Epson SRC520 User manual

SRC520
Rev.4 EM015C868F
ROBOT CONTROLLER

ROBOT CONTROLLER SRC520 Rev.4

i




ROBOT CONTROLLER

SRC520
Rev.4
Copyright 1998, 2000-2001 SEIKO EPSON CORPORATION. All rights reserved.

ii
FOREWORD
Thank you for the purchase of our robot for use in precision construction applications.
This manual contains information that you need to know how to use the robot controller
correctly. Please thoroughly read this and other related manuals before and while using
the equipment.
• Robot controller SRC500/520 (including SRC520CE) is shown as “SRC5**” in relevant
manual.
• Only SRC520CE is a robot controller meets to the CE marking.
• The following mark is put to the description corresponding to only SRC520CE.
WARRANTY
The robot 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.
1. Warranty Period: The warranty period is 12 months after delivery.
2. Warranty Coverage: 1) We warrant only the product we delivered.
2) Product’s malfunctions resulting from normal handling and
operation will be repaired free of charge within this warranty
period.
Any other repairs after this warranty period ought to be in-
voiced.
3. Escape Clause: Customers will be charged for repairs in the following cases even
if it is within 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 customer’s unauthorized reconstruc-
tion or disassembly.
3) Damage due to improper adjustments or unauthorized repair
attempts.
4) Damage caused by natural disasters such as earthquake,
flood, etc.
4. Caution: 1) If the robot is used outside of the usage conditions and prod-
uct 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) Of course, we cannot foresee all possible dangers and con-
sequences. Therefore, this manual cannot warn the user of
all possible hazards.
520CE

iii
NOTICE

No part of this manual may be copied or reproduced without authorization.

The content of this manual is subject to change without notice.

We ask that you please notify us if you should find any errors in this manual or if you
have any comments regarding its content.
TRADEMARKS
Pentium is a trademark of the Intel Corporation.
Microsoft is a registered trademark and Windows and Windows logo are registered
trademarks of the Microsoft Corporation.
Other brand and product names are trademarks or registered trademarks of the respective
holders.
Please direct any inquiries about the use of this manual to:
SRC520
SEIKO EPSON CORPORATION
Sales Engineering Group
TEL: [phone]
FAX: [phone]

iv
Safety Precautions
Please carefully read this manual and any other manuals before installing this robot system
(and definitely before connecting cables). Keep this manual in a handy location for easy
access at all times.

This sign indicates that a danger of serious injury or
death will exist if the instructions thereunder are not
followed.
This sign indicates that ignoring the instructions there-
under may cause harm to people or physical damage to
equipment and facilities.

The manufacturer/supplier must design and construct this robot system in
accordance with the principles described in the “Safety” section of the
SRC5**/SPEL 95 Introduction Manual. Please read the Introduction Man-
ual first to follow Safety Precautions therein.

This robot has been designed and manufactured strictly for use in a normal
indoor environment. Do not use the robot in an environment that exceeds
the conditions set forth in the manuals for the manipulator and controller.

Do not use the robot outside of the usage conditions and product specifica-
tions described in the manuals. Doing so will not only adversely affect the
life of the product, but may also present a serious safety problem.

Only trained personnel should be allowed to design, install, operate, perform
function testing, and maintain this robot and the robot system. Trained per-
sonnel are those who have taken a robot training course (held by the dealer
on a regular basis) or those who have carefully read the manuals and have
equivalent knowledge or skill.
WARNING



CAUTION
WARNING

v
Manuals (Relevant documentation)
1.SRC5**/SPEL 95 Introduction Manual
SRC5**/SPEL 95 User’s Guide
SRC5**/SPEL 95 Appendix
These manuals that describe the outline of SRC5** controller, manipulator, and SPEL
95 program development software. These manuals include explanations regarding
basic operation, teaching, programming, and file management. Read these manuals
first and learn the required operations.
2.Manipulator manual
This manual describes the manipulator, which performs the actual movements.
It contains requirements and safety-related information that should be read before
installation.
3.Robot Controller manual
This manual describes the controller functions, setup, and peripheral equipment wiring.
It contains requirements and safety-related information that should be read before
installation.
Controller options:
z
Multi-Manipulator Manual
z
Pulse Generating Board Manual
z
Ethernet Board Manual
z
Remote I/O Board Manual
z
Vision Calibration Guide
z
M300 Micro Image-checker
z
Custom Manipulator Tuning
z
Operation Pendant OP500 Manual
Revised Points from SRC500
SRC520 is a succeeding model to SRC500. The function, operation and external
dimension have not been changed. The main revised points are as follows:
z
The unit for 2.5-inch hard disk drive has been able to be replaced from the front
panel.
z
The emergency stop circuit has been changed for double structure for safety.
Therefore, the emergency connector standard has been changed.
When connecting SRC520 to the emergency stop circuit that used to be connected to
SRC500, a converting connector (option) is necessary.
Parts Compatibility between SRC500 and SRC520
The maintenance parts list in the “Maintenance 5. Maintenance Parts List” describes
whether the maintenance parts for SRC520 are applicable to SRC500.
For more details, please contact us.

vi
Differences between SRC520 and SRC520CE
This manual describes about the robot controller SRC520 (including SRC520CE).
The controller consists of one Control Unit and Drive Unit(s). You may find the
controller model name on the front panels of them.
The model, SRC520 and SRC520CE, are quite different. Only SRC520CE is in
conformity with the following EC directives:
Conformed to: Applied Standards
Machinery directive EN775, EN60204-1
EMC directive EN55011, EN50082-2
Low Voltage directive EN60950
SRC520CE Drive Unit(s) and SRC520CE Control Unit (with SPEL 95) compose
a SRC520CE.
SRC520CE will not meet the above-mentioned Standards when the SRC520CE is
remodeled and/or when the SRC520CE is connected with other controller.
SRC520CE provides only PNP-type I/O.
SRC520 provides NPN-type I/O, but PNP-type is prepared as an option.
SERVICE CENTER
Contact the following service center for robot repairs, inspections or adjustments.
Please have the model name, the Serial No. of each unit, software version and
a description of the problem ready when you call.
MANUFACTURER
SEIKO EPSON CORPORATION
Okaya Plant No. 2
1-16-15, Daiei-cho, Okaya-shi, Nagano-ken, 394-0025, Japan
TEL: [phone] (switchboard)
81-266-24-2004 (direct)
FAX: [phone]
520CE

vii
TABLE OF CONTENTS

Function
1. For Safety 3
1.1 Safety Precautions .............................................................. 3
1.2
Safety Features ................................................................... 5
2. Part Names and Functions 7
2.1 System Configuration.......................................................... 7
2.2 Standard Specifications ...................................................... 9
2.3 Control Unit ....................................................................... 12
2.3.1 Control Unit ........................................................... 12
2.3.2 Front Panel............................................................ 12
2.3.3 Rear Panel ............................................................ 15
2.3.4 Dimensions ........................................................... 17
2.3.5 Control Unit Capability .......................................... 18
2.4 Drive Unit........................................................................... 19
2.4.1 Drive Unit............................................................... 19
2.4.2 Front Panel............................................................ 19
2.4.3 Rear Panel ............................................................ 20
2.4.4 Drive Unit – Interior Layout ................................... 21
2.4.5 Dimensions ........................................................... 23
3. Installation 25
3.1 Box Contents..................................................................... 25
3.2 Environmental Requirements ........................................... 26
3.3 Power Supply .................................................................... 27
3.3.1 Specifications ........................................................ 27
3.3.2 Power Plug ............................................................ 28
3.4 Cable Connection.............................................................. 29
3.4.1 Typical Cable Connection (Single Manipulator) ..... 30
3.4.2 Connecting Drive Unit and Control Unit ............... 33
3.4.3 Connecting a Drive Unit to the Manipulator.......... 35
3.5 Noise Countermeasures ................................................... 36
4. OPTIONAL DEVICE Connector 39
4.1 OPTIOINAL DEVICE Connector....................................... 39
4.2 Operation Unit (JP500/OP500) .........................................39
4.3 OPTIOINAL DEVICE Port Short Connector ..................... 39
4.4 Pin Assignments ............................................................... 40
5. EMERGENCY Connector 41
5.1 Safety Door Switch and Latch Release Switch ................ 41
5.1.1 Safety Door Switch ............................................... 41
5.1.2 Latch Release Switch ........................................... 42

viii
5.1.3 Checking the Functions ........................................ 42
5.2 Emergency Stop Switch.................................................... 43
5.2.1 Emergency Stop Switch ....................................... 43
5.2.2 Checking the Functions ........................................ 43
5.3 Pin Assignments ............................................................... 44
5.4 Circuit Diagrams ............................................................... 45
5.4.1 Example 1: External emergency stop switch
typical application ............................ 45
5.4.2 Example 2: External safety relay typical
application........................................ 46
6. D-I/O Connector 47
6.1 Input Circuit ....................................................................... 48
6.2 Output Circuit .................................................................... 50
6.3 Pin Assignments ............................................................... 52
6.3.1 Pin Assignments ................................................... 52
6.3.2 Optional cable – Pin Assignments ....................... 53
7. Extension I/O Board - Optional 55
7.1 Extension I/O Board.......................................................... 55
7.2 Protected Extension I/O Board ......................................... 56
7.2.1 Jumper Settings.................................................... 56
7.2.2 Input Circuit........................................................... 57
7.2.3 Output Circuit ........................................................ 59
7.3 Extension I/O Board
(the standard for the regions outside Europe) ................. 61
7.3.1 Jumper Settings.................................................... 61
7.3.2 Input Circuit........................................................... 62
7.3.3 Output Circuit ........................................................ 62
7.4 Extension I/O Board : Pin Assignments ........................... 64
7.4.1 Pin Assignments (NPN type)................................ 64
7.4.2 Pin Assignments (PNP type) ................................ 66
7.5 Extension I/O Connector................................................... 68
7.5.1 Pin Layout of Extension I/O Connector ................ 68
7.5.2 Extension I/O Connector Cable............................ 68
7.5.3 Cable - Pin Assignment ........................................ 69
8. I/O Remote Settings 73
8.1 I/O Signal Description ....................................................... 74
8.1.1 Input Signal ........................................................... 74
8.1.2 Output Signal ........................................................ 76
8.2 Timing Specifications........................................................ 78
8.2.1 Design Notes for Input Signal............................... 78
8.2.2 Diagram for Operation Execution Sequence ....... 78
8.2.3 Diagram for Program Execution Sequence ......... 79
8.2.4 Diagram for Safety Door Input Sequence ............ 79
8.2.5 Diagram for Emergency Stop Sequence.............. 80
8.2.6 Diagram for Error Generating Sequence ............. 80

ix
9. RS-232C Settings 81
9.1 RS-232C cable.................................................................. 81
9.1.1 Pin Assignments ................................................... 81
9.1.2 Connection Example............................................. 82
9.2 Preparation for Communication ........................................ 83
10. Jumper Settings for MIB 85
11. Stand-alone Option for SRC520 87
11.1 Stand-alone Option ........................................................... 87
11.2 System Configuration........................................................ 87
11.3 Installation ......................................................................... 87
11.4 Power Supply .................................................................... 88
11.5 Extension Emergency Connector Unit.............................. 88
11.5.1 Appearance........................................................... 88
11.5.2 Components.......................................................... 89
11.5.3 Safety Door and Emergency Stop Switch ............ 89
11.5.4 Pin Assignments ................................................... 90
11.5.5 Circuit Diagram ..................................................... 91
11.6 MIB .................................................................................... 93
11.6.1 Board Number....................................................... 93
11.6.2 Jumper Settings .................................................... 93
11.7 Option ................................................................................ 93
Maintenance
1. Safety Precautions on Maintenance 97
2. Hardware Configuration 99
2.1 Control Unit, Drive Unit and Manipulator .......................... 99
2.2 Optional Boards .............................................................. 100
3. Control Unit 101
3.1 Overview.......................................................................... 101
3.2 Replacing the MIB........................................................... 102
3.3 Replacing the Extension Emergency Connector Unit ....106
3.4 Replacing an Optional Board.......................................... 109
3.5 Replacing the System Panel........................................... 110
3.5.1 Removable HD Unit Model ................................. 110
3.5.2 Built-in HDD Model ............................................. 116
3.6 Cleaning and Replacing the Fan Filter ........................... 121
3.7 Replacing the HDD for Removable HD Unit Model........ 122
4. Drive Unit 123
4.1 Overview ......................................................................... 123

x
4.2 Pin Assignments for the System Connectors................. 124
4.2.1 M/C Power .......................................................... 124
4.2.2 M/C Signal .......................................................... 125
4.2.3 MOTION.............................................................. 126
4.3 Drive Unit ........................................................................ 127
4.3.1 System Configuration ......................................... 127
4.3.2 Module Functions and Layout ............................ 128
4.3.3 Inspecting a Switching Power Supply Module ... 129
4.4 Motor Driver Module ....................................................... 130
4.4.1 Layout and Functions ......................................... 130
4.4.2 Replacing a Motor Driver Module....................... 131
4.4.3 Setting Up the New CT Data on the SPEL 95 ... 133
4.5 DPB (Drive Power Board)............................................... 134
4.5.1 Layout and Functions ......................................... 134
4.5.2 Adjusting Encoder Voltage ................................. 136
4.5.3 Adjusting +5V Voltage ........................................ 137
4.6 DMB (Drive Main Board)................................................. 138
4.6.1 Layout and Functions ......................................... 138
4.6.2 Replacing DMB................................................... 139
4.7 Cooling Fan..................................................................... 142
4.7.1 Layout ................................................................. 142
4.7.2 Inspecting the Fan Filter ..................................... 142
4.7.3 Replacing the Fan ............................................. 143
4.8 Regeneration Module ..................................................... 145
4.8.1 Layout and Function ........................................... 145
4.8.2 Replacing a Regeneration Module..................... 145
5. Check List for the Manipulator Operation 147
6. Maintenance Part List 149

Function
The manual herein explains in detail the functions of the
robot controller, SRC520.

Function
2

Function 1. For Safety
3
1. For Safety
1.1 Safety Precautions
WARNING This sign indicates that a danger of serious injury or death
will exist if instructions there under are not followed.
CAUTION
This sign indicates that ignoring the instructions there under
may cause harm to people or physical damage to equipment
and facilities.
WARNING

Do not open the cover(s) of the Control and Drive Units except while
maintaining them. Because of the high voltage charger inside the Control
Unit and Drive Unit, there is a risk of fatal electrical shock even when its
main power is OFF.
If it is necessary to change the plug to fit the outlet in your factory, be certain
to connect the earth wire of the AC power cable colored green/yellow 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. Never connect the controller directly to the factory power
supply.
Make sure that the power to the Control Unit and Drive Unit is turned OFF
before connecting or disconnecting any cables. Failure to do so may cause
electric shock and may damage the units.
The interlock of the Safety Door must be functioning when the system is
operated. It is dangerous to operate the system unless the Safety Door
switch is in a completely functioning condition.
Do refer to the typical application diagram in “Function 5.4 Circuit Diagrams”
in this manual when wiring to the EMERGENCY connector so that it should
not dysfunction the emergency stop input at the Optional Units via the
OPTIONAL DEVICE connector.

Function 1. For Safety
4
CAUTION

The power supply voltage switch on the Control Unit must be set and kept at
[230] side (AC200V to AC240V) when using the Control Unit with other
equipment. If connecting the equipment with AC200V (or the local
equivalent) under the condition that the power supply voltage switch is set at
[115] side (AC100V to AC120V), the equipment will be damaged seriously.
Only install optional hardware specifically designed for the SRC520 in the
Control Unit. Do not install any other software than originally installed in
the Control Unit at shipping. Otherwise, the warranty is void.
Check on the Connection Check Label, DU number (at Control Unit) and
Signature Labels (at Drive Unit & Manipulator) when connecting those units.
If those units are misconnected, the robot may not function properly or may be
damaged.
If there are more than one Drive Units connected to the Control Unit, make
sure that the DU numbers (DU1 - DU3) indicated at the Control Unit (above
the MIB connector) and the Drive Unit (above the MOTION connector)
match. It is highly dangerous if those do not match, causing to activate an
unintended robot.
Ensure all cables are securely connected. Avoid placing anything heavy on
the cables, and, do not bend them excessively, because this may damage the
cables, preventing the robot from functioning properly.
The AC power cable and the AC OUTLET connector on the Drive Unit are
directly connected inside the unit. Therefore, no matter if the Drive Unit is
ON or OFF, the AC OUTLET connector is constantly outputting AC200V (or
the local equivalent) power which requires extra caution.
When using I/O at the remote setup, always make sure before allowing
current to flow that the cable connection matches to the pin assignments.
Failure to do so may cause damage to/by the peripheral equipment.
At performance testing, prepare for some kind of failure with initial settings
or cable connection and, therefore, take extra caution.

Function 1. For Safety
5
1.2 Safety Features
Provided against unexpected contingencies, the robot features the following safety
measures. However, the user is recommended to strictly follow the proper usage of the
robot by thoroughly reading the attached manuals at the very beginning. Skipping the
proper steps of usage relying on the featured safety functions is highly dangerous.
Among the following safety functions featured, the Emergency Stop Switch and Safety
Door Input are particularly important. Make sure that those and other features function
properly before operating the robot.
Emergency Stop Switch:
Optional operation units, JP500 (Jog Pad) and OP500 (Operation Pendant), are equipped
with the Emergency Stop Switch that connects to the OPTIONAL DEVICE connector at
the Control Unit. The emergency stop switch can also be provided on an external
devices/unit that connects to the EMERGENCY connector at the Drive Unit.
By connecting those switches to the relays in the Motor Driver modules at the Drive Unit,
they activate as dynamic braking. When the switch is pressed, the motor power is shut
down right away, and the robot will enter the emergency stop condition.
Safety Door Input:
Opening the Safety Door stops the robot right away for the time being. In order to
activate this feature, make sure that the Safety Door Input switch is connected to the
EMERGENCY connector at the Drive Unit.
Low Power Mode:
The motor power is reduced in this mode. During the ATTEND operation mode to
perform teaching, the robot automatically operates with slower speed. When the Safety
Door is open while the robot operates in the NORMAL operation mode, the robot
temporarily stops and enters the operation-prohibited status.
Dynamic Brake:
The dynamic brake circuit includes the relays that shorting the motor power cable at the
motor module or connecting it to the motor driver module. When those relays are short,
the power to the Motor Driver module is cut off thus stopping the motor. The dynamic
brake circuit is activated when there is an Emergency Stop input or when any of the
following errors is detected: encoder cable disconnection, motor overload, irregular motor
torque, motor speed error, servo error (positioning or speed overflow), irregular CPU,
memory check-sum error and overheat inside the Motor Driver Module.

Function 1. For Safety
6
Encoder Cable Disconnection Error Detection:
The dynamic brake circuit is activated when the Motor Encoder Signal cable (connecting
to the Drive Unit) is disconnected.
Motor Overload Detection:
The dynamic brake circuit is activated when the load on the motor is detected to exceed
its capacity.
Irregular Motor Torque (out-of-control manipulator) Detection:
The dynamic brake circuit is activated when irregularity with the motor torque (motor
output) is detected (in which case the manipulator is out of control).
Motor Speed Error Detection:
The dynamic brake circuit is activated when the motor is detected running at the speed
not as specified.
Positioning Overflow - Servo Error - Detection:
The dynamic brake circuit is activated when the robot’s “actual position” is detected to
mark an overflow (the actual position is outside the nominal range) error.
Speed Overflow - Servo Error - Detection:
The dynamic brake circuit is activated when the robot’s actual speed is detected to mark
an overflow (the actual speed is outside the nominal range) error.
CPU Irregularity Detection:
Irregularity at the motor controlling CPU is detected by the watch-dog timer. Also, the
system CPU inside the Control Unit and the motor controlling CPU inside the Drive Unit
are designed to constantly check against each other for any discrepancies between the
units. If the discrepancy error is detected, the dynamic brake circuit is activated.
Memory Check-sum Error Detection:
The dynamic brake circuit is activated when the check-sum error of memory is detected.
Overheat Detection at the Motor Driver Module:
The dynamic brake circuit is activated when the temperature of the power device inside
the Motor Driver module goes up above the nominal limit.

Function 2.1 System Configuration (Part Names and Functions)
7
2. Part Names and Functions
2.1 System Configuration
The SRC520 is consisted of one Control Unit and Drive Unit(s). One Drive Unit
enables controlling up to 4 axes/motors at once. Up to three Drive Units can be
connected to one Control Unit.
For details of the Control Unit, refer to the “Function 2.3 Control Unit”.
For details of the Drive Unit, refer to the “Function 2.4 Drive Unit”.
Example 1 ：One Drive Unit and One Manipulator
Control Unit
Drive Unit
Manipulator
Jog Pad (option)

Function 2.1 System Configuration (Part Names and Functions)
8
Example 2 ：Three Drive Units and Three Manipulators
Control Unit
Jog Pad
(option)
3rd
Manipulator
2nd
Manipulator
1st
Manipulator
1st
Drive Unit
2nd
Drive Unit
3rd
Drive unit