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.
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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
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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
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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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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