RC180 Safety and Installation Read this manual first Rev.
RC180 Safety and Installation Rev.
RC180 Safety and Installation Rev.19 Copyright © 2006-2013 SEIKO EPSON CORPORATION. All rights reserved. RC180 Safety and Installation Rev.
FOREWORD Thank you for purchasing our robot products. This manual contains the information necessary for the correct use of the Operator Panel. Please carefully read this manual and other related manuals before installing the robot system. Keep this manual handy for easy access at all times.
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.
MANUFACTURER Toyoshina Plant Industrial Solutions Division 6925 Toyoshina Tazawa, Azumino-shi, Nagano, 399-8285 JAPAN TEL : +81-(0)263-72-1530 FAX : +81-(0)263-72-1495 SUPPLIERS North & South America EPSON AMERICA, INC. Factory Automation/Robotics 18300 Central Avenue, Carson, CA 90746 USA TEL : +1-562-290-5900 FAX : +1-562-290-5999 E-MAIL : info@robots.epson.com Europe EPSON DEUTSCHLAND GmbH Factory Automation Division Otto-Hahn-Str.
Taiwan EPSON Taiwan Technology & Trading Ltd. Factory Automation Division 14F, No.7, Song Ren Road, Taipei 110 Taiwan, ROC TEL : +886-(0)-2-8786-6688 FAX : +886-(0)-2-8786-6677 Southeast Asia Epson Singapore Pte Ltd. India Factory Automation System 1 HarbourFrontPlace, #03-02 HarbourFront Tower one, Singapore 098633 Korea TEL : +65-(0)-6586-5696 FAX : +65-(0)-6271-3182 EPSON Korea Co, Ltd.
For Customers in the European Union The crossed out wheeled bin label that can be found on your product indicates that this product and incorporated batteries should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health please separate this product and its batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner.
Before Reading This Manual NOTE ) Do not connect the followings to TP/OP port of RC180. Connecting to the followings may result in malfunction of the device since the pin assignments are different. OPTIONAL DEVICE dummy plug Operation Pendant OP500 Operator Pendant OP500RC Jog Pad JP500 Teaching Pendant TP-3** NOTE ) For RC180, be sure to install the EPSON RC+5.0 to the development PC first, then connect the development PC and RC180 with the USB cable.
NOTE ) Every data of the Controller is stored to the Compact Flash inside the Controller. When you execute the commands listed below, data is written to the Compact Flash. Frequent data writing to the Compact Flash may shorten the Compact Flash life. It is recommended to use the following commands only when it is necessary.
TABLE OF CONTENTS 1. Safety 1 1.1 Conventions.................................................................... 1 1.2 Design and Installation Safety ........................................ 2 1.3 Operation Safety............................................................. 3 1.4 Maintenance Safety ........................................................ 9 1.5 Emergency Stop ........................................................... 12 1.6 Labels ..................................................
5. General Maintenance 5.1 88 Schedule for Maintenance Inspection........................... 88 5.2 Inspection Point ............................................................ 90 x 6. Manual 96 7. Directives and Norms 99 RC180 Safety and Installation Rev.
1. Safety 1. Safety Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. Please read this manual and other related manuals before installing the robot system or before connecting cables. Keep this manual handy for easy access at all times. 1.1 Conventions Important safety considerations are indicated throughout the manual by the following symbols.
1. Safety 1.2 Design and Installation Safety Only trained personnel should design and install the robot system. Trained personnel are defined as those who have taken robot system training held by the manufacturer, dealer, or local representative company, or those who understand the manuals thoroughly and have the same knowledge and skill level as those who have completed the training courses. To ensure safety, a safeguard must be installed for the robot system.
1. Safety 1.3 Operation Safety The following items are safety precautions for qualified Operator personnel: ■ Please carefully read the Safety-related Requirements in this manual before operating the robot system. Operating the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system. ■ Do not enter the operating area of the Manipulator while the power to the robot system is turned ON.
1. Safety Safety-related Requirements Specific tolerances and operating conditions for safety are contained in the manuals for the robot, controller and other devices. Be sure to read those manuals as well. For the installation and operation of the robot system, be sure to comply with the applicable local and national regulations. Robot systems safety standards and other examples are given in this chapter.
1. Safety Part Names and Arm Motion G series The motion range of each arm is shown in the figure below. Take all necessary safety precautions. Joint #2 (Rotate) + Joint #1 (Rotate) Arm #2 + + Joint #3 (Up/Down) - Shaft Arm #1 + Joint #4 (Rotate) RC180 Safety and Installation Rev.
1. Safety RS series The motion range of each arm is shown in the figure below. Take all necessary safety precautions. Joint #1 (rotating) − + Joint #2 (rotating) − + Base Arm #1 Arm #2 + Joint #3 (up and down) − − 6 Shaft + Joint #4 (rotating) RC180 Safety and Installation Rev.
1. Safety C3 series The motion range of each arm is shown in the figure below. Take all necessary safety precautions. LED Lamp This lamp lights up while the motors are ON. Upper Arm (Arms #3 to #6) Arm #4 J6− J5+ Joint #4 J4− J3+ Arm #3 Arm #6 Joint #6 J6+ Arm #5 J5− J4+ J3− Joint #3 Joint #5 Arm #2 (Lower Arm) J2− J2+ J1+ Joint Motion Joint #1 : The whole Manipulator revolves. Joint #2 Arm #1 J1− Joint #2 : The lower arm swings. Joint #3 : The upper arm swings.
1. Safety S5 series The motion range of each arm is shown in the figure below. Take all necessary safety precautions. Upper Arm (Arms #3 to #6) LED Lamp (This lamp lights up while the motors are ON.) J3− J4+ Arm #5 Joint #5 J5+ J6+ Joint #6 Arm #3 Arm #6 J3+ Ｊ5− J4− Joint #3 Joint #4 J6− Arm #4 Arm #2 (Lower Arm) J2+ J2− Joint #2 Joint #1 Arm Motion Arm #1 : The whole Manipulator revolves. J1+ Arm #1 Arm #2 : The lower arm swings. Arm #3 : The upper arm swings.
1. Safety 1.4 Maintenance Safety Please read this section, Maintenance of the Manipulator manual, Maintenance of the Controller manual, and other related manuals carefully to understand safe maintenance procedures before performing any maintenance. Only authorized personnel who have taken the safety training should be allowed to maintain the robot system. The safety training is the program for the industrial robot operator that follows the laws and regulations of each nation.
1. Safety ■ Be sure to connect the AC power cable to a power receptacle. NOT connect it directly to a factory power source. DO To shut off power to the robot system, pull out the power plug from the power source. Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and/or malfunction of the robot system.
1. Safety ■Wear protective gear including a mask, protective goggles, and oil-resistant gloves during grease up. If grease gets into your eyes, mouth, or on your skin, follow the instructions below. If grease gets into your eyes : Flush them thoroughly with clean water, and then see a doctor immediately. CAUTION If grease gets into your mouth: If swallowed, do not induce vomiting. See a doctor immediately. If grease just gets into your mouth, wash out your mouth with water thoroughly.
1. Safety 1.5 Emergency Stop If the Manipulator moves abnormally during operation, immediately press the Emergency Stop switch. The motor power will be turned OFF, and the arm motion by inertia will be stopped with the electromagnetic brake and dynamic brake. However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator is running normally.
1. Safety For details of the Safeguard system, refer to the following manuals. EPSON RC+ User’s Guide 2. Safety - Installation and Design Precautions - Safeguard System Safety and Installation 2.6 Connection to EMERGENCY Connector To check brake problems, refer to the following manuals. Manipulator Manual Maintenance 2.2.2 Inspection While the Power is ON (Manipulator is operating) Safety and Installation 5.
1. Safety 1.6 Labels Labels are attached around the locations of the Controller and Manipulator where specific dangers exist. Be sure to comply with descriptions and warnings on the labels to operate and maintain the Robot system safely. Do not tear, damage, or remove the labels. Use meticulous care when handling those parts or units to which the following labels are attached as well as the nearby areas. Label types differ according to the specifications. 14 RC180 Safety and Installation Rev.
1. Safety Controller Location Label Note Residual voltage exists. To avoid electric shock, do not open the cover while the Power is ON, or for 2 minutes after the Power is OFF. A Residual voltage exists. To avoid electric shock, do not open the cover while the Power is ON, or for 300 seconds after the Power is OFF. Disconnect and lockout main power before performing maintenance and repair. B Do not connect the followings to TP/OP port of RC180.
1. Safety Manipulator Location Label Note Before loosening the base mounting screws, hold the arm and secure it tightly with a band to prevent hands or fingers from being caught in the Manipulator. Follow the directions in this manual for installation and transportation. A 16 RC180 Safety and Installation Rev.
1. Safety Location Label Note Do not enter the operation area while the Manipulator is moving. The robot arm may collide against the operator. This is extremely hazardous and may result in serious safety problems. B C RC180 Safety and Installation Rev.19 Hazardous voltage exists while the Manipulator is ON. To avoid electric shock, do not touch any internal electric parts.
1. Safety Location D Label Note You can catch your hand or fingers between the shaft and cover when bringing your hand close to moving parts. Manipulators with bellows do not have this label for no danger of your hand or fingers being caught Be careful of the arm falling due to the arm’s own weight while the brake release button is being pressed. * This label is attached to the option brake release box.
1. Safety Location Label Note Do not lift without the shipping bracket. To pick up the manipulator arm, use two wire ropes of equal length. Remove the shipping brackets and eyebolts before turning power on. Follow the directions in this manual for installation and transportation. F RC180 Safety and Installation Rev.
1. Safety Location Label Note Arm weight may cause arm to fall during disassembly operation. Follow the directions in this manual for disassembly operation. G Only authorized personnel should perform sling work and operate a crane and a forklift. H (Only UL model) When these operations are performed by unauthorized personnel, it is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system. I J 20 RC180 Safety and Installation Rev.
1. Safety Location of Labels G1 E I C B H A J RC180 Safety and Installation Rev.
1. Safety G3 Common C D E Table Top Mounting J I B H C A Multiple Mounting B H 22 A I J C RC180 Safety and Installation Rev.
1. Safety G6 Table Top Mounting G6-***S C E D B H I C A J Ceiling Mounting G6-***SR J A C C E Wall Mounting G6-***SW E I H D J I C H A D B B G10/G20 Table Top Mounting: G10/G20-**** Wall Mounting: G10/G20-****W J E C I C F E F D A B I A D C B J Ceiling Mounting: G10/G20-****R A J C F E C B D RC180 Safety and Installation Rev.
1. Safety RS J Top C C Side D C H B (Both sides) E Front C I Bottom A 24 RC180 Safety and Installation Rev.
1. Safety C3 I C Top View C C C C A B Front View RC180 Safety and Installation Rev.
1. Safety S5 C B G A I Lateral View (Left side) Lateral View (Right side) C F D C Back View 26 Front View RC180 Safety and Installation Rev.
1. Safety 1.7 Safety Features The robot control system supports safety features described below. However, the user is recommended to strictly follow the proper usage of the robot system by thoroughly reading the attached manuals before using the system. Failure to read and understand the proper usage of the safety functions is highly dangerous. Among the following safety features, the Emergency Stop Switch and Safety Door Input are particularly important.
1. Safety Low Power Mode The motor power is reduced in this mode. Executing a power status change instruction will change to the restricted (low power) status regardless of conditions of the safety door or operation mode. The restricted (low power) status ensures the safety of the operator and reduces the possibility of peripheral equipment destruction or damage caused by careless operation. Dynamic Brake The dynamic brake circuit includes relays that short the motor armatures.
1. Safety Speed Overflow -Servo Error- Detection The dynamic brake circuit is activated when the Manipulator’s actual speed is detected to mark an overflow (the actual speed is outside the nominal range) error. CPU Irregularity Detection Irregularity of CPU that controls the motor is detected by the watchdog timer. The system CPU and the motor controlling CPU inside the Controller are also designed to constantly check each other for any discrepancies.
2. Installation 2. Installation This chapter contains precautions for safe and accurate installation of the robot system. The outline to install the robot system is indicated on 2.1 Outline from Unpacking to Operation of Robot System. Refer to each section and/or the Manipulator manual and the Controller manual for unpacking, transportation, and installation. 30 RC180 Safety and Installation Rev.
2. Installation System Example PLC (Sequencer) Operation Panel Motion Controller * Option Unit Expansion I/O Board G series RC180 Fieldbus - Profibus - Devicenet - CC-LINK - EtherNet/IP ProSix Driver Unit Standard Installation S5 series - Standard I/O - Remote I/O - Ethernet * RS-232C Board * C3 series USB2.0 or Ethernet * Controls one of the robots. PC RS series Windows *1 (XP or Vista or 7) OP1 (Option) TP1 (Option) * Connect OP1, TP1, and / or TP2 EPSON RC+ 5.
2. Installation 2.1 Outline from Unpacking to Operation of Robot System 2. Installation Unpacking Transportation Installation Power-on Yes Error? No Procedures to install the Robot system and turn ON the power properly 3. First Step Procedures to install EPSON RC+5.0 to the development PC and enable the operation of the robot system 4. Second Step Manual information to connect or setup the equipment and options 32 RC180 Safety and Installation Rev.
2. Installation 2.2 Unpacking Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. Using a cart or similar equipment, transport the Manipulator in the same conditions as it was delivered. Observe the following when unpacking the Manipulator. Package Components Example The following figure illustrates the package at delivery. Manipulator Attached Equipment Controller etc.
2. Installation 2.3 Transportation Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. Transportation Precautions Transportation procedure : Using a cart or similar equipment, transport the Manipulator in the same conditions as it was delivered. Observe the following when unpacking the Manipulator. Only authorized personnel should perform sling work and operate a crane or forklift.
2. Installation Manipulator Transportation G1 To carry the Manipulator, secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand. Never hold the duct to carry the Manipulator. Duct DO NOT hold here for carrying G1-171* approx. 8 kg :18 lb. Hold here for carrying G1-221* approx. 8 kg :18 lb.
2. Installation G6 To carry the Manipulator, have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the figure (bottom of Arm #1 / bottom of the base) by hand. When holding the bottom of the base by hand, be very careful not to get hands or fingers caught. Table Top Mounting G6-45**/G6-55** Approx. 27 kg: 60 lb. G6-65** Approx. 28 kg: 62 lb. Wall Mounting G6-45**W/G6-55**W Approx. 29 kg: 64 lb. G6-65**W Approx. 29.5 kg: 65 lb.
2. Installation G10 / G20 To carry the Manipulator, secure the Manipulator to the delivery equipment, or pass belts through the eyebolts and hoist it with your hands. Make sure to hold the areas indicated in gray in the figure (bottom of Arm #1 and bottom of the base) by hand. Wall Mounting: W Table Top Mounting: * Ceiling Mounting: R G10 65**/**R 65**W : Approx. 46 kg : 102 lb : Approx. 51 kg : 113 lb G10/G20 85**/**R 85**W : Approx. 48 kg : 106 lb : Approx. 53 kg : 117 lb G20 A0**/**R : Approx.
2. Installation C3 To carry the Manipulator, have at least 2 people to work on it and secure the Manipulator to the delivery equipment or hold it by hand. Do not hold the bottom of the base (the screened parts in the figure). Holding these parts by hand is extremely hazardous and may cause your hands and fingers to be caught. Manipulator weight : 27 kg (59.5 lb.) DO NOT hold the bottom of the base by hand.
2. Installation Using a Crane To hoist the Manipulator with a crane, secure the Manipulator with shipping bolts and jigs and posture the Manipulator as shown in the figures below (the posture at shipment from the manufacturer). Use a cable threaded through the eyebolts attached to the Manipulator as shown. (Make sure that they are not loose.
2. Installation 2.4. Manipulator Installation Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. For details, refer to the Manipulator manual. Installation Precautions Safeguard installation : To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to the Installation and Design Precautions in the Safety chapter of the EPSON RC+ User’s Guide.
2. Installation For Protected-model : Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation. The Manipulator without connecting them may result in electric shock and/or malfunction of the robot system as it cannot ensure IP65. Noise level Noise level by movement of manipulator.
2. Installation G / RS series RS G Max. Reaction torque on the horizontal plate (Nm) Max. Horizontal reaction force (N) Max. Vertical reaction force (N) Threaded holes for Mounting screw G1 G3 G6 G10 G20 RS3 RS4 100 300 500 1000 1000 500 500 200 300 2000 1000 2500 1500 4500 2000 7500 2000 1200 1100 1400 1100 M6 M8 M8 M12 M12 M6 M6 The plate for the Manipulator mounting face should be 20 mm thick or more and made of steel to reduce vibration.
2. Installation NOTE ) Installation Procedure When the Manipulator is Clean-model, unpack it outside of the clean room. Secure the Manipulator not to fall, and then wipe off the dust on the Manipulator with a little alcohol or distilled water on a lint-free cloth. After that, carry the Manipulator in the clean room. Connect an exhaust tube to the exhaust port after installation. G1 There are 4 threaded holes for the Manipulator base.
2. Installation G3 : Table Top Mounting■ Install the Table Top Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G3-251* : approx. 14 kg: 31 lb. CAUTION G3-301* : approx. 14 kg: 31 lb. G3-351* : approx. 14 kg: 31 lb. (1) Secure the base to the base table with four bolts.
2. Installation G3 : Multiple Mounting ■ Install the Multiple Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G3-301*M : approx. 14 kg: 31 lb. G3-351*M : approx. 14 kg: 31 lb. WARNING ■ When installing the Manipulator to the wall, support the Manipulator, and then secure the anchor bolts.
2. Installation G6 : Table Top Mounting ■ Install the Table Top Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. WARNING G6-45** : Approximately 27 kg: 60 lb. G6-55** : Approximately 27 kg: 60 lb. G6-65** : Approximately 28 kg: 62 lb. (1) Secure the base to the base table with four bolts.
2. Installation G6 : Wall Mounting ■ Install the Wall Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G6-45**W : Approximately 29 kg: 64 lb. G6-55**W : Approximately 29 kg: 64 lb. WARNING G6-65**W : Approximately 29.5 kg: 65 lb. ■ When installing the Manipulator to the wall, support the Manipulator, and then secure the anchor bolts.
2. Installation G6 : Ceiling Mounting ■ Install the Ceiling Mounting Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G6-45**R : Approximately 27 kg: 60 lb. G6-55**R : Approximately 27 kg: 60 lb. WARNING G6-65**R : Approximately 28 kg: 62 lb. ■ When installing the Manipulator to the ceiling, support the Manipulator, and then secure the anchor bolts.
2. Installation G10/G20 : Table Top Mounting ■ Install the Table Top Mounting Manipulator with four or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. CAUTION G10-65** G10/G20-85** : Approximately 48 kg :106 lb. G20-A0** (1) : Approximately 46 kg :102 lb. : Approximately 50 kg :111 lb. Secure the base to the base table with four bolts.
2. Installation G10/G20 : Wall Mounting ■ Install the Wall Mounting Manipulator with four or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G10-65**W : Approximately 51 kg :113 lb. G10/G20-85**W : Approximately 53 kg :117 lb. G20-A0**W WARNING : Approximately 55 kg :122 lb. ■ When installing the Manipulator to the wall, support the Manipulator, and then secure the anchor bolts.
2. Installation G10/G20 : Ceiling Mounting ■ Install the Ceiling Mounting Manipulator with four or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. G10-65**R : Approximately 46 kg :102 lb. G10/G20-85**R: Approximately 48 kg :106 lb. WARNING G20-A0**R : Approximately 50 kg :111 lb.
2. Installation RS ■ Install the Manipulator with two or more people. The Manipulator weights are as follows. Be careful not to get hands, fingers, or feet caught and/or have equipment damaged by a fall of the Manipulator. RS3-351*: approx. 17 kg : 38 Ib. (except cables) RS4-551*: approx. 19 kg : 42 Ib. (except cables) CAUTION ■ When installing the Manipulator to the ceiling, support the Manipulator, and then secure the anchor bolts.
2. Installation S5 The shipping bolts and jigs are attached to the Manipulator as shown the figure below (points A, B) for protecting the Manipulator from various external forces during transportation. Be sure to remove the bolts from the Point A first, and then, remove the bolts from Point B. The jigs are painted yellow.
2. Installation 2.5 Controller Installation Installation Precautions Environment conditions : 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.
2. Installation Installation - Mount the Controller mounting screws with 80 to 110 Ncm torque. - Install the controller on a flat surface such as wall, floor, and controller box in the direction shown from (A) to (D). (A) (B) Fixture L Base Table Fixture L (C) (D) Rack Fixture L Base Table Base Table Fixture S There are two types of fixtures. Mount the fixture to the Controller with the four attached screws.
2. Installation - For Controller installation to the Controller box or the base table, process screw hole drilling as follows. When mounting direction is (A) or (B) 8-M5 (1) Outline of the RC180 Unit [mm] 59.8 59.8 57.2 57.2 76.1 76.1 57.2 57.2 (4) 24.7 (2) 24.7 (5) (6) (3) When mounting direction is (C) : Fixture S: 4-M5 20.5 20.5 90.0 (1) (2) (3) 90.0 60.0 (4) (5) (Front Side) 60.0 (Front Side) (6) No screw hole processing is required for mounting direction (D).
2. Installation - Ensure the draft around the in/out and also install the controller by keeping the distance as follows to prevent the nose influence from other equipment such as large contactor and relay. 100 mm 100 mm 100 mm Air flow of the Controller Fan 100 mm Excluding the installation side such as base table - Hot air with higher temperature than the ambient temperature (about 10 deg.C) comes out from the in/out of the Controller.
2. Installation 2.6 Connection to EMERGENCY Connector (Controller) Connect a safeguard switch or Emergency Stop switch to the Controller EMERGENCY connector for safety. When nothing is connected to the EMERGENCY connector, Controller does not operate normally. ■ Before connecting the connector, make sure that the pins are not bent. Connecting with the pins bent may damage the connector and result in WARNING malfunction of the robot system.
2. Installation In order to maintain a safe working zone, a safeguard must be erected around the Manipulator. The safeguard must have an interlock switch at the entrance to the working zoon. The Safety Door that is described in this manual is one of the safeguards and an interlock of the Safety Door is called a Safety Door switch. Connect the Safety Door switch to the Safety Door input terminal on the EMERGENCY connector.
2. Installation Checking Latch Release Switch Operation NOTE ) Refer to 3.2 Development PC and Controller Connection and connect the development PC and Controller before checking the function. After connecting the safety door switch and latch release switch to the EMERGENCY connector, be sure to check the switch operation for safety by following the procedures described below before operating the Manipulator.
2. Installation NOTE ) The signal from the Emergency Stop switch is designed to use two redundant circuits. If the signals at the two circuits differ by two seconds or more, the system recognizes it as a critical error. Therefore, make sure that the Emergency Stop switch has double contacts and that each circuit connects to the specified pins on the EMERGENCY connector at the Controller. Refer to the Controller Manual RC170 / RC180 Setup & Operation: 5.5 Circuit Diagrams.
2. Installation Pin Assignments The EMERGENCY connector pin assignments are as follows: Pin No. Signal 1 ESW11 2 ESW12 3 ESTOP1+ 4 ESTOP1− NC NC SD11 SD12 24V 24V 24VGND 24VGND NC 5 6 7 8 9 10 11 12 13 Function Emergency Stop switch contact (1) *3 Emergency Stop switch contact (1) *3 Emergency Stop circuit 1 (+) Emergency Stop circuit 1 (-) *1 *1 Safety Door input (1) *2 Safety Door input (1) *2 +24V output +24V output +24V GND output +24V GND output Pin No.
2. Installation Circuit Diagrams Example 1: External emergency stop switch typical application Controller +24V External Emergency Stop switches 9 Emergency Stop switch of an Operation Unit 10 22 23 1 2 14 15 3 +5V 16 Main Circuit Control Motor Driver + + − AC Input 4 17 Emergency Stop detection 11 12 24 25 External +24V 7 Safety Door input 1 8 20 Safety Door input 2 21 18 Latch release input NOTE:+24V GND + 5V GND RC180 Safety and Installation Rev.
2. Installation Example 2: External safety relay typical application Controller External +24V Fuse +24V 9 Emergency Stop switch of an Operation Unit 10 22 23 External +24V GND 1 2 14 15 3 +5V 16 External safety relay (The above diagram is simplified for representation.) Main Circuit Control Motor Driver + + External +24V * 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.
2. Installation 2.7 AC power cable ■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect it directly to a factory power source. To shut off power to the robot system, pull out the power plug from the power source.
2. Installation 2.8 Connecting Manipulator and Controller Connecting Precautions Before Connection : Before connecting the connector, make sure that the pins are not bent. Connecting with the pins bent may damage the connector and result in malfunction of the robot system. Connecting procedure : Before performing any connecting procedure, turn OFF the Controller and related equipment, and then pull out the power plug from the power source.
2. Installation For Protected-model : Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation. The Manipulator without connecting them may result in electric shock and/or malfunction of the robot system as it cannot ensure IP65.
2. Installation C3 series C3 series Manipulator Controller RC180 M/C power cable M/C signal cable S5 series S5 series Manipulator Controller RC180 M/C power cable M/C signal cable 68 RC180 Safety and Installation Rev.
2. Installation 2.9 Power-on Power-on Precautions Manipulator check before installation : Before installing and operating the Manipulator, make sure that all parts of the Manipulator are in place and have no external defects. Missing or defective parts may cause improper operation of the Manipulator. Improper operation of the Manipulator is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.
2. Installation G series (Figure: G6-553S) (3) (5) (1) (2) (4) RS series (Figure: RS3-351S) (3) (1) (2) (5) (4) C3 series (3) (5) (1) (2) 70 (4) RC180 Safety and Installation Rev.
2. Installation S5 series (3) (5) (1) (2) (4) (7) Seven-segment LED (6) POWER Switch * POWER switch is not available for RC180-UL. Instead, turn ON the external disconnecting means. RC180 Safety and Installation Rev.
3. First Step 3. First Step This section indicates the procedure to install the development PC EPSON RC+ 5.0, and execute simple program after connecting the development PC and Controller with a USB. Make sure that the Robot system is installed safely by following the description in 1. Safety and 2. Installation. Then, operate the Robot system in the following procedures. 3.1 Installing EPSON RC+ 5.0 Software NOTE ) The EPSON RC+ 5.0 software needs to be installed on your development PC. EPSON RC+ 5.
3. First Step 3. The welcome dialog will be displayed as shown below. button to continue. Click the Next 4. Enter your user name and company name, then click Next. RC180 Safety and Installation Rev.
3. First Step 5. Select the drive where you want to install EPSON RC+ 5.0 and click Next. NOTE ) The installation directory is called EpsonRC50 and cannot be changed. 6. You will be prompted to confirm installation. Click Yes to continue. 7. If required, Windows Installer and Microsoft .NET Framework 2.0 are installed on your system. This may take several minutes. NOTE ) Adobe Reader needs to be installed on your PC in order to view the EPSON RC+ 5.0 manuals.
3. First Step 3.2 Development PC and Controller Connection Connect the development PC and the USB port for connection (USB B series connector). Development PC connection Port NOTE ) For other details of development PC and Controller connection, refer to EPSON RC+ 5.0 User’s Guide 5.12.1 PC to Controller Communications Command. For RC180, be sure to install the EPSON RC+5.0 to the development PC first, then connect the development PC and RC180 with the USB cable.
3. First Step Precaution When connecting the development PC and the Controller, make sure of the followings. - Connect the development PC and the Controller with 5 m or shorter USB cable. Do not use the USB hub or extension cable. - Make sure that no other devices except development PC is used for development PC connection port. - Use PC or USB cable that supports USB2.0 HighSpeed mode to operate in USB2.0 HighSpeed mode. - Do not pull or bend the cable strongly.
3. First Step (6) Select the “No.1 USB” and click the button. (7) After development PC and the Controller connection is completed, “Connected” is displayed in the [Connection status:]. Make sure that “Connected” is displayed and click the button to close the [PC to Controller Communications] dialog. Connection of the development PC and the Controller is completed. system can be used from EPSON RC+ 5.0.
3. First Step Disconnection of Development PC and Controller Disconnection of the development PC and the Controller is indicated. (1) Select the EPSON RC+ 5.0 menu-[Setup]-[PC to Controller Communications] to display the [PC to Controller Communications] dialog. (2) Click the button. Controller and the development PC is disconnected and USB cable can be removed. NOTE ) 78 If USB cable is removed when the Controller and the development PC is connected, stop occurs to the Robot.
3. First Step 3.3 Writing your first program After installing the controller, robot, and EPSON RC+ 5.0 software on your PC, follow these instructions to create a simple application program so that you will become more familiar with the EPSON RC+ 5.0 development environment. 1. Connect your PC to the RC180 Controller Install a USB cable between your PC and the Controller. Refer to the 3.2 Development PC Connection Port. 2. Start EPSON RC+ 5.0 Simple Mode Double-click the EPSON RC+ 5.
3. First Step 4. Edit the program Type in the following program lines in the Program.prg edit window. Function main Print "This is my first program." Fend 80 RC180 Safety and Installation Rev.
3. First Step 5. Run the program Press F5 to run the program. (F5 is the hot key for the Run Window selection of the Run menu). You will see the Status window located at the bottom of the main window showing the build operation status. During project build, your program is compiled and linked. Then communications is established with the controller and project files are sent to the controller. If there are no errors during build, the Run window will appear.
3. First Step 6. Teach robot points (1) Ensure that it is safe to operate the robot. Click the on the toolbar. You will see the [Robot Manager] window button with the [Control Panel] page displayed. (2) Click on the button to turn on the robot motors. You will be prompted to confirm the operation. (3) Answer to continue. (4) Click the [Jog & Teach] tab in the Robot Manager. 82 RC180 Safety and Installation Rev.
3. First Step (5) Click the button in the lower right corner to teach point P0. You will be prompted for a point label and description. (6) Jog the robot by clicking the <+Y> jog button. Hold the button down to continue jogging. Let go when the robot is about half way out in the work envelope. (7) Jog the robot down by clicking the <-Z> button. (8) Now change the current point to P1 by selecting P1 in the Point dropdown list next to the button. (9) Click the button.
3. First Step 8. Modify the program to change speed of robot motion commands (1) Insert the Power, Speed, and Accel commands as shown in the program below: Function main Print "This is my first program." Power High Speed 20 Accel 20, 20 Go P1 Go P2 Go P0 Fend (2) Press F5 to display the [Run] window. (3) Click on the button to run the program. The robot should go to each of the points you taught at 20% of speed, acceleration, and deceleration.
3. First Step 9. Backup the project and system configuration Even though this is only a sample project, we will backup the project and controller configuration. This is easy to do with EPSON RC+ 5.0. It is important that you keep regular backups of your applications on external media such as USB memory. Follow these steps to backup the project and system configuration: (1) From the [Project] menu, select [Copy]. (2) Change the [Destination Drive] to a certain drive. (3) Click .
4. Second Step 4. Second Step Setup other necessary functions after operating the robot system as indicated in 3. First Step. Manuals that indicate necessary setups and procedures are guided in this section. (For descriptions of each manual, refer to 6. Manual.) 4.1 Connection with External Equipment Remote Control EPSON RC+ 5.0 User’s Guide 10. Remote Control ROBOT CONTROLLER RC180 manual Setup & Operation 11. I/O Remote Set Up I/O EPSON RC+ 5.0 User’s Guide 9.
4. Second Step 4.3 Connection and Display Language of Option TP1 and OP1 Controller RC180 TP1 OP1 Cable A OP1 Connection Cable B OP1+TP1 Connection TP1 Connection TP1 Connection ROBOT CONTROLLER RC180 Setup & Operation 8. TP/OP Port RC180 Option TP1 Function & Installation 3. Installation NOTE ) NOTE ) Cable A and cable B have different connector shapes. Changing Display Language RC180 Option TP1 Operation 3.6 Program Mode Operation 3.6.
5. General Maintenance 5. General Maintenance This chapter describes maintenance inspections and procedures. Performing maintenance inspections and procedures properly is essential for preventing trouble and ensuring safety. Be sure to perform the maintenance inspections in accordance with the schedule. 5.1 Schedule for Maintenance Inspection G / C3 / RS series Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and annual. The inspection points are added every stage.
5. General Maintenance S5 series Inspection points are divided into five stages: daily, four months, two years, four years, and eight years. If the Manipulator is operated for predetermined hours of operation, perform maintenance inspections. Inspection Inspection Interval Daily Hours of operation Inspect every day 4-month 4 months 1000 hours 24-month 24 months 6000 hours 48-month 48 months 12000 hours 96-month 96 months 24000 hours RC180 Safety and Installation Rev.
5. General Maintenance 5.2 Inspection Point Inspection While the Power is OFF (Manipulator is not operating) Manipulator Inspection Point Check looseness or backlash of bolts/screws. Tighten them if necessary. (For the tightening torque, refer to Tightening Hexagon Socket Head Cap Bolts.) Check looseness of connectors. If the connectors are loosen, push it securely or tighten.
5. General Maintenance Controller Inspection Point Visually check for external defects. Clean up if necessary. Inspection Place Daily Monthly Quarterly Biannual Annual External appearance of √ √ √ √ √ Controller Clean the fan filter - Battery - √ √ √ √ Every 5 years Inspection While the Power is ON (Manipulator is operating) Manipulator (G / C3 / RS series) Inspection Point Check motion range Move the cables back and forth lightly to check whether the cables are disconnected.
5. General Maintenance Manipulator (S5 series) Inspection Point Inspection Space Check for tram mark misalignment or damage at the home position. (Visual) Clean the area of motion range for each joint if dust or spatter is present. Check for damage and outside cracks. (Visual) Tighten loose bolts. Replace if necessary. (Use Spanner, Wrench) Tighten loose screws. Replace if necessary (Use Spanner, Wrench) Check for loose connectors.
5. General Maintenance Tightening Hexagon Socket Head Cap Bolts Hexagon socket head cap bolts are used in places where mechanical strength is required. (A hexagon socket head cap bolt will be called a “bolt” in this manual.) These bolts are fastened with the tightening torques shown in the following table.
5. General Maintenance Greasing The ball screw spline and reduction gear units need greasing regularly. the grease specified. Only use Parts and Interval when the greasing is necessary have been described. the manipulator manual for details of the greasing procedure. Refer to ■ Keep enough grease in the Manipulator. Operating the Manipulator with insufficient grease will damage sliding parts and/or result in insufficient function of the Manipulator.
5. General Maintenance G / RS series Greasing part Joint #1, #2 Reduction gear units Joint #3 Ball screw spline shaft Joint #4 Backlash less gear Greasing Interval Remarks At the replacement of motor* Every 6 months At greasing of Joint #3 Only G10 * Under normal conditions, the reduction gear units (G, RS series) shall be greased only when the motor is replaced. However, in case of severe working conditions (such as high duty, high speeds, large payloads, etc.
6. Third Step 6. Manual Descriptions of manual contents are indicated in this section. Manuals are supplied by Acrobat PDF to use the Robot system. Select EPSON RC+ 5.0-[Help]-[PDF Manual] to view the PDF manuals from a PC. (Click -[Program]-[EPSON RC+ 5.0] from the Windows desktop.) Software EPSON RC+ 5.0 User’s Guide This manual indicates descriptions of the Robot system and program development software.
6. Manual Controller ROBOT CONTROLLER RC180 This manual indicates descriptions of the Robot Controller RC180 and Robot system. - Safety - Specification, Installation, Operation, and Setup - Backup and Restore - Maintenance - Verifying Robot System Operation - Error Codes etc. Option RC180 Option Teach Pendant TP1 RC90/RC180 Option Teach Pendant TP2 This manual indicates descriptions of option Teach Pendant.
6. Third Step Manipulator The manuals indicate descriptions of the manipulator(s) you purchased. There are manuals for each manipulator. EPSON SCARA ROBOT : G1, G3, G6, G10/G20, RS EPSON ProSix : C3, S5 - Safety - Specification, Installation, Setting - Maintenance - Calibration 98 etc. RC180 Safety and Installation Rev.
7. Directives and Norms 7. Directives and Norms These products conform to the following directives and norms. For more details of Controllers and Manipulators, please refer to each manual. Product Name Controller Manipulator RC180 Safety and Installation Rev.
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