release rated input current 10 mA/+24 V input NOTE The total electrical resistance of the Emergency Stop switches and their circuit should be 1  Ω or less. RC180 Rev.17...

  • Page 69: Circuit Diagrams

    Control − Motor Driver AC Input Emergency Stop detection External +24V Safety Door input 1 Safety Door input 2 Latch release input External +24V Latch release input Close :Latch off NOTE:+24V GND Open :Latch on + 5V GND RC180 Rev.17...

  • Page 70: External Safety Relay Typical Application

    - 0.4A or less AC Input Emergency Stop detection External +24V External +24V Safety Door input 1 Safety Door input 2 Latch Release input External +24V Latch release input Close :Latch off NOTE:+24V GND Open :Latch on + 5V GND RC180 Rev.17...

  • Page 71: I/o Connector

    4 Input No.2 (Same) 5 Input No.3 (Same) 6 Input No.4 (Same) 7 Input No.5 (Same) 8 Input No.6 (Same) 9 Input No.7 (Same) 18 Input No.8 to 15 common 19 Input No.8 (Same) 20 Input No.9 Omit RC180 Rev.17...

  • Page 72

    4 Input No.2 (Same) 5 Input No.3 (Same) 6 Input No.4 (Same) 7 Input No.5 (Same) 8 Input No.6 (Same) 9 Input No.7 (Same) 18 Input No.8 to 15 common (Same) 19 Input No.8 20 Input No.9 Omit RC180 Rev.17...

  • Page 73: Output Circuit

    14 Output No.4 (Same) 15 Output No.5 (Same) 27 Output No.6 (Same) 28 Output No.7 17 Output No.0 to 7 common (GND) (Same) 29 Output No.8 (Same) 30 Output No.9 (Same) Omit 33 Output No.8 to 15 common (GND) RC180 Rev.17...

  • Page 74

    14 Output No.4 (Same) 15 Output No.5 (Same) 27 Output No.6 (Same) 28 Output No.7 17 Output No.0 to 7 common (+DC) (Same) 29 Output No.8 (Same) 30 Output No.9 (Same) Omit 33 Output No.8 to 15 common (+DC) RC180 Rev.17...

  • Page 75: Pin Assignment

    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.17...

  • Page 76: I/o Remote Set Up

    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.

  • Page 77: 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).

  • Page 78

    Main7 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.

  • Page 79

    Setup & Operation 11. I/O Remote Settings For details of the controller preferences, refer to EPSON RC+ 7.0 User’s Guide [Setup]-[System Configuration]-[Controller]-[Preferences] in 5.12.2 [System Configuration] Command (Setup Menu). All tasks and Preferences (1) Preferences (2) ForcePowerLow Power mode PowerHigh commands 1→0...

  • Page 80: Remote Output Signals

    ErrorCode1 Not Set Indicates the error number. ErrorCode8192 InsideBox1(*3) Not Set 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. InsideBox15 InsidePlane1 Not Set Turns ON when the robot is in the approach check plane.

  • Page 81

    (*3) When the Controller firmware version is Ver.1.4.*.* or before, the remote outputs do not provide InsideBox1 to 15 and InsidePlane1 to 15. It is supported by EPSON RC+ 5.0 Ver.5.4 and Firmware Ver. 1.10.*.*. (*4) (*5) The signal turns on when the alarm occurs either in the controller alarm information or the robot alarm information.

  • Page 82: Timing Specifications

    Output Running Output * Paused Output 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 RC180 Rev.17...

  • Page 83: Timing Diagram For Safety Door Input Sequence

    11.2.4 Timing Diagram for Safety Door Input Sequence Running 1052 Output Paused 1052 Output SafeguardOn Output MotorsOn Output Safety Input Latch Input Continue Input 11.2.5 Timing Diagram for Emergency Stop Sequence Running Output MotorsOn Output EStopOn Output Emergency Input Reset Input RC180 Rev.17...

  • Page 84: Option Units

    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.

  • Page 85: Confirmation With Epson Rc+5.0

    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].

  • Page 86

    4 Input No.66 (Same) 5 Input No.67 (Same) 6 Input No.68 (Same) 7 Input No.69 (Same) 8 Input No.70 (Same) 9 Input No.71 (Same) 18 Input No.72 to 79 common (Same) 19 Input No.72 20 Input No.73 Omit RC180 Rev.17...

  • Page 87: Output Circuit

    (Same) 14 Output No.68 (Same) 15 Output No.69 (Same) 27 Output No.70 (Same) 28 Output No.71 17 Output No.64 to 71 common (Same) 29 Output No.72 (Same) 30 Output No.73 (Same) Omit 33 Output No.72 to 79 common RC180 Rev.17...

  • Page 88

    (Same) 14 Output No.68 (Same) 15 Output No.69 (Same) 27 Output No.70 (Same) 28 Output No.71 (Same) 17 Output No.64 to 71 common 29 Output No.72 (Same) 30 Output No.73 (Same) Omit 33 Output No.72 to 79 common RC180 Rev.17...

  • Page 89: Pin Assignments

    Output common No.64 to 71 Not Used 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.17...

  • Page 90

    Output common No.80 to 87 Not Used 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.17...

  • Page 91: Fieldbus I/o Board

    Fieldbus 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.

  • Page 92: Fieldbus I/o Board Configuration

    12.3.3 Fieldbus I/O Board Configuration The Fieldbus I/O board is configured as follows at shipment. Board Appearance Configuration DSW2 DSW1 JMP1 IRQ15 IRQ11 IRQ10 DSW2 IRQ7 DSW1 IRQ5 JMP1 All Open All ON Fixed as above All Open RC180 Rev.17...

  • Page 93: Devicenet

    Master Device DeviceNet Network Photo Sensor Analog Device from Company E from Company G Motor Driver Motor Driver Intelligent I/O Intelligent I/O HMI Device from Company A from Company B from Company C from Company D from Company F RC180 Rev.17...

  • Page 94

    * When thin cable is used for trunk line, the maximum network length is 100 m. DeviceNet Appearance NS LED : Network status display MS LED : Module status display Status Display LED Refer to the following table for functions of Configure Switch LED. DeviceNet Connector RC180 Rev.17...

  • Page 95

    (LSB) (at shipment) (2) Set the DeviceNet baud rate. Check the master configuration and set the same baud rate. Refer to the following table for configuration settings. Switch Baud Rate 125 K 250 K 500 K Configuration prohibited RC180 Rev.17...

  • Page 96

    DeviceNet Confirmation with EPSON RC+ 5.0 When the DeviceNet board is installed to the Controller, it is recognized automatically. Confirm whether EPSON RC+ 5.0 has recognized the DeviceNet board using the following procedure. (1) Select EPSON RC+ 5.0 menu-[Setup]-[Controller] to display the [Setup Controller] dialog.

  • Page 97: Profibus-dp

    Master Device PROFIBUS-DP Network Photo Sensor Analog Device from Company E from Company G Motor Driver Motor Driver Intelligent I/O Intelligent I/O HMI Device from from Company A from Company B from Company C from Company D Company F RC180 Rev.17...

  • Page 98

    : Online status display OFFLINE LED : Offline status display Status Display LED ERROR LED Address Configure Switch (×1) : Error status display Address Configure Switch (×10) Terminator Switch Refer to the following table for PROFIBUS-DP Connector functions of LED. RC180 Rev.17...

  • Page 99

    Prepare the cable for PROFIBUS-DP sold in the market as a communication cable.  NOTE Install terminating resistors at both ends of the network. A terminating resistor is installed in the PROFIBUS-DP board. Turn the terminating resistor ON or OFF using the terminator switch on the front panel. RC180 Rev.17...

  • Page 100

    PROFIBUS-DP Confirmation with EPSON RC+ 5.0 When a PROFIBUS-DP board is installed to the Controller, it is recognized automatically. Confirm whether EPSON RC+ 5.0 has recognized the PROFIBUS-DP board using the following procedure. (1) Select EPSON RC+ 5.0 menu-[Setup]-[Controller] to display the [Setup Controller] dialog.

  • Page 101: Cc-link

    Master Device CC-Link Network Photo Sensor Analog Device from Company E from Company G Motor Driver Motor Driver Intelligent I/O Intelligent I/O HMI Device from Company A from Company B from Company C from Company D from Company F RC180 Rev.17...

  • Page 102

    No data reception No data transmission Device power supply Device power supply Device power supply Device power supply CRC error: station Normal operation Data reception Data transmission Address error Baud rate configuration error − − − − Blinking RC180 Rev.17...

  • Page 103

    Connect the CC-Link master module and the CC-Link board as follows. RC180 CC-Link Master Station CC-Link Board Module Terminating Terminating Resistor Resistor Twisted-pair Cable Twisted-pair Cable with Shield with Shield Prepare the cable for CC-Link Ver.1.10 sold in the market as a communication cable. RC180 Rev.17...

  • Page 104

    Error: 7101 Communication error occur during transform 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. (1) Select EPSON RC+ 5.0 menu-[Setup]-[Controller] to display the [Setup Controller] dialog.

  • Page 105

    Remote Output RYn0 to RY(n+5)F → RY60 to RYAF Remote 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.17...

  • Page 106

    System reservation RX(n+5)E System reservation RX(n+5)F System reservation *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. RC180 Rev.17...

  • Page 107

    System reservation RY(n+5)E System reservation RY(n+5)F System reservation *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. RC180 Rev.17...

  • Page 108

    Signal direction: Master station (PLC) → Remote device station (CC-Link board) Bits indicated as “NA” are left for user. Use these free for SPEL+ program. Address Signal Name Controller Word No Controller Bit No RWwm 608 to 623 RWwm+9 752 to 767 RWwm+A System reservation RWwm+B System reservation RC180 Rev.17...

  • Page 109

    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.17...

  • Page 110

    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 RC180 Rev.17...

  • Page 111: Etherneti/p

    Baud Rates Standard Ethernet protocol Transfer Distance Cable Standard Ethernet protocol Mode Slave Interface 1 EtherNet/IP port Connection type Cyclic Explicit message Supported connection Input data size 256 bits (32 bytes) Output data size 256 bits (32 bytes) RC180 Rev.17...

  • Page 112

    Set all EtherNet/IP board configure switches OFF. If all EtherNet/IP board configure switches are not OFF, reset error occurs. All the EtherNet/IP communication configurations are set by the development software (EPSON RC+ 5.0). Wiring (EtherNet/IP) Use a standard Ethernet connector for wiring to the board.

  • Page 113

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

  • Page 114

    For details, refer to 12.3.9 Operation. Electronic Information File (EDS file) An EDS file is supplied for EtherNet/IP network 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 RC180 Rev.17...

  • Page 115: Profinet

    100M bps, full duplex Maximum segment length 100 m Cable RJ45 with connector 100BASE-TX (Cat5) Cycle time 2 ms RJ45 port × 1 Interface Input Data Size 256 bits (32 bytes) Output Data Size 256 bits (32 bytes) RC180 Rev.17...

  • Page 116

    No IP address has been set Blinking Internal error 4 times Board Configuration (PROFINET) 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. RC180 Rev.17...

  • Page 117

    When PROFINET board is installed in the controller, it is recognized automatically. Confirm that EPSON RC+ the board in the following procedure. 5.0 has recognized (1) Select EPSON RC+ 5.0 menu-[Setup]-[Controller] to display the [Setup Controller] dialog. (2) Select the [Inputs / Outputs]. (3) Make sure that following is displayed.

  • Page 118

    For details, refer to 12.3.9 Operation. 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 RC180 Rev.17...

  • Page 119: Operation (devicenet, Profibus-dp, Etherneti/p)

    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 commands are listed in the following table. For command details, refer to EPSON RC+ 5.0 Online Help or SPEL Language Reference.

  • Page 120

    ErrorCode512 InsidePlane11 Not Set ErrorCode1024 InsidePlane12 Not Set InsidePlane13 Not Set ErrorCode2048 ErrorCode4096 InsidePlane14 Not Set ErrorCode8192 InsidePlane15 Not Set Reserved Not Set Alive Not Set ExtCmdGet Not Set ExtRespSet Not Set ExtCmdResult Not Set ExtError Not Set RC180 Rev.17...

  • Page 121: Rs-232c Board

    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 and configures the DeviceNet / EtherNet/IP I/O area. Supported function and Class ID configurations are as follows:...

  • Page 122: Board Setup (rs-232c)

    When an RS-232C board is mounted in as option unit, the Controller software automatically identifies the RS-232C board. Therefore, no software configuration is needed. Correct identification can be confirmed from EPSON RC+ 5.0. (1) Select the EPSON RC+ 5.0 menu-[Setup]-[Controller] to display the [Setup Controller] dialog. (2) Select the [RS-232C].

  • Page 123: Rs-232c Software Communication Setup (rs-232c)

    Parity Odd, even, NA Terminator 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...

  • Page 124

    Setup & Operation 12. Option Units RC180 Rev.17...

  • Page 125: Maintenance

    Maintenance This section contains maintenance procedures for the Robot Controller.

  • Page 127: Safety Precautions On Maintenance

    Performing any maintenance procedure while the main power is ON or the high voltage charged area isn’t WARNING discharged completely is extremely hazardous and may result in electric shock and/or cause serious safety problems. RC180 Rev.17...

  • Page 128: Lockout / Tagout

    (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.17...

  • Page 129: Regular Maintenance Inspection

    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) RC180 Rev.17...

  • Page 130: Inspection Point

    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 Entire Controller is occurring. Project and Whenever data is changed. Make a backup of data. system data RC180 Rev.17...

  • Page 131: Controller Structure

    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.17...

  • Page 132

    15V Switching Power Supply Module Regeneration Module Encoder I/F Board 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 RC180 Rev.17...

  • Page 133: Diagram Of Cable Connections

    -240V Power Supply (5V) Motor Control Circuit AC200 Encoder Receiving Circuit Switching -240V Power Supply (5V) Motor Power Junction Circuit Temperature Sensor Regenerative Resistor 7-segment Encoder I/F Board Option Board (EIB) EMERGENCY M/C Signal M/C Power Option Board RC180 Rev.17...

  • Page 134

    Switching Power Supply (15V) (11) (10) to Noise Filter (13) Switching Power Supply (24V) Switching Power Supply (5V) Back Plane Board (12) (14) (15) (21) (18) (19) (16) (21) (22) (17) ProSix Driver Unit I/F Board (20) CPU Board Cable RC180 Rev.17...

  • Page 135

    (19) CPU Board Temperature Sensor (20) CPU Board 80<F> Back Plane Board (21) M/C POWER 4,4,4,4 4,4,4,4 (22) M/C POWER 4,4,8 ProSix Driver Unit I/F Board <F> Flat cable When connected to ProSix Driver unit When connected to Option unit RC180 Rev.17...

  • Page 136: 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 EMERGENCY and TP/OP connectors, refer to Setup & Operation. 3.3.1 M/C Power Connector G, RS series C3, S5 series RC180 Rev.17...

  • Page 137: M/c Signal Connector

    3.3.2 M/C Signal Connector G, RS C3, S5 G, RS C3, S5 26 ENC_GND ENC_GND ENC_5V ENC_5V EMC_PWR ENC_GND ENC_GND ENC_GND ENC_5V ENC_5V ENC_5V ENC_GND ENC_GND ENC_GND ENC_5V ENC_5V ENC_GND ENC_GND ENC_5V ENC_5V MPOWER MPOWER EMB_J3 24VGND 24VGND 24VGND RC180 Rev.17...

  • Page 138: Backup And Restore

    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 NOTE ...

  • Page 139: Backup

    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.

  • Page 140: Backup From The Teach Pendant (option)

    <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. RC180 Rev.17...

  • Page 141

    Overwrites the file. Moves the [Programming] screen. <F2> (7) After execution has completed, the following screen appears. ■ Do not edit the backup files. Otherwise, operation of the robot system after data restoration to the Controller is not assured. CAUTION RC180 Rev.17...

  • Page 142: Restore

    Maintenance 4. Backup and Restore 4.4 Restore Restore the Controller status from the Teach Pendant (Option) or EPSON RC+ 5.0. 4.4.1 Restore from EPSON RC+ 5.0 ■ Make sure that the data used for restore was saved previously for same Controller.

  • Page 143

    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  NOTE RC+ 5.0 Ver.5.0.*, this dialog does not appear.

  • Page 144: Restore From Teach Pendant (option)

    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. Press the <OK> key The following screen appears. Press the <OK> key. RC180 Rev.17...

  • Page 145

    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.17...

  • Page 146

    Maintenance 4. Backup and Restore After execution is completed, the following screen appears. Press the <OK> key and the Controller reboots. RC180 Rev.17...

  • Page 147: Firmware Update

    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.

  • Page 148

    (7) Check the current firmware version and the new firmware version and click the <Install> button. (8) The firmware upgrade starts. It takes several minutes to complete. NOTE Do not unplug the USB cable during transfer or turn OFF the Controller or the  development PC. RC180 Rev.17...

  • Page 149

    (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. RC180 Rev.17...

  • Page 150: Controller Recovery

    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. RC180 Rev.17...

  • Page 151: Firmware Initialization Procedure

    (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.

  • Page 152

    (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.

  • Page 153: Maintenance Parts Replacement Procedures

    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. RC180 Rev.17...

  • Page 154: Fan And Fan Filter

    Flared Parts plate. Make sure that the plate is mounted properly. (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.17...

  • Page 155: Replacing Fan Unit

    (5) Pull out the two fan cable connectors from the CPU board to the direction shown by the arrow. (6) Remove the fan filter from the fan unit. NOTE  When the Option Unit is mounted, the fan filter is not used. RC180 Rev.17...

  • Page 156

    Flared Parts plate. Make sure that the plate is mounted properly. (8) 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.17...

  • Page 157: Cleaning And Replacing Fan Filter Of Option Unit

    (1) Insert the fan filters into the Option Unit and secure each of them with a screw. Fan Filter (2) Plug in the power connector. Turn ON the Controller and make sure that the Mount Controller starts properly without any vibration or abnormal noise. RC180 Rev.17...

  • Page 158: Battery

    ・Soldering the terminal of the lithium battery directly ・Forced Discharge CAUTION ■ 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.

  • Page 159

    (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. RC180 Rev.17...

  • Page 160: Motor Driver

    Controller. M/C Power Cable Front Side M/C Signal Cable EMERGENCY Cable Thumb Head (3) Remove the four screws shown in the photo. Screws The thumb head screws are used to pull out the NOTE  Motor Driver. RC180 Rev.17...

  • Page 161

    Push the latch A shown in the photo first and then open the clamp. (7) Insert the top of the support bar into the support hole as shown without moving the base point. Front Cover Support Bar Base Point Support Hole RC180 Rev.17...

  • Page 162

    ■ 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 CAUTION the Motor Driver heat sink. RC180 Rev.17...

  • Page 163

    (8) Secure the two screws on the side of the front cover. (9) Close the front cover and secure it with four screws. NOTE  Make sure to keep cables from becoming trapped or damaged. RC180 Rev.17...

  • Page 164

    (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. RC180 Rev.17...

  • Page 165: Replacing Motor Driver (axis 5 And 6)

    ■ 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 CAUTION the Motor Driver heat sink. RC180 Rev.17...

  • Page 166

    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. RC180 Rev.17...

  • Page 167: Cpu Board Unit

    Perform steps (4) to (6) to remove the ProSix Driver Unit. Connected to the G or RS series manipulator Go on to step (7). (4) Remove the screw on the top and bottom to remove the two covers. RC180 Rev.17...

  • Page 168

    The CPU board unit cable is connected to  the main chassis. Be sure to remove slowly. (10) Disconnect the four connectors connected to the CPU board. Refer : Maintenance 3.2 Diagram of Cable Connections - Cable Layout Drawing RC180 Rev.17...

  • Page 169

    (8) Connect the following cables to the CPU board. USB PC USB memory TP/OP (9) 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.17...

  • Page 170: Cf (compact Flash)

    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. RC180 Rev.17...

  • Page 171: Fuse

    Maintenance 6. Maintenance Parts Replacement Procedures 6.6 Fuse NOTE  The fuse is not used for RC180-UL. Fuse (1) Turn OFF the Controller and unplug the power connector. Remove (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...

  • Page 172

    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.17...

  • Page 173: Option Unit

    NOTE 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. RC180 Rev.17...

  • Page 174: Mount Option Unit 1

    Option Units 1 and 2 to remove the covers. (4) Pull out the flat cable connector connected on the backside of Option Units 1 and 2. NOTE Compress both ends of the connector to pull out  the connector. RC180 Rev.17...

  • Page 175

    Unit mounting bracket from the Option Unit Option Unit Mounting Brackets (8) Remove the Option Unit 2 filter units (two places). Refer : Maintenance 6.1.3 Cleaning and Replacing Fan Filter Mounted (9) Mount the fan filters (two places) to Option Unit 1. Filter Units RC180 Rev.17...

  • Page 176: Mount Option Unit 2

    Units 1 and 2 with two screws for each. Orient the cover so that there is no gap when mounted. (7) 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.17...

  • Page 177: Remove Option Unit 1, 2

    NOTE 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.17...

  • Page 178: Mount Option Unit 1, 2

    (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.17...

  • Page 179: Replacing Adding Option Board

    (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. RC180 Rev.17...

  • Page 180: Verifying Manipulator Operation

    (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.17...

  • Page 181: Troubleshooting

    Controller control program Stores this log when the controller is completed. rebooted from EPSON RC+ or TP1. Preserve variables save area has been cleaned. Function Main started. Function Main started. Later same logs Skip the log "Function Main started." to are skiped.

  • Page 182

    1000 times of 1000 times of After replacing the ball screw spline, occurred. Replace the ball screw spline consumption boundary reset the alarm in EPSON RC+ rate value and reset the alarm. 5.0-[Tools]-[Controller]-[Maintenance]. Replace the battery. The battery alarm for the controller...

  • Page 183

    The battery alarm for the robot occurred. 1000 times of 1000 times of After replacing the ball screw spline, Grease the reduction gear units and reset consumption boundary reset the alarm in EPSON RC+ rate value the alarm. 5.0-[Tools]-[Controller]-[Maintenance]. Replace the timing belt. 1000 times of 1000 times of The belt alarm for the robot occurred.

  • Page 184

    Replace the motor driver. Encoder has been reset. Reboot the Reboot the controller. controller. Low voltage from the encoder battery. Replace the battery for the robot with the Replace the battery with the controller ON. controller ON. Servo alarm D. RC180 Rev.17...

  • Page 185

    The command cannot be executed by the Cannot execute in Remote enable console except the remote I/O when 1035 except from the Remote. AutoMode output of the remote I/O is Cannot execute in OP enable except 1036 from the OP. RC180 Rev.17...

  • Page 186

    File failure. Project file is corrupt. Rebuild the project. 1122 File failure. Point file is corrupt. Rebuild the project. 1123 File failure. I/O label file is corrupt. Rebuild the project. File failure. 1124 Rebuild the project. User error file is corrupt. RC180 Rev.17...

  • Page 187

    File failure. Failed to save the settings 1156 Restore the controller configuration. file. File failure. Failed to read the settings 1157 Restore the controller configuration. file. File failure. Failed to write the settings 1158 Restore the controller configuration. file. RC180 Rev.17...

  • Page 188

    1502 between PC and Controller. and controller. Re-establish communication. Check the connection between the 1503 Disconnection while executing a task. console device and controller. Check the IP address setting of the 1510 Out of IP Address range. controller. RC180 Rev.17...

  • Page 189

    Parser communication error. 2. Upgrade the firmware. Parser communication failure. Timeout 1. Reboot the controller. 1581 error occurred during communication 2. Reinstall the firmware. with parser. Parser communication failure. Parser Reboot the controller. 1582 transmission error. Rebuild the project. RC180 Rev.17...

  • Page 190

    Parameter is invalid. Rebuild the project. 1586 Parser communication failure. Busy. Parser communication failure. Invalid 1587 Upgrade the firmware. data is detected. Unsupported. Unsupported command 1901 Update the firmware. was attempted. Unsupported. Unsupported parameter 1902 was specified. 1903 System error. RC180 Rev.17...

  • Page 191

    1703 data file. Failed to read the setting file. 1704 Failed to open the TP port. 1706 Failed to read the key table for TP. 1708 Failed to change the language. 1709 Failed to make the screen. 1710 RC180 Rev.17...

  • Page 192

    Timeout during connection 1806 Ethernet. 1807 Timeout during connection via USB. Failed to install EPSON RC+ 5.0. 1808 USB driver is not installed. Install EPSON RC+ 5.0 again. Unsupported. Unsupported command 1851 was attempted. 1. Reboot the EPSON RC+5.0.

  • Page 193

    Maintenance 8. Trouble Shooting Simulator Message Remedy Note 1 Note 2 1. Reboot the EPSON RC+ 5.0. Initialization failure. Failed 1861 2. Reboot the PC. initialize SimulatorMNG. 3. Reinstall the EPSON RC+ 5.0. 1. Reboot the EPSON RC+ 5.0. Initialization failure.

  • Page 194

    7767 Failed to cut the layout objects. Reboot RC+ 7768 Failed to paste the layout objects. Reboot RC+ 7769 Failed to remove the Robot. Reboot RC+ Cannot execute with unsupported 7770 Update RC+ to the latest version version. RC180 Rev.17...

  • Page 195

    Stack area size exceeded. Stack error. If using many local variables, especially 2021 Function call or local variable is out of String type, replace them to global range. variables. RC180 Rev.17...

  • Page 196

    Synchronize the files of the project. 2057 Synchronize project. Global Rebuild the project. Preserve variable ID failure. Object file operation failure. Failed to Synchronize the files of the project. 2058 calculate the variable size. Rebuild the project. RC180 Rev.17...

  • Page 197

    Check the number of fieldbus boards. beyond the maximum count. Reboot the controller. Initialization failure. 2116 Check the fieldbus board. Failed to initialize fieldbus. Replace the fieldbus board. Initialization failure. 2117 Reboot the controller. Failed to terminate fieldbus. RC180 Rev.17...

  • Page 198

    Operation failure. Failed to allocate the 2158 Reboot the Controller. area for the break point. Operation failure. 2159 Break point number is beyond the Reduce the break points. allowable setup count. Operation failure. 2160 Reboot the Controller. Failed to allocate the function ID. RC180 Rev.17...

  • Page 199

    Cannot assign same input number to Check the remote setting. some remote functions. Remote setup error. 2180 Cannot assign same output number to Check the remote setting. some remote functions. Cannot calculate because it was queue 2190 Review the program. data. RC180 Rev.17...

  • Page 200

    Plane number is out of range. Review the program. Specified Plane is not defined. Review 2219 Plane number is not defined. the Plane number. PRM failure. No PRM file data is Reboot the controller. Restore the 2220 found. controller configuration. RC180 Rev.17...

  • Page 201

    Check the variable type and calculation 2244 Specified variable was below the result. Review the program. minimum allowed value. This command cannot be executed for Cannot execute this command with a 2245 Real or Double type. Review the floating point number. program. RC180 Rev.17...

  • Page 202

    Available timer number is from 0 to 15. specified 2267 range. Review the program. timer number Available trap number is from 1 to 4. specified 2268 Trap number is out of available range. Review the program. trap number RC180 Rev.17...

  • Page 203

    I/O command cannot be executed while 2294 an error has been detected. Need an error occurs. Review the program. Forced. For details on inexecutable commands, Cannot execute this command from a 2295 refer to the online help. NoEmgAbort Task. Review the program. RC180 Rev.17...

  • Page 204

    Cannot execute a motion command Execute the motion command after 2318 when an error has been detected. resetting the error by Reset. Cannot execute a I/O command during 2319 Check the emergency stop status. emergency stop condition. RC180 Rev.17...

  • Page 205

    Review the program. I/O input/output bit number. is out of Check whether the expansion I/O board 2344 available range or the board is not Bit number and Fieldbus I/O board are correctly installed. detected. RC180 Rev.17...

  • Page 206

    For...Next using a Goto statement. Cannot execute Return while executing 2382 Review the program. OnErr. Return was used without GoSub. 2383 Review the program. Review the program. Case or Send was used without Select. 2384 Review the program. Review the program. RC180 Rev.17...

  • Page 207

    32. Curve failure. Check whether the specified Curve file 2419 Curve file path is too long. name is correct. 2420 Curve file name is invalid. Error message failure. Error message 2430 Reboot the controller. file does not exist. RC180 Rev.17...

  • Page 208

    Review the program. 2461 The database is not open. Open the database. Database Error. 2462 The database number is being used by Review the program. another task. Windows Communication Error. Reboot the Controller. 2470 Invalid status. Rebuild the project. RC180 Rev.17...

  • Page 209

    Specified point label is not defined. registered. Check the point file. Failed to obtain the motor on time of 2514 Reboot the controller. the robot. Failed to configure the date or the Check whether a date and time is set 2515 time. correctly. RC180 Rev.17...

  • Page 210

    Failed to open as client to the Ethernet 2901 properly. Check whether the Ethernet port. cable is connected properly. Check whether port 2902 Failed to read from the Ethernet port. communication recipient is not close. 2904 Invalid IP Address was specified. Review the IP address. RC180 Rev.17...

  • Page 211

    Daemon failure. Timeout while 2951 Reboot the Controller. creating the daemon thread. Set the TP key switch to TEACH or TEACH/AUTO switching key input 2952 AUTO properly. Check whether the TP signal failure was detected. is connected properly. RC180 Rev.17...

  • Page 212

    If you use the simulator, check if the 2997 Collision was detencted. object is placed in the direction of the robot motion. AbortMotion attempted when robot 2998 See Help for AbortMotion. was not moving AbortMotion attempted when robot 2999 See Help for AbortMotion. was moving RC180 Rev.17...

  • Page 213

    Corresponding Loop cannot be found. correspond to Do statements is not enough. Add the Loop statements. The number of Next statements that 3120 Corresponding Next cannot be found. correspond to For statements is not enough. Add the Next statements. RC180 Rev.17...

  • Page 214

    ByRef was not specified on Function 3138 function declaration that is called by Call declaration. statement. The Xqt statement cannot be executed Cannot execute the Xqt statement for a function needing ByRef 3139 function that needs ByRef parameter. Delete the ByRef parameter. parameter. RC180 Rev.17...

  • Page 215

    Ident length is beyond the available 3143 characters so as not to exceed the size. available length. For details of the available length, refer to EPSON RC+ User’s Guide “6.4 Function Variable Names (Naming restriction)”. Correct the identifier ' ** ' or the function 3144 ' ** ' already used for a function name.

  • Page 216

    Call command cannot be used in Call command cannot be used parallel 3188 parallel processing. processing. Correct the program. Change of local variable cannot be Local variables cannot be used with 3189 waited by Wait statement. Correct the the Wait command. program. RC180 Rev.17...

  • Page 217

    High/Low was not specified. power mode setting of Power statement. Specify High or Low. Input bit label is not specified in SetSW, 3217 Input bit label was not specified. CTReset statement, Sw, and Ctr function. Specify a valid input bit label. RC180 Rev.17...

  • Page 218

    Setting value for the hand orientation is 3232 Righty/lefty was not specified. specified Hand statement. Specify either Righty or Lefty. Setting value for the wrist orientation is 3233 NoFlip/Flip was specified. specified Wrist statement. Specify either NoFilip or Flip. RC180 Rev.17...

  • Page 219

    Refer to SPEL+ Language 3244 Software flow was not specified. Reference “SetCom Statement” and specify a proper flow control. “NONE” is not specified for software 3245 None was not specified. flow control setting in SetNet statement. Specify “NONE”. RC180 Rev.17...

  • Page 220

    Boolean value. Correct the condition expression to return a Boolean value. RS-232C port number is not specified in ChkCom function. Refer to SPEL+ RS232C port number 3258 Language Reference “ChkCom specified. Function” and specify a proper port number. RC180 Rev.17...

  • Page 221

    “BackColorMode Property” and specify a proper setting value. BorderStyle property setting value is not specified in GSet statement. Refer to 3272 BorderStyle was not specified. GUI Builder 5.0 manual “BorderStyle Property” and specify a proper setting value. RC180 Rev.17...

  • Page 222

    TextAlign property setting value is not specified in GSet statement. This error occurs when the control is a 3282 TextAlign was not specified. text box. Refer to GUI Builder 5.0 manual “TextAlign Property” and specify a proper setting value. RC180 Rev.17...

  • Page 223

    Correct the program (variable name). 3311 File cannot be found. 3312 OBJ file is corrupt. The specified file name includes 3313 character(s) that cannot be used. The file is used for other application. 3314 Cannot open the file. Quit the other application. RC180 Rev.17...

  • Page 224

    Correct the data type of the variable and 3336 Variable was redefined. rebuild the project. DialogResult property setting value is not specified in GSet statement. Refer 3405 DialogResult was not specified. to GUI Builder 5.0 “DialogResult Property” and specify a proper setting value. RC180 Rev.17...

  • Page 225

    #define, #ifdef, #ifndef, #else, #endif, #undef variable declaration Check and correct the content of include 3506 statements are only valid in an include file. file. Reduce the nesting level to under the 3507 Over #ifdef or #ifndef nesting level. limited value. RC180 Rev.17...

  • Page 226

    PerformMode parameter: 7.0.4.x or later Check the compiler version from the project property. Module variable cannot be accessed from Module variable cannot be used from 3809 the command window. Check the input the Command window. command. RC180 Rev.17...

  • Page 227

    Invalid ICode. Rebuild the project. 3916 Invalid ICode. Rebuild the project. 3917 Invalid ICode. Rebuild the project. 3918 Invalid ICode. Rebuild the project. 3919 Invalid ICode. Rebuild the project. 3920 Invalid ICode. 3921 Invalid ICode. Rebuild the project. RC180 Rev.17...

  • Page 228

    4024 using the current Fine specification. are secured firmly. Increase the Fine setting value. Cannot execute a motion command Clear the emergency stop condition and 4025 during emergency stop condition. execute the motion command. RC180 Rev.17...

  • Page 229

    Curve failure. Parallel process was Create a Curve file again with the Curve 4048 specified before the point designation. statement. Curve failure. Number of parallel Create a Curve file again with the Curve 4049 processes is out of the allowable statement. range. RC180 Rev.17...

  • Page 230

    ROT modifier parameter was specified Delete the ROT from the CP motion 4068 for the CP motion command without command. orientation rotation. Specified ECP without selecting ECP 4069 Specify a valid ECP. in CP statement. RC180 Rev.17...

  • Page 231

    Redundant input signal failure of the 4150 Check whether no disconnection, earth emergency stop. fault, or short-circuit of the emergency stop input signal exits. Then reboot the controller. RC180 Rev.17...

  • Page 232

    DMB. noise. Replace the DMB. RAM for the main and servo CPU communication failure. Reboot the Reboot the controller, take the measure 4212 controller. Measure the noise. Replace against noise, or replace the DMB. the DMB. RC180 Rev.17...

  • Page 233

    A free running counter error was detected in the controller. Servo real time status failure. Check the short-circuit and improper 4232 Free running counter error with the connection of the peripheral equipment servo. wiring. (Emergency, D-I/O, Expansion I/O connectors) Replace the controller. RC180 Rev.17...

  • Page 234

    Arm reached the limit of XY motion 4251 range specified by XYLim during the Check the XYLim setting. operation. Coordinate conversion error occurred Check whether a CP motion trajectory is 4252 during the operation. within the motion range. RC180 Rev.17...

  • Page 235

    Manipulator motion did not match to 4277 with ElbowFlag which differs from the ElbowFlag of the target point one specified for the target point. Change ElbowFlag for the target point. RC180 Rev.17...

  • Page 236

    Manipulator motion did not match to 4278 with WristFlag which differs from the WristFlag of the target point one specified for the target point. Change WristFlag for the target point. RC180 Rev.17...

  • Page 237

    Replace the DMB and encoder I/F board. Serial encoder initialization failure. Check the robot configuration. Reboot the controller. 5010 Check the signal cable connection. Check the motor, the DMB, or the Replace the DMB and encoder I/F board. encoder IF board. RC180 Rev.17...

  • Page 238

    Replace the DMB. Data update stopped. Parity error. Check the noise countermeasure. D-DSP communication failure. Reboot the controller. 5029 Check-sum error, Free-run counter Replace the DMB. error Check the noise countermeasure. 5032 Servo alarm A. Reboot the controller. RC180 Rev.17...

  • Page 239

    Check the power cable connection. the motor. 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. RC180 Rev.17...

  • Page 240

    Check the power cable connection. connection, robot, brake, drive, or Check the robot power wiring. (Missing motor. pin, disconnection, short-circuit) Check the power supply voltage. (Low power supply voltage) Replace the motor driver. Replace the DMB. Replace the motor. RC180 Rev.17...

  • Page 241

    Replace the DMB. Replace the motor. Check the short-circuit and earth fault of Over current of the motor driver. the power line. 5049 Check the power cable connection or Replace the motor driver. the robot internal wiring. Replace the DMB. RC180 Rev.17...

  • Page 242

    High temperature of the motor driver . Clean the cooling fan filter. Clean the controller fan filter. Check Lower the motion duty. 5099 the ambient temperature. Decrease the Check the Weight/Inertia setting. duty. Lower the ambient temperature. 5112 Servo alarm C. Reboot the controller. RC180 Rev.17...

  • Page 243

    Perform point teaching and Specify continuous 9 data and 1 reference point 6018 calibration again. for the Robot coordinate. Perform point teaching and Specify continuous 9 data and 2 reference 6019 calibration again. points for the Robot coordinate. RC180 Rev.17...

  • Page 244

    Point area is allocated beyond the There are too many points. 7028 available point number. Review the number of points. Specified point file name is not 7029 correct. Specify a valid point file Check the file extension. name. RC180 Rev.17...

  • Page 245

    The point label is not correct. Specify 7040 name is improper. Correct the label a valid point point label. name. The point label is not correct. Specify Inadequate character is used. 7041 a valid point point label. Correct the label name. RC180 Rev.17...

  • Page 246

    Restore the controller firmware. (If Code 1 is 1, 2, or 3) Timeout error occurs during 7103 communication data error transform. detected during communication. communication cable has a problem. Check the communication cable and its related units. RC180 Rev.17...

  • Page 247

    Cannot execute a Vision statement Execute the command from the program. from the command window. Initialize the camera. 7500 Smart camera. Out of memory. Reduce the project size. 7501 Smart camera. Project does not exist. Rebuild the project. RC180 Rev.17...

  • Page 248

    Vision object not found. the result. 7516 No vision calibration. Check the calibration name. 7517 Incomplete vision calibration. Perform calibration. Smart camera. 7518 Check the camera connection. Cannot connect with camera. Smart camera. 7519 Check the camera connection. Communication error. RC180 Rev.17...

  • Page 249

    Check the property value and specify the valid 7656 Invalid property value. value. MDL failure. Reboot the controller. 7847 Failed to open the MDL file. Reinstall the firmware. MDL failure. Reboot the controller. 7848 Failed to read the MDL file. Reinstall the latest firmware version. RC180 Rev.17...

  • Page 250

    Check the noise countermeasures. 9613 controller. Check for noise. Replace the Replace the DMB. DMB. Initialization communication of main CPU servo CPU failure. Reboot the Check the noise countermeasures. 9614 Controller. Check for noise. Replace Replace the DMB. DMB. RC180 Rev.17...

  • Page 251

    Replace the DMB. Interruption duplicate. Check the noise countermeasures. Check short-circuit improper connection of the peripheral equipment wiring. Servo control gate array failure. Check the 9700 (Emergency and I/O connectors) DMB. Replace the DMB. Replace the additional axis unit. RC180 Rev.17...

  • Page 252

    Reset the encoder. 9716 Replace the battery to a new one. Check Check the signal cable connection. the robot internal wiring. Backup data failure of the absolute encoder. Reset the encoder. 9717 Reset the encoder. Check the signal cable connection. RC180 Rev.17...

  • Page 253

    Current data failure. 9728 Replace the DMB. Data update stopped. Parity error. Check the noise countermeasure. Reboot the controller. D-DSP communication failure. 9729 Replace the DMB. Check-sum error, Free-run counter error Check the noise countermeasure. 9732 Servo alarm A. RC180 Rev.17...

  • Page 254

    Commands cannot be executed because Execute after the project build is 10023 completed. the project build is not complete. Check the task name. 10024 Invalid task name. 10025 Trial runtime expired. 10100 Command already in cycle. 10101 Command aborted by user. RC180 Rev.17...

  • Page 255: Cannot Connect The Development Pc And The Controller Using The Usb Cable

    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.

  • Page 256

    (4) The [System Properties] dialog appears. Select the [Hardware] tab and click the <Device Manager> button. (5) The [Device Manager] dialog appears. Click <Universal Serial Bus controllers> and make sure that “EPSON Robot Controller RC170 (or RC180)” is registered. RC180 Rev.17...

  • Page 257

    !! 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”...

  • Page 258: 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.

  • Page 259

    TP/OP Bypass Plug R13B071302 Controller Mounting Metal Hasp R13B071303 R12B040301 Expansion I/O Board Option R12B040705 RS-232C Board Option R12B040706 DeviceNet Board Option R12B040707 PROFIBUS-DP Board Option R12B040708 CC-Link Board Option R12B040719 EtherNet/IP Board Option R12B040728 PROFINET board Option RC180 Rev.17...

  • Page 260

    When installed to the firmware version 1.16.4.x, and 1.24.4.x or later, the parts NOTE  consumption management will be disabled (default). For details for enabling or disabling the parts consumption management, refer to the EPSON RC+ 5.0 User’s Guide 5.12.2 [Controller] Command (Setup Menu) - [Setup]-[Controller]-[Preferences] Page. RC180 Rev.17...

  • Page 261

    The following parts are subject to grease up: SCARA (including RS series): Ball screw spline unit on the Joint # 3 For details on the robot configuration, refer to the EPSON RC+ 5.0 User’s Guide 9.1 Setting the Robot Model.

  • Page 262

    Appendix. Alarm 2. How to View the Maintenance Information The configured maintenance information can be checked in the EPSON RC+ 5.0 Ver.5.4.7 or later. (1) Select the EPSON RC+ 5.0 menu-[Tools]-[Maintenance] to display the [Controller Tools] dialog box. (2) To check the controller maintenance information, click the <Maintenance> button and display the [Maintenance] dialog box.

  • Page 263

    10% failure probability). In the dialog window, the L10 life is displayed as 100%. 3. How to Edit the Maintenance Information The configured maintenance information can be edited in the EPSON RC+ 5.0 Ver.5.4.7 or later. (1) Select the EPSON RC+ 7.0 menu-[Tools]-[Maintenance] to display the [Controller Tools] dialog box.

  • Page 264

    4. Alarm Notifying Method The alarm notifying method can be configured by the output bit of the Remote I/O. The Remote I/O can be configured in the EPSON RC+ 5.0- [Setup] - [Controller] - [Remote Control]. For details, refer to EPSON RC+ 5.0 User’s Guide 11.8...

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