Epson RC620 CU User manual

Rev.8 EM15XC3076F
ROBOT CONTROLLER
RC620

ROBOT CONTROLLER RC620 Rev.8

RC620 Rev.8 i
ROBOT CONTROLLER
RC620
Rev.8
Copyright © 2009-2015 SEIKO EPSON CORPORATION. All rights reserved.

ii RC620 Rev.8
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

RC620 Rev.8 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 RC620 Rev.8
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

RC620 Rev.8 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]
Korea
Epson Korea Co., Ltd.
Marketing Team (Robot Business)
27F DaeSung D-Polis A, 606

vi RC620 Rev.8
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

RC620 Rev.8 vii
Before Reading This Manual
Do not connect TP1 to the following Robot Controllers. Connecting to the following Robot
Controllers may result in malfunction of the device since the pin assignments are different.
RC420 / RC520 / SRC5** / SRC-3** / SRC-2**
Be careful of the operating instructions of the TP1 when connecting it to the Robot
Controller RC180/RC170, it is different from the explanation in this manual.
When using the TP1 with the RC180/RC170, refer to the RC170 / RC180 Option Teach
Pendant TP1.
Do not connect the followings to the TP port of RC620. Connecting to the followings may
result in malfunction of the device since the pin assignments are different.
OPTIONAL DEVICE dummy plug
Operation Pendant OP500
Operator Pendant OP500RC
Operator Panel OP1
Jog Pad JP500
Teaching Pendant TP-3**
Security support for the network connection
The network connecting function (Ethernet) on our products assumes the use in the local
network such as the factory LAN network. Do not connect to the external network such
as Internet.
In addition, please take security measure such as for the virus from the network connection
by installing the antivirus software.
Security support for the USB memory
Make sure the USB memory is not infected with virus when connecting to the Controller.

NOTE

NOTE

NOTE

Table of Contents
viii RC620 Rev.8
Safety 1. Safety 3
2. Conventions 3
3. Safety Precautions 4
Setup & Operation
1. Specifications 9
1.1 System Example.......................................................................................9
1.2 Standard Specifications..........................................................................10
1.3 Outer Dimensions...................................................................................13
2. Part Names and Functions 14
2.1 Part Names.............................................................................................14
2.2 Functions................................................................................................16
2.3 LED and LCD..........................................................................................19
2.4 Safety Features......................................................................................22
3. Installation 24
3.1 Unpacking...............................................................................................24
3.2 Environmental Requirements.................................................................24
3.2.1 Environment............................................................................24
3.2.2 Installation...............................................................................25
3.3 Power Supply..........................................................................................26
3.3.1 Specifications..........................................................................26
3.3.2 AC Power Cable......................................................................27
3.4 Cable Connection...................................................................................27
3.4.1 Typical Cable Connection.......................................................28
3.4.2 Connecting Manipulator to Controller.....................................29
3.5 Noise Countermeasures.........................................................................30

Table of Contents
RC620 Rev.8 ix
4. Operation Mode (TEACH/AUTO) 31
4.1 Overview.................................................................................................31
4.2 Switch Operation Mode ..........................................................................31
4.3 Program Mode (AUTO)...........................................................................32
4.3.1 What is Program Mode (AUTO)?............................................32
4.3.2 Setup from EPSON RC+6.0....................................................32
4.4 Auto Mode (AUTO).................................................................................33
4.4.1 What is Auto mode (AUTO)? ..................................................33
4.4.2 Setup from EPSON RC+ 6.0...................................................33
4.4.3 Setup from Control Device......................................................35
5. Memory Port 36
5.1 What is Controller Status Storage Function?.........................................36
5.2 Before Using Controller Status Storage Function..................................36
5.2.1 Precautions .............................................................................36
5.2.2 Adoptable USB Memory..........................................................37
5.3 Controller Status Storage Function ........................................................37
5.3.1 Controller Status Storage with Trigger Button........................37
5.3.2 Controller Status Storage with Teach Pendant (Option)........38
5.3.3 Load Data with EPSON RC+ 6.0............................................38
5.3.4 Transfer with E-mail ................................................................39
5.4 Details of Data ........................................................................................40
6. LAN (Ethernet Communication) Port 41
6.1 About LAN (Ethernet Communication) Port ...........................................41
6.2 IP Address ..............................................................................................42
6.3 Changing Controller IP Address.............................................................42
7. TP Port 44
8. EMERGENCY 45
8.1 Safety Door Switch and Latch Release Switch......................................46
8.1.1 Safety Door Switch..................................................................46
8.1.2 Latch Release Switch..............................................................47
8.1.3 Checking Latch Release Switch Operation ............................47

Table of Contents
xRC620 Rev.8
8.2 Emergency Stop Switch Connection......................................................48
8.2.1 Emergency Stop Switch..........................................................48
8.2.2 Checking Emergency Stop Switch Operation.........................48
8.2.3 Recovery from Emergency Stop.............................................48
8.3 Pin Assignments.....................................................................................49
8.4 Circuit Diagrams.....................................................................................50
8.4.1 Example 1:
External emergency stop switch typical application ...............50
8.4.2 Example 2:
External safety relay typical application..................................51
9. I/O Connector 52
9.1 Input Circuit.............................................................................................52
9.2 Output Circuit..........................................................................................54
9.3 Pin Assignment.......................................................................................56
10. I/O Remote Settings 57
11. R-I/O Connector 58
11.1 Input Circuit.............................................................................................58
11.2 Pin Assignment.......................................................................................59
12. Option Units 60
12.1 What are Option Units?..........................................................................60
12.2 Expansion I/O Board ..............................................................................61
12.2.1 About Expansion I/O Board...................................................61
12.2.2 Board Configuration (Expansion I/O)....................................61
12.2.3 Confirmation with EPSON RC+6.0 .......................................62
12.2.4 Input Circuit ...........................................................................62
12.2.5 Output Circuit.........................................................................64
12.2.6 Pin Assignments....................................................................66
12.3 Fieldbus I/O Board..................................................................................67
12.4 RS-232C Board......................................................................................68
12.4.1 About RS-232C Board...........................................................68
12.4.2 Board Setup (RS-232C)........................................................68
12.4.3 Verify with EPSON RC+5.0 (RS-232C)................................69
12.4.4 RS-232C Software Communication Setup (RS-232C).........70
12.4.5 Communication Cable (RS-232C).........................................70
12.5 PG Board................................................................................................70

Table of Contents
RC620 Rev.8 xi
13. UPS 71
14. Option : Teach Pendant TP1 73
14.1 Function..................................................................................................73
14.1.1 Safety.....................................................................................73
14.1.2 Specifications.........................................................................77
14.1.3 Installation..............................................................................79
14.1.4 Operation Mode (TEACH / AUTO)........................................84
14.1.5 Operation Panel (Key Description)........................................86
14.1.6 Enable Switch........................................................................89
14.1.7 Warning Sound (Beep)..........................................................89
14.2 Teaching Procedure ..............................................................................90
14.2.1 Jog Operation ......................................................................90
14.2.2 Teaching ..............................................................................91
14.2.3 Direct Teaching ....................................................................92
14.3 TEACH Mode ........................................................................................94
14.3.1 Jog & Teach .........................................................................95
14.3.2 Point Editor ..........................................................................99
14.3.3 Robot...................................................................................101
14.3.4 Motion Command ..............................................................102
14.3.5 I/O Command .....................................................................103
14.3.6 Jog Distance ......................................................................104
14.3.7 Free Joints .........................................................................105
14.3.8 Brake (For 6-Axis robots) ...................................................106
14.4 AUTO Mode ........................................................................................108
14.4.1 Program Command Display ..............................................109
14.4.2 I/O Monitor .........................................................................110
14.4.3 Memory I/O Monitor ...........................................................110
14.4.4 Task Monitor ......................................................................111
14.4.5 System History ...................................................................112
14.4.6 Controller Statuses Preservation .......................................113
14.4.7 Date / Time ........................................................................113
14.4.8 Brightness / Contrast .........................................................114
14.4.9 Language ...........................................................................114
14.4.10 Error .................................................................................115
14.5 Password Setup ..................................................................................115
14.6 Troubleshooting ..................................................................................116

Table of Contents
xii RC620 Rev.8
15. Option : RAID 117
15.1 Overview...............................................................................................117
15.2 Data Protection Status Confirmation....................................................117
15.2.1 Normal Status......................................................................117
15.2.2 Status for Restore ...............................................................118
15.3 Restoring the Data Protection Status...................................................119
15.3.1 Shutdown the system..........................................................119
15.3.2 Replace the HDD ................................................................119
15.3.3 Restore the data protection status......................................119
Maintenance 1. Safety Precautions on Maintenance 123
1.1 Safety Precautions ...............................................................................123
1.2 Lockout / Tagout...................................................................................124
2. Regular Maintenance Inspection 125
2.1 Schedule for Maintenance Inspection..................................................125
2.2 Inspection Point....................................................................................126
2.2.1 Inspection While the Controller is Turned OFF ....................126
2.2.2 Inspection While the Controller is Turned ON......................126
3. Controller Structure 127
3.1 Location of Parts...................................................................................127
3.2 Diagram of Cable Connections ............................................................127
3.3 Connector Pin Assignment...................................................................132
3.3.1 M/C Power Connector...........................................................132
3.3.2 M/C Signal Connector...........................................................133
4. Backup and Restore 134
4.1 What is Backup Controller?..................................................................134
4.2 Backup Data Types..............................................................................135
4.3 Backup..................................................................................................136
4.4 Restore.................................................................................................137
5. Firmware Update 139
5.1 Updating Firmware...............................................................................139
5.2 Firmware Upgrading Procedure...........................................................139

Table of Contents
RC620 Rev.8 xiii
5.3 Controller Recovery..............................................................................142
5.4 Firmware Initialization Procedure.........................................................143
6. Maintenance Parts Replacement Procedures 145
6.1 Fan / Fan Filter ....................................................................................146
6.1.1 Cleaning and Replacing the Fan Filters ..............................145
6.1.2 Replacing the Large Fan .....................................................147
6.1.3 Replacing the Small Fan ......................................................149
6.2 Battery .................................................................................................151
6.2.1 Replacing the Small Fan ......................................................151
6.2.2 Replacing the UPS Battery ..................................................154
6.3 Motor Driver ........................................................................................157
6.3.1 Part Name ............................................................................157
6.3.2 Replacing the Motor Driver (DMB side) ...............................158
6.3.3 Replacing the Motor Driver (ADMB side) ............................161
6.4 CPU Board / BIOS Backup Battery / Memory ....................................164
6.4.1 Normal ..................................................................................164
6.4.2 Faster ...................................................................................173
6.5 CF (Compact Flash) ............................................................................186
6.6 Switching Power Supply .....................................................................188
6.6.1 Switching Power Supply (15W) ...........................................188
6.6.2 Switching Power Supply (75W) ...........................................190
6.6.3 Switching Power Supply (ATX) ............................................192
6.7 PCI Board ............................................................................................196
6.8 Special Board ......................................................................................198
6.8.1 Replacing the Special Option Board ....................................198
6.8.2 Adding the Special Option Board ........................................198
6.9 HDD .....................................................................................................199
6.9.1 Standard (HDD without RAID option) ..................................199
6.9.2 HDD with RAID option .........................................................199
7. Recovering the HDD 201
7.1 HDD Recovery Procedure (S/N 01/02-00501 to 01/02-01000) ..........201
7.1.1 Recovering Windows ............................................................201
7.2 HDD Recovery Procedure (S/N 01/02-01001 or later) .......................203
7.2.1 Backing up EPSON RC+ data .............................................203
7.2.2 Recovering Windows ............................................................204
7.2.3 Restoring EPSON RC+ data ...............................................207

Table of Contents
xiv RC620 Rev.8
8. Troubleshooting 208
If the display is blank ...................................................................................208
9. Maintenance Parts List 209
9.1 RC620...................................................................................................209
9.2 Option TP1............................................................................................210

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

Safety 1. Safety
RC620 Rev.8 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.
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
4RC620 Rev.8
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 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
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 s
witch 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 th
at the Emergency Stop switch in the Teach
Pendant connected to the TP
port always functions. (Refer to the typical
application diagram in Setup & Operation
8.4 Circuit Diagrams.)