Hiwin RC4 Operation instructions

www.hiwin.tw
User Manual
Robot Controller
RC4 Series
Original Instruction

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CONTENTS
0. Safety Precautions ...................................................................................4
1. Specification ..........................................................................................17
1.1. Standard Specification.............................................................................................17
1.2. Standard and Optional Equipment...........................................................................19
1.3. Appearance Dimensions..........................................................................................23
1.4. Appearance Component..........................................................................................25
1.5. Indicator light Signal................................................................................................27
1.6. Operating Environment ...........................................................................................28
1.7. Sticker and Label .....................................................................................................29
2. Installation.............................................................................................33
2.1. Installation Dimensions...........................................................................................33
2.2. Multifunctional Installation Handler........................................................................39
2.3. Basic Architecture ...................................................................................................42
2.3.1. Connection Method .....................................................................................................................42
2.3.2. Transformer Installation (Optional) .............................................................................................45
2.4. Controller Boot/Shutdown Program Description......................................................47
2.5. Power and Signal Cable Connection.........................................................................48
2.6. Emergency Stop Switch Connection (E-STOP) (optional) ...........................................51
2.7. Remote Control Connect Description.......................................................................56
3. External Input / Output .........................................................................58
3.1. Function I/O............................................................................................................59
3.2. Digital I/O ...............................................................................................................60
3.3. Example of Connection............................................................................................61
3.4. RS-232 Port .............................................................................................................65
3.5. RS-485 Port .............................................................................................................67
3.6. External I/O expansion interface (optional) .............................................................69
3.6.1. CC-LINK Interface (optional) ........................................................................................................70
3.6.2. PROFINET IO Interface (optional).................................................................................................71
3.6.3. Encoder data acquisition module (optional)................................................................................72
3.6.4. I/O Module with 32CH Digital Outputs (optional) .......................................................................74

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3.6.5. I/O Module with 32CH Digital Inputs (optional) ..........................................................................76
3.6.6. I/O Module with 16CH DO and 16CH DI (optional)......................................................................79
4. Teach Pendant .......................................................................................82
4.1. Teach Pendant Description ......................................................................................82
4.2. Teach Pendant Connector Description .....................................................................85
4.3. Teach Pendant Shortcut Connector ..........................................................................86
5. Maintenance and Inspection..................................................................87
5.1. Periodic Maintenance..............................................................................................87
5.2. Fan Filter.................................................................................................................89
5.3. Confirmation of Robot System Operation ................................................................90
5.4. Fuse ........................................................................................................................91
5.5. Description of abnormal Industrial Computer System ..............................................93
5.6. Robot/Controller Requirements Questionnaire........................................................94

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Warranty Terms and Conditions
The period of warranty shall commence at the received date of HIWIN product (hereafter called
“product”) and shall cover a period of 12 months. The warranty does not cover any of the damage and
failure resulting from:
1. The damage caused by using with the production line or the peripheral equipment not
constructed by HIWIN.
2. Operating method, environment and storage specifications not specifically recommended in
the product manual.
3. The damage caused by changing installation place, changing working environment, or
improper transfer after being installed by the professional installer.
4. Product or peripheral equipment damaged due to collision or accident caused by improper
operation or installation by the unauthorized staff.
5. Installing non-genuine HIWIN products.
The following conditions are not covered by the warranty:
1. Product serial number or date of manufacture (month and year) cannot be verified.
2. Using non-genuine HIWIN products.
3. Adding or removing any components into/out the product without authorized.
4. Any modification of the wiring and the cable of the product.
5. Any modification of the appearance of the product; removal of the components inside the
product. e.g., remove the outer cover, product drilling or cutting.
6. Damage caused by any natural disaster. i.e., fire, earthquake, tsunami, lightning, windstorms
and floods, tornado, typhoon, hurricane etc.
HIWIN does not provide any warranty or compensation to all the damage caused by above-mentioned
circumstances unless the user can prove that the product is defective.
For more information towards warranty terms and conditions, please contact the technical staff or the
dealer who you purchased with.
Improper modification or disassemble the robot might reduce the robot function, stability or lifespan.
The end-effector or the cable for devices should be installed and designed by a professional staff to
avoid damaging the robot and robot malfunction.
Please contact the technical staff for special modification coming from production line set up.
For the safety reason, any modification for HIWIN product is strictly prohibited.

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0. Safety Precautions
Safety Information
Safety Responsibility and Effect
1. This chapter explains how to use the robot safely. Be sure to read this chapter carefully before using the
robot.
2. The user of the HIWIN industrial robot has responsibility to design and install the safety device meeting
the industrial safety regulations in order to ensure personal safety.
3. In compliance with the safety information on industrial robot described in this manual can’t guarantee
that HIWIN robot will not occur any safety problems.
4. This machine is defined as a partly completed machinery, the associated hazards must be handled by
system integrator in accordance with ISO 10218-1/ ISO 10218-2.
5. A safety-related part of control system (SRP/CS) should conform to the requirement of performance
level (PL=) d and category 3 according to ISO 13849-1.
6. The installation for emergency functions shall be defined by the system integrator in accordance with
ISO 10218-1/ ISO 10218-2.
Safety Operation Principles
1. Before connecting the power supply for HIWIN industrial robot startup assembly procedure, check
whether the specification of factory output voltage matches the specification of input voltage of the
product. If it does not match, ensure to use the corresponding transformer (HIWIN optional
transformer is recommended).
2. Emergency Stop button (on Teach Pendant or from external emergency stop switch) must be pressed
before turning off the power, and then switch off the power switch.
3. While connecting to the external I/O or the signal, please operate in the condition that the power
switch is turned off to prevent from a shortcut caused by mistaken touch in the process, and resulting in
damage.

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Safety Precautions
i.General
All personnel involved in the use or setup of the industrial robot arm must read the safety related
literature for the robot arm and instruction manual in detail and operate it in accordance with the
specifications.
Safety Symbol
Users must strictly abide by the content description, otherwise it will cause serious casualties.
Users must strictly abide by the content instructions, otherwise it may cause minor injuries or
equipment damage.
User must strictly abide by the content description, otherwise it may cause poor product
performance.
Use Limit
Robotic arm is prohibited for use in the following environments and uses
Personnel carrying purposes
Explosive environment
Environment without safety precautions
Outdoor environment
Environment affected by oil, water, dust, etc.

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ii.Relevant Personnel
Electrical or mechanical work on industrial robot arms is only permitted by professionals.
All personnel working on industrial robotic arms must read and understand the manual containing the
safety section of the system of the robotic arm.
System Integrator
Refers to the person who integrates the industrial robot arm into a set of equipment according to
safety regulations and puts it into operation.
The system integrator is responsible for the following tasks:
Install industrial robot arm.
Industrial machinery arm related equipment connection work.
Risk assessment of the overall system.
Use safe guard devices.
Confirm that the components used by the safe guard devices are in compliance with regulations.
Placement, replacement, setup, operation, maintenance and repair work are only permitted for
specially trained personnel in accordance with the operating instructions for the components of the
industrial robot arm.

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User
Users must be professionally trained, have the knowledge and experience in this area, and be familiar
with the prescribed standards, and thus be able to make a correct judgment of the work to be performed
and identify potential hazards.
Users can be defined into three categories based on operational permissions:
1. Operator
System startup and shutdown
Power on and off
Alarm system status recovery
2. Engineer
Operating personnel usage authority
Programming and changing
Arm teaching operation
3. Expert
Engineer usage authority
Mechanical arm maintenance work
Operator Safety Precautions
The manner and scale of the work and the possible hazards must be explained to the relevant
personnel before work, and relevant training courses must be carried out on a regular basis. In the event of
an accident or technical correction, a training course must be re-run.
System Set Up Safety Precautions
The system set up only allows specially trained personnel to perform and work in accordance with the
installation, setup, operation and other relevant documents provided by the original manufacturer.
Maintenance Personnel’s Precautions
Maintenance should only be carried out by specially trained personnel in accordance with the
instructions and operating instructions.

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iii.Robotic Arm Working Range Definition
Working area
The working area of the robot is defined as the area of motion under motion constraints, and the
working area must be limited to the minimum required.
Protective area
Operation must be carried out outside the protected area.
A protected area is an area of the working area that is protected by a safe guard device. Please
ensure the protective area includes working area of the robot. A safety-related part of control system
(SRP/CS) should conform to the requirement of Performance Level (PL)= d and category 3 according
to ISO 13849-1.
Please ensure the emergency stop switch is in reset status before the robot functions.
The external device connected to the emergency stop switch circuit should be dry contact (uncharged)
switch. It is forbidden to use a live circuit to connect to the controller emergency stop switch circuit.

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It must use EMO-Emergency stop (EN 60947-5-1 positive opening) with safety module to meet ISO
13849-1 Performance Level (PL)= d
Interlock switch

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iv.Description of Safety Functions
Industrial robotic arms must have the following safety features:
Selection of operating mode of the robot arm
Safe guard devices
Emergency stop device
The safety function of the robot arm system is to prevent loss of personnel or property. If the function
is not complete or in failure state, the industrial robot arm must be prohibited from operating.
Manual Operation Mode
The manual operation mode is used for program design, program operation check or teaching, etc.
When performing manual operation, pay attention to the followings:
All actions must be operated within the protection area.
Do not damage or potentially damage the relevant equipment due to operates the robotic arm.
Operation must be carried out outside the protected area as much as possible.
Both manual and automatic modes of operation in the protected area are not permitted unless the
arm is equipped with a certified speed monitoring accessory from the manufacturer.
Automatic Mode
The automatic mode startup should include the following conditions:
The safe guard devices have been set up and confirmed that their functions are working
properly.
All suspended security should restore its full functionality.
Confirm that there are no people in the protected area.
Relevant workflow rules are complied.
To enter the protection area in this mode, the emergency stop function must be activated before
entering.

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Safe Guard Devices Description
The safe guard device must use the components approved by the safety regulations and set and plan
according to the relevant regulations.
The robotic arm system must be automatically activated to receive the safety signal. In the event of a
connection failure during automatic mode operation, an emergency stop must be triggered. When
reconnecting after disconnection, the device cannot be automatically started directly and must be started
manually. Manual slow running (T1) and manual fast running (T2) modes allow the guard not activate. A
method must be provided to confirm that no personnel are in the protected area when the automatic
mode is activated.
Users must strictly abide by the content description, otherwise it will cause serious casualties.
Temporary fences can be used during system installation and can be set according to ISO 10218-2
regulations
Stop Functions
Emergency Stop Description
Emergency stop related precautions
Confirm that the function is functioning normally every six months.
System integrators should provide emergency stop devices to ensure that the machine is operational
or that a hazardous situation exists.
At least one external emergency stop device is installed. Make sure that additional emergency stop
devices are available for use without or losing the teach pendant.
Provide interface to connect external emergency stop devices.
The emergency stop function can be triggered when the safety control system connected to the robot
arm is cut off.
The risk assessment should assess whether the emergency stop is not triggered when the robotic arm
control system is turned off and provides a response.
If a tool or other device connected to the robot is dangerous, it must be connected to the emergency
stop circuit on the equipment side.

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v.Warnings and Precautions
General considerations
1. All operating procedures should be assessed by professional and in compliance with related
industrial safety regulations.
2. When operating robot, operator needs to wear safety equipment, such as workwear for working
environment, safety shoes and helmets.
3. When encountering danger or other emergency or abnormal situation, please press the emergency
stop button immediately. After danger is eliminated, move the robot away with low speed in manual
mode.
4. When considering safety of the robot, the robot and the system must be considered at the same time.
Be sure to install safety fence or other safety equipment and the operator must stand outside the
safety fence while operating the robot.
5. A safety zone should be established around the robot with an appropriate safety device to stop the
unauthorized personnel from access.
6. While installing or removing mechanical components, be aware of a falling piece which may cause
injury to operator.
7. Ensure the weight of workpiece does not exceed the rated load or allowable load moment at wrist.
Exceeding these values could lead to the driver alarm or malfunction of the robot.
8. Do not climb on manipulator.
9. Do not store the machine in the environment with corrosion and flammable gas or close to the
flammable object.
10. Do not operate the machine in the environment with moisture, water or grease.
11. Do not operate the machine at the place where vibration or the strong impact occurs.
12. Do not immerse the electric wires into grease or water.
13. Do not connect or operate the machine with wet hands.
14. Do not operate the machine in potentially explosive environment.
15. Please ensure the controller is grounded.
16. Keep hands away from the inner part of the controller while it is connecting to the power or during
operating.
17. Do not touch the heat sink, regenerative resistance, the power supply or the computer inside the
controller while it is operating due to its high temperature.
18. Be sure power is disconnected prior to repair and maintenance, and ensure to operate under the
condition of no electrical shock risk.
19. Do not disassembly the controller without permission. If there’s any issues, please contact our
engineers.

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1. The personnel installing robot should be trained and licensed.
2. To ensure personal safety, robot installation must comply with this manual and related industrial
safety regulations.
3. The control cabinet should not be placed near high voltage or machines that generate
electromagnetic fields to prevent interference that could cause the robot to deviation or malfunction.
4. Using non-HIWIN spare parts to repair may cause robot damage or malfunction.
5. Beware of the heat generated by the controller and servo motor.
6. Do not overbend the cable to avoid poor circuit contact or unexpected damage.
7. Do not stand on the controller or put heavy objects on it.
8. Do not block the vent or put foreign objects into the controller.
9. Please ensure the controller is fixed on the base.
10. Do not pull the connector violently or twist the electric wires excessively.
11. Do not frequently switch ON/OFF the power switch and the control button.
12. Please ensure that the robot, the emergency stop switch and the controller are functioning properly
before performing any work.
13. Do not shutdown the power switch during the operation.
14. Do not open, modify, disassemble and maintain the machine without permission.
15. The power must be disconnected when the machine does not operate in a long time.
16. Do not turn off the power of the controller when modifying the program or parameter. Otherwise, the
data stored in the controller will be damaged.
17. When changing the program or parameters inside the robot controller, do not turn off the power of
the controller. Otherwise, the internal data of the controller will be damaged.
18. After the brake of a servo motor is released, the robot will be moved due to gravity and it may injured
the operator.
19. The industrial robots can be applied for the different industrial environments, but the applicable
environment should be determined by professionals.
20. When the operating procedures are interrupted, the special attention should be paid during the
troubleshooting.

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Precautions during operations
1. Teaching, jogging or programming should be done outside of the safety fence. If it is inevitable to
enter the safety fence, press the emergency stop button before entrance. Operation should be
restricted at low speed and beware of surrounding safety.
2. All operations shall be executed by trained staff.
3. All operations are required to perform in the safe area.
Maintenance Precautions
1. Please contact us if the procedure not specified by HIWIN is needed.
2. Please contact us if the replacement of the component not specified by HIWIN is needed.
3. Be sure to carry out regular maintenance, otherwise it will affect the service life of the robot or other
unexpected danger.
4. Prior to repair and maintenance, please switch off the power supply.
5. Maintenance and repair should be performed by a qualified operator with a complete understanding
of the entire system to avoid the risk of robot damage and personal injury.
6. When replacing the components, avoid foreign object going into the robot.
Precautions for using End Effector
End effectors can be basically divided into the following two categories:
A. Gripper: Mainly for pick and place operations, such as pneumatic, electric gripper, vacuum suction
cup, etc.
B. Tools: Mainly for processing operations, such as welding, cutting, surface treatment, etc.
1. More attention must be paid to the design of the end effector to prevent power loss or any other
errors that could lead to workpiece falling or damage.
2. The tool-type end effector is usually equipped with high voltage, high temperature and active rotary
shaft. Special attention should be paid to the operating safety.
3. The end effector should be mounted firmly on the robot to avoid workpiece fall during operation
which may cause personal injury or hazard.

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1. The end effector may be equipped with its own control unit. During installation, pay attention to
installed location. Ensure that the control unit does not interfere with robot operation.
2. The gripper-type end effector should prevent the workpiece from dropping or damaging when the
robot experiences a power error or other errors. If potential dangers or abnormal situations exist
when using end effector, the associated hazards must be handled by the system integrator in
accordance with the related standards.
Precautions for using Hydraulic and Pneumatic
1. When using the pneumatic or hydraulic system, the gripped workpiece may fall due to insufficient
pressure or gravity.
2. The pneumatic or hydraulic system must be equipped with the relief valve, so that it can be applied in
an emergency.
1. More attention should be paid to the pressure remained in the pneumatic systems after the power is
disconnected.
2. The internal pressure must be released before the pneumatic systems are maintained.
3. More attention should be paid to the pressure in the pneumatic system as it is several times more
than the atmosphere pressure.

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Emergency Stop Switch Precautions
1. The robot or other control component should have at least one device for immediate halt, such as an
emergency stop switch.
2. The emergency stop button must be installed in an easily accessible location for quick stop.
3. While executing an emergency stop, power to the servo motor will be cut, and all movements will be
stopped. And the control system will be shut down. Emergency stop should be reset if the restoration
of operating procedure is wanted.
4. Avoid using emergency stop to replace a normal stop procedure. This could reduce the lifespan of the
robot.
1. When an emergency stop is performed, the power of the drive is cut off, all operations are stopped,
and the control system of the robot arm is turned off.
2. To resume execution, reset the emergency stop switch.
3. Emergency stop is immediate stop: Immediately stop the movement of the robot arm and cut off the
power of the drive.
4. The emergency stop switch is for emergency stop only.
5. HIWIN's industrial robot arm has two emergency stop switches, one of which is located on the teach
pendant and the other is automatically connected to the controller via a dedicated cable. If there is a
need for other emergency stop switches, the other means of connection can be used to achieve the
purpose of emergency stop.
6. Based on the relevant industrial safety regulations, the emergency stop switch needs to be directly
connected to the control box of the robot arm through a physical connection line.
7. Additional installed safety equipment must comply with PLD level.

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1. Specification
1.1.Standard Specification
Table 1-1 RC4-A Controller specification
Item
RC4-A Controller
Model RC4-A
Controllable robot type RS405-LU Series RS410-LU Series
Positioning control PTP (point-to-point)
CP (continuous path)
Joint control AC servo
Operating system
Caterpillar/
Software development Kit(HRSDK)
control
Memory
capacity
Point data 5000
Step number 10000
Teaching method
Teach pendant / Remote
Communication
interface
RS232
1
RS485
(Modbus RTU)
1
Ethernet
2
USB
2
External I/O
signals
(standard)
Emergency stop Input:1
Function I/O
Input:8 / Output:8
Digital I/O Input:16 / Output:8
Power
Power source (VAC)
Single-phase 200-240
Power capacity (KVA) 3.3
Power frequency (Hz)
50/60
Voltage drop (msec) 10 or less
Rating output current (A)
14
Current leakage (mA) < 30
Weight (kg)
14
protection rating 23
Temperature range for workplaces (
℃
)
5~45
Relative humidity for workplaces (%RH) 20~75(non-condensing)
Storage temperature range (
℃
)
5~45
Storage relative humidity (%RH) 20~75(non-condensing)
Power signal cable [ Note1]
3 m
Note1: The power signal cable has a bending radius of at least 70 mm and is not allowed for use with the
cable drag chain.

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Table 1-2 RC4 Controller specification
Note1: The power signal cable has a bending radius of at least 70 mm and is not allowed for use with the
cable drag chain.
Item RC4 Controller
Model
RC4
Controllable robot type RS405-LU Series RS410-LU Series
Positioning control
PTP (point-to-point)
CP (continuous path)
Joint control AC servo
Operating system
Caterpillar/
Software development Kit(HRSDK) control
Memory capacity Point data 5000
Step number
10000
Teaching method Remote
Communication
interface
RS232
1
RS485 1
Ethernet
1
USB 2
External I/O signals
(standard)
Emergency stop
Input:1
Function I/O Input:8 / Output:8
Digital I/O
Input:16 / Output:8
Power
Power source (VAC) Single-phase 200-240
Power capacity (KVA)
1.65
Power frequency (Hz) 50/60
Voltage drop (msec) 10 or less
Rating output current (A) 6
Current leakage (mA) 30
Weight (kg)
13
protection rating 20
Temperature range for workplaces (
℃
)
5~45
Relative humidity for workplaces (%RH) 20-75 (non-condensing)
Storage temperature range (
℃
)
5~45
Storage relative humidity (%RH) 20-75 (non-condensing)
Power signal cable [ Note1] 3 m