Appendix B: Troubleshooting

This chapter describes the firmware upgrade procedure and the firmware and data file initialization procedure needed when errors in firmware or robot setting information cause the Controller to fail to start properly or to fail to connect to the development PC.

Upgrading Firmware

Software (firmware) and data files necessary to control the Controller and the robot are preinstalled in the Controller. Controller setting information that was set by the user from the development software is also saved in the Controller as needed.

If necessary, the firmware is available on CD-ROM and other sources. For details on how to get the firmware, please contact the supplier.

To upgrade the firmware, a development PC where the development software Epson RC+ is installed must be connected to a Controller by a USB cable. (Firmware cannot be upgraded over an Ethernet connection.)

KEY POINTS

When installing firmware version 7.5.0.x or later, be sure to use a PC where EPSON RC+ 7.0 Ver.7.5.0 or later is installed.

Firmware Upgrade Procedure

This section explains the firmware upgrade procedure.

  1. Connect the development PC and the Controller by a USB cable.
    (Firmware cannot be upgraded over an Ethernet connection.)

  2. Turn on the Controller.
    (Do not start the development software Epson RC+ until the firmware upgrade process is completed.)

  3. Load the "Firmware CD-ROM" to be installed into the CD-ROM drive of the development PC.

  4. Execute "Ctrlsetup70.exe." The following dialog box appears.

  5. Select the [Upgrade] button, and click the [Next] button.

  6. Make sure that the development PC is connected to the Controller by a USB cable, and click the [Next] button.

  7. Check the current firmware version and the new firmware version, and click the [Install] button.

  8. The firmware transfer is started. The transfer process takes several minutes to complete.

    KEY POINTS

    During transfer, do not disconnect the USB cable or turn off the Controller or development PC.

  9. Next, data file transfer is started.

  10. The following dialog box appears when the transfer process has been completed.
    Click the [Next] button to reboot the Controller.

  11. The following dialog box appears after the Controller is rebooted.
    Click the [Finish] button.

    This completes the firmware upgrade.

    KEY POINTS

    When you install the firmware version 7.4.0.2 or later on the Controller where firmware before a version earlier than 7.4.0.2 was installed, the following message is displayed.

    When this message is displayed, reinstall the firmware.

Controller Recovery

If the Controller becomes inoperable for any reason, perform the recovery operation.

KEY POINTS

Backup of the system being run is recommended beforehand to ensure that the system can be easily restored to its operational state.

Refer to the following section.

Backup and Restore

When the Controller is in an error state, it appears in one of two ways immediately after the Controller power is turned on.

  • Error state A
    The Controller automatically changes to recovery mode and the LEDs for ERROR, TEACH, and PROGRAM are turned on.
    Communication with the development PC is possible, but the Controller does not operate properly.

  • Error state B
    The Controller LEDs for TEACH, AUTO, and PROGRAM do not blink.
    Communication with the development PC is not possible.

The corrective actions for the error states are as follows:

  • Error state A
    Follow the procedure below to initialize the firmware.
    "Firmware Initialization Procedure"

  • Error state B
    Perform the following procedure.

    1. Turn off the Controller.

    2. Turn on the Controller power while holding down the trigger button on the front side of the Controller, and continue to hold down the trigger button for about 30 seconds. (This causes the Controller to start in recovery mode.)

    3. Make sure that the LEDs for ERROR, TEACH, and PROGRAM are turned on.

    4. Perform the procedure from step (3) in the section below to initialize the firmware.
      "Firmware Initialization Procedure"

Firmware Initialization Procedure

This section explains the firmware initialization procedure.

  1. Connect the development PC and the Controller by a USB cable.
    (Firmware cannot be upgraded over an Ethernet connection.)

  2. Turn on the Controller.
    (Do not start the development software Epson RC+ until the firmware upgrade process is completed.)

  3. Load the "Firmware CD-ROM" to be installed into the CD-ROM drive of the development PC.

  4. Execute "Ctrlsetup70.exe."

  5. Select the [Initialize] button, and click the [Next] button.

  6. Make sure that the development PC is connected to the Controller by a USB cable, and click the [Next] button.

  7. Check the version information, and click the [Install] button.

  8. The firmware and data file transfer process is started. The transfer process takes several minutes to complete.
    During the transfer process, do not disconnect the USB cable or turn off the Controller or development PC.

  9. The following dialog box appears when the transfer process has been completed.
    Click the [Next] button to reboot the Controller.

  10. The following dialog box appears after the Controller is rebooted.
    Click the [Finish] button.

This completes the firmware initialization process.

Start Epson RC+, and restore the running system.
Refer to the following section.
Backup and Restore

KEY POINTS

When you install the firmware version 7.4.0.2 or later on the Controller where firmware before a version earlier than 7.4.0.2 was installed, the following message is displayed.

When this message is displayed, reinstall the firmware.

Addition of Confirmation Step due to Higher Security of Ethernet Connection

Starting from the following firmware version, password authentication was added for greater security when connecting Controllers and PCs.

  • F/W : Ver.7.4.8.x

In the following cases, connections cannot be established with an Ethernet (PC) connector or by remote Ethernet.

  • The Controller IP address is set to a global IP address
  • Firmware version is 7.4.8.x or later
  • EPSON RC+ 7.0 is version 7.4.7 or earlier

In the following cases, when the Controller firmware is upgraded, an additional step may be performed to confirm whether to continue the firmware upgrade depending on the configuration settings of the Controller. (This applies starting from step3below.)

  • The Controller IP address is set to a global IP address
  • Firmware version to be installed is 7.4.8.x or later

This describes the step to confirm whether to continue the firmware upgrade.

  1. Load the "Firmware CD-ROM" to be installed into the CD-ROM drive of the development PC.

  2. Execute "CtrlSetup70.exe."

  3. The Controller setup window appears.
    Select the [Upgrade] button, and click the [Next] button.

  4. The Step 2 window is displayed.
    Click the [Next] button.

  5. The Step 3 window is displayed.

    1. When the step to confirm whether to continue the firmware upgrade is not executed:
      The Step 3 window is displayed.
      Follow the on-screen instructions to install the firmware.
    2. When the step to confirm whether to continue the firmware upgrade is executed:
      The following window appears.

      Once the [I understand the contents] button is selected, the [OK] button is enabled.
      After the [OK] button is clicked, the Step 3 window is displayed. Go to step6.
      After the [Cancel] button is clicked, the Step 3 window is displayed. The [Disable connection password] checkbox and the [Install] button are grayed out and unable to be selected.

  6. The Step 3 window is displayed.

    1. If the [Disable connection password] checkbox is selected, connection authentication after upgrading the firmware can be set to [Disabled].

    2. Click the [Install] button to display the confirmation window.
      When the [Disable connection password] checkbox is selected:

      When the [Disable connection password] checkbox is not selected:

      After the [OK] button is clicked, the Step 4 window is displayed. Go to step7.
      After the [Cancel] button is clicked, the confirmation window is closed.

  7. Firmware installation is started.
    When firmware installation is complete, click the [Next] button. The Controller is rebooted.

  8. After the Controller is rebooted, the following window is displayed.
    Confirm that the firmware installation is completed.
    Click the [Finish] button.

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