Epson RC620+ User manual

Rev.5 EM15XC3078F
ROBOT CONTROLLER / Drive Unit
RC620DU

ii
ROBOT CONTROLLER / Drive Unit RC620DU Rev.5

RC620DU Rev.5 i
ROBOT CONTROLLER / DRIVE UNIT
RC620DU
Rev.5
Copyright © 2009-2015 SEIKO EPSON CORPORATION. All rights reserved.

ii RC620DU Rev.5
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the robot controller.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
RC620 robot controller consists of the following:
RC620 CU (Control Unit)
RC620 DU (Drive Unit)
This manual contains the information for the RC620 CU (Control Unit).
For RC620 DU (Drive Unit), refer to the Robot Controller / Drive Unit RC620DU manual.
The information for the robot controller is describes as below, indicating both RC620 CU
and RC620 DU:
Robot controller
Controller
RC620
The information for the either unit (CU or DU) is described as below:
RC620CU Control Unit
RC620DU Drive Unit

RC620DU Rev.5 iii
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.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1.
Damage or malfunction caused by improper use which is not described in the manual,
or
careless use.
2.
Malfunctions caused by customers’ unauthorized disassembly.
3.
Damage due to improper adjustments or unauthorized
repair attempts.
4.
Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1.
If the
robot system
associated equipment is used outside of the usage conditions and
product
specifications described in the manuals, this warranty is void.
2.
If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3.
We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.

iv RC620DU Rev.5
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.
TRADEMARK NOTATION IN THIS MANUAL
Microsoft® Windows® XP Operating system
Microsoft® Windows® Vista Operating system
Microsoft® Windows® 7 Operating system
Throughout this manual, Windows XP, Windows Vista, and Windows 7 refer to above
respective operating systems. In some cases, Windows refers generically to Windows XP,
Windows Vista, and Windows 7.
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

RC620DU Rev.5 v
MANUFACTURER
Seiko Epson Corporation
Toyoshina Plant
Robotics Solutions Operations Division
6925 Toyoshina Tazawa,
Azumino
-shi, Nagano, 399-8285
Japan
TEL
: [phone]
FAX
: [phone]
SUPPLIERS
North & South America
Epson
America, Inc.
Factory Automation/Robotics
18300 Central Avenue
Carson, CA 90746
USA
TEL
: [phone]
FAX
: [phone]
E-MAIL
: [e-mail]
Europe
Epson Deutschland GmbH
Factory Automation Division
Otto
-Hahn-Str.4
D
-40670 Meerbusch
Germany
TEL
: [phone]
FAX
: [phone]
E-MAIL
: [e-mail]
China
Epson (China) Co., Ltd.
Factory Automation Division
7F, Jinbao Building No. 89, Jinbao Street,
Dongcheng District, Beijing,
China, 100005
TEL
: [phone]
FAX
: [phone]
Taiwan
Epson Taiwan Technology & Trading Ltd.
Factory Automation Division
14F, No.7, Song Ren Road, Taipei 110,
Taiwan, ROC
TEL
: [phone]
FAX
: [phone]

vi RC620DU Rev.5
Korea
Epson Korea Co., Ltd.
Marketing Team (Robot Business)
27F DaeSung D
-Polis A, 606
Seobusaet
-gil, Geumcheon-gu, Seoul, 153-803
Korea
TEL
: [phone]
FAX
: [phone]
SoutheastAsia
Epson Singapore Pte. Ltd.
Factory Automation System
1 HarbourFront Place, #03
-02,
HarbourFront Tower One,
Singapore 098633
TEL
: [phone]
FAX
: [phone]
India
Epson India Pvt. Ltd.
Sales & Marketing (Factory Automation)
12th Floor, The Millenia, Tower A, No. 1,
Murphy Road, Ulsoor, Bangalore,
India 560008
TEL
: [phone]
FAX
: [phone]
Japan
Epson Sales Japan Corporation
Factory Automation Systems Department
Nishi
-Shinjuku Mitsui Bldg.6-24-1
Nishishinjuku, Shinjuku
-ku, Tokyo 160-8324
Japan
TEL
: +81
-(0)3-5321-4161

Table of Contents
RC620DU Rev.5 vii
Safety 1. Safety 3
2. Conventions 3
3. Safety Precautions 4
Setup & Operation
1. Specifications 9
1.1 System Example.......................................................................................9
1.2 Drive unit Standard Specifications..........................................................10
1.3 Outer Dimensions...................................................................................11
2. Part Names and Functions 12
2.1 Part Names.............................................................................................12
2.2 Functions.................................................................................................13
2.3 LED .........................................................................................................15
2.4 Safety Features.......................................................................................16
3. Installation 18
3.1 Unpacking...............................................................................................18
3.2 Environmental Requirements .................................................................18
3.2.1 Environment................................................................................18
3.2.2 Installation...................................................................................19
3.2.3 Install inside the Cabinet.............................................................21
3.3 Power Supply..........................................................................................22
3.3.1 Specifications..............................................................................22
3.3.2 AC Power Cable.........................................................................23
3.4 Cable Connection ...................................................................................23
3.4.1 Typical Cable Connection...........................................................24
3.4.2 Connecting Manipulator to Drive unit.........................................25
3.5 Noise Countermeasures.........................................................................26
4. Drive Unit Connection 27
5. Drive Unit Confirmation 28

Table of Contents
viii RC620DU Rev.5
6. EMERGENCY 29
6.1 Safety Door Switch and Latch Release Switch......................................29
6.1.1 Safety Door Switch.....................................................................29
6.1.2 Latch Release Switch.................................................................30
6.1.3 Checking Latch Release Switch Operation................................30
6.2 Emergency Stop Switch Connection......................................................32
6.2.1 Emergency Stop Switch.............................................................32
6.2.2 Checking Emergency Stop Switch Operation............................32
6.2.3 Recovery from Emergency Stop................................................32
6.3 Pin Assignments.....................................................................................33
6.4 Circuit and Wiring Example....................................................................34
6.4.1 Circuit Diagrams .......................................................................34
6.4.2 Wiring Example for Emergency Stop .......................................35
6.4.3 Wiring Example for Safety Door Input / Latch Release Input....37
7. I/O Connector 38
7.1 Input Circuit.............................................................................................38
7.2 Output Circuit..........................................................................................40
7.3 Pin Assignment.......................................................................................42
8. R-I/O Connector 43
8.1 Input Circuit.............................................................................................43
8.2 Pin Assignment.......................................................................................44
Maintenance 1. Safety Precautions on Maintenance 47
1.1 Safety Precautions..................................................................................47
1.2 Lockout / Tagout.....................................................................................48
2. Regular Maintenance Inspection 49
2.1 Schedule for Maintenance Inspection....................................................49
2.2 Inspection Point......................................................................................49
2.2.1 Inspection While the Drive unit is Turned OFF..........................49
2.2.2 Inspection While the Drive unit is Turned ON............................49

Table of Contents
RC620DU Rev.5 ix
3. Drive unit Structure 50
3.1 Location of Parts.....................................................................................50
3.2 Diagram of Cable Connections...............................................................52
3.3 Connector Pin Assignment.....................................................................55
3.3.1 M/C Power Connector ................................................................55
3.3.2 M/C Signal Connector.................................................................56
4. Maintenance Parts Replacement Procedures 57
4.1 Fan and Fan Filter...................................................................................58
4.1.1 Cleaning and Replacing Fan Filter.............................................58
4.1.2 Replacing Fan Unit.....................................................................59
4.2 Motor Driver............................................................................................61
4.2.1 Part Names.................................................................................61
4.2.2 Replacing Motor Driver (Axis from 1 to 4)..................................61
4.2.3 Replacing Motor Driver (Axis 5 and 6) .......................................66
4.3 SMB Unit.................................................................................................68
5. Maintenance Parts List 73

Table of Contents
xRC620DU Rev.5

Safety
This section contains information for safety
of the Robot System.

Safety 1. Safety
RC620DU Rev.5 3
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 in a handy location for easy access at all
times.
Read the Safety chapter in EPSON RC+ 5.0 User’s Guide and confirm Safety-related
requirements.
2. Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
This symbol indicates that a danger of possible serious injury or
death exists if the associated instructions are not followed
properly.
WARNING
This symbol indicates that a danger of possible harm to people
caused by electric shock exists if the associated instructions are
not followed properly.
CAUTION
This symbol indicates that a danger of possible harm to people or
physical damage to equipment and facilities
exists if the
associated instructions are not followed properly.

Safety 3. Safety Precautions
4RC620DU Rev.5
3. Safety Precautions
Only trained personnel should design and install the robot system.
Trained personnel are defined as those who have taken robot system training class 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.
The following items are safety precautions for qualified design or installation
personnel:
WARNING

Personnel
who design and/or construct the robot system with this product must
read the Safety chapter in User
’
s Guide to understand the safety requirements
before designing and/or constructing the robot system. Designing and/or
constructing the robot system without understanding the safety requirements is
extremely hazardous, may result in serious bodily injury and/or severe
equipment damage to the robot system, and may cause serious safety problems.

The Manipulator and the
Drive unit
must be used within the environmental
conditions described in their respective manuals. This product has been
designed and manufactured strictly for use in a normal indoor environment.
Using the product in an environment that exceeds the specified enviro
nmental
conditions may not only shorten the life cycle of the
product but may also cause
serious safety problems.

The
robot system must be used within the installation requirements described in
the manuals.
Using the robot system outside of the installation requirements
may
not only shorten the life cycle of the product but also cause serious safety
problem
s.

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. (I.E. the condition where the switch is disabled)
(Example: Tape is put around the switch to hold it closed.) Operating the robot
system when the switch is not
functioning properly is extremely hazardous and
may
cause serious safety problem
s as the Safety Door input cannot fulfill its
intended function
.

Connect input signal wires for Emergency Stop and Safety Door to the
EMERGENCY connector so that the Emergency Stop switch in the
whole system
always functions. (Refer to the typical application diagram in
Setup & Operation
6
.4 Circuit and Wiring.)

Safety 3. Safety Precautions
RC620DU Rev.5 5
WARNING

Do not open the cover(s) of the
Drive unit except while maintaining it. Opening
the cover(s) of the
Drive unit is extremely hazardous
and may result in electric
shock
even when its main power is OFF because of the high voltage charge
inside the
Drive unit.

Make sure that the power to the
Drive unit is turned OFF
before connecting or
disconnecting any cables.
Connecting or disconnecting
any cables with the
power ON
is extremely hazardous and may result in electric shock and/or
ma
lfunction of the Drive unit.

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.

When
connecting the plug to fit the outlet in your factory, make sure that it is done
by qualified personnel. When connecting the plug,
be sure to connect the earth
wire of the AC power c
able colored green/yellow on the Drive unit
to the earth
terminal of the factory power supply.
The equipment must be grounded properly
at all times to avoid the risk of electric shock.
Always use a power plug and
receptacle
. Never connect the Drive unit directly to the factory power supply.
(Field wiring)
CAUTION

The serial number of the Manipulator that should be connected is indicated on
the
Connection Check Label on the Drive unit. Connect the Drive unit and the
Manipulator correctly.
Improper connection between the Drive unit and the
Manipulator may cause improper function of the robot system and also safety
problems.
The following items are safety precautions for qualified operator personnel:
WARNING

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. (I.E. the condition where the switch is disabled)
(Example: Tape is put around
the switch to hold it closed.) Operating the robot
system when the switch is not
functioning properly
is extremely hazardous and
may
cause serious safety problem
s as the Safety Door input cannot fulfill its
intended function
.
WARNING

Do not open the cover(s) of the
Drive unit except while maintaining it. Opening
the cover(s) of the
Drive unit is extremely hazardous and may result in electric
shock
even when its main power is OFF because of the high voltage charge
inside the
Drive unit.

Safety 3. Safety Precautions
6RC620DU Rev.5

Setup & Operation
This section contains information for setup and operation
of the Drive Unit.