Epson RC520 User manual

ROBOT CONTROLLER
RC520
Rev.7 EM058C1220F

ROBOT CONTROLLER RC520 Rev.7

ROBOT CONTROLLER
RC520
Rev.7
Copyright ©2002-2005 SEIKO EPSON CORPORATION. All rights reserved.
RC520 Rev.7 i

ii RC520 Rev.7
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the RC520 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.
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 or 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.

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® 95 Operating system
Microsoft® Windows® 98 Operating system
Microsoft® Windows® Millennium Edition Operating system
Microsoft® Windows® NT Operating system
Microsoft® Windows® 2000 Operating system
Throughout this manual, Windows 95, Windows 98, Windows Me, Windows NT, and
Windows 2000 refer to above respective operating systems. In some cases, Windows
refers generically to Windows 95, Windows 98, Windows Me, Windows NT, and
Windows 2000.
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
RC520 Rev.7 iii

iv RC520 Rev.7
MANUFACTURER & SUPPLIER
Japan & Others SEIKO EPSON CORPORATION
Suwa Minami Plant
Factory Automation Systems Dept.
1010 Fujimi, Fujimi-machi,
Suwa-gun, Nagano, 399-0295
JAPAN
TEL: [phone]
FAX: [phone]
SUPPLIERS
North & South America EPSON AMERICA, INC.
Factory Automation/Robotics
18300 Central Avenue
Carson, CA 90746
TEL: [phone]
FAX: [phone]
E-MAIL: [email protected]
Europe EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto-Hahn-Str.4
D-40670 Meerbusch
Germany
TEL: + 49 (0) - 2159/ 538-1391
FAX: + 49 (0) - 2159/ 538-3170
E-MAIL: [email protected]

Before Reading This Manual
This section describes what you should know before reading this manual.
Control System
The RC520 Robot Controller can be used with either the EPSON RC+ or SPEL CT
systems. For users of each system, the section or chapter to refer in the related manual is
indicated as follows in this manual.
EPSON RC+ : User’s Guide
SPEL CT : User’s Guide introduction or Setup & Operation
RC520 Rev.7 v

vi RC520 Rev.7

TABLE OF CONTENTS
Before Reading This Manual.................................................................... v
Setup & Operation
1. Safety 3
1.1 Conventions .......................................................................3
1.2 Safety Precautions .............................................................3
1.3 Safety Features ..................................................................6
2. Part Names and Functions 9
2.1 Model Number....................................................................9
2.2 System Configuration .........................................................9
2.3 Standard Specifications....................................................11
2.4 Control Unit ......................................................................13
2.4.1 Control Unit ..........................................................13
2.4.2 Front Panel...........................................................13
2.4.3 Rear Panel ...........................................................16
2.4.4 Dimensions...........................................................18
2.4.5 Control Unit Capability..........................................18
2.5 Four-axis Drive Unit (RC520DU) ......................................19
2.5.1 Four-axis Drive Unit..............................................19
2.5.2 Front Panel...........................................................19
2.5.3 Locking out the Four-axis Drive Unit.....................20
2.5.4 Rear Panel ...........................................................20
2.5.5 Four-axis Drive Unit - Interior Layout....................21
2.5.6 Dimensions...........................................................23
2.6 Six-axis Drive Unit (RC520DU6) ......................................24
2.6.1 Six-axis Drive Unit ................................................24
2.6.2 Front Panel...........................................................24
2.6.3 Locking out the Six-axis Drive Unit.......................25
2.6.4 Rear Panel ...........................................................25
2.6.5 Six-axis Drive Unit - Interior Layout ......................26
2.6.6 Dimensions...........................................................28
3. Installation 29
3.1 Environmental Requirements ...........................................29
3.2 Power Supply ...................................................................30
3.2.1 Specifications .......................................................30
3.2.2 Power Plug ...........................................................31
3.3 Cable Connection.............................................................32
3.3.1 Typical Cable Connections (Single Manipulator)..33
3.3.2 Connecting Drive Unit and Control Unit................36
3.3.3 Connecting a Drive Unit to the Manipulator ..........38
3.4 Noise Countermeasures...................................................40
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viii RC520 Rev.7
4. OPTIONAL DEVICE Connector 43
4.1 OPTIONAL DEVICE Connector....................................... 43
4.2 ATTEND (TEACH) Control Device .................................. 44
4.3 OPTIOINAL DEVICE Dummy Plug.................................. 45
4.4 Pin Assignments .............................................................. 46
5. EMERGENCY Connector 47
5.1 Safety Door Switch and Latch Release Switch ................ 47
5.1.1 Safety Door Switch .............................................. 47
5.1.2 Latch Release Switch .......................................... 48
5.1.3 Checking Latch Release Switch Operation.......... 48
5.2 Emergency Stop Switch................................................... 49
5.2.1 Emergency Stop Switch....................................... 49
5.2.2 Checking Emergency Stop Switch Operation ...... 49
5.3 E. STOP Box ................................................................... 50
5.3.1 E. STOP Box ....................................................... 50
5.3.2 Checking E. STOP Box Operation....................... 50
5.4 Pin Assignments .............................................................. 51
5.5 Circuit Diagrams .............................................................. 52
5.5.1 Example 1: External emergency stop switch
typical application ............................. 52
5.5.2 Example 2: External safety relay typical
application ........................................ 53
5.5.3 Example 3: Emergency Stop input circuit for
Multi-Manipulator.............................. 54
6. D-I/O Connector 55
6.1 Input Circuit...................................................................... 56
6.2 Output Circuit................................................................... 58
6.3 Pin Assignments .............................................................. 60
6.3.1 D-I/O connector - Pin Assignments...................... 60
6.3.2 D-I/O connector optional cable -
Pin Assignments .................................................. 61
6.3.3 D-I/O connector optional cable for USA
Specification - Pin Assignments .......................... 62
7. Expansion I/O Board - Optional 63
7.1 Expansion I/O Board........................................................ 63
7.2 Protected Expansion I/O Board ....................................... 64
7.2.1 Jumper Settings................................................... 64
7.2.2 Input Circuit.......................................................... 65
7.2.3 Output Circuit....................................................... 67
7.3 Expansion I/O Board........................................................ 69
7.3.1 Jumper Settings................................................... 69
7.3.2 Input Circuit.......................................................... 69
7.3.3 Output Circuit....................................................... 70

7.4 Expansion I/O Board: Pin Assignments............................72
7.4.1 Pin Assignments (NPN type) ................................72
7.4.2 Pin Assignments (PNP type) ................................74
7.5 Expansion I/O Connector .................................................76
7.5.1 Pin Layout of Expansion I/O Connector................76
7.5.2 Expansion I/O Connector Cable ...........................76
7.5.3 Expansion I/O Connector Cable -
Pin Assignments...................................................77
8. I/O Remote Settings 81
8.1 Remote I/O Signal Descriptions (EPSON RC+) ...............81
8.1.1 Remote Input Signals ...........................................82
8.1.2 Remote Output Signals ........................................84
8.2 Remote I/O Signal Descriptions (SPEL CT) .....................85
8.2.1 Remote Input Signals ...........................................85
8.2.2 Remote Output Signals ........................................87
8.3 Timing Specifications (EPSON RC+) ...............................89
8.3.1 Design Notes for Remote Input Signals................89
8.3.2 Timing Diagram for Operation Execution
Sequence .............................................................89
8.3.3 Timing Diagram for Program Execution
Sequence .............................................................90
8.3.4 Timing Diagram for Safety Door Input Sequence .91
8.3.5 Timing Diagram for Emergency Stop Sequence ..91
8.3.6 Timing Diagram for RECOVER Sequence ...........92
8.4 Timing Specifications (SPEL CT) .....................................94
8.4.1 Design Notes for Remote Input Signal .................94
8.4.2 Timing Diagram for Operation Execution
Sequence .............................................................94
8.4.3 Timing Diagram for Program Execution
Sequence .............................................................95
8.4.4 Timing Diagram for Safety Door Input Sequence .96
8.4.5 Timing Diagram for Emergency Stop Sequence ..97
8.4.6 Timing Diagram for Error Generating Sequence ..97
8.4.7 Timing Diagram for RECOVER Sequence ...........98
9. RS-232C Settings 101
9.1 RS-232C cable ...............................................................101
9.1.1 Pin Assignments.................................................101
9.1.2 Connection Example ..........................................102
9.2 Preparation for Communication......................................102
10. Jumper Settings for MIB 103
11. Stand-alone Option for RC520 107
11.1 Stand-alone Option ........................................................107
11.2 System Configuration .....................................................107
11.3 Installation ......................................................................107
11.4 Power Supply .................................................................108
11.5 Emergency Connector Plate Kit .....................................108
RC520 Rev.7 ix

x RC520 Rev.7
11.5.1 Appearance of Emergency Connector Plate Kit . 108
11.5.2 Components of Emergency Connector Plate Kit 109
11.5.3 Safety Door Switch and Emergency Stop Switch 109
11.5.4 Pin Assignments................................................. 110
11.5.5 Circuit Diagram................................................... 111
11.6 MIB ............................................................................... 113
11.6.1 Board Number.................................................... 113
11.6.2 Jumper Settings................................................. 113
11.7 Option ............................................................................ 113
Maintenance
1. Safety Precautions for Maintenance 117
1.1 Procedure for Lockout ................................................... 119
1.2 Tagout............................................................................ 119
2. Regular Maintenance Inspection 121
2.1 Schedule for Maintenance Inspection............................ 121
2.2 Inspection Point ............................................................. 122
2.2.1 Inspection While the Controller is Turned OFF .. 122
2.2.2 Inspection While the Controller is Turned ON.... 122
2.3 Cleaning the Fan Filter................................................... 122
2.4 Replacing a Lithium Battery on the CPU Board ............. 122
2.5 Backup of Data .............................................................. 124
2.5.1 EPSON RC+ ...................................................... 124
2.5.2 SPEL CT............................................................ 129
3. Hardware Configuration 133
3.1 Control Unit, Drive Unit and Manipulator........................ 133
3.2 Optional Boards ............................................................. 134
4. Control Unit 135
4.1 Overview........................................................................ 135
4.2 Replacing the MIB ......................................................... 135
4.3 Replacing CPU Board.................................................... 136
4.4 Replacing an Optional Board ......................................... 138
4.5 Replacing the System Panel.......................................... 138
4.5.1 Removal of the System Panel............................ 138
4.5.2 Installation of the System Panel......................... 139
4.6 Cleaning and Replacing the Fan Filter........................... 140
4.7 Replacing the Fan.......................................................... 141
4.8 Replacing the HDD (Hard Disk Drive)............................ 142
4.9 Replacing the Emergency Connector Plate Kit .............. 142

5. Four-axis Drive Unit (RC520DU) 143
5.1 Overview........................................................................143
5.2 Pin Assignments for the System Connectors .................144
5.2.1 M/C Power..........................................................144
5.2.2 M/C Signal..........................................................145
5.2.3 MOTION .............................................................146
5.3 Four-axis Drive Unit........................................................147
5.3.1 System Configuration of Four-axis Drive Unit.....147
5.3.2 Module Functions and Layout ............................148
5.3.3 Inspecting the Switching Power Supply Module .149
5.4 Motor Driver Module.......................................................150
5.4.1 Layout and Functions .........................................150
5.4.2 Replacing a Motor Driver Module .......................151
5.5 DPB (Drive Power Board)...............................................153
5.5.1 Layout and Functions .........................................153
5.5.2 Adjusting Encoder Voltage .................................155
5.5.3 Adjusting +5V Voltage ........................................156
5.6 DMB (Drive Main Board) ................................................157
5.6.1 Layout and Functions .........................................157
5.6.2 Replacing the DMB ............................................158
5.7 Cooling Fan....................................................................161
5.7.1 Layout.................................................................161
5.7.2 Inspecting the Fan Filter .....................................161
5.7.3 Replacing the Fan ..............................................162
5.8 Regeneration Module (For RC520DU) ...........................164
5.8.1 Layout and Function...........................................164
5.8.2 Replacing a Regeneration Module (For RC520DU)
...........................................................................164
6. Six-axis Drive Unit (RC520DU6) 167
6.1 Overview........................................................................167
6.2 Pin Assignments for the System Connectors .................168
6.2.1 M/C Power..........................................................168
6.2.2 M/C Signal..........................................................169
6.2.3 MOTION .............................................................169
6.3 Six-axis Drive Unit ..........................................................170
6.3.1 System Configuration of Six-axis Drive Unit .......170
6.3.2 Module Functions and Layout ............................171
6.3.3 Inspecting the Switching Power Supply Module .172
6.4 Motor Driver Module.......................................................173
6.5 DPB (Drive Power Board)...............................................173
6.5.1 Layout and Functions .........................................173
6.6 DMB (Drive Main Board) ................................................175
6.6.1 Layout and Functions .........................................175
6.6.2 Replacing the DMB ............................................175
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xii RC520 Rev.7
6.7 Cooling Fan .....................................................................178
6.7.1 Layout..................................................................178
6.7.2 Inspecting the Fan Filter......................................178
6.7.3 Replacing the Fan .............................................179
6.8 Regeneration Module and Over-voltage Detection
Module (For RC520DU6) ................................................181
6.8.1 Regeneration Module..........................................181
6.8.2 Over-voltage Detection Module...........................182
7. Verifying Manipulator Operation 183
8. Recovering the HDD 185
8.1 Recovering Windows.......................................................185
8.2 Configuring Windows ......................................................188
8.3 Setting Up EPSON RC+ (For EPSON RC+ User)..........189
8.3.1 Installing EPSON RC+........................................189
8.3.2 Reserving Address Resources of EPSON RC+
Options ................................................................190
8.4 Setting Up SPEL CT (For SPEL CT User)......................191
8.4.1 Installing SPEL CT..............................................191
8.4.2 Reserving Address Resources of SPEL CT
Options ................................................................192
9. Maintenance Parts List 193

Setup & Operation
This manual contains information for setup and operation
of the RC520 Robot Controller.

Setup & Operation
2 RC520 Rev.7

Setup & Operation 1. Safety
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.
Please read the Safety chapter in User’s Guide to understand safety requirements before
installing the robot system.
EPSON RC+ :User’s Guide - chapter Safety
SPEL CT :User’s Guide Introduction
:Safety - 1. Safety and 2. Basic Safety-related Matters
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.
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.
1.2 Safety Precautions
Only trained personnel should design and install the robot system.
Trained personnel are defined as those who have taken robot system training and
maintenance training classes 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
ersonnel:p
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.
RC520 Rev.7 3

Setup & Operation 1. Safety
■The Manipulator and the Controller 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 environmental
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
problems.
■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 problems as the Safety Door input cannot fulfill its
intended function.
WARNING
■Connect input signal wires for Emergency Stop and Safety Door to the
EMERGENCY connector so that the Emergency Stop switch in the operation
unit or the ATTEND (TEACH) control device connected to the OPTIONAL
DEVICE connector always functions. (Refer to the typical application diagram
in the Setup & Operation 5.5 Circuit Diagrams.)
■Do not open the cover(s) of the Controller except while maintaining it. Opening
the cover(s) of the Controller is extremely hazardous and may result in electric
shock even when its main power is OFF because of the high voltage charge
inside the Controller.
■Make sure that the power to the Controller is turned OFF and locked out 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 malfunction of the Controller.
■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.
WARNING
■If it is necessary to change the plug to fit the outlet in your factory, make sure
that it is done by qualified personnel. When changing the plug be sure to
connect the earth wire of the AC power cable colored green/yellow on the
Controller 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 Controller directly
to the factory power supply. (Field wiring)
4 RC520 Rev.7

Setup & Operation 1. Safety
WARNING
■Do not touch the inside of the AC OUTLET connector. The AC power cable
and the AC OUTLET connector on the Drive Unit are directly connected inside
the Drive Unit by the cable. The AC200V OUTLET connector on the Drive Unit
is constantly ON, whether the Drive Unit power is ON or OFF. Therefore,
touching the inside of the AC OUTLET connector is extremely hazardous and
may result in electric shock.
■Only install optional hardware specifically designed for the robot system. If any
other hardware is installed to the robot system, the robot system may function
improperly and also cause safety problems. (For EPSON RC+ Users, only the
hardware that has been approved by EPSON can be installed on the robot
system.)
■Do not install any other software in the robot system except for the software that
was originally installed at ship time. If any other software is installed, the robot
system may function improperly and also cause safety problems. (For EPSON
RC+ Users, only the software that has been approved by EPSON can be
installed on the robot system.)
■The serial numbers of the Drive Unit and Manipulator that should be connected
are indicated on the Connection Check Label on the Control Unit. Connect the
Control Unit, the Drive Unit and the Manipulator correctly. Improper
connections between the Drive Unit and the Manipulator and between the
Control Unit and the Drive Unit may cause improper function of the robot
system and also safety problems.
■If there is more than one Drive Unit connected to the Control Unit in the robot
system, make sure that the DU numbers (DU1 - DU3) indicated above the MIB
connector on the Control Unit and the Drive Unit (above the MOTION
connector) match. Improper connection between the Control Unit and the
Drive Unit may cause malfunction of the robot system and/or safety problems
as it may make the Manipulator move abnormally.
CAUTION
■When using remote I/O, always make sure of the following. Using the robot
system under unsatisfactory conditions may cause malfunction of the system
and/or safety problems.
- Assign remote functions to inputs/outputs correctly and wire correctly when
setting up remote I/O signals.
- Make sure that the functions correspond to the correct input/output signals
before turning ON the system.
- When verifying the robot system operation, prepare for failures with initial
settings or wiring. If the Manipulator functions unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to stop
the Manipulator.
RC520 Rev.7 5

Setup & Operation 1. Safety
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 problems as the Safety Door input cannot fulfill its
intended function.
WARNING
Do not open the cover(s) of the Controller except while maintaining it. Opening
the cover(s) of the Controller is extremely hazardous and may result in electric
shock even when its main power is OFF because of the high voltage charge
inside the Controller.
1.3 Safety Features
The RC520 robot control system supports safety features described below. However,
the user is recommended to strictly follow the proper usage of the robot system by
thoroughly reading the attached manuals before using the system. Failure to read and
understand the proper usage of the safety functions is highly dangerous.
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.
Refer to the Setup & Operation 5.1 Safety Door Switch and Latch Release Switch and
Setup & Operation 5.2 Emergency Stop Switch for details.
ATTEND (TEACH) Control Device:
To operate the Manipulator at a short distance without any operation unit (option), you
must create an ATTEND (TEACH) control device and connect it to the OPTIONAL
DEVICE connector on the front of the Control Unit in order to operate the Manipulator at
a short distance. The ATTEND (TEACH) control device should consist of the
Emergency Stop switch, 3-position enable switch (dead-man switch), and ATTEND
(TEACH) control device enable/disable switch.
The name of the control device depends on the software used in your Control Unit as
shown below:
EPSON RC+ : TEACH control device
SPEL CT : ATTEND control device
Emergency Stop Switch:
The ATTEND (TEACH) control device and operation unit (option) and must be equipped
with the Emergency Stop switch. The EMERGENCY connector on the Drive Unit has
extension Emergency Stop input terminals used for connecting the Emergency Stop
switches.
These Emergency Stop inputs are internally connected to the relays for the dynamic brake.
Therefore, pressing any Emergency Stop switch can shut off the motor power
immediately and the robot system will enter the Emergency Stop condition.
6 RC520 Rev.7