Debugging and maintenance of EPSON RC90/RC90-B controller

Key timing sequence:

The pulse width of the remote input signal must be ≥ 25 ms to be reliably detected.

Effective from Start input to MotorsOn output, with a typical delay of approximately 40 ms.

After the emergency stop is triggered, the EStopOn output immediately turns on and the motor power is cut off.

Option board expansion

RC90/RC90-B provides two option slots for installing the following cards:

Expansion I/O board: Each board adds 24 inputs/16 outputs (similar to standard I/O, sink/source type needs to be selected).

Fieldbus board: Supports DeviceNet, PROFIBUS-DP, CC Link, PROFINET, EtherNet/IP, EtherCAT for high-speed data exchange with PLCs.

RS-232C board: Provides two additional RS-232C ports (up to 4 expansion serial ports).

Analog I/O board: Optional 1 channel (DAC only) or 4 channels (2 in/2 out), 16 bit resolution, configurable voltage/current.

EUROMOP67 board: a standard interface designed for injection molding machines and robots, including 15 inputs/16 outputs and emergency stop safety relays.

When installing the option board, it is necessary to remove the top cover, fix the board, and set the DIP switch as needed (such as setting SW1 to the corresponding position for EUROMOP67 board). The slots are counted as slot 1 and slot 2 from the left side of the front of the controller.

9、 Maintenance and Parts Replacement

9.1 Regular inspection cycle

Component maintenance operation cycle

Fan filter cleaning or replacement>once a month

Fan replacement (abnormal noise or error 515) for approximately 30000 hours

Battery replacement (error 511 or 9011) every 5 years

CF card replacement (damaged or firmware upgrade failure) as needed

9.2 Battery replacement steps

The controller motherboard battery (model 2113554) is used to save project files, parameters, and globally retained variables. When replacing:

Backup controller data (via RC+or USB state storage).

Turn off the controller power and unplug the power plug.

Remove the top cover (6 or 10 screws).

Disconnect the battery connector and remove the old battery.

Install the new battery within 10 minutes and ensure that the fixing buckle is in place.

Reinstall the top cover, power on, and clear the battery alarm (reset through RC+'s [Tools] → [Controller] → [Maintenance]).

Attention: It is recommended to power on the controller for at least 1 minute before replacement to charge the internal capacitor, which can extend the memory retention time.

9.3 Fan and Filter Cleaning

The fan filter is located under the front panel, and the filter can be removed by removing two screws. Use a vacuum cleaner to clean, and replace if the blockage is severe (part number 2195107 white or 1520975 black). Clean and reinstall to ensure good ventilation.

9.4 Firmware Upgrade and Recovery

When the controller fails to start or has abnormal functions, a dedicated firmware CD ROM can be used for upgrading or initialization:

Connect the PC to the controller using a USB cable (Ethernet upgrade not supported).

Execute Ctrlsetup70.exe and select Upgrade or Initialize.

Follow the prompts to complete the firmware transfer (approximately a few minutes), during which do not power off or unplug the USB.

After initialization, the previously backed up data recovery project needs to be used.

Starting from firmware Ver.7.4.8. x, if the controller IP is set to the global address, an additional security confirmation dialog box will pop up during the upgrade. The user can check "Disable connection password" to disable password authentication (not recommended for use in the Internet environment).

Common faults and error code troubleshooting

When the controller malfunctions, the front panel LED will indicate the error type:

Meaning of LED status

ERROR constantly on fatal error (system stopped)

ERROR flashing non fatal error (warning)

E-STOP constantly on emergency stop status

TEACH/AUTO/PROGRAMME is flashing and running normally

The following are high-frequency faults and solutions:

10.1 Error 511 (low battery voltage)

Phenomenon: ERROR flashes and the system prompts "Battery voltage of the CPU board backup is lower than the allowed voltage".

Solution: Immediately replace the CPU board battery (refer to 9.2), and keep the controller powered on before replacement.

10.2 Error 515/516 (low fan speed)

Phenomenon: The internal temperature of the controller rises, which may trigger an overheating alarm.

Solution: Clean the fan filter. If it is ineffective, replace the fan (part number 2157260).

10.3 Unable to connect to PC via USB

Phenomenon: RC+reports "Connection failure (1805)".

handle:

Confirm that EPSON RC+7.0 has been installed and version ≥ 7.0.2.

Open Windows Device Manager and check if there is "EPSON Robot Controller RC170" under "Universal Serial Bus Controller". If it appears in "Other Devices", please uninstall and re plug the USB.

Replace the USB cable with a length not exceeding 5 meters and avoid using a USB hub.

10.4 Emergency stop cannot be lifted

Phenomenon: The E-STOP LED is constantly on, and the Remote reset is ineffective.

handle:

Check if pins 1-2 and 14-15 of the EMERGENCE interface are conductive (should be 0 Ω after emergency stop release).