Epson RC520 Safety And Installation

Safety and Inst

Rev.2 EM089B1742F

RC520

allation

Read this manual first

.2 RC520 Safety and Installation Rev

0 Safety and Installation

RC52

R

ev.2

Copyright © 2007-2008 SEIKO EPSON CORPORATION. All rights reserved.

RC520 Safety and Installation Rev.2 i

n

FOREWORD

Thank you for purchasing our robot products.

This manual contains the information necessary for the correct use of the Operator

Panel.

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 i

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.

ii RC520 Safety and Installation Rev.2

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® 2000 Operating system

Throughout this manual, Windows XP, and Windows 2000 refer to above

respective operating systems. In some cases, Windows refers generically to

Windows XP, and Windows 2000.

NOTICE

No part of this manual may be copied or reproduced without authorization.

The contents of this manual are subject to change without notice.

Please notify us if you should find any errors in this manual or if you have any

comments regarding its contents.

INQUIRIES

Contact the following service center for robot repairs, inspections or adjustments.

If service center information is not indicated below, please contact the supplier

office for your region.

Please prepare the following items before you contact us.

- Your controller model and its serial number

- Your manipulator model and its serial number

- Software and its version in your robot system

- A description of the problem

SERVICE CENTER

RC520 Safety and Installation Rev.2 iii

MANUFACTURER & SUPPLIER

SUPPLIERS

Japan & Others

Suwa Minami Plant

TEL : [phone]

FAX : [phone]

SEIKO EPSON CORPORATION

Factory Automation Systems Dept.

1010 Fujimi, Fujimi-machi,

Suwa-gun, Nagano, 399-0295

JAPAN

North & South America

TEL : [phone]

FAX : [phone]

E-MAIL : [e-mail]

Europe

TEL : [phone]

FAX : [phone]

E-MAIL : [e-mail]

EPSON AMERICA, INC.

Factory Automation/Robotics

18300 Central Avenue

Carson, CA 90746

USA

EPSON DEUTSCHLAND GmbH

Factory Automation Division

Otto-Hahn-Str.4

D-40670 Meerbusch

Germany

iv RC520 Safety and Installation Rev.2

Before Reading This Manual

NOTE

)

Do not connect the followings to OPTIONAL DEVICE Connector of RC520.

Connecting to the followings may result in malfunction of the device since the

pin assignments are different.

Operator Panel OP1

Teach Pendant TP1

Teaching Pendant TP-3**

Operating Unit OPU-320

RC+ Software Key

RC520 Safety and Installation Rev.2 v

TABLE OF CONTENTS

1. Safety 1

1.1 Conventions································································ 1

1.2 Design and Installation Safety ···································· 2

1.3 Operation Safety························································· 3

1.4 Maintenance Safety ···················································· 6

1.5 Emergency Stop ························································· 9

1.6 Manipulator Labels ··················································· 10

1.7 Safety Features ························································ 11

2. Installation 15

Example ············································································ 16

2.1 Outline from Unpacking to Operation of Robot System

···················································································· 17 ·····

2.2 Unpacking································································· 18

2.3 Transportation··························································· 19

2.4 Manipulator Installation············································· 23

2.5 Controller Installation ················································ 27

2.6 Connecting Manipulator and Controller ···················· 31

2.7 Connecting Manipulator and Controller ···················· 41

2.8 Power-on ·································································· 45

3. First Step 47

3.1 windows XP Setup···················································· 47

3.2 Installing EPSON RC+ Software······························· 48

3.3 Writing your first program·········································· 49

4. Second Step 53

4.1 Connection with External Equipment ························ 53

4.2 Connection and Display Language4

tion OP500RC ························································· 54 of Op

5. Third Step 55

vi RC520 Safety and Installation Rev.2

1. Safety

Installation and transportation of robots and robotic equipment shall be performed
by qualified personnel and should conform to all national and local codes.

Please read this manual and other related manuals before installing the robot
system or before connecting cables.
Keep this manual handy for easy access at all times.

1.1 Conventions

Important safety considerations are indicated throughout the manual by the
following symbols. Be sure to read the descriptions shown with each symbol.

WARNING

WARNING

CAUTION

This symbol indicates that a danger of possible serious injury
or death exists if the associated instructions are not followed
properly.

This symbol indicates that a danger of possible harm to
people caused by electric shock exists if the associated
instructions are not followed properly.

This symbol indicates that a danger of possible harm to
people or physical damage to equipment and facilities exists
if the associated instructions are not followed properly.

1. Safety

RC520 Safety and Installation Rev.2 1

1. Safety

1.2 Design and Installation Safety

Only trained personnel should design and install the robot system. Trained
personnel are defined as those who have taken robot system training 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.
To ensure safety, a safeguard must be installed for the robot system. For details
on the safeguard, refer to the Installation and Design Precautions in the Safety
chapter of the EPSON RC+ User’s Guide.

The following items are safety precautions for design personnel:

■

Personnel who design and/or construct the robot system with this

product must read the Safety chapter in the EPSON RC+ 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, and may result in serious bodily injury and/or

severe equipment damage to the robot system.

■

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

WARNING

normal indoor environment. Using the product in an environment that

exceeds the specified environmental conditions may not only shorten

the life cycle of the product but may also cause serious safety

problems.

■

The robot system must be used within the installation requirements

described in the manuals. Using the robot system outside of the

installation requirements may not only shorten the life cycle of the

product but also cause serious safety problems.

Further precautions for installation are mentioned in the following manuals.
Please read this chapter carefully to understand safe installation procedures before
installing the robots and robotic equipment.

Relevant Manuals

Refer



2 RC520 Safety and Installation Rev.2

This manual : 2. Installation
Manipulator manual : Setup & Operation 3. Environment and Installation

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

■

Please carefully read the Safety-related Requirements in the Safety

chapter of the EPSON RC+ User’s Guide before operating the robot

system. Operating the robot system without understanding the safety

requirements is extremely hazardous and may result in serious bodily

injury and/or severe equipment damage to the robot system.

■

Do not enter the operating area of the Manipulator while the power to

the robot system is turned ON. Entering the operating area with the

power ON is extremely hazardous and may cause serious safety

problems as the Manipulator may move even if it seems to be stopped.

■

Before operating the robot system, make sure that no one is inside the

safeguarded area. The robot system can be operated in the mode for

WARNING

teaching even when someone is inside the safeguarded area.

The motion of the Manipulator is always in restricted status (low

speeds and low power) to secure the safety of an operator. However,

operating the robot system while someone is inside the safeguarded

area is extremely hazardous and may result in serious safety problems

in case that the Manipulator moves unexpectedly.

1. Safety

■

Immediately press the Emergency Stop switch whenever the

Manipulator moves abnormally while the robot system is operated.

Continuing the operating the robot system while the Manipulator

moves abnormally is extremely hazardous and may result in serious

bodily injury and/or severe equipment change to the robot system.

■

Be sure to connect the AC power cable to a power receptacle. DO

NOT connect it directly to a factory power source. To shut off power

to the robot system, pull out the power plug from the power source.

Performing any work while connecting the AC power cable to a factory

WARNING

power source is extremely hazardous and may result in electric shock

and/or malfunction of the robot system.

RC520 Safety and Installation Rev.2 3

1. Safety

A

Part Names and Arm Motion

E2 series

The motion range of each arm is shown in the figure below. Take all
necessary safety precautions.

Arm #2

Joint #3

(Up/Down)

+

-

-

Joint #4
(Rotate)

+

Joint #2
(Rotate)

−

Shaft

+

rm #1

Joint #1
(Rotate)

-

+

(Figure of E2C)

4 RC520 Safety and Installation Rev.2

1. Safety

PS series

The motion range of each arm is shown in the figure below. Take all
necessary safety precautions.

LED Lamp
(This lamp lights up

while the motors are ON.)

Arm #J3

Arm #J2 (Lower Arm)

Arm #J1

Joint #J1

Upper Arm (Arms #J3 to #J6)

Joint #J5

J5

+

J6

J4

J3

+

J3

−

Joint #J3

J2

+

J1

−

J1

+

Base

J2−

Joint #J2

+

J4

−

Joint #J4

Arm #J1 : The whole Manipulator revolves.

Arm #J2 : The lower arm swings.

Arm #J3 : The upper arm swings.

Arm #J4 : The wrist revolves.

Arm #J5 : The wrist swings.

Arm #J6 : The wrist rotates.

J5

Arm #J4

(Figure of PS3)

Arm Motion

+

Joint #J6

Arm #J6

J6

−

−

Arm #J5

RC520 Safety and Installation Rev.2 5

1. Safety

1.4 Maintenance Safety

Please read this section, Maintenance of the Manipulator manual, and other related
manuals carefully to understand safe maintenance procedures before performing
any maintenance.

Only authorized personnel who have taken the safety training should be allowed to
maintain the robot system. The safety training is the program for the industrial
robot operator that follows the laws and regulations of each nation.
The personnel who have taken the safety training acquire knowledge of industrial
robots (operations, teaching, etc.), knowledge of inspections, and knowledge of
related rules/regulations. Only personnel who have completed the robot
system-training and maintenance-training classes held by the manufacturer, dealer,
or locally-incorporated company should be allowed to maintain the robot system.

■

Do not remove any parts that are not covered in this manual. Follow

the maintenance procedure strictly as described in this manual and the

Maintenance of the Manipulator manual. Improper removal of parts

or improper maintenance may not only cause improper function of the

robot system but also serious safety problems.

■

Keep away from the Manipulator while the power is ON if you have not

taken the training courses. Do not enter the operating area while the

power is ON. Entering the operating area with the power ON is

extremely hazardous and may cause serious safety problems as the

Manipulator may move even though it seems to be stopped.

■

When you check the operation of the Manipulator after replacing parts,

WARNING

be sure to check it while you are outside of the safeguarded area.

Checking the operation of the Manipulator while you are inside of the

safeguarded area may cause serious safety problems as the

Manipulator may move unexpectedly.

■

Before operating the robot system, make sure that both the

Emergency Stop switches and safeguard switches function properly.

Operating the robot system when the switches do not function properly

is extremely hazardous and may result in serious bodily injury and/or

serious damage to the robot system as the switches cannot fulfill their

intended functions in an emergency.

6 RC520 Safety and Installation Rev.2

WARNING

■

Be sure to connect the AC power cable to a power receptacle. DO

NOT connect it directly to a factory power source. To shut off power to

the robot system, pull out the power plug from the power source.

Performing any work while connecting the AC power cable to a factory

power source is extremely hazardous and may result in electric shock

and/or malfunction of the robot system.

■

Before performing any replacement procedure, turn OFF the Controller

and related equipment, and then pull out the power plug from the power

source.

Performing any replacement procedure with the power ON is extremely

hazardous and may result in electric shock and/or malfunction of the

robot system.

■

Be sure to connect the cables properly. Do not allow unnecessary

strain on the cables. (Do not put heavy objects on the cables. Do not

bend or pull the cables forcibly.) The unnecessary strain on the cables

may result in damage to the cables, disconnection, and/or contact

failure. Damaged cables, disconnection, or contact failure is extremely

hazardous and may result in electric shock and/or improper function of

the robot system.

1. Safety

■

Carefully use alcohol, liquid gasket, and adhesive following respective

instructions and also instructions below. Careless use of alcohol, liquid

gasket, or adhesive may cause a fire and/or safety problems.

- Never put alcohol, liquid gasket, or adhesive close to fire.

- Use alcohol, liquid gasket, or adhesive while ventilating the room.

- Wear protective gear including a mask, protective goggles, and

CAUTION

RC520 Safety and Installation Rev.2 7

oil-resistant gloves.

- If alcohol, liquid gasket, or adhesive gets on your skin, wash the area
thoroughly with soap and water.

- If alcohol, liquid gasket, or adhesive gets into your eyes or mouth,
flush your eyes or wash out your mouth with clean water thoroughly,
and then see a doctor immediately.

1. Safety

CAUTION

■

Wear protective gear including a mask, protective goggles, and

oil-resistant gloves during grease up. If grease gets into your eyes,

mouth, or on your skin, follow the instructions below.

If grease gets into your eyes :

Flush them thoroughly with clean water, and then see a doctor
immediately.

If grease gets into your mouth:

If swallowed, do not induce vomiting. See a doctor immediately.
If grease just gets into your mouth, wash out your mouth with
water thoroughly.

If grease gets on your skin:

Wash the area thoroughly with soap and water.

8 RC520 Safety and Installation Rev.2

1.5 Emergency Stop

If the Manipulator moves abnormally during operation, immediately press the

Emergency Stop switch. The motor power will be turned OFF, and the arm

motion by inertia will be stopped with the electromagnetic brake and dynamic

brake.

However, avoid pressing the Emergency Stop switch unnecessarily while the

Manipulator is running normally. Otherwise, the Manipulator may hit the

peripheral equipment since the operating trajectory while the robot system stops is

different from that in normal operation.

To place the robot system in emergency mode during normal operation, press the

Emergency Stop switch when the Manipulator is not moving.

Refer to the Controller manual for instructions on how to wire the Emergency Stop

switch circuit.

Free running distance in emergency

The operating Manipulator cannot stop immediately after the Emergency Stop
switch is pressed.
Remember that the values vary depending on conditions such as the weight of the
end effector and work piece, Weight/Speed/Accel settings, operating pose, etc.

1. Safety

RC520 Safety and Installation Rev.2 9

1. Safety

1.6 Manipulator Labels

Labels are attached around the locations of the Manipulator where specific dangers
exist.
Be sure to comply with descriptions and warnings on the labels to operate and
maintain the Manipulator safely.
Do not tear, damage, or remove the labels. Use meticulous care when handling
those parts or units to which the following labels are attached as well as the nearby
areas:

Examples of Manipulator Labels

E2 series

PS3 series

All
Manipulators

10 RC520 Safety and Installation Rev.2

NOTE:

Hazardous voltage exists while the
Manipulator is ON. To avoid electric
shock, do not touch any internal
electric parts.

1.7 Safety Features

The robot control system supports safety features described below. However, the

user is recommended to strictly follow the proper usage of the robot system by

thoroughly reading the attached manuals before using the system. Failure to read

and understand the proper usage of the safety functions is highly dangerous.

Among the following safety features, the Emergency Stop Switch and Safety Door

Input are particularly important. Make sure that these and other features function

properly before operating the robot system.

For details, refer to the 2.5 Controller Installation - Safety Door Switch and Latch

Release Switch.

ATTEND (TEACH) Control Device

To operate the Manipulator at a short distance without any operation unit (option),

you must create an ATTEND (TEACH) control device and connect it to the

OPTIONAL DEVICE connector on the front of the Control Unit in order to

operate the Manipulator at a short distance. The ATTEND (TEACH) control

device should consist of the Emergency Stop switch, 3-position enable switch

(dead-man switch), and ATTEND (TEACH) control device enable/disable switch.

The name of the control device depends on the software used in your Control Unit

as shown below:

EPSON RC+ : TEACH control device

SPEL CT : ATTEND control device

Emergency Stop Switch

The ATTEND (TEACH) control device must be equipped with the Emergency

Stop switch. The EMERGENCY connector on the Drive Unit has extension

Emergency Stop input terminals used for connecting the Emergency Stop switches.

These Emergency Stop inputs are internally connected to the relays for the

dynamic brake. Therefore, pressing any Emergency Stop switch can shut off the

motor power immediately and the robot system will enter the Emergency Stop

condition.

1. Safety

RC520 Safety and Installation Rev.2 11

1. Safety

Safety Door Input

In order to activate this feature, make sure that the Safety Door Input switch is

connected to the EMERGENCY connector on the Drive Unit.

When the safety door is opened, normally the Manipulator immediately stops the

current operation, and the status of Manipulator power is operation-prohibited

until the safety door is closed and the latched condition is released. In order to

execute the Manipulator operation while the safety door is open, you must change

the ATTEND (TEACH) control device enable/disable switch to “enable” or

change the mode selector switch on the operation unit to the mode for teaching and

then engage the 3-position enable switch. In this case, the Manipulator is

operated in low power status.

Lockout

Turn OFF the power supply and use a lockout procedure to prevent anyone from

turning ON the power supply by mistake while someone else is in the safeguarded

area for maintenance or repairs.

The procedure for lockout is described in the Maintenance 1. Safety Precautions

for Maintenance.

Low Power Mode

The motor power is reduced in this mode. A shift into restricted status (low

power status) can be done through the execution of a power status change

instruction, regardless of the safety door or operation mode. This ensures the

safety of the operator and reduces the possibility of peripheral equipment being

destroyed or damaged as a result of careless operation.

Dynamic Brake

The dynamic brake circuit includes relays that short the motor armatures. When

the motor armatures are shorted, the power to the Motor Driver modules is cut off

and the reverse EMF caused by the short stops the motors. 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 condition inside

the Motor Driver Module.

12 RC520 Safety and Installation Rev.2

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 system detects that the load on the

motor has exceeded its capacity.

Irregular Motor Torque (out-of-control manipulator) Detection

The dynamic brake circuit is activated when irregularity with 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 system detects that the motor is

running at incorrect speed.

Positioning Overflow - Servo Error - Detection

The dynamic brake circuit is activated when the system detects that the difference

between the Manipulator’s actual position and commanded position exceeds the

margin of error allowed.

Speed Overflow - Servo Error - Detection

The dynamic brake circuit is activated when the system detects that motor speed

has overflowed.

CPU Irregularity Detection

Irregularity in the motor controlling CPU is monitored by a 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 each other for any

discrepancies between the units. If a discrepancy is detected, the dynamic brake

circuit is activated.

Memory Check-sum Error Detection

The dynamic brake circuit is activated when a memory check-sum error is

detected.

1. Safety

RC520 Safety and Installation Rev.2 13

1. Safety

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 is above the nominal limit.

Over-Voltage Detection

The dynamic brake circuit is activated when the voltage of the Controller is above

the normal limit. (When mounting a regeneration module toDU4, or using DU6)

14 RC520 Safety and Installation Rev.2

0B2. Installation

This chapter contains precautions for safe and accurate installation of the robot
system.
The outline to install the robot system is indicated on 2.1 Outline from Unpacking
to Operation of Robot System. Refer to each section and/or the Manipulator
manual and the Controller manual for unpacking, transportation, and installation.

The numbers of controllable motor axes per Drive Unit are as shown below:
Each four-axis Drive Unit (RC520DU) : Up to four axes
Each six-axis Drive Unit (RC520DU6) : Up to six axes

Up to three Drive Units are connected to one Control Unit. The following table
shows available connections of the Drive Units per Control Unit.

Four-axis Drive Units Six-axis Drive Units

Case 1 3 Drive Units -

Case 2 2 Drive Units 1 Drive Unit

Case 3 - 2 Drive Units

For details on the Control Unit, refer to the Setup & Operation 2.4 Control Unit
(RC520DU).

For details on the Drive Unit, refer to the Setup & Operation 2.5 Four-axis Drive
Unit and the Setup & Operation 2.6 Six-axis Drive Unit (RC520DU6).

2. Installation

RC520 Safety and Installation Rev.2

15

2. Installation

9BExample 1 : One Drive Unit and One Manipulator

Robot Manipulator

Drive Unit

Control Unit

10BExample 2 : Three Drive Units and Three Manipulators

1st

Robot Manipulator

1st

Drive Unit

Control Unit

2nd

Robot Manipulator

OP500 /

OP500RC

2nd

Drive Unit

3rd

Robot Manipulator

3rd

Drive unit

16

RC520 Safety and Installation Rev.2

1B 2.1 Outline from Unpacking to Operation of Robot System

2. Installation

Unpacking

2. Installation

Yes

Transportation

Installation

Power-on

Error?

No

Procedur es to install the Robot system
and turn ON the power properly

3. First Step

Procedures to enable operation of the
robot system after turning ON the
power

4. Second Step

Manual information to connect or
setup the equipment and options

RC520 Safety and Installation Rev.2

17

2. Installation

A

2B 2.2 Unpacking

Installation and transportation of robots and robotic equipment shall be performed
by qualified personnel and should conform to all national and local codes.

Using a cart or similar equipment, transport the Manipulator in the same
conditions as it was delivered. Observe the following when unpacking the
Manipulator.

11BPackage Components Example

The following figure illustrates the package at delivery.

Manipulator

ttached Equipm ent

Controll er etc.

12BUnpacking Precautions

Transportation procedure

: Only authorized personnel should perform sling work and operate a crane or

forklift. When these operations are performed by unauthorized personnel, it
is extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.

Vibration at transportation

: Avoid excessive vibration or shock during Manipulator transporting.

Excessive vibration or shock may cause equipment damage to and/or
malfunction of the Manipulator.

Anchor bolt

: When removing the anchor bolts, support the Manipulator to prevent falling.

Removing the anchor bolts without supporting the Manipulator may get
hands, fingers, or feet caught as the Manipulator will fall.

Wire tie

: Do not remove the wire tie securing the arm until you finish the installation.

You may get your hands caught in the Manipulator when the wire tie is

18

removed before completing the installation.

RC520 Safety and Installation Rev.2

3B 2.3 Transportation

Installation and transportation of robots and robotic equipment shall be performed
by qualified personnel and should conform to all national and local codes.

13BTransportation Precautions

Transportation procedure

: Using a cart or similar equipment, transport the Manipulator in the same

conditions as it was delivered. Observe the following when unpacking
the Manipulator.

Only authorized personnel should perform sling work and operate a crane

or forklift. When these operations are performed by unauthorized

personnel, it is extremely hazardous and may result in serious bodily

injury and/or severe equipment damage to the robot system.

Vibration at transportation

: Avoid excessive vibration or shock during Manipulator transporting.

Excessive vibration or shock may cause equipment damage to and/or

malfunction of the Manipulator.

Anchor bolt

: When removing the anchor bolts, support the Manipulator to prevent

falling.

Removing the anchor bolts without supporting the Manipulator may get

hands, fingers, or feet caught as the Manipulator will fall.

Wire tie

: Do not remove the wire tie securing the arm until you finish the

installation.

You may get your hands caught in the Manipulator when the wire tie is

removed before completing the installation.

Hoisting procedure

: Stabilize the Manipulator with your hands when hoisting it. Unstable

hoisting is extremely hazardous and may results in serious bodily injury

and/or severe equipment damage to the robot system as the fall of the

Manipulator.

2. Installation

RC520 Safety and Installation Rev.2

19

2. Installation

PS series

To carry the Manipulator, have at least 3 people to work on it and secure the

Manipulator to the delivery equipment or hold it by hand. Do not hold the

bottom of the base (the screened parts in the figure). Holding these parts by hand

is extremely hazardous and may cause your hands and fingers to be caught.

Reference:
Pulse values at Manipulator transport (PS series) : 0, 2621440, −3140167, 0,

−1847207, 0

E2C, E2S, E2L

To carry the Manipulator, have two or more people to work on it and secure the

Manipulator to the delivery equipment or hold the areas indicated in gray in the

figure (bottom of Arm #1 / main cable elbow fitting / bottom of the base) by hand.

When holding the bottom of the base by hand, be very careful not to get hands or

fingers caught.

14BManipulator Transportation

(Figure of PS3)

Shipping
Bolts and Jigs

DO NOT hold
the bottom of
the base by hand.

Table Top

(Figure of E2S)

PS3 : Approx. 47 kg
(Manipulator weight: 45 kg (100 lb.))
PS5 : Approx. 51 kg
(Manipulator weight: 49 kg (109 lb.))
PS3L : Approx. 53 kg
(Manipulator weight: 51 kg (113 lb.))
PS3LP : Approx. 53 kg
(Manipulator weight: 51 kg (113 lb.))

Multiple Mountings

(Figure of E2S)

E2C : Approx. 14 kg (31 lb.)
E2S : Approx. 22 kg (49 lb.) E2C : Approx. 16 kg (36 lb.)
E2L : Approx. 33 kg (73 lb.) E2S : Approx. 22 kg (49 lb.)

20

RC520 Safety and Installation Rev.2

E2H

2. Installation

To carry the Manipulator, secure the Manipulator to the delivery equipment, or

pass belts through the eyebolts (as shown in the figure) and hoist it with your

hands. Do not hold the duct joint on the back of the base. When holding the

bottom of the base by hand, be very careful not to get hands or fingers caught.

Threaded holes
for eye bolts
(M12 × 25)

E2H : Approx. 37 kg (83 lb.)

15BUsing a Crane

To hoist the Manipulator with a crane, secure the Manipulator with shipping bolts

and jigs and posture the Manipulator as shown in the figures below (the posture at

shipment from the manufacturer).

Use a cable threaded through the eyebolts attached to the Manipulator as shown.

(Make sure that they are not loose.)

18°

45°

RC520 Safety and Installation Rev.2

(Figures of PS3)

21

2. Installation

16BUsing a Forklift

Position the Manipulator as shown in the figures below (the posture at shipment

from the manufacturer) and secure it onto a pallet with shipping bolts and jigs.

Insert the forklift claws under the pallet and transport the Manipulator together

with the pallet. The pallet must have enough strength to bear the weight of the

Manipulator. Transporting of the Manipulator must be performed slowly in order

to avoid overturning or slippage.

18°

45°

Bolt

(4-M10)

Pallet

Controller

22

Inset here the forklift claws.

(Figures of PS3)

RC520 Safety and Installation Rev.2

4B 2.4. Manipulator Installation

Installation and transportation of robots and robotic equipment shall be performed

by qualified personnel and should conform to all national and local codes.

For details, refer to the Manipulator manual.

(1) When the Manipulator is Clean-model, unpack it outside of the clean room.

NOTE



PS series

Secure the Manipulator not to fall, and then wipe off the dust on the

Manipulator with a little alcohol or distilled water on a lint-free cloth. After

that, carry the Manipulator in the clean room. Connect an exhaust tube to

the exhaust port after installation.

(2) Remove the shipping bolt and jigs.

The shipping bolts and jigs are attached to the Manipulator as shown the

figure below (points A, B, and C) for protecting the Manipulator from

various external forces during transportation. Remove the shipping bolts B,

A, and C in this order. The jigs are painted yellow.

Point A : 4-M5×12 hexagon socket head cap bolts with plain washers and

disc spring washers

Point B : 2-M5×12 hexagon socket head cap bolts with plain washers and

disc spring washers

Point C : 2-M6×15 hexagon socket head cap bolts with disc spring washers

2. Installation

18

°

45°

NOTE



RC520 Safety and Installation Rev.2

Before turning on the power, be sure that the shipping bolts and jigs have

been removed. The shipping bolts and jigs must then be stored for future use,

in the event that the Manipulator must be moved again.

(° = deg.)

Point A

Point B

Point C

The figure is PS3

23

2. Installation

A

A

E2H, E2S, E2L

(1) Using nippers, cut off the wire tie securing Arm #2.

(2) Unscrew the cable clamp (E2H), or remove the M4 screw (E2S, E2L) on

the end of Arm #2.

(3) Push Arm #1 slowly in the direction shown with an arrow in the figure

below.

Remove the arm retaining bracket and bolt form the base.

E2C

NOTE



NOTE



If the bolt is not removed, the motion range of Joint #1 will be limited.

Be sure to remove the bolt.

rm retaining bracket

Bolt
E2H : M12×20
E2S : M8×10
E2L : M12×20

The figure is E2S

(1) Using nippers, cut off the wire tie securing Arm #2.

(2) Unscrew the M4 screw on the end of Arm #2.

(3) Push Arm #1 slowly in the direction shown with an arrow in the figure on

the right. Fasten the arm retaining bolt on the base.

The arm retaining bolt must be fastened. Otherwise, the motion range of

Joint #1 is limited.

rm retaining bolt

M8×30

24

RC520 Safety and Installation Rev.2

2. Installation

17BInstallation Precautions

Safeguard installation

: To ensure safety, a safeguard must be installed for the robot system. For

details on the safeguard, refer to the Installation and Design Precautions
in the Safety chapter of the EPSON RC+ User’s Guide.

Space between safeguard and Manipulator

: Install the Manipulator at a location with sufficient space so that a tool or

a work piece on the end effector does not reach a wall or a safeguard
when the Manipulator extends its arm fully while holding a work piece.
Installing the Manipulator at a location with insufficient space is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system as a tool or a work piece may
collide with a wall and a safeguard.

Manipulator check before installation

: Before installing and operating the Manipulator, make sure that all parts

of the Manipulator are in place and have no external defects. Missing or

defective parts may cause improper operation of the Manipulator.

Improper operation of the Manipulator is extremely hazardous and may

result in serious bodily injury and/or severe equipment damage to the

robot system.

Base table

: A base table for anchoring the Manipulator is not supplied. Please

make or obtain the base table for your Manipulator. The shape and
size of the base table will differ depending on the use of the robot
system.
For details, refer to the manual of each Manipulator.

Side mounting and ceiling mounting

: When mounting the Manipulator on a wall or ceiling, secure the

Manipulator to the wall or ceiling that has enough strength and rigidity.
Mounting the Manipulator on a wall or ceiling that has insufficient
strength and rigidity is extremely hazardous and may result in serious
bodily injury and/or severe equipment damage to the robot system as
the Manipulator may fall or vibrate.

RC520 Safety and Installation Rev.2

25

2. Installation

Side mounting and ceiling mounting

For Protected-model

: When mounting the Manipulator on a wall or ceiling, for safety

purposes, attach the support to the Manipulator base to prevent the
Manipulator from falling. If the Manipulator falls, it is extremely
hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.

: Connect the power cable connection and the signal cable connector to

the Manipulator immediately after the Manipulator installation. The
Manipulator without connecting them may result in electric shock
and/or malfunction of the robot system as it cannot ensure IP65.

26

RC520 Safety and Installation Rev.2

5B 2.5 Controller Installation

18BInstallation Precautions

Environment conditions

: The Controller must be used within the environmental conditions

described in their manuals. This product has been designed and
manufactured strictly for use in a normal indoor environment.
Using the product in the environment that exceeds the conditions
may not only shorten the life cycle of the product but also cause
serious safety problems.

For Clean-room installation

: The Controller is not designed for clean-room specification. If it

must be installed in a clean room, make sure to install it in the
proper enclosure with adequate ventilation and cooling.

Installation procedure

: Before performing any installation procedure, turn OFF the

Controller and related equipment, and then pull out the power plug
from the power source.
Performing any replacement procedure with the power ON is
extremely hazardous and may result in electric shock and/or
malfunction of the robot system.

Cable

: Be sure to connect the cables properly. Do not allow unnecessary

strain on the cables. (Do not put heavy objects on the cables. Do
not bend or pull the cables forcibly.) The unnecessary strain on
the cables may result in damage to the cables, disconnection, and/or
contact failure.
Damaged cables, disconnection, or a contact failure is extremely
hazardous and may result in electric shock and/or improper
function of the system.

Installing direction

: The Controller must be normally placed horizontally.

Rubber feet

: Do not remove any feet of the Controller.

2. Installation

RC520 Safety and Installation Rev.2

27

2. Installation

Power

Cable

Connection of Control Unit, Drive Unit, and Manipulator

19BConnecting Drive Unit and Control Unit

The configuration data for the Drive Unit is stored in the Control Unit. When

connecting these units, it is crucial that the Drive Unit must be connected to the

specified Control Unit. The Connection Check label on the front door of the

Control Unit indicates the serial number of the Drive Unit to be connected and the

DU (Drive Unit) number. (See the picture in the next page.) Connect the

appropriate Drive Unit.

Connect the Drive Unit and the Control Unit by using Motion cable. The Motion

Interface cable has a rectangular, 100-pin connector on both ends, which must go

into the MOTION connectors on both the Control Unit and the Drive Unit.

Connect the AC OUTLET connector of the Drive Unit to the AC IN connector of

the Control Unit with the Power cable to supply AC200V power to the Control

Unit from via the Drive Unit.

: Make sure that the power to the Controller is turned OFF and locked

out before connecting or disconnecting any cables. Connecting or
disconnecting any cables with the power ON is extremely hazardous
and may result in electric shock and/or malfunction of the
Controller.

: Be sure to connect the cables properly. Do not allow unnecessary

strain on the cables. (Do not put heavy objects on the cables. Do
not bend or pull the cables forcibly.) The unnecessary strain on the
cables may result in damage to the cables, disconnection, and/or
contact failure. Damaged cables, disconnection, or a contact
failure is extremely hazardous and may result in electric shock
and/or improper function of the system.

: The serial numbers of the Drive Unit and Manipulator that should be

connected are indicated on the Connection Check Label on the
Control Unit. Connect the Control Unit, the Drive Unit and the
Manipulator correctly. Improper connections between the Drive
Unit and the Manipulator and between the Control Unit and the
Drive Unit may cause improper function of the robot system and
also serious safety problems.

28

RC520 Safety and Installation Rev.2

NOTE



2. Installation

Connection of Drive Unit and MIB

: If there is more than one Drive Unit connected to the Control Unit in

the robot system, make sure that the DU numbers (DU1 - DU3)
indicated above the MIB connector on the Control Unit and the
Drive Unit (above the MOTION connector) match. Improper
connection between the Control Unit and the Drive Unit may cause
malfunction of the robot system and/or serious safety problems as it
may make the Manipulator move abnormally.

20BConnection Check label(s) at the front of Control Unit:

There is a Connection Check label for each Drive Unit. The same number of

labels as Drive Units used in the robot system is attached on the bottom of the

inside of the front door.

DRIVE UNIT MANIPULATOR

00007 DU100002ES551S

Model

Serial number

DU number

Serial number

21BDU number label(s) at the back of Control Unit:

Drive Unit’s No. is indicated on the label as shown below.

RC520 Safety and Installation Rev.2

29

2. Installation

22BDrive Unit serial number - Identifying proper unit:

Drive Unit’s serial number is indicated on the label as shown below.

(The following photo is the six-axis Drive Unit.)

MODEL

DRIVE UNIT

SERIAL NO. :00006

:RC520DU6

30

RC520 Safety and Installation Rev.2

6B 2.6 Connection to EMERGENCY Connector (Controller)

Connect a safeguard switch or Emergency Stop switch to the RC520
EMERGENCY connector for safety.
When nothing is connected to the EMERGENCY connector, RC520 does not
operate normally.

Connector Pin

: Before connecting the connector, make sure that the pins are not

bent. Connecting with the pins bent may damage the connector
and result in malfunction of the robot system.

Four-axis Drive Units （RC520DU）

2. Installation

EMERGENCY connector

Six-axis Drive Units

（RC520DU6）

EMERGENCY connector

23BSafety Door Switch and Latch Release Switch

The EMERGENCY connector has input terminals for the Safety Door switch and

the Emergency Stop switch. Be sure to use these input terminals to keep the

system safe.

Connector Standard

EMERGENCY connector

Rectangular half-pitch 20-pin M2.6 screw

RC520 Safety and Installation Rev.2

31

2. Installation

The interlock of the Safety Door

24BSafety Door Switch

: 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 (e.g. The tape is put
around the switch.). Operating the robot system when the switch is
not functioning properly is extremely hazardous and may cause
serious safety problems as the Safety Door input cannot fulfill its
intended function.

In order to maintain a safe working zone, a safeguard must be erected around the
Manipulator. The safeguard must have an interlock switch at the entrance to the
working zoon. The Safety Door that is described in this manual is one of the
safeguards and an interlock of the Safety Door is called a Safety Door switch.
Connect the Safety Door switch to the Safety Door input terminal on the
EMERGENCY connector.

The Safety Door switch has safety features such as temporary hold-up of the ｓ

program or the operation-prohibited status that are activated whenever the Safety
Door is opened.

Observe the following in designing the Safety Door switch and the Safety Door.

- For the Safety Door switch, select a switch that opens as the Safety Door
opens, and not by the spring of the switch itself.

32

- The signal from the Safety Door (Safety Door input) is designed to input to
two redundant signals. If the signals at the two inputs differ by two seconds
or more, the system recognizes it to be a critical error. Therefore, make sure
that the Safety Door switch has two separate redundant circuits and that each
connects to the specified pins at the EMERGENCY connector on the
Controller.

-

The Safety Door must be designed and installed so that it does not close

accidentally.

25BLatch Release Switch

The controller software latches the following conditions:

- The safety door is open.

- The operation mode is for teaching.

RC520 Safety and Installation Rev.2

NOTE



2. Installation

The EMERGENCY connector has an input terminal for a latch release switch that
cancels the latched conditions.

Open : The latch release switch latches conditions that the safety door is open

or the operation mode is for teaching.

Closed : The latch release switch releases the latched conditions.

When the latched operation mode for teaching is released while the safety door is
open, the status of Manipulator power is operation-prohibited because the safety
door is open at that time.
To execute a Manipulator operation, close the safety door again, and then close the
latch release input.

26BChecking Latch Release Switch Operation

After connecting the safety door switch and latch release switch to the
EMERGENCY connector, be sure to check the switch operation for safety by
following the procedures described below before operating the Manipulator.

(1)

Turn ON the Controller while the safety door is open in order to boot the

controller software.

(2)

Make sure that “Safety” is displayed on the main window status bar.

(3) Close the safety door, and turn ON the switch connecting to the latch release

input. Make sure that the “Safety” is dimmed on the status bar.

The information that the safety door is open can be latched by software based on
the latch release input condition.

Open : The latch release switch latches condition that the safety door is open.

To cancel the condition, close the safety door, and then close the
safety door latch release input.

Closed : The latch release switch does not latch the condition that the safety

door is open.

NOTE



RC520 Safety and Installation Rev.2

The latch release input also functions to acknowledge the change of operation
mode for teaching.
In order to change the latched condition of the operation mode for teaching, turn
the mode selector switch on the operation unit to the mode for normal or turn the
ATTEND (TEACH) control device enable/disable switch to “disable”. Then,
close the latch release input.

33

2. Installation

NOTE



NOTE



27BEmergency Stop Switch

If it is desired to create an external Emergency Stop switch(es) in addition to the

Emergency Stop on the Teach Pendant and Operator Panel, make sure to connect

such Emergency Stop switch(es) to the Emergency Stop input terminal on the

EMERGENCY connector.

The Emergency Stop switch connected must comply with the following:

- It must be a push button switch that is “normally closed”.

- A button that does not automatically return or resume.

- The button must be mushroom-shaped and red.

- The button must have a double contact that is “normally closed”.

The signal from the Emergency Stop switch is designed to use two redundant
circuits.
If the signals at the two circuits differ by two seconds or more, the system
recognizes it as a critical error. Therefore, make sure that the Emergency Stop
switch has double contacts and that each circuit connects to the specified pins on
the EMERGENCY connector at the Controller. Refer to Circuit Diagrams
indicated later in this section.

28BChecking Emergency Stop Switch Operation

Once the Emergency Stop switch is connected to the EMERGENCY connector,
continue the following procedure to make sure that the switch functions properly.
For the safety of the operator, the Manipulator must not be powered ON until the
following test is completed.

(1)

Turn ON the Controller to boot the controller software while pressing the

Emergency Stop switch.

Make sure that both the “E-STOP” LEDs on the Control Unit’s system panel

(2)

and the Drive Unit’s front panel are ON.

Make sure that “E.Stop” is displayed on the status bar on the main window.

(3)

(4)

Release the Emergency Stop Switch.

(5) Execute the RESET command.

(6)

Make sure that “E-STOP” LEDs are turned OFF and the “Emergency Stop”

is no longer visible (or dimmed) from the status bar.

For the Emergency Stop condition to work with the peripheral equipment at the
input of the Emergency Stop at the Drive Unit via the EMERGENCY connector,
make sure that the desired equipment is connected to the Emergency Stop output
terminals. The relay contacts at the EMERGENCY connector (#5 & #6)
(normally closed) will open at the input of Emergency Stop state.

34

RC520 Safety and Installation Rev.2

2. Installation

29BE. STOP Box

The E. STOP box is a unit for performing an emergency stop. When using the E.
STOP box, connect it to the EMERGENCY connector.

The E. STOP box is provided with the Controller as a standard accessory when the
Controller you purchased is UL specifications.

When connecting the Safety Door switch or Emergency Stop switch to the
EMERGENCY connector, remove the E. STOP box from the connector.

Cable (4 m)

E. STOP Box

Once the E. STOP box is connected to the EMERGENCY connector, continue the
following procedure to make sure that the E. STOP box functions properly. For
the safety of the operator, the Manipulator must not be powered ON until the
following test is completed.

(1)

Turn ON the Control Unit and the Drive Unit to boot the Controller while

pressing the E. STOP box switch.

Make sure that the “E-STOP” LEDs on the Control Unit’s system panel and

(2)

the Drive Unit’s front panel are ON.

Make sure that “Emergency Stop” is displayed on the status bar on the

(3)

monitor window.

Release the E. STOP box switch.

(4)

(5) Execute the RESET command.

Make sure that “E-STOP” LEDs are turned OFF and the “Emergency Stop”

(6)

is no longer visible (or dimmed) from the status bar.

RC520 Safety and Installation Rev.2

Connect to
EMERGENCY connector

35

2. Installation

30BPin Assignments

The EMERGENCY connector pin assignments are as follows:

Pin No. Signal Function

1 E_SW11

Emergency Stop switch output (1)

2 E_SW12

3 E.STOP1+ Emergency Stop input 1 (+)

4

5 E.STOP OUT

6 E.STOP OUT

7 GUARD11

E.STOP1- Emergency Stop input 1 (-)

Emergency Stop condition output
(Relay contact) *1

Safety Door input (1)

8 GUARD12

9 +24V +24V output

10 +24VGND +24V GND output

11 E_SW21

Emergency Stop switch output (2)

12 E_SW22

13 E.STOP2+ Emergency Stop input 2 (+)

14

15 RELEASE

E.STOP2- Emergency Stop input 2 (-)

Latch Release input

16 RELEASE

17 GUARD21

Safety Door input (2)

18 GUARD22

19 +24V +24V output

20 +24VGND +24V GND output

*3

*2

*3

*2

36

*1 The Emergency Stop condition is output via relay contact when it is open (it is

normally closed).

*2 A critical error occurs if the input values from Safety Door 1 and Safety Door

2 are different for two or more seconds. They must be connected to the same

switch with two sets of contacts.

*3 The signal from the Emergency Stop switch is designed to use two redundant

circuits. An error occurs if the statuses of the two redundant circuits are

different for two or more seconds. They must be connected to the same

switch with two sets of contacts.

RC520 Safety and Installation Rev.2

Emergency Stop switch output rated load +30V 1A or under

2. Installation

1-2,

11-12 pin

NOTE



Emergency Stop rated input voltage range

Emergency Stop rated input current

Safety Door rated input voltage range

Safety Door rated input current

Latch Release rated input voltage range

Latch Release rated input current

Emergency Stop output relay contact

rated load

The total electrical resistance of the Emergency Stop switches and their circuit

should be 1 Ω or less.

+24V ±10%

10mA/24V input

+12V to +24V ±10%

10mA/24V input

+12V to +24V ±10%

10mA/24V input

+30V 0.5A or under 5-6 pin

3-4,

13-14 pin

7-8,

17-18 pin

15-16 pin

RC520 Safety and Installation Rev.2

37

2. Installation

Emergency Stop
switches of an
operation unit

31BCircuit Diagrams

Example 1: External emergency stop switch typical application

Control Unit (MIB)

Emergency
Stop
detection

Dynamic brake relay of
each motor driver module

Emergency
Stop d ete ction

*1

Dynamic
brake
control

Emergency
Stop detection

Drive Unit (DMB)

+24V

+24V

External
Emergency
Stop switches

9

19

1

2

11

12

3

13

5

6

38

Dynamic
brake
control

*1: The part indicated with a broken line shows

the circuit for the four-axis Drive Unit.
For the six-axis Drive Unit, there are six
motor driver modules in the circuit.

4

14

10

External

20

+24V

8

Safety Door input 1

Safety Door input 2

Latch release input

Latch release input

Close: latch off
Open: latch on

7

18

17

16

15

External
+24V GND

RC520 Safety and Installation Rev.2

Emergency Stop
switches of an
operation unit

Example 2: External safety relay typical application

Control Unit (MIB)

Emergency
Stop
detection

Dynamic
brake
control

Dynamic brake relay of
each motor driver module

Emergency
Stop detection

*2

Dynamic
brake
control

Emergency
Stop detection

Drive Unit (DMB)

+24V

+24V

Safety Door input 1

Safety Door input 2

Latch release input

2. Installation

External +24V

9

Fuse *1

19

1

2

11

12

3

13

5

External safety relay
(The above diagram
is simplified for
representation.)

*1 For the protection of

6

4

14

10

20

8

7

18

17

16

15

External
+24V GND

External
+24V

the emergency stop
circuit, the fuse’s
capacity should be
as follows:

- Meets the capacity
of the external
safety relay.

- 1A or less.

External
+24V
GND

External
+24V

*2: The part indicated with a broken line shows

the circuit for the four-axis Drive Unit.
For the six-axis Drive Unit, there are six
motor drive modules in the circuit.

RC520 Safety and Installation Rev.2

Safety Door latch release input

Close: latch off
Open: latch on

External
+24V
GND

39

2. Installation

Example 3: Emergency Stop input circuit for Multi-Manipulator

Relay placed on the outside

 Rated electric current

consumption of the coil:
1A or under

 Minimum applicable load:

10mA or under

External +24V

External +24V GND

External +24V

External
Emergency
Stop switch

External
+24V GND

External
+24V GND

External
+24V GND

EMERGENCY
connector

Drive
Unit 1

1

11

2

12

3

13

4

14

3

Drive

13

Unit 2

4

14

3

Drive

13

Unit 3

4

14

RC520

OPTIONAL DEVICE
connector

Control
Unit

Emergency
Stop switch
at the Jog Pad
/Operation
Pendant

40

RC520 Safety and Installation Rev.2

7B 2.7 Connecting Manipulator and Controller

32BConnecting Precautions

Before Connection

: Before connecting the connector, make sure that the pins are not bent.

Connecting with the pins bent may damage the connector and result in
malfunction of the robot system.

AC power cable

: Be sure to connect the AC power cable to a power receptacle. DO NOT

connect it directly to a factory power source. To shut off power to the robot
system, pull out the power plug from the power source. Performing any
work while connecting the AC power cable to a factory power source is
extremely hazardous and may result in electric shock and/or malfunction of
the robot system.

Connecting procedure

: Before performing any connecting procedure, turn OFF the Controller and

related equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely
hazardous and may result in electric shock and/or malfunction of the robot
system.

Cable

: Be sure to connect the cables properly. Do not allow unnecessary strain on

the cables. (Do not put heavy objects on the cables. Do not bend or pull
the cables forcibly.) The unnecessary strain on the cables may result in
damage to the cables, disconnection, and/or contact failure. Damaged
cables, disconnection, or contact failure is extremely hazardous and may result
in electric shock and/or improper function of the robot system.

Controller power

: Make sure that the power to the Controller is turned OFF and locked out

before connecting or disconnecting any cables. Connecting or disconnecting
any cables with the power ON is extremely hazardous and may result in
electric shock and/or malfunction of the Controller.

Connection

: The serial numbers of the Drive Unit and Manipulator that should be

connected are indicated on the Connection Check Label on the Control Unit.
Connect the Control Unit, the Drive Unit and the Manipulator correctly.
Improper connections between the Drive Unit and the Manipulator and
between the Control Unit and the Drive Unit may cause improper function of
the robot system and also safety problems.

2. Installation

RC520 Safety and Installation Rev.2

41

2. Installation

Wiring

: Only authorized or certified personnel should be allowed to perform wiring.

Wiring by unauthorized or uncertified personnel may result in bodily injury
and/or malfunction of the robot system.

Connector lock (PS series)

: Be careful not to get hands or fingers caught while pushing down the

connector lock lever because you should apply strong force to it.

For Clean-model

: When the Manipulator is a Clean-model, use it with an exhaust system.

For details, refer to the Manipulator manual.

For Protected-model

: Connect the power cable connection and the signal cable connector to the

Manipulator immediately after the Manipulator installation. The
Manipulator without connecting them may result in electric shock and/or
malfunction of the robot system as it cannot ensure IP65.

42

RC520 Safety and Installation Rev.2

2. Installation

Connect a Drive Unit to the Manipulator by using M/C Power cable and M/C
Signal cable.

33BM/C power cable

For the four-axis Drive Unit

: The M/C power cable has round connectors with 17 pins on both ends.

Connect the female connector to the POWER connector on the
Manipulator and the male connector to the M/C POWER connector on the
Drive Unit. Insert the connectors and rotate clockwise until you hear a
“click” to secure the connection.

For the six-axis Drive Unit

: This cable has a round connector with 37 pins on the controller-side and a

rectangular connector with 36 pins on the Manipulator-side. Connect the
round connector to the M/C POWER connector on the Drive Unit and the
rectangular connector to the POWER connector on the Manipulator.

34BM/C Signal cable

For the four-axis Drive Unit

: the M/C Signal cable has rectangular connectors with 68 pins on both

ends.

For the six-axis Drive Unit

: the cable has a D-Sub connector with 37 pins on the Controller-side end

and a rectangular connector with 40 pins on the Manipulator-side end.

Connect the signal cable to the SIGNAL connector on the Manipulator and the
M/C SIGNAL connector on the Drive Unit.

35BSerial Number of Connectable Manipulator

You can find the serial number of the Manipulator that should be connected to the
Drive Unit on your left hand side facing the Drive Unit. The Manipulator’s serial
number is indicated on the signature label of the Manipulator. (The following
photo is the six-axis Drive Unit.)

MANIPULATOR

00002PS3-AS00

Model

RC520 Safety and Installation Rev.2

Serial number

43

2. Installation

36BPS series and RC520 Connection

M/C Power Cable

M/C Signal Cable

37BE2 series and RC520 Connection

44

M/C Power Cable

M/C Signal Cable

RC520 Safety and Installation Rev.2

8B 2.8. Power-on

38BPower-on Precautions

Plug change

: If it is necessary to change the plug to fit the outlet in your factory, make sure

that it is done by qualified personnel. When changing the plug, be sure to
connect the earth wire of the AC power cable colored green/yellow on the
Controller to the earth terminal of the factory power supply. The equipment
must be grounded properly at all times to avoid the risk of electric shock.
Always use a power plug and receptacle. Never connect the Controller
directly to the factory power supply. (Field wiring)

Power activation

: Anchor the Manipulator before turning ON the power to or operating the

Manipulator. Turning ON the power to or operating the Manipulator that is
not anchored is extremely hazardous and may result in serious bodily injury
and/or severe equipment damage to the robot system as the Manipulator may
fall down

Manipulator check before installation

: Before installing and operating the Manipulator, make sure that all parts of the

Manipulator are in place and have no external defects. Missing or defective
parts may cause improper operation of the Manipulator. Improper operation
of the Manipulator is extremely hazardous and may result in serious bodily
injury and/or severe equipment damage to the robot system.

Shipping bolts and jigs check before turning ON

: Before first turning ON the power, be sure to remove the shipping bolts and

jigs from the Manipulator. Turning ON the power while the shipping bolts
and jigs are attached may result in equipment damage to the Manipulator.

39BPower ON Procedure

(1) Check the M/C power cable connection.

Check the M/C signal cable connection.

(2)

Check the EMERGENCY connector connection.

(3)

(4)

Connect the Dummy Plug or OP500RC to the OPTIONAL DEVICE

(5) Connect the AC power cable to the power supply socket.

Turn ON both the Drive Unit and Control Unit.

(6)

2. Installation

connector.

RC520 Safety and Installation Rev.2

45

2. Installation

When an error appears, check the connection in step (1) to (5) to turn ON the power
again. If an error appears after checking the connection contact the supplier.

46

Boot the Controller. During this process, watch and monitor the Drive Unit

(7)

LED status as described in the following list:

POWER LED : The LED will be ON if the system is operating properly.

When the LED is OFF, suspect that either there is an
input/output failure in the Switching Power Supply
module or a wiring failure in the Control Power Supply
circuit.

MOTOR POWER : The LED must be OFF.

E-STOP : The LED must be ON when the system is in E-STOP

condition.
This LED turns ON when there is an EMERGENCY
STOP input to the Control Unit’s OPTIONAL DEVICE
connector and the Drive Unit’s EMERGENCY
connector.

RUN : The LED must be blinking.

ERROR : The LED must be blinking.

1 : The LED must be OFF.

2 : The LED must be OFF.

(8)

Boot the Controller. During this process, watch and monitor the Control

Unit LED status as described in the following list:

E-STOP : When the main power is turned ON, the LED must turn

ON momentarily and must go OFF unless there is an
emergency stop input.
If there is an emergency stop input at this time, the LED
must stay ON.
This LED turns ON when there is an EMERGENCY
STOP input to the Control Unit’s OPTIONAL DEVICE
connector and the Drive Unit’s EMERGENCY
connector.

RUN : The LED must be blinking.

ERROR : The LED must be blinking.

7 segment : When the main power is turned ON, “8” lights up

momentarily and goes OFF.
The displayed data must change from “0” in order to
indicate the system condition that is checked at the
beginning of the Controller.

RC520 Safety and Installation Rev.2

3. First Step

This section indicates the procedure to execute simple program after turning ON
the power.
Make sure that the Robot system is installed safely by following the description in

1. Safety and 2. Installation. Then, operate the Robot system in the following
procedures.

3.1 Windows XP Setup

When using Windows XP, make sure to set up the system.

3. First Step

NOTE

)

Do NOT stop the Windows XP Setup and turn OFF the Controller before
completing this setup.
Otherwise the Controller will NOT start up again and you must execute Windows
recovery.

After a short time after turning ON the Controller, “Windows XP Setup” starts
automatically.
Setup procedure is as follows. Follow the instruction in the dialog.

(1) Welcome to Microsoft Windows XP

Click the <Next> button to continue the setup.

(2) License Agreement

This dialog is for selecting agree or disagree to the displayed agreement.
When you agree to the agreement, select the option to agree and click the
<Next> button. (If you select the option to disagree, the Windows setup will
be canceled.)
After agreeing to the “License Agreement”, the setup starts automatically.

(3) Windows Startup

Windows reboot automatically after finishing the setup and will be able to
use the Controller.

RC520 Safety and Installation Rev.2

47

3. First Step

p

NOTE

)

Settings at Shipment

The RC520 robot controller is configured at factory as shown below:

User name and the password for Auto Log In

Log In User Name : EPSON RC User (with Administrator authority)

Log In Password : epson

Windows Administrator Password

Administrator Password : epson

* The password is case-sensitive.

For details of other settings at shipment, refer to Appendix A Settings at Shipment

in the EPSON RC+ User’s Guide.

3.2 Installing EPSON RC+ Software

EPSON RC+ is installed at the factory before shipment with the specified
configuration. However, if you need to add an option, upgrade, or re-install, refer
to the section Installing EPSON RC+ Software in Appendix A for instructions on
installing EPSON RC+.

Installing the software options key

Included with the EPSON RC+ Software is a software key device that enables
options. Without this device, the options you have installed will not be enabled.
All options are enabled on one key. Options can also be enabled in the field.
See the chapter Installing Options for details.

The software options key is installed
by simply plugging the male end of the
key into the parallel port connector on
the PC Control Unit.
Do not plug the options key into the
Option Device connector or any other

ort other than the parallel port.

Permanent damage can occur.

PC Configuration

Refer to Appendix A and configure Date, Time, and screen resolution.

48

RC520 Safety and Installation Rev.2

3.3 Writing your first program

Follow these instructions to create a simple application program so that you will
become more familiar with the EPSON RC+ development environment.

1. Start EPSON RC+

Double-click the EPSON RC+ icon on the desktop.

2. Create a new project

a. Select New from the Project menu.

b. Type in a name for a project, for example, FirstApp.

c. Choose Ok to create the new project.

When the new project is created, a program called Main.prg is created. You will
see a window open with the title Main.prg with a cursor flashing in the upper left
corner. Now you are ready to start entering your first program.

3. Edit the program

Type in the following program lines in the Main.prg edit window. You can use
upper or lower case characters.

Function main

Print "This is my first program."

Fend

4. Run the program

Press F5 to run the program. (F5 is the hot key for the Start selection of the Run
menu). You will see the Status window showing the build operation.

3. First Step

Your program is compiled and loaded into memory. If there are no errors during
build, the Run window will appear.

Press the Start button on the Run window to run the program.

You should see the following displayed on the Run window:

-> main started as Task 1

This is my first program.

-> All Tasks Stopped

Now let's teach some robot points and modify the program to move the robot.

RC520 Safety and Installation Rev.2

49

3. First Step

5. Teach robot points

Click on the Jog and Teach button
Teach dialog box.

Look at the lower left hand corner of the screen. You will see a drop down list
box called Point File Name. The current selection is robot1.pnt. This is the
default robot point file for your application. Any points that you teach will be
saved with this filename.

on the toolbar. You will see the Jog and

Click on the Robot Control Panel toolbar button
button to turn on the robot motors. You will be prompted to confirm the
operation. Answer Yes to continue.

If the MCal button is enabled, press it now to calibrate the robot. You will be
prompted to confirm the operation. Answer Yes to continue. Then you will see
a status window appear and the robot should start calibrating. Type any key, or
click the Stop button if you need to abort the MCal command. The MCal button
is not enabled if you are using an absolute encoder robot.

Exit the Robot Control Panel by clicking on the Close button.

Press the Teach P0 button.

Jog the robot by pressing the +Y jog button. Hold the button down to continue
jogging. Let go when the robot is about half way out in the work envelope.

Jog the robot down by pressing the -Z button.

Now change the current point to P1 by clicking on the right arrow on the Point #
slider until the point number is 1.

Press the Teach P1 button. You will see a confirmation message to teach the
point. Answer Yes.

Press the +X button to jog the robot in the +X direction.

Change the current point to P2 by clicking on the right arrow on the Point # slider
until the point number is 2.

. Click on the Motor On

50

Press the Teach P2 button. You will see a confirmation message to teach the point.
Answer Yes.

Leave the jog screen by pressing the Close button located in the lower right corner
of the screen. You will see a message saying that changes have been made.
Click Yes to save the changes.

RC520 Safety and Installation Rev.2

3. First Step

6. Modify the program to include robot motion commands

Insert three new Jump statements into the Main.prg program as shown below:

Function main

Print "This is my first program."

Jump P1

Jump P2

Jump P0

Fend

Run the program by pressing F5 and then click on the Start button on the Run
window. The robot should jump to each of the points you taught.

7. Modify the program to change speed of robot motion commands

Insert the Power, Speed, and Accel commands as shown in the program below:

Function main

Print "This is my first program."

Power High

Speed 20

Accel 20, 20

Jump P1

Jump P2

Jump P0

Fend

Run the program by pressing F5 and then click on the Start button on the Run
window. The robot should jump to each of the points you taught at 20% speed,
acceleration, and deceleration. The Power High statement enables your program
to run the robot at high (normal) power, which in turn allows the robot speed and
acceleration to be increased.

RC520 Safety and Installation Rev.2

51

3. First Step

8. Backup the project and system configuration

Even though this is only a sample project, we will backup the project and system
configuration on floppy disk. This is easy to do with EPSON RC+. It is
important that you keep regular backups of your applications on external media
such as floppy disks.

Follow these steps to backup the project and system configuration:

1. Insert a blank floppy disk in the floppy drive.

2. From the Project menu, select Copy.

3. Change the Destination Drive to A:.

4. Click OK. The project will be copied to the floppy disk.

5. From the Tools menu, select Maintenance.

6. Click on the MKVER button.

7. Enter the MKVER name "sample".

8. Select the A: drive.

9. Click OK. The system configuration will be backed up on the floppy disk.

Now that you have written your first program.

52

RC520 Safety and Installation Rev.2

4. Second Step

Setup other necessary functions after operating the robot system as indicated in 3.
First Step.

Manuals that indicate necessary setups and procedures are guided in this section.
(For descriptions of each manual, refer to 5. Third Step.)

4.1 Connection with External Equipment

Remote Control

EPSON RC+ User’s Guide

Remote Control

ROBOT CONTROLLER RC520 manual

Setup & Operation 8. I/O Remote Set Up

I/O

EPSON RC+ User’s Guide

I/O Setup

ROBOT CONTROLLER RC520 manual

Setup & Operation 6. I/O Connector
Setup & Operation 7 Expansion I/O Board (Option)

Fieldbus I/O (Option)

EPSON RC+ Option Fieldbus I/O manual

Ethernet I/O (Option)

EPSON RC+ User’s Guide

Ethernet Communication

ROBOT CONTROLLER RC520 manual

Setup & Operation 8. I/O Remote Set Up

RS-232C (Option)

EPSON RC+ User’s Guide

RS-232C Communication

ROBOT CONTROLLER RC520 manual

Setup & Operation 9. RS-232C Board

4. Second Step

RC520 Safety and Installation Rev.2

53

4. Second Step

4.2 Connection and Display Language of Option OP500RC

Connection

ROBOT CONTROLLER RC520 manual

Setup & Operation 4. OPTIONAL DEVICE connector

EPSON RC+ Option OP500RC manual

1.6. Installation

Changing Display Language

EPSON RC+ Option OP500RC manual

1.9 Setting Language

54

RC520 Safety and Installation Rev.2

5. Third Step

Descriptions of manual contents are indicated in this section.
Manuals are supplied by Acrobat PDF to use the Robot system.

Select EPSON RC+-[Help]-[PDF Manual] to view the PDF manuals from a PC.

(Click <Start>-[Program]-[EPSON RC+] from the Windows desktop.)

Software

EPSON RC+ User’s Guide

This manual indicates descriptions of the Robot system and program development

software.

- Safety

- Robot System Operation and Configuration

- Operation of Program Development Software EPSON RC+ GUI

- SPEL+ Language and Application

- Configuration of Robot, I/O, Communication etc.

EPSON RC+ SPEL+ Language Reference

This manual indicates descriptions of the SPEL+ language for robot program.

- Details of the commands

- Error Messages etc.

Option

The manuals indicate descriptions of the Option(s) you purchased. There are

manuals for each Option.

EPSON RC+ Option VB Guide 4.0

EPSON RC+ Option Vision Guide 4.0

EPSON RC+ Option Vision Guide 4.0 Properties and Results Reference

EPSON RC+ Option PG Motion System

EPSON RC+ Option Fieldbus I/O

EPSON RC+ Option Operator Pendant OP500RC

5. Third Step

RC520 Safety and Installation Rev.2

55

5. Third Step

Controller

ROBOT CONTROLLER RC520

This manual indicates descriptions of the Robot Controller RC520 and Robot

system.

- Safety

- Specification, Installation, Operation, and Setup

- Backup and Restore

- Maintenance

- Verifying Robot System Operation

- Error Codes etc.

Robot

The manuals indicate descriptions of the Robot(s) you purchased. There are

manuals for each Robot.

EPSON ProSix PS series (PS3, PS3L/PS3LP, PS5)

EPSON SCARA ROBOT E2 series (E2S/E2L, E2C, E2H)

EZ MODULES X4 series

- Safety

- Specification, Installation, Setting

- Maintenance

- Calibration etc.

56

RC520 Safety and Installation Rev.2