Robot System: Safety and Installation
Robot System: Safety and Installation
Robot System: Safety and Installation
Rev.4 EM145B2737F
Manipulator LS series
(LS3 / LS6)
Robot System Safety and Installation (RC90 / EPSON RC+ 7.0) Rev.4
Robot System Safety and Installation
(RC90 / EPSON RC+ 7.0)
Rev.4
WARRANTY
The robot system and its optional parts are shipped to our customers only after
being subjected to the strictest quality controls, tests, and inspections to certify its
compliance with our high performance standards.
However, customers will be charged for repairs in the following cases (even if they
occur during the warranty period):
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any
comments regarding its contents.
INQUIRIES
Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier
office for your region.
Please prepare the following items before you contact us.
- Your controller model and its serial number
- Your manipulator model and its serial number
- Software and its version in your robot system
- A description of the problem
SERVICE CENTER
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
China EPSON China Co., Ltd
Factory Automation Division
7F, Jinbao Building No. 89 Jinbao Street
Dongcheng District, Beijing
China, 100005
TEL : +86-(0)-10-8522-1199
FAX : +86-(0)-10-8522-1120
The crossed out wheeled bin label that can be found on your product indicates that this
product and incorporated batteries should not be disposed of via the normal household
waste stream. To prevent possible harm to the environment or human health please
separate this product and its batteries from other waste streams to ensure that it can be
recycled in an environmentally sound manner. For more details on available collection
facilities please contact your local government office or the retailer where you purchased
this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are
used in the battery.
NOTE TP port of RC90 is for the Teach Pendant TP1 and TP2. Do not connect
NOTE For RC90, be sure to install the EPSON RC+7.0 to the development PC first,
then connect the development PC and RC90 with the USB cable.
If RC90 and the development PC are connected without installing the EPSON
RC+7.0 to the development PC, [Add New Hardware Wizard] appears. If
this wizard appears, click the <Cancel> button.
The network connecting function (Ethernet) on our products assumes the use
in the local network such as the factory LAN network. Do not connect to the
external network such as Internet.
In addition, please take security measure such as for the virus from the
network connection by installing the antivirus software.
Make sure the USB memory is not infected with virus when connecting to the
Controller.
OK: Compatible All functions of the EPSON RC+ 7.0 and the Controller are
available.
NOTE
NOTE
Manual PDF for this robot system is available from EPSON RC+ 7.0 Ver. 7.0.2
This option is not available for Robot Controller RC90 (EPSON RC+ 5.0) without
the label.
2. Installation 32
System Example ····················································· 33
2.1 Outline from Unpacking to Operation of
Robot System ··················································· 34
2.2 Unpacking ······················································ 35
2.2.1 Package Components Example .................... 35
2.2.2 Unpacking Precautions ................................. 35
2.3 Transportation ················································· 36
2.3.1 Transportation Precautions ........................... 36
2.3.2 Manipulator Transportation ........................... 37
2.4 Manipulator Installation ······································ 38
3. First Step 60
3.1 Installing EPSON RC+ 7.0 Software ························60
3.2 Development PC and Controller Connection ···········63
3.2.1 About Development PC Connection Port ...... 63
4. Second Step 78
4.1 Connection with External Equipment ···················· 78
4.1.1 Remote Control ............................................. 78
4.1.2 Ethernet ........................................................ 78
4.1.3 RS-232C (Option) ......................................... 78
4.2 Ethernet Connection of Development PC
and Controller ··················································· 79
4.3 Connection of Option Teaching Pendant ··············· 79
5. General Maintenance 80
5.1 Schedule for Maintenance Inspection ··················· 80
5.2 Inspection Point ··············································· 81
5.2.1 Inspection While the Power is OFF
(Manipulator is not operating) ....................... 81
5.2.2 Inspection While the Power is ON
(Manipulator is operating) ............................. 82
5.2.3 Tightening Hexagon Socket Head Cap Bolts 83
5.2.4 Greasing ....................................................... 84
5.2.5 Handling and Disposal of Batteries ............... 85
6. Manuals 87
Software ································································ 87
Software Options ····················································· 87
Controller ······························································· 88
Controller Options···················································· 88
Manipulator ···························································· 88
1. Safety
Installation and transportation of robots and robotic equipment shall be performed
by qualified personnel and should conform to all national and local codes.
Please read this manual and other related manuals before installing the robot
system or before connecting cables.
Keep this manual handy for easy access at all times.
1.1 Conventions
Important safety considerations are indicated throughout the manual by the
following symbols. Be sure to read the descriptions shown with each symbol.
This section summarizes the minimum conditions that should be observed when
using EPSON robots in your robot systems.
Please design and manufacture robot systems in accordance with the principles
described in this and the following sections.
Environmental Conditions
Carefully observe the conditions for installing robots and robot systems that are
listed in the “Environmental Conditions” tables included in the manuals for all
equipment used in the system.
System Layout
When designing the layout for a robot system, carefully consider the possibility of
error between robots and peripheral equipment. Emergency stops require
particular attention, since a robot will stop after following a path that is different
from its normal movement path. The layout design should provide enough
margins for safety. Refer to the manuals for each manipulator, and ensure that
the layout secures ample space for maintenance and inspection work.
When designing a robot system to restrict the area of motion of the robots, do so in
accordance with the methods described in each manipulator manual. Utilize both
software and mechanical stops as measures to restrict motion.
Install the emergency stop switch at a location near the operation unit for the robot
system where the operator can easily press and hold it in an emergency.
Do not install the controller at a location where water or other liquids can leak
inside the controller. In addition, never use liquids to clean the controller.
Disabling Power to the System using lock out / tag out
The power connection for the robot controller should be such that it can be locked
and tagged in the off position to prevent anyone from turning on power while
someone else is in the safeguarded area.
For further details, refer to the following section:
1.8 Lockout/Tagout
Design the robot end effector such that its weight and moment of inertia do not
exceed the allowable limits. Use of values that exceed the allowable limits can
subject the robot to excessive loads. This will not only shorten the service life of
the robot but can lead to unexpectedly dangerous situations due to additional
external forces applied to the end effector and the work piece.
Design the size of the end effector with care, since the robot body and robot end
effector can interfere with each other.
Remote Control
To prevent operation by remote control from being dangerous, start signals from
the remote controller are allowed only when the control device is set to REMOTE,
TEACH mode is OFF, and the system is configured to accept remote signals.
Also when remote is valid, motion command execution and I/O output are
available only from remote. For the safety of the overall system, however, safety
measures are needed to eliminate the risks associated with the start-up and
shutdown of peripheral equipment by remote control.
Emergency Stop
Each robot system needs equipment that will allow the operator to immediately
stop the system’s operation. Install an emergency stop device that utilizes
emergency stop input from the controller and all other equipment.
During an emergency stop, the power that is supplied to the motor driving the
robot is shut off, and the robot is stopped by dynamic braking.
The emergency stop circuit should also remove power from all external
components that must be turned off during an emergency. Do not assume that the
robot controller will turn off all outputs if configured to. For example, if an I/O
card is faulty, the controller cannot turn off a component connected to an output.
The emergency stop on the controller is hardwired to remove motor power from
the robot, but not external power supplies.
Safeguard System
To ensure safety, a safeguard system should be installed for the robot system.
When installing the safeguard system, strictly observe the following points:
Refer to each robot manual, and install the safeguard system outside the maximum
space. Carefully consider the size of the end effector and the work pieces to be
held so that there will be no error between the moving parts and the safeguard
system.
When designing the safeguard system, make sure that it is free of sharp corners
and projections, and that the safeguard system itself is not a hazard.
Make sure that the safeguard system can only be removed by using a tool.
There are several types of safeguard devices, including safety doors, safety barriers,
light curtains, safety gates, and safety floor mats. Install the interlocking function
in the safeguard device. The safeguard interlock must be installed so that the
safeguard interlock is forced to work in case of a device failure or other
unexpected accident. For example, when using a door with a switch as the
interlock, do not rely on the switch’s own spring force to open the contact. The
contact mechanism must open immediately in case of an accident.
Connect the interlock switch to the safeguard input of the drive unit’s
EMERGENCY connector. The safeguard input informs the robot controller that
an operator may be inside the safeguard area. When the safeguard input is
activated, the robot stops immediately and enters pause status, as well as either
operation-prohibited status or restricted status (low power status).
Make sure not to enter the safeguarded area except through the point where the
safeguard interlock is installed.
The safeguard interlock must be installed so that it can maintain a safe condition
until the interlock is released on purpose once it initiates. The latch-release input
is provided for the EMERGENCY connector on the Controller to release the latch
condition of the safeguard interlock. The latch release switch of the safeguard
interlock must be installed outside of the safeguarded area and wired to the
latch-release input.
Design the system so that when the presence sensing device is not activated
or a dangerous situation still exists that no personnel can go inside the
safeguard area or place their hands inside it.
Design the presence sensing device so that regardless of the situation the
system operates safely.
If the robot stops operating when the presence sensing device is activated, it
is necessary to ensure that it does not start again until the detected object has
been removed. Make sure that the robot cannot automatically restart.
For the installation and operation of the robot system, be sure to comply with the
applicable local and national regulations.
Robot systems safety standards and other examples are given in this chapter.
Therefore, to ensure that safety measures are complete, please refer to the other
standards listed as well.
(Note: The following is only a partial list of the necessary safety standards.)
EN ISO 10218-1 Robots and robotic devices -- Safety requirements for industrial
robots -- Part 1: Robots
EN ISO 10218-2 Robots and robotic devices -- Safety requirements for industrial
robots -- Part 2: Robot systems and integration
ANSI/RIA R15.06 American National Standard for Industrial Robots and Robot
Systems -- Safety Requirements
(Left side)
(5) (1)
(6)
(3) (20)
(2)
(18)
(20)
(8) (10) (11) (12) (13) (14) (15) (16) (17) (7)
The motion range of each arm is shown in the figure below. Take all
necessary safety precautions.
Joint #2
(Rotation)
-
+
Joint #3
Brake release switch
Joint #1
(Rotation)
-
+
Arm #2
+ Base
Joint #3
(Up/Down) Shaft Arm #1
-
- +
Joint #
(Rotation)
MT label Fittings (black or blue) Fittings (black or blue)
(only for custom for ø6 mm for ø4 mm pneumatic tube
specification) pneumatic tube User connector
(15-pin
Signature label D-sub connector)
(Serial No. Fittings (white)
of Manipulator) for ø6 mm Power cable
pneumatic tube Signal cable
CE label
When the system is placed in emergency mode, push the arm or joint of
the Manipulator by hand as shown below:
Arm #1 Push the arm by hand.
NOTE
LS3: The brake release switch affects only Joint #3. When the brake
release switch is pressed in emergency mode, the brake for Joint #3
is released.
Be careful of the shaft while the brake release switch is pressed
because the shaft may be lowered by the weight of an end effector.
LS6: The brake release switch affects both Joints #3 and #4. When the
brake release switch is pressed in emergency mode, the brake for both
Joints #3 and #4 are released simultaneously.
Be careful of the shaft falling and rotating while the brake release
switch is pressed because the shaft may be lowered by the weight of
an end effector.
There are four operation modes for the controller: AUTO, PROGRAM,
TEACH, and TEST.
■ Do not remove any parts that are not covered in this manual. Follow
the maintenance procedure strictly as described in this manual,
Maintenance of the Manipulator manual, and Maintenance of the
Controller manual. Improper removal of parts or improper
maintenance may not only cause improper function of the robot system
but also serious safety problems.
■ Keep away from the Manipulator while the power is ON if you have not
taken the training courses. Do not enter the operating area while the
power is ON. Entering the operating area with the power ON is
extremely hazardous and may cause serious safety problems as the
Manipulator may move even though it seems to be stopped.
■ When you check the operation of the Manipulator after replacing parts,
WARNING be sure to check it while you are outside of the safeguarded area.
Checking the operation of the Manipulator while you are inside of the
safeguarded area may cause serious safety problems as the
Manipulator may move unexpectedly.
■ Before operating the robot system, make sure that both the Emergency
Stop switches and safeguard switches function properly. Operating
the robot system when the switches do not function properly is
extremely hazardous and may result in serious bodily injury and/or
serious damage to the robot system as the switches cannot fulfill their
intended functions in an emergency.
However, avoid pressing the Emergency Stop switch unnecessarily while the
Manipulator is running normally. Otherwise, the Manipulator may hit the
peripheral equipment since the operating trajectory while the robot system stops is
different from that in normal operation. It may also result in short life of the
reduction gear unit due to the shock or the electromagnetic brake due to the worn
friction plate.
To place the robot system in emergency mode during normal operation, press the
Emergency Stop switch when the Manipulator is not moving.
Refer to the Controller manual for instructions on how to wire the Emergency Stop
switch circuit.
Do not press the Emergency Stop switch unnecessarily while the Manipulator is
operating. Pressing the switch during the operation makes the brakes work.
This will shorten the life of the brakes due to the worn friction plates.
Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)
Stop point
Joint #2
Controller RC90
Manipulator LS3-401* LS6-602*
Joint #1 + Joint #2 [sec.] 0.4 0.7
Free running time
Joint #3 [sec.] 0.1 0.2
Joint #1 [deg.] 110 100
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:
1.6.1 Controller
1.6.2 Manipulator
LS3-401*
C
B A
(Figure: LS3-401S)
LS6-602*
C (Arm #1 Cover)
B A
(Figure: LS6-602S)
Among the following safety features, the Emergency Stop Switch and Safety Door
Input are particularly important. Make sure that these and other features function
properly before operating the robot system.
For details, refer to the 2.5 Controller Installation - Safety Door Switch and Latch
Release Switch.
Dynamic Brake
The dynamic brake circuit includes relays that short the motor armatures. The
dynamic brake circuit is activated when there is an Emergency Stop input or when
any of the following errors is detected: encoder cable disconnection, motor
overload, irregular motor torque, motor speed error, servo error (positioning or
speed overflow), irregular CPU, memory check-sum error and overheat condition
inside the Motor Driver Module.
Over-Voltage Detection
The dynamic brake circuit is activated when the voltage of the Controller is above
the normal limit.
(1) Turn OFF the POWER switch and place the lockout attachment on the
POWER switch.
Insert the pin in the holes under the retractable actuator.
Pin
Lockout
Attachment
Hole
(2) Turn the lockout (3) Install the lockout (4) Slide the pin to
attachment. attachment on the switch. the lock position.
Lock position
The padlock is not supplied with the lockout attachment and must be supplied by
the user.
The total weight of the padlock can be a maximum of 45 g.
Make sure the padlock weight does not exceed 45 g, otherwise the POWER switch
may be damaged.
Applicable Padlock
Safety Precautions
When using the padlock, do not use the controller where it is subject to vibration
or shock, otherwise failure or damage may result.
Do not apply a force of more than 50N on the lockout attachment; otherwise the
lockout attachment will be damaged.
Both Joints #1 and #2 have threaded holes in the positions corresponding to the
angle for the mechanical stop settings. Install the bolts in the holes
corresponding to the angle that you want to set.
Joints #3 can be set to any length less than the maximum stroke.
LS3 / LS6
Mechanical stop of
Joint #2 (Adjustable)
Mechanical stop of
(Do not move the upper Joint #1 (Fixed)
limit mechanical stop.)
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.
System Example
RC90
Option Standard
Expansion I/O Board Standard I/O
Remote I/O
Fieldbus Ethernet
PROFIBUS-DP
DeviceNet RS-232C
CC-Link
EtherNet/IP
PROFINET
EtherCAT
RS-232C Board
PG Board
LS series
USB 2.0
or
Ethernet
PC
TP1
Windows *1 (Option)
Option
2. Installation Unpacking
Transportation
Installation
Power-on
Yes
Error?
No
3. First Step
4. Second Step
Manual information to connect or
setup the equipment and options
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.
Controller etc.
Attached Equipment
Manipulator
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.
Anchor bolt
: When removing the anchor bolts, support the Manipulator to prevent
falling.
Removing the anchor bolts without supporting the Manipulator may get
hands, fingers, or feet caught as the Manipulator will fall.
Wire tie
: Do not remove the wire tie securing the arm until you finish the
installation.
You may get your hands caught in the Manipulator when the wire tie is
removed before completing the installation.
Hoisting procedure
: Stabilize the Manipulator with your hands when hoisting it. Unstable
hoisting is extremely hazardous and may results in serious bodily injury
and/or severe equipment damage to the robot system as the fall of the
Manipulator.
2.4.2 Environment
In order to optimize the robot system’s performance for safety, the Controller must
be placed in an environment that satisfies the following conditions:
NOTE - The Controller is not designed for clean-room specification. If it
Item Condition
Ambient temperature 5 to 40 deg.C (with minimal variation)
Ambient relative humidity 20% to 80% (with no condensation)
First transient burst noise 2 kV or less (Power supply wire)
1 kV or les (Signal wire)
Electrostatic noise 4 kV or less
Base table Use a base table that is at least 100 mm off the
floor. Placing the Controller directly on the
floor could allow dust penetration leading to
malfunction.
Operating conditions
Under rated load, 4-joints simultaneous motion, maximum speed, maximum
acceleration, and duty 50%.
Measurement point
In front of the Manipulator, 1000 mm apart from the motion range, 50 mm
above the base-installed surface.
The torque and reaction force produced by the movement of the Manipulator are
as follows:
LS3-401* LS6-602*
Max. Reaction torque 250 Nm 350 Nm
on the horizontal plate
Max. Horizontal reaction force 1000 N 1500 N
Max. Vertical reaction force 1000 N 1500 N
The threaded holes required for mounting the Manipulator base are LS3/LS6:M8.
Use mounting bolts with specifications conforming to ISO898-1 property class:
10.9 or 12.9.
The plate for the Manipulator mounting face should be 20 mm thick or more and
made of steel to reduce vibration. The surface roughness of the steel plate should
be 25 μm or less.
The table must be secured on the floor or wall to prevent it from moving.
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.
LS3 / LS6
■ Install the LS3 / LS6 series 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.
CAUTION LS3-401* : approx. 14 kg: 31 lb.
LS6-602* : approx. 17 kg: 37.5 lb.
conforming to ISO898-1
Property Class: 10.9 or 12.9.
4-M8×25
Spring
Washer
Plane
Washer
Screw Hole
(depth 20 mm
or more)
10 mm
Wire tie
Bolt
M4×20
Installation procedure
: Before performing any installation procedure, turn OFF the
Controller and related equipment, and then pull out the power plug
from the power source.
Performing any replacement procedure with the power ON is
extremely hazardous and may result in electric shock and/or
malfunction of the robot system.
Cable
: Be sure to connect the cables properly. Do not allow unnecessary
strain on the cables. (Do not put heavy objects on the cables. Do
not bend or pull the cables forcibly.) The unnecessary strain on
the cables may result in damage to the cables, disconnection, and/or
contact failure.
Damaged cables, disconnection, or a contact failure is extremely
hazardous and may result in electric shock and/or improper
function of the system.
2.5.2 Installation
Install the controller on a flat surface such as wall, floor, and controller box in the
direction shown from (A) to (C).
NOTE For Controller installation to the Controller box or the base table, process screw hole
drilling as follows.
463 mm
133.35 mm
Ensure the draft around the in/out and also install the controller by keeping the
distance as follows to prevent the nose influence from other equipments such as large
contactor and relay.
100 mm
50 mm 50 mm
100 mm
Excluding the installation
side such as base table
Hot air with higher temperature than the ambient temperature (about 10 deg.C)
comes out from the in/out of the Controller.
Make sure that heat sensitive devices are not placed near the outlet.
Arrange the cables in front of the Controller so that you can pull the Controller
forward.
EMERGENCY Connector
Connector Standard
EMERGENCY connector D-sub 25 Pin (male)
(Controller side) Mounting style #4-40
■ The interlock of the Safety Door must be functioning when the robot
system is operated. Do not operate the system under the condition that
the switch cannot be turned ON/OFF (e.g. The tape is put around the
switch.). Operating the robot system when the switch is not functioning
WARNING properly is extremely hazardous and may cause serious safety problems
as the Safety Door input cannot fulfill its intended function.
In order to maintain a safe working zone, a safeguard must be erected around the
Manipulator. The safeguard must have an interlock switch at the entrance to the
working zoon. The Safety Door that is described in this manual is one of the
safeguards and an interlock of the Safety Door is called a Safety Door switch.
Connect the Safety Door switch to the Safety Door input terminal on the
EMERGENCY connector.
The Safety Door switch has safety features such as temporary hold-up of the
program or the operation-prohibited status that are activated whenever the Safety
Door is opened.
Observe the following in designing the Safety Door switch and the Safety Door.
- For the Safety Door switch, select a switch that opens as the Safety Door
opens, and not by the spring of the switch itself.
- The signal from the Safety Door (Safety Door input) is designed to input to
two redundant signals. If the signals at the two inputs differ by two seconds
or more, the system recognizes it to be a critical error. Therefore, make sure
that the Safety Door switch has two separate redundant circuits and that each
connects to the specified pins at the EMERGENCY connector on the
Controller.
- The Safety Door must be designed and installed so that it does not close
accidentally.
The EMERGENCY connector has an input terminal for a latch release switch that
cancels the latched conditions.
Open : The latch release switch latches conditions that the safety door is
open or the operation mode is “TEACH”.
Open : The latch release switch latches condition that the safety door is open.
To cancel the condition, close the safety door, and then close the
safety door latch release input.
Closed : The latch release switch does not latch the condition that the safety
door is open.
NOTE The latch release input also functions to acknowledge the change of TEACH
mode.
In order to change the latched condition of the TEACH mode, turn the mode
selector key switch on the Teach Pendant to “Auto”. Then, close the latch release
input.
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
RC90 Setup & Operation: Circuit Diagrams.
(1) Turn ON the Controller to boot the controller software while pressing the
Emergency Stop switch.
(6) Make sure that E-STOP LED is turned OFF and that “E-Stop” is dimmed on
the main window status bar.
Emergency Stop switch output rated load +30 V 0.3 A or under 1-2, 14-15 pin
Emergency Stop rated input voltage range +24 V ±10%
3-4, 16-17 pin
Emergency Stop rated input current 37.5 mA ±10% / +24V input
Safety Door rated input voltage range +24 V ±10%
7-8, 20-21 pin
Safety Door rated input current 10 mA / +24 V input
Latch Release rated input voltage range +24 V ±10%
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.
Emergency 10
Stop switch of 22
an Operation
23
Unit
1
2
14
15
3
+5V
16
Main Circuit
Control
+ −
Motor Driver +
AC Input 4
17
Emergency 11
Stop detection
12
24
25 External
+24V
7
Safety Door input 1
8
20
18
External +24V
NOTE:+24V GND Latch release input Close :Latch off
GND
+ 5V GND Open :Latch on
14
15
External
3 +24V
+5V
16
AC Input 4
17
Emergency 11
Stop detection
12 External
+24V
24 GND
25 External
+24V
7
Safety Door input 1
8
20
Safety Door input 2
21
18
Latch Release input
19
External +24V
NOTE:+24V GND Latch release input Close :Latch off GND
+ 5V GND Open :Latch on
Item Specification
Voltage 200 VAC to 240 VAC
Phase Single phase
Frequency 50/60 Hz
Momentary
10 msec. Or less
Power Interrupt
Power Max. 2.5 kVA
Consumption Actual consumption depends on the model, motion, and
load of the Manipulator.
Rated consumption
= ( 150 W + total Manipulator rated consumption ×
0.8) / 0.6
Refer to Manipulator manual for Manipulator rated
consumption.
Peak Current When power is turned ON: approximately 70 A (2 msec.)
When motor is ON: approximately 50 A (2 msec.)
Leakage Current Max. 3.5 mA
Ground Resistance 100 Ω or less
Install an earth leakage circuit breaker or a circuit breaker in the AC power cable
line at 15 A or less rated electric current. Both should be a two-pole disconnect
type. If you install an earth leakage circuit breaker, make sure to use an inverter
type that does not operate by induction of a 10 kHz or more leakage current. If
you install a circuit breaker, please select one that will handle the above mentioned
“peak current”.
The power receptacle shall be installed near the equipment and shall be easily
accessible.
(2) Set the M/C Power Cable in the clamp for the
M/C Power Cable.
LS series Manipulator
(Figure: LS3-401S)
Controller RC90
2.9 Power-on
2.9.1 Power-on Precautions
Manipulator check
: Before 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.
Power activation
: Anchor the Manipulator before turning ON the power to or operating the
Manipulator. Turning ON the power to or operating the Manipulator that is
not anchored is extremely hazardous and may result in serious bodily injury
and/or severe equipment damage to the robot system as the Manipulator may
fall down.
LS series Manipulator
(Figure: LS3-401S)
Controller RC90
(1)
(4)
(5)
(2)
(3)
3. First Step
This section indicates the procedure to install the development PC EPSON RC+,
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) Enter your user name and company name and click <Next>.
(4) Select the drive where you want to install EPSON RC+ 7.0 and click <Next>.
The installation directory is called EpsonRC70. This cannot be changed.
(5) The dialog for selecting the options to be installed will be displayed. Check
the options you want to install and click <Next>.
(6) The dialog to review the settings will be displayed. If you are satisfied with
the settings, click <Next>.
(7) If required, install “Windows Installer” and “Microsoft .NET Framework 3.5”
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+ 7.0 manuals. If the installer cannot find Adobe Reader on your
system, it will be installed at this time. Follow the instructions in the
Adobe installer. Do not restart the system after the Adobe Reader
installation has completed.
(8) After the installation has completed, restart your computer.
The EPSON RC+ 7.0 software installation is now completed.
62 Safety and Installation (RC90 / EPSON RC+ 7.0) Rev.4
3. First Step
NOTE For other details of development PC and Controller connection, refer to EPSON
For RC90, be sure to install the EPSON RC+7.0 to the development PC first, then
connect the development PC and RC90 with the USB cable.
If RC90 and the development PC are connected without installing the EPSON
RC+7.0 to the development PC, [Add New Hardware Wizard] appears. If this
wizard appears, click the <Cancel> button.
3.2.2 Precaution
When connecting the development PC and the Controller, make sure of the
followings.
- Connect the development PC and the Controller with 5 m or shorter USB
cable.
Do not use the USB hub or extension cable.
- Make sure that no other devices except development PC is used for
development PC connection port.
- Use PC or USB cable that supports USB2.0 HighSpeed mode to operate in
USB2.0 HighSpeed mode.
- Do not pull or bend the cable strongly.
- Do not allow unnecessary strain on the cable.
- When development PC and the Controller is connected, do not insert or
remove other USB devices from the development PC. Connection with the
Controller may disconnect.
(6) Select the “No.1 USB” and click the <Connect> button.
(7) After development PC and the Controller connection is completed, “Connected”
is displayed in the [Connection status:]. Make sure that “Connected” is
displayed and click the <Close> button to close the [PC to Controller
Communications] dialog.
NOTE If USB cable is removed when the Controller and the development PC is
connected, stop occurs to the Robot. Make sure to click the <Disconnect> button
in the [PC to Controller Communications] dialog before USB cable is removed.
Manual operation
Jog motion by the Teach Pendant
Command execution from the EPSON RC+
Jog motion from the EPSON RC+
A: Manual operation
Move the non-excited robot manually.
■ Normally, release the brake of joints one by one. Take extra care if
you need to release the brakes of two or more joints simultaneously.
Releasing the brakes of two or more joints simultaneously may
cause hands and fingers to be caught and/or equipment damage to
or malfunction of the Manipulator as the arms of the Manipulator
may move in unexpected directions.
■ Be careful of the arm falling when releasing the brake. While the
brake is being released, the Manipulator’s arm falls by its own
weight. The arm falling may cause hands and fingers to be caught
CAUTION and/or may cause equipment damage to or malfunction of the
Manipulator.
Following explains the example of moving all joints to the 0 pulse positions by
specifying the pulse for each joint.
(2) Type in a name for a project in the [New Project Name] box.
(e.g. FirstApp)
(3) Click OK to create the new project.
When the new project is created, a program called Main.prg is created.
You will see a window open with the title Main.prg with a cursor
flashing in the upper left corner. Now you are ready to start entering
your first program.
(3) Click the Start button on the Run window to run the program.
(4) You should see text similar to the following displayed in the Status
window:
19:32:45 Task main started
On the Run window, you will see the output of the print statement.
Now let's teach some robot points and modify the program to move the robot.
5. Teach robot points
(1) Ensure that it is safe to operate the robot. Click the <Robot
Manager> button on the toolbar. You will see the [Robot
Manager] window with the [Control Panel] page displayed.
(2) Click on the <Motor On> button to turn on the robot motors. You
will be prompted to confirm the operation.
(3) Answer <Yes> to continue.
(5) Click the <Teach> button in the lower right corner to teach point P0.
You will be prompted for a point label and description.
(6) Jog the robot by clicking the <+Y> jog button. Hold the button
down to continue jogging. Let go when the robot is about half way
out in the work envelope.
(7) Jog the robot down by clicking the <-Z> button.
(8) Now change the current point to P1 by selecting P1 in the Point
dropdown list next to the <Teach> button.
(9) Click the <Teach> button. You will see a confirmation message to
teach the point.
(10) Answer <Yes>.
(11) Click the <+X> button to jog the robot in the +X direction.
(12) Change the current point to P2 by selecting P2 in the Point dropdown
list.
(13) Click the <Teach> button. You will see a confirmation message to
teach the point.
(14) Answer <Yes>.
(15) Click the <Save Project> toolbar button to save the changes.
6. Modify the program to include robot motion commands
(1) Insert three new Go statements into the Main.prg program as shown
below:
Function main
Print "This is my first program."
Go P1
Go P2
Go P0
Fend
(2) Run the program by pressing F5 and then click on the <Start> button
on the Run window.
(3) The robot should move to each of the points you taught.
7. 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 50
Accel 50, 50
Go P1
Go P2
Go P0
Fend
(2) Run the program by pressing F5
(3) Click on the <Start> button on the Run window.
The robot should go to each of the points you taught at 50% speed,
acceleration, and deceleration. The Power High statement enables
your program to run the robot at high (normal) power, which in turn
allows the robot speed and acceleration to be increased.
(3) Click <OK>. The project will be copied to the external media.
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. Manuals.)
I/O
EPSON RC+ 7.0 User’s Guide
I/O Setup
ROBOT CONTROLLER RC90 (EPSON RC+ 7.0) manual
Setup & Operation: 11. I/O Connector
Setup & Operation: 13.2 Expansion I/O Board (Option)
4.1.2 Ethernet
EPSON RC+ 7.0 User’s Guide
Ethernet Communication
ROBOT CONTROLLER RC90 (EPSON RC+ 7.0) manual
Setup & Operation: 7. LAN Ethernet) Port
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.
6 months(1500 h) √ √ √
7 months(1750 h) √
8 months(2000 h) √
9 months(2250 h) √ √
10 months(2500 h) √
11 months(2750 h) √
12 months(3000 h) √ √ √ √
13 months(3250 h) √
…
h = hour
Controller
Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual
Visually check for External
external defects. appearance of √ √ √ √ √
Clean up if necessary. Controller
Clean the fan filter -
√ √ √ √
Battery - Every 5 years
Controller
Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual
Check whether unusual Entire Controller
sound or vibration is √ √ √ √ √
occurring.
Make a backup of data. Project and
Whenever data is changed.
system data
5.2.4 Greasing
The ball screw spline and reduction gear units need greasing regularly. Only use
the grease specified.
Parts and Interval when the greasing is necessary have been described. Refer to
the manipulator manual for details of the greasing procedure.
■ If grease gets into your eyes, mouth, or on your skin, follow the
instructions below.
■ Do not insert or pull out the motor connectors while the power to the
robot system is turned ON. Inserting or pulling out the motor
connectors with the power ON is extremely hazardous and may
result in serious bodily injury as the Manipulator may move
abnormally, and also may result in electric shock and/or malfunction
of the robot system.
■ To shut off power to the robot system, pull out the power plug from
the power source. Be sure to connect the AC power cable to a
power receptacle. DO NOT connect it directly to a factory power
WARNING source.
■ Before performing any replacement procedure, turn OFF the
Controller and related equipment, and then pull out the power plug
from the power source.
Performing any replacement procedure with the power ON is
extremely hazardous and may result in electric shock and/or
malfunction of the robot system.
Robot Controller
Before starting battery replacement, turn on the controller for approximately one
minute. Perform the replacement within 10 minutes to prevent data loss.
Make sure to use the designated lithium battery.
Manipulator
When the lithium battery power is low, an error will occur to warn the user about
the low battery status when the Controller is turned ON (when software is started
up).
When the error occurs, the position data in motors will be lost and all joints need
to be completely calibrated again.
The life span of the lithium battery is 1.5 years. Even if the Manipulator is
constantly connected to power, the lithium battery needs to be replaced every 1.5
years.
Be sure to use the designated lithium battery and the battery board.
Be sure to set the correct polar when installing the battery.
6. Manuals
Descriptions of manual contents are indicated in this section.
Manuals are supplied by Acrobat PDF to use the Robot system.
Select EPSON RC+ 7.0-[Help]-[PDF Manual] to view the PDF manuals from a
PC. (Click <Start>-[Program]-[EPSON RC+ 7.0] from the Windows desktop.)
Software
EPSON RC+ 7.0 User’s Guide
This manual indicates descriptions of the Robot system and program development
software.
- Safety
- Robot System Operation and Configuration
- Operation of Program Development Software EPSON RC + GUI
- SPEL+ Language and Application
- Configuration of Robot, I/O, Communication etc.
Software Options
Followings manuals contain information on the software options and commands.
- RC+ API 7.0
- Vision Guide 7.0
- Vision Guide 7.0 Properties & Results Reference
- GUI Builder 7.0
- Remote Control Reference
Controller
ROBOT CONTROLLER RC90 (EPSON RC+ 7.0)
This manual indicates descriptions of the Robot Controller RC90 and Robot
system.
- Safety
- Specification, Installation, Operation, and Setup
- Backup and Restore
- Maintenance
- Verifying Robot System Operation
- Error Codes etc.
Controller Options
This manual indicates descriptions of the Controller option.
- PG Motion System
- Fieldbus I/O
- Teach Pendant TP1
- Teach Pendant TP2
Manipulator
EPSON SCARA ROBOT LS series (LS3 / LS6)
This manual indicates descriptions of the LS3, LS6 series manipulator.
- Safety
- Specification, Installation, Setting
- Maintenance
- Calibration etc.
Name Definition
Directive 2006/42/EC Directive 2006/42/EC of the European Parliament and of the
Council of 17 May 2006 on machinery, and amending
Directive 95/16/EC
Directive 2004/108/EC Directive 2004/108/EC relating to electromagnetic
compatibility and repealing Directive 89/336/EEC
EN ISO 12100 (2010) Safety of machinery -- General principles for design -- Risk
assessment and risk reduction
EN ISO 10218-1 (2011) Robots and robotic devices -- Safety requirements for
industrial robots -- Part 1: Robots
EN 60204-1 (/A1:2009) Safety of machinery -- Electrical equipment of machines --
Part 1: General requirements
EN ISO 13849-1 (2008) Safety of machinery -- Safety -- related parts of control
* systems -- Part 1: General principles for design
EN ISO 13850 (2008) Safety of machinery -- Emergency stop -- principles for
design
EN 55011 (2009) Industrial, scientific and medical (ISM) radio-frequency
equipment -- Electromagnetic disturbance characteristics --
Limits and methods of measurement
EN 61000-6-2 (2005) Electromagnetic compatibility (EMC) -- Part 6-2: Generic
standards -- Immunity for industrial environments