EPSON RC90/RC90-B Robot Controller

Epson RC90/RC90-B Robot Controller Hardware User Manual, compatible with EPSON RC+7.0 software, for LS series robotic arms, providing full process guidance on safety specifications, hardware specifications, installation wiring, mode operation, interface configuration, expansion board, backup upgrade, maintenance, and troubleshooting, emphasizing mandatory safety requirements such as dual circuit emergency stop, safety door interlock, power-off discharge, lock out/tagout, etc. It supports USB/Ethernet/RS-232C communication and I/O/fieldbus/analog/EUROMOP67 expansion, covering 4-axis servo control, status storage, firmware upgrade, scheduled maintenance, and complete error code table. It is the core basis for robot system installation, debugging, and operation and maintenance.

Core security standards (mandatory requirement)

Emergency stop system

Adopting dual redundant normally closed contacts, any emergency stop press immediately cuts off motor power

The safety door input has the same dual circuit, and if the difference is greater than 2 seconds, a serious fault will be reported

Power off operation

After power failure, wait for at least 10 minutes to confirm that the busbar discharge is complete before proceeding

maintain safety

Lockout/Tagout must be executed to prevent accidental power on

Only for trained personnel to operate

Hardware specifications

Project parameters

Control axis number 4-axis AC servo

Power supply single-phase 200-240VAC, 50/60Hz

Maximum power consumption of 2.5kVA

Working temperature 5-40 ℃

Humidity 20-80% RH (no condensation)

Weight 7.5kg/10kg (depending on the model)

Protection IP20

Panel and Interface

Status LEDs: ERROR, E-STOP, TEACH, AUTO, GRAM

standard interface

USB: Connect and debug PC

LAN: 10/100M, default IP 192.168.0.1

RS-232C: Standard 1-port, expandable

TP: Teaching pendant port (must be connected to TP or short circuiting cap)

EMERGENCE: Emergency Stop+Safety Door+Latch Unlock

I/O: 24 in/16 out

Three operating modes

TEACH mode

Teaching demonstration, jog, low speed and low power consumption, safety door can be opened for operation

AUTO mode

Automatically running programs, supporting remote I/O start and stop

Program mode

Programming, debugging, parameter configuration

I/O and Remote Control

Standard I/O: 24 in/16 out

Default allocation for remote I/O

Input: Start, Stop, Pause, Reset, SelProg

Output: Ready, Running, Error, EStopOn, SafeguardOn

Signal pulse width requirement: ≥ 25ms to be recognized

Optional expansion board (up to 2 pieces can be installed)

Expansion I/O board: Add 24 inputs/16 outputs per board

Fieldbus board: DeviceNet, PROFIBUS, PROFINET, EtherCAT, CC Link

Analog I/O board: 16 bit precision, 0-10V/4-20mA

EUROMOP67 board: Injection molding machine interface, 15 in/16 out, with safety circuit

Backup, Recovery, and Firmware Upgrade

Backup content

Parameters, programs, point data, global variables, configurations

backup method

EPSON RC+7.0 Backup Controller

USB storage: One click save with Trigger on the front panel

Upgrade requirements

Must be connected via USB, network port not available

Upgrade without power outage or unplugging cables

Recovery mode

Press and hold Trigger to power on → enter Recovery → refresh firmware

Regular maintenance 

Performance of Component Maintenance Cycle Malfunctions

Fan dust filter screen cleaned monthly, overheating, error 514/515

Fan abnormal noise replacement error 9015

The battery reports 511 parameter loss and needs to be recalibrated every 5 years with errors

CF card failure, immediate replacement, unable to start, file error

Fault diagnosis

LED judgment

E-STOP on: Emergency stop pressed/circuit disconnected

ERROR on: Fault; Flashing: Warning

Typical Error

511: Low voltage of CPU board battery

514: Internal overheating of the controller

515: Fan speed too low

1041: Unable to operate in emergency stop state

1042: The safety door is open

Key issues

Question 1: Why does the emergency stop and safety door of RC90/RC90-B require dual circuit wiring? What will happen if I make a mistake?

answer:

The emergency stop and safety door adopt dual redundant independent circuits, and any fault system in either circuit can be detected and alarmed; If the difference between the two states exceeds 2 seconds, it will trigger a serious safety fault and shut down.

Consequences of incorrect connection: inability to release emergency stop normally, failure of safety interlock, robot inoperability, posing serious safety risks.

Question 2: What data can be stored in USB Controller Status Storage? What should I pay attention to when restoring?

answer:

Save contents: controller parameters, robotic arm parameters, programs, point data, error history, I/O configuration, global variables.

Notes:

Only supports USB 2.0 unencrypted USB flash drives

Do not turn off the power when saving

Recovery can only be used for controllers with the same serial number, otherwise an error will be reported

After recovery, a restart is required to take effect

Question 3: What is the function of EUROMOP67 board? What are the key points of wiring?

answer:

Function: Provide standard interfaces between injection molding machines and robots to achieve mold cavity signals, mold opening and closing, ejector pin, and safety linkage.

Key points of wiring:

Emergency stop and safety circuits must be connected in both directions

Signal voltage * * ≤ 24V * *, otherwise the board will be burned out

I/O logic confirmation based on injection molding machine model

Shielded wire is grounded at both ends to reduce interference