Epson RC620 CU, RC620 Series, RC620 DU User Manual

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Rev.8 EM15XC3076F

ROBOT CONTROLLER

RC620

ROBOT CONTROLLER RC620 Rev.8

ROBOT CONTROLLER

RC620

Rev.8

RC620 Rev.8 i

FOREWORD

Thank you for purchasing our robot products. This manual contains the information necessary for the correct use of the robot controller. Please carefully read this manual and other related manuals before installing the robot system. Keep this manual handy for easy access at all times.

RC620 robot controller consists of the following:

This manual contains the information for the RC620 CU (Control Unit). For RC620 DU (Drive Unit), refer to the Robot Controller / Drive Unit RC620DU manual.

The information for the robot controller is describes as below, indicating both RC620 CU and RC620 DU:

The information for the either unit (CU or DU) is described as below:

RC620 CU (Control Unit) RC620 DU (Drive Unit)

Robot controller Controller RC620

RC620CU Control Unit RC620DU Drive Unit

ii RC620 Rev.8

WARRANTY

1. Damage or malfunction caused by improper use which is not described in the manual, or

Malfunctions caused by customers’ unauthorized disassembly.

Damage due to improper adjustments or unauthorized repair attempts.

Damage caused by natural disasters such as earthquake, flood, etc.

1. If the

associated equipment is used outside of the usage conditions and

product

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.

Warnings, Cautions, Usage:

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):

careless use.

robot system

specifications described in the manuals, this warranty is void.

RC620 Rev.8 iii

TRADEMARKS

Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Other brand and product names are trademarks or registered trademarks of the respective holders.

TRADEMARK NOTATION IN THIS MANUAL

Microsoft® Windows® XP Operating system Microsoft® Windows® Vista Operating system Microsoft® Windows® 7 Operating system Throughout this manual, Windows XP, Windows Vista, and Windows 7 refer to above respective operating systems. In some cases, Windows refers generically to Windows XP, Windows Vista, and Windows 7.

NOTICE

No part of this manual may be copied or reproduced without authorization. The contents of this manual are subject to change without notice. Please notify us if you should find any errors in this manual or if you have any comments regarding its contents.

INQUIRIES

Contact the following service center for robot repairs, inspections or adjustments. If service center information is not indicated below, please contact the supplier office for your region.

Please prepare the following items before you contact us.

- Your controller model and its serial number

- Your manipulator model and its serial number

- Software and its version in your robot system

- A description of the problem

SERVICE CENTER

iv RC620 Rev.8

MANUFACTURER

Seiko Epson Corporation

Toyoshina Plant Robotics Solutions Operations Division 6925 Toyoshina Tazawa, Azumino Japan

TEL

: +81-(0)263-72-1530

FAX

: +81-(0)263-72-1495

North & South America

Epson

Factory Automation/Robotics 18300 Central Avenue Carson, CA 90746

USA

TEL

: +1-562-290-5900

FAX

: +1-562-290-5999

E-MAIL

: info@robots.epson.com

Europe

Epson Deutschland GmbH

Factory Automation Division Otto D

Germany

TEL

: +49-(0)-2159-538-1391

FAX

: +49-(0)-2159-538-3170

E-MAIL

: robot.infos@epson.de

China

Epson (China) Co., Ltd.

Factory Automation Division 7F, Jinbao Building No. 89, Jinbao Street, Dongcheng District, Beijin g , China, 100005

TEL

: +86-(0)-10-8522-1199

FAX

: +86-(0)-10-8522-1120

Taiwan

Epson T ai wan Technology & Trading Ltd.

Factory Automation 14F, No.7, Song Ren Road, Taipei 110, Taiwan, ROC

TEL

: +886-(0)-2-8786-6688

FAX

: +886-(0)-2-8786-6677

Korea

Epson Korea Co., Ltd.

Marketing Team (Robot Business) 27F DaeSung D-Polis A, 606

-shi, Nagano, 399-8285

SUPPLIERS

America, Inc.

-Hahn-Str.4

-40670 Meerbusch

Division

RC620 Rev.8 v

Seobusaet

-gil, Geumcheon-gu, Seoul, 153-803

Korea

TEL

: +82-(0)-2-3420-6692

FAX

: +82-(0)-2-558-4271

Southeast Asia

Epson Singapore Pte. Ltd.

Factory Automation System 1 HarbourFront Place, #03 HarbourFront Tower One, Singapore 098633

TEL

: +65-(0)-6586-5696

FAX

: +65-(0)-6271-3182

India

Epson India Pvt. Ltd.

Sales & Marketing (Factory Automation) 12th Floor, The Millenia, Tower A, No. 1, Murphy Road, Ulsoor, Bangalore, India 560008

TEL

: +91-80-3051-5000

FAX

: +91-80-3051-5005

Japan

Epson Sales

Factory Automation Systems Department Nishi Nishishinjuku, Shinjuku Japan

TEL : +81

-02,

Japan Corporation

-Shinjuku Mitsui Bldg.6-24-1

-ku, T o kyo 160-8324

-(0)3-5321-4161

vi RC620 Rev.8

Before Reading This Manual

NOTE

Do not connect TP1 to the following Robot Control lers. Connecting to the following Robot Controllers may result i n ma l fun c t io n of the d evice sinc e the pin assignm ents are different. RC420 / RC520 / SRC5** / SR C-3** / S R C-2** Be careful of the operating instructions of the TP1 w hen connecting it to the Rob ot

Controller RC180/RC170, it is different from the explanation in this manual. When using the TP1 with the RC180/RC170, refer to the RC170 / RC180 Option Teach Pendant TP1.

Do not connect the followings t o the TP port of RC620. Connecting to the followings may result in malfunction of the device since the pin assignments ar e different.

OPTIONAL DEVICE dummy plug Operation Pendant OP50 0 Operator Pendant OP50 0RC Operator Panel OP1 Jog Pad JP500 Teaching Pendant TP-3**

Security support for the network connection

The network connecting function (Ethernet) on our products assumes the use in the local network such as the factory LAN network. Do not connect to the external network such as Internet. In addition, please take se curity measure suc h as for the virus fro m the netw ork conn ectio n by installing the antiviru s software.

Security support for the USB memory

Make sure the USB memory is not infected with virus when connecting to the Controller.

RC620 Rev.8 vii

Safety

1. Safety 3

2. Conventions 3

3. Safety Precautions 4

Setup & Operation

1. Specifications 9

1.1 System Example ....................................................................................... 9

1.2 Standard Specifications .......................................................................... 10

1.3 Outer Dimensions ................................................................................... 13

2. Part Names and Functions 14

2.1 Part Names ............................................................................................. 14

2.2 Functions ................................................................................................ 16

2.3 LED and LCD .......................................................................................... 19

2.4 Safety Features ...................................................................................... 22

3. Installation 24

3.1 Unpacking ............................................................................................... 24

3.2 Environmental Requirements ................................................................. 24

3.2.1 Environment ............................................................................ 24

3.2.2 Installation ............................................................................... 25

3.3 Power Supply .......................................................................................... 26

3.3.1 Specifications .......................................................................... 26

3.3.2 AC Power Cable...................................................................... 27

3.4 Cable Connection ................................................................................... 27

3.4.1 Typical Cable Connection ....................................................... 28

3.4.2 Connecting Manipulator to Controller ..................................... 29

3.5 Noise Countermeasures ......................................................................... 30

viii RC620 Rev.8

Table of Contents

4. Operation Mode (TEACH/AUTO) 31

4.1 Overview ................................................................................................. 31

4.2 Switch Operation Mode .......................................................................... 31

4.3 Program Mode (AUTO) ........................................................................... 32

4.3.1 What is Program Mode (AUTO)? ............................................ 32

4.3.2 Setup from EPSON RC+6.0 .................................................... 32

4.4 Auto Mode (AUTO) ................................................................................. 33

4.4.1 What is Auto mode (AUTO)? .................................................. 33

4.4.2 Setup from EPSON RC+ 6.0 ................................................... 33

4.4.3 Setup from Control Device ...................................................... 35

5. Memory Port 36

5.1 What is Controller Status Storage Function? ......................................... 36

5.2 Before Using Contro ll er Status Storage Function .................................. 36

5.2.1 Precautions ............................................................................. 36

5.2.2 Adoptable USB Memory .......................................................... 37

5.3 Controller Status Storage Funct ion ........................................................ 37

5.3.1 Controller Status St or age with Trigger Button ........................ 37

5.3.2 Controller Status Storage with Teach Pendant (O pt ion) ........ 38

5.3.3 Load Data with EPSON RC+ 6.0 ............................................ 38

5.3.4 Transfer with E-mail ................................................................ 39

5.4 Details of Data ........................................................................................ 40

6. LAN (Ethernet Communication) Port 41

6.1 About LAN (Ethernet Com mu nication) Port ........................................... 41

6.2 IP Address .............................................................................................. 42

6.3 Changing Controller IP Address ............................................................. 42

7. TP Port 44

8. EMERGENCY 45

8.1 Safety Door Switch and Latch Release Switch ...................................... 46

8.1.1 Safety Door Switch .................................................................. 46

8.1.2 Latch Release Switch .............................................................. 47

8.1.3 Checking Latch Release Sw it ch Operation ............................ 47

RC620 Rev.8 ix

Table of Contents

8.2 Emergency Stop Switch Connection ...................................................... 48

8.2.1 Emergency Stop Switch .......................................................... 48

8.2.2 Checking Emergency St op Switch Operation ......................... 48

8.2.3 Recovery from Emergency Stop ............................................. 48

8.3 Pin Assignments ..................................................................................... 49

8.4 Circuit Diag ra ms ..................................................................................... 50

8.4.1 Example 1:

External emergency stop switch typical application ............... 50

8.4.2 Example 2:

External safety relay typical application .................................. 51

9. I/O Connector 52

9.1 Input Circuit ............................................................................................. 52

9.2 Output Circuit .......................................................................................... 54

9.3 Pin Assignment ....................................................................................... 56

10. I/O Remote Settings 57

11. R-I/O Connector 58

11.1 Input Circuit ............................................................................................. 58

11.2 Pin Assignment ....................................................................................... 59

12. Option Units 60

12.1 What are Option Units? .......................................................................... 60

12.2 Expansion I/O Board .............................................................................. 61

12.2.1 About Expansion I/O Board ................................................... 61

12.2.2 Board Configuration (Expans ion I/O) .................................... 61

12.2.3 Confirmation with EPSON R C+6.0 ....................................... 62

12.2.4 Input Circuit ........................................................................... 62

12.2.5 Output Circuit......................................................................... 64

12.2.6 Pin Assignments .................................................................... 66

12.3 Fieldbus I/O Board .................................................................................. 67

12.4 RS-232C Board ...................................................................................... 68

12.4.1 About RS-232C Board........................................................... 68

12.4.2 Board Setup (RS-232C) ........................................................ 68

12.4.3 Verify with EPSON RC+5.0 (RS-232C) ................................ 69

12.4.4 RS-232C Software Communication Setup (RS-232C) ......... 70

12.4.5 Communication Cable (RS-232C)......................................... 70

12.5 PG Board ................................................................................................ 70

x RC620 Rev.8

Table of Contents

13. UPS 71

14. Option : Teach Pendant TP1 73

14.1 Function .................................................................................................. 73

14.1.1 Safety ..................................................................................... 73

14.1.2 Specifications ......................................................................... 77

14.1.3 Installation .............................................................................. 79

14.1.4 Operation Mode (TEACH / AUTO) ........................................ 84

14.1.5 Operation Panel (Key Description) ........................................ 86

14.1.6 Enable Switch ........................................................................ 89

14.1.7 Warning Sound (Beep) .......................................................... 89

14.2 Teaching Procedure .............................................................................. 90

14.2.1 Jog Operation ...................................................................... 90

14.2.2 Teaching .............................................................................. 91

14.2.3 Direct Teaching .................................................................... 92

14.3 TEACH Mode ........................................................................................ 94

14.3.1 Jog & Teach ......................................................................... 95

14.3.2 Point Editor .......................................................................... 99

14.3.3 Robot ................................................................................... 101

14.3.4 Motion Command .............................................................. 102

14.3.5 I/O Command ..................................................................... 103

14.3.6 Jog Distance ...................................................................... 104

14.3.7 Free Joints ......................................................................... 105

14.3.8 Brake (For 6-Axis robots) ................................................... 106

14.4 AUTO Mode ........................................................................................ 108

14.4.1 Program Command Display .............................................. 109

14.4.2 I/O Monitor ......................................................................... 110

14.4.3 Memory I/O Monitor ........................................................... 110

14.4.4 Task Monitor ...................................................................... 111

14.4.5 System History ................................................................... 112

14.4.6 Controller Statuses Preservation ....................................... 113

14.4.7 Date / Time ........................................................................ 113

14.4.8 Brightness / Contrast ......................................................... 114

14.4.9 Language ........................................................................... 114

14.4.10 Error ................................................................................. 115

14.5 Password Setup .................................................................................. 115

14.6 Troubleshooting .................................................................................. 116

RC620 Rev.8 xi

Table of Contents

15. Option : RAID 117

15.1 Overview ............................................................................................... 117

15.2 Data Protection Status Co nf irmation .................................................... 117

15.2.1 Normal Status ...................................................................... 117

15.2.2 Status for Restore ............................................................... 118

15.3 Restoring the Data Protec tion Status ................................................... 119

15.3.1 Shutdown the system .......................................................... 119

15.3.2 Replace the HDD ................................................................ 119

15.3.3 Restore the data protection stat us ...................................... 119

Maintenance

1. Safety Precautions on Maintenance 123

1.1 Safety Precautions ............................................................................... 123

1.2 Lockout / Tagout ................................................................................... 124

2. Regular Maintenance Inspection 125

2.1 Schedule for Maintenance Inspection .................................................. 125

2.2 Inspection Point .................................................................................... 126

2.2.1 Inspection While the Controller is Turned OFF .................... 126

2.2.2 Inspection While the Controller is Turned ON ...................... 126

3. Controller Structure 127

3.1 Location of Parts ................................................................................... 127

3.2 Diagram of Cable Connections ............................................................ 127

3.3 Connector Pin Assignment ................................................................... 132

3.3.1 M/C Power Connector ........................................................... 132

3.3.2 M/C Signal Connector ........................................................... 133

4. Backup and Restore 134

4.1 What is Backup Controller? .................................................................. 134

4.2 Backup Data Types .............................................................................. 135

4.3 Backup .................................................................................................. 136

4.4 Restore ................................................................................................. 137

5. Firmware Update 139

5.1 Updating Firmware ............................................................................... 139

5.2 Firmware Upgrading Procedure ........................................................... 139

xii RC620 Rev.8

Table of Contents

5.3 Controller Recovery .............................................................................. 142

5.4 Firmware Initialization Procedure ......................................................... 143

6. Maintenance Parts Replacement Procedures 145

6.1 Fan / Fan Filter .................................................................................... 146

6.1.1 Cleaning and Replacing the Fan Filters .............................. 145

6.1.2 Replacing the Large Fan ..................................................... 147

6.1.3 Replacing the Small Fan ...................................................... 149

6.2 Battery ................................................................................................. 151

6.2.1 Replacing the Small Fan ...................................................... 151

6.2.2 Replacing the UPS Battery .................................................. 154

6.3 Motor Driver ........................................................................................ 157

6.3.1 Part Name ............................................................................ 157

6.3.2 Replacing the Motor Driver (DMB side) ............................... 158

6.3.3 Replacing the Motor Driver (ADMB side) ............................ 161

6.4 CPU Board / BIOS Backup Bat t er y / Memory .................................... 164

6.4.1 Normal .................................................................................. 164

6.4.2 Faster ................................................................................... 173

6.5 CF (Compact Flash) ............................................................................ 186

6.6 Switching Power Supply ..................................................................... 188

6.6.1 Switching Power Supply ( 15W) ........................................... 188

6.6.2 Switching Power Supply ( 75W) ........................................... 190

6.6.3 Switching Power Supply ( ATX ) ............................................ 192

6.7 PCI Board ............................................................................................ 196

6.8 Special Board ...................................................................................... 198

6.8.1 Replacing the Special Option Board .................................... 198

6.8.2 Adding the Special Option B oar d ........................................ 198

6.9 HDD ..................................................................................................... 199

6.9.1 Standard (HDD without RAID option) .................................. 199

6.9.2 HDD with RAID option ......................................................... 199

7. Recovering the HDD 201

7.1 HDD Recovery Procedure (S/N 01/02-00501 to 01/02-01000) .......... 201

7.1.1 Recovering Windows ............................................................ 201

7.2 HDD Recovery Procedure (S/N 01/02-01001 or later) ....................... 203

7.2.1 Backing up EPSON RC+ data ............................................. 203

7.2.2 Recovering Windows ............................................................ 204

7.2.3 Restoring EPSO N RC+ data ............................................... 207

RC620 Rev.8 xiii

Table of Contents

8. Troubleshooting 208

If the display is blank ................................................................................... 208

9. Maintenance Parts List 209

9.1 RC620 ................................................................................................... 209

9.2 Option TP1 ............................................................................................ 210

xiv RC620 Rev.8

Safety

This section contains information for safety of the Robot System.

WARNING

serious injury or

properly.

WARNING

This symbol indicates that a danger of possible harm to people

not followed properly.

CAUTION

exists if the

associated instructions are not followed properly.

1. Safety

Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. Please read this manual and other related manuals before installing the robot system or before connecting cables. Keep this manual in a handy location for easy access at all times.

2. Conventions

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

Safety 1. Safety

This symbol indicates that a danger of possible death exists if the associated instructions are not followed

caused by electric shock exists if the associated instructions are

This symbol indicates that a danger of possible harm to people or physical damage to equipment and facilities

RC620 Rev.8 3

Safety 3. Safety Precautions

Personnel who design and/or construct the robot system with this product must read the Safety chapter in User’s Guide to understand the safety requirements before designing and/or constructing the robot system. Designing and/or constructing the robot system without understanding the safety requirements is extremely hazardous, may result in serious bodily injury and/or severe equipment damage to the robot syst em, and may cause serious

The Manipulator and the Controller must be used within the environmental conditions described in their respective manuals. This product has been designed and manufactured strictly for use in a normal indoor environment. Using the product in an environment that exceeds the specified environmental conditions may not only shorten the life cycle of the

but may also cause

serious safety problems.

The the manuals. may

serious safety

problem

The interlock of the Safety Door must be functioning when the operated. Do not operate the sy stem under the c onditi on that the sw itch can not be turned ON/OFF. (I.E. the condition where the switch is disabled) (Example: Tape is put around the switch to hold it closed.) Operating the robot system when the s

is extremely hazardous and

may

s as the Safety Door input cannot fulfill its

intended function

Connect input signal wires for Emergency Stop and Safety Door to the EMERGENCY connector so th Pendant connected to the TP port always functions. (Refer to the typical application diagram in Set up & O per ation

3. Safety Precautions

Only trained personnel should design and install the robot system. Trained personnel are defined as those who have taken robot system training class held by the manufacturer, dealer, or local representative company, or those who understand the manuals thoroughly and have the same knowledge and skill level as those who have completed the training courses.

The following items are safety precautions for qualified design or installation personnel:



safety problems.

WARNING



product

robot system must be used within the installation requirements described in

Using the robot system outside of the installation requirements

not only shorten the life cycle of the product but also cause

robot system is

witch is not functioning properly

cause serious safety problem

at the Emergency Stop switch in the Teach

8.4 Circuit Diagrams.)

4 RC620 Rev.8

Safety 3. Safety Precautions

Do not open the cover(s) of the Control the cover(s) of the Controller is

and may result in electric shock inside the Control

Make sure that the power to the Control

before connecting or

disconnecting any cables.

any cables with the power ON ma

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 syst em.

When by qualified personnel. When connecting the plug, wire of the AC power cable colored green/yellow

to the earth terminal of the factory pow at all times to avoid the risk of electric shock. receptacle (Field wirin g )

The serial number of the Manipulator that should be connected is indicated on the Manipulator correctly. Improper connection between the Controller and the Manipulator may cause improper function of the robot system and also safety problems.

When using remote I/O, always make sure of the following. Using the robot system under

conditions may cause malfunction of the system

and/or safety problems.

inputs/outputs correctly and wire correctly when

- Make sure that the functions correspond to the correct input/output signals

ith initial

initial settings or wiring, press the Emergency Stop switch immediately to stop

The following items are safety precautions for qualified design or installation personnel: (cont.)

WARNING



even when its main power is OFF because of the high voltage charge



is extremely hazardous and may result in electric shock and/or

lfunction of the Controller.



connecting the plug to fit the outlet in your factory, make sure that it is done

. Never connect the Controller directly to the factory power supply.

ler except while maintaining it. Opening

extremely hazardous

ler.

ler is turned OFF

Connecting or disconnecting

be sure to connect the earth

on the Controller

er supply . The equipment must be grounded prop erly

Always use a power plug and



Connection Check Label on the Controller. Connect the Controller and the



unsatisfactory

CAUTION

Assign remote functions to

setting up remote I/O sign als.

before turning ON the system.

When verifying the robot system operation, prepare for failures w

settings or wiring. If the Manipulator functions unusually by the failures with

the Manipulator.

RC620 Rev.8 5

Safety 3. Safety Precautions

The interlock of the Safety Door must be functioning when the operated. Do not operate the system under the condition that the switch cannot be turned ON/OFF. (I.E. the condition where the switch is disabled (Example: Tape is put around the switch to hold it closed.) Operating the robot system when the switch is not

is extremely hazardous and

may

s as the Safety Door input cannot fulfill its

intended functio

Do not open the cover(s) of the Control the cover(s) of the Controller is

and may result in electric shock inside the Control

The following items are safety precautions for qualified operator personnel:

WARNING



robot system is

)

functioning properly

cause serious safety problem



ler except while maintaining it. Opening

extremely hazardous

even when its main power is OFF because of the high voltage charge

ler.

6 RC620 Rev.8

Setup & Operation

This section contains information for setup and operation of the Robot Controller.

8 RC620 Rev.8

Setup & Operation 1. Specifications

RC620

Special slot

Standard Equipment

I/O Board

EMERGENCY

Fieldbus I/O Slave Board

Standar d I/O

PROFIBUS-DP

Remote I/O

DeviceNET

EtherNet

CC-LINK

RS-232C

EtherNet/IP

PROFINET

RS-232C Board

Pulse Generating Board

PCl slot

Windows XP Frame Grabber Board

Fieldbus I/O Master Board

EPSON RC+ 6.0 PROFIBUS-DP

DeviceNET

Vision Guide 6.0 (option)

EtherNet/IP

VB Guide 6.0 (option)

GUI Builder 6.0 (option)

Additional axis

(option)

(Tw o units can be conne cted.

Drive Unit

Display Keyboard Mouse

1. Specifications

1.1 System Example

RC620 Rev.8 9

Setup & Operation 1. Specifications

Item

Specification

Robot Controller RC620 control unit (UL specification: RC620-UL)

Standard : Intel® CeleronTM M Processor High-speed (option) : Intel® CoreTM Duo Processor

Up to eight (8) connectable AC servo motors

Programming

software

Up to eight (8) joints Simultaneous control

PTP motion : Programmable in the range of 1 to 100%

manually entered.)

PTP motion : Programmable in the range of 1 to

Maximum Object Size : 8 MB

of array variables.)

MDI (Manual Data Input)

Including 8 inputs,

assignment change allowed

Standard I/O (Drive Unit)

Input : 24 Output : 16

Refer to Setup & Operation:

Communication) Port

1.2 Standard Specifications

Model

CPU

Controllable axes

Robot manipulator control

Positioning control

Memory capacity

(Limited by the total motor power.)

language and Robot control

Joint Control

Speed Control

Acceleration/ deceleration control

Connectable Manipulator

PTP (Point-To-Point control) CP (Continuous Path control)

Point data area : 1000 points (per file) Backup variable area : Max. 400 kB (Includes the memory area for

EPSON RC+ 6.0 (a multi-tasking robot language)

Software AC servo control

CP motion : Programmable (Actual value to be

100%; Automatic

CP motion : Programmable (Actual value to be

manually entered.)

Max. 16 units (Max. 20 axes)

the management table.) Approx. 4000 variables (Depends on the size

Remote

Teaching method

External input/output signals (standard)

Communication interface (standard)

10 RC620 Rev.8

Direct

Standard I/O

Ethernet 2 channel

RS-232C 1 or 2 channel Depends on CPU Board

Input : 24 Output : 16

8 outputs with remote function

per Drive Unit

6.1 LAN (Ethernet

Setup & Operation 1. Specifications

Item

Specification

PROFINET

Generator

4ch per board

Standard frame grabber

EtherNet/IP

Rated Ambient

Rated Relative

Special slot (Max. 4 slots)

PCI slot

Safety features

I/O

RS-232C

Input : 32 per board Output : 32 per board

4ch per board

Addition of 4 boards allowed

Addition of 2 boards allowed

1ch per board

PROFIBUS-DP

Fieldbus I/O slave

DeviceNet CC-Link

Addition of 1 board allowed

EtherNet/IP

Pulse

Number of Controlling axis

Addition of 4 boards allowed

Frame grabber

Advanced frame grabber

Addition of 2 board allowed

1ch per board FieldbusI/O master

PROFIBUS-DP DeviceNet

Addition of 1 board allowed

- Emergency stop switch

- Safety door input

- Low power mode

- Dynamic brake

- Encoder cable disconnection error detection

- Motor overload detection

- Irregular motor torque (out-of-control Manipulator) detection

- Motor speed error detection

- Positioning overflow - servo error - detection

- Speed overflow - servo error - detection

- CPU irregularity detection

- Memory check-sum error detection

- Overheat detection at the Motor Driver Module

- Relay welding detection

- Over-voltage detection

- AC power supply voltage reduction detection

- Temperature error detection

- Fan error detection

RC620 Rev.8 11

Power Source

Maximum Power Consumption

Insulation Resistance

Temperature

Humidity

AC 200 V to AC 240 V Single phase 50/60 Hz

2.5 kVA (Depending on the Manipulator model)

100 MΩ or more

5 to 40 deg.C

20% to 80% (with no condensation)

Setup & Operation 1. Specifications

Item Specification

4 axes spec : 22.5 kg

Weight *1

6 axes spec : 24.5 kg 8 axes spec : 25.5 kg

*1 Weight of the unit is indicated on the Controller itself.

Make sure to check the weight before units transfer or relocation and prevent throwing out your back at holding the unit. Also, make sure to keep your hands, fingers, and feet safe from being caught or serious injury.

12 RC620 Rev.8

4-M4

NOTE

1.3 Outer Dimensions

Dimension of RC620-UL is the same as RC620.

Setup & Operation 1. Specifications

[Unit : mm]

RC620 Rev.8 13

Setup & Operation 2. Part Names and Funct io ns

(9)

(12)

(1)

(11)

(15)

(8)

(2)

(3)

(4)

(5)

(6)

(7)

(10)

(13)

(14)-1

(14)-2

(9)

(12)

(1)

(15)

(8)

(2)

(3)

(4)

(5)

(6)

(7)

(13)

(14)-1

(14)-2

2. Part Names and Functions

2.1 Part Names

Front RC620

RC620-UL (Side and Back are the same as RC620.)

14 RC620 Rev.8

(16)

(17)

(28)

(18)

(19)

(20

)

(21)

(23)

(24)

(25)

(26)

(27)

(29)

(30)

(31)

(32)

(33)

(34)

(22)

Side

Back

Setup & Operation 2. Part Names and Functions

RC620 Rev.8 15

Setup & Operation 2. Part Names and Funct io ns

NOTE

2.2 Functions

(1) TP port

Connects Teach Pendant TP1 (Option). For details, refer to Setup & Operation 7. TP Port.

- When connecting the Teach Pendant (option) to the TP port, make sure the connector is right side up.

- Do not connect the following to the TP port of RC620. Connecting to the followings may result in malfunction of the device since the pin assignments are different.

OPTIONAL DEVICE dummy plug Operation Pendant OP500 Operator Pendant OP500RC Operator Panel OP1 Jog Pad JP500

(2) LED

The LED indicates current operation mode (TEACH, AUTO, or PROGRAM mode). For details, refer to Setup & Operation 2.3 LED and LCD.

(3) Trigger Switch

This switch is for Controller status storage function using the USB memory. For details, refer to Setup & Operation 5. Memory Port.

(4) Memory port

This port connects the common USB memory for Controller status storage function. Do not connect other USB devices except the USB memory. For details, refer to Setup & Operation 5. Memory Port.

(5) HDD access LED

This LED displays the HDD access condition.

(6) Shutdown switch

If you want to shutdown the Windows when the keyboard is not connected, use this switc h (turn it on). Also, if for some reason you cannot shutdown normally, press this switch for more than 5 seconds, the ATX power inside the controller is turned off.

(7) USB port

This port is for the USB device such as USB memory.

(8) DVD drive (option)

You can install the optional DVD drive.

(9) LCD

The LCD of 2 lines × 20 characters displays the line number and the status of the controller (error number, warning number, status of Emergency Stop and Safety Door). For details, refer to Setup & Operation 2.3 LED and LCD.

(10) POWER switch

Teaching Pendant TP-3**

Turns ON or OFF the Controller. * This is not available for RC620-UL. For details, refer to Setup & Operation 3.3.2 AC Power Cable, For RC620-UL.

16 RC620 Rev.8

(11) Lockout key for POWER switch

Lock the POWER switch in Off status. You need this method in the maintenance or repair of the robot system and make sure the power is locked in Off status and other operators cannot operate. * This is not available for RC620-UL. For details, refer to Setup & Operation 3.3.2 AC Power Cable, For RC620-UL.

(12) Large Fan Filter

A protective filter is installed in front of the fan to filter out dust. Check the condition of the filter regularly and clean it when necessary. A dirty filter may result in malfunction of the robot system due to temperature rise of the Controller.

(13) Small Fan Filter

(14) Controller Number label

The serial number of the Controller is indicated.

(15) Drive Unit Serial Number Label

The label indicates the DU number and serial number of Drive Unit. When connecting Drive Unit, this label is attached according to the number of Drive Unit(s).

(16) Signature label

The serial number of the Controller and other information are shown.

(17) MT label

The label indicates the specification number for the customized Manipulator and is attached only to the customized Manipulator. If your Manipulator indicates this label, it may require a specific maintenance procedure. In this case, make sure to contact your dealer before performing any maintenance procedures.

(18) Connector panel for CPU boar d (option)

This panel is for the installation of USB port and COM port on the CPU board. Note that each CPU board type has different available connector.

(19) PCI slot

PCI board can be installed. For the option, we provide the Frame Grabber boar and Fieldbus I/O master board. For details, refer to Setup & Operation 11. Option Slot.

(20) CPU board slot

CPU board can be installed.

(21) LAN (Ethernet communic at ion) por t 2

This port (LAN-2) is for the Controller and the Ethernet cable. The general port. For details, refer to Setup & Operation 6. LAN (Ethernet Communication) Port.

(22) DU OUT connector (opti on)

This connector is for Drive Unit.

Setup & Operation 2. Part Names and Functions

RC620 Rev.8 17

Setup & Operation 2. Part Names and Funct io ns

(28)

The details of the Manipulator to be connected are recorded on

label indicates the

Manipulator model and Manipulator serial number.

MANIPULATOR

00003

G3-351S

The details of the Manipulator to be connected are recorded on

label indicates the

Manipulator model and Manipulator serial number.

MANIPULATOR

00002

3-351S

(23) R-I/O connector

This connector is for the input signals used for the real time I/O function.

(24) EMERGENCY connector

This connector is for input/output from/to Emergency Stop and Safety Door switches. For details, refer to the Setup & Operation 8. EMERGENCY.

(25) LAN (Ethernet communication) port1

This port (LAN-1) is for the Controller and the Ethernet cable. The SPEL port. For details, refer to Setup & Operation 6. LAN (Ethernet Communication) Port.

(26) I/O connector

This connector is for input/output device. There are 24 inputs and 16 outputs. For details, refer to Setup & Operation 9. I /O Conne ctor.

(27) M/C SIGNAL connector 1

This connector is for signals such as the Manipulator’s motor encoders etc. Connect the Manipulator’s dedicated signal cable.

Connection Check label 2 (option)

dedicated

the label as shown in the right. The

9) Connection Check label 1

the label as shown in the right. The

(30) M/C SIGNAL connector 2 ( opt ion)

This connector is for signals such as the Manipulator’s motor encoders etc. Connect the Manipulator’s dedicated signal cable.

(31) M/C POWER connector 2 (option)

This connector is for the Manipulator power source. Connect the dedicated power cable attached to the Manipulator.

(32) M/C POWER connector 1

This connector is for the Manipulator power source. Connect the dedicated power cable attached to the Manipulator.

(33) AC IN connector

This connector is for AC 200V power input. For details, refer to Setup & Operation 3.3.2 AC Power Cable.

(34) Special slot

Option boards such as expansion I/O board, Fieldbus I/O slave board, RS-232C board, Pulse generating board can be installed. For details, refer to Setup & Operation 11. Option Slots.

18 RC620 Rev.8

LED

Status

TEACH

PROGRAM

HDD

It lights up during the HDD access.

EPSON Robot Controller

Line

2nd Line

EStop Safety

Displays the controller conditio n. Blinking indicates that the controller is running.

EStop

Indicates the Emergency status.

Safety

Indicates the Safeguard Open.

Message

Displays a message according to the status.

1st Line 2nd Line

EP SG

2.3 LED and LCD

LED and LCD

Four LEDs and a LCD (2 lines × 20 characters) are located on the front panel of the Controller.

LED

Setup & Operation 2. Part Names and Functions

AUTO

LED (TEACH, AUTO, PROGRAM) turns ON according to the current operation mode (TEACH, Auto, Program).

LCD : Indicates the line number and Controller status (error number, warning number,

Emergency Stop or Safeguard status)

From turning ON the Contr oller t o completing startup

LED : All three LEDs blink. LCD : The 1

line lights up and the 2nd line is turned off for approx. 10 seconds.

Then for few seconds, it displays as below:

After Controller Startup

LED : LED (TEACH, AUTO, PROGRAM) turns ON according to the current

operation mode (TEACH, Auto, Program).

LCD : The display varies depending on the controller status.

The basic layout is shown below:

RC620 Rev.8 19

Status

In the Error status or Pause status, it displays as below. This is because the information of <status> is too many. (Estop : EP / Safety : SG)

Setup & Operation 2. Part Names and Funct ions

Controller status

Display of LCD

- Status Backup

-OKBackup

-NGBackup Failed

---Waiting for RC+

Err2200 r01a03 Robot in use. Cannot

----Teach V.6.0.0.1

----Ready V.6.0.0.1

Task123 P1234 Paused

Task123 L1234 Tasks Running

When several Controller statuses occurred at one time, the status indicated earlier on the following table is displa yed. For an example, when both “Error” and “Teach” occurred at one time, “Error” is displayed.

Execute Controller status storage function to the USB memory

Complete Controller status storage to USB memory

Failure of Controller status storage to USB memory

Wait for RC+ startup

Error

TEACH

READY

PAUSE

(for 2 seconds)

START

*1 For error numbers and warning numbers, refer to SPEL+ Language Reference manual.

The 1

line displays “Err” and 4 figures.

For the error numbers, refer to the SPEL

Language Reference manual.

XX in rXXaYY is a robot number and YY is an axis number. 00 is displayed for errors unrelated to the robot or axis.

The 2

line displays the error message.

If the message is long, scroll the message for display.

*2 The 2

line displays the firmware version number. However if the warning occurs, it displays the warning number. It displays the user message when Print #28 specifies the message.

20 RC620 Rev.8

Setup & Operation 2. Part Names and Functions

LCD

Status

Initialize Error 16

P-*** Controller startup mode

9999 Recovery Mode

9998 AC Power Off

9997 Controller shutdown

*3 The 1

line displays “Task” and a task number in 3 figures, and “L” or “P” and an execution line in 4 figures. In initial status, execution line of task number 1 is displayed in three-digit. Use Ton statement to change the displayed task number. For details, refer to SPEL

The 2

line displays “Tasks Running” or “Paused”.

Language Reference manual or Online Help.

However if the warning occurs, it displays the warning number. It displays the user message when Print #28 specifies the message.

Particular Status Display

When particular status occurs, LCD displays the followings.

Controller startup failure *1

Controller startup failure

*1 When the Initialize Error occurs, reboot the Controller. If the Initialize Error is

displayed again after the Controller is rebooted, please contact the supplier of your region.

Controller in Recovery mode Refer to Maintenance 4. Backup and Restore.

AC power supply drop is detected and software shut down.

Software shut down is specified from the EPSON RC+ 6.0 (software) or the SPEL

program.

RC620 Rev.8 21

Setup & Operation 2. Part Names and Funct ions

2.4 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 s afety funct ions is highly dangerous.

Among the fol lowing sa fety fea tures, the E mergenc y Stop S witch and Safety Doo r Input are particularly important. Make sure that these and other features function properly before operating the robot system. For details, refer to the Setup & Operation 8. EMERGENCY.

Emergency Stop Switch

The EMERGENCY connector on the Controller has expansion Emergency Stop input terminals used for connecting the Emergency Stop switches. Pressing any Emergency Stop switch can shut off the motor power immediately and the robot system will enter the Emergency Stop condition.

Safety Door Input

In order to activate this feature, make sure that the Safety Door Input switch is connected to the EMERGENCY connector at the Controller. 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 mode selector key s witch on the T each Pendant to the “Teach” mode. Manipulator operation is available only when the enable switch is on. I n this case, the Ma nipulator is operated in low power mode.

Low Power Mode

The motor power is reduced in this mode. Executing a power status change instruction will change to the restricted (low power) status regardless of conditions of the safety door or operation mode. The restricted (low power) status ens ures the safe ty of the operator and reduces the possibility of peripheral equipment destruction or damage caused by careless operation.

Dynamic Brake

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

Encoder Cable Disconnection Error Detecti on

The dynamic brake circuit is activated when the Motor Encoder Signal cable 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) Detect ion

The dynamic brake circuit is activated whe n irregularity with motor tor que (motor outp ut) is detected (in which case the Manipulator is out of control).

22 RC620 Rev.8

Motor Speed Error Detect ion

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 Manipulator’s actual speed is detected to mark an overflow (the actual speed is outside the nominal range) error.

CPU Irregu la rity Detec tion

Irregularity of CPU tha t controls the motor is detected by the watchdog ti mer. The system CPU and the motor controlling CPU inside the Controller are also designed to constantly check each other for any discrepancies. 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.

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.

Setup & Operation 2. Part Names and Functions

Relay Deposition Detection

The dynamic brake circuit is activated when relay deposition, junction error, or open fault is detected.

Over-Voltage Detection

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

AC Power Supply Voltage Drop Detection

The dynamic brake circuit is activated when the drop of the power supply voltage is detected.

Temperature Anomaly Detection

The temperature anomaly is detected.

Fan Malfunction Detection

Malfunction of the fan rotation speed is detected.

RC620 Rev.8 23

Setup & Operation 3. Installation

■

The Manipulator and the C ontroller m ust be used withi n the envir onm ental cond iti ons described in their manuals. This product has been strictly for use in a normal indoor environment that exc cause serious safety problems.

Item

Condition

Use a base table that is at least 100 mm off the floor.

NOTE

3. Installation

3.1 Unpacking

TP/OP bypass plug 1 unit (Installed before shipment) Lockout key 2 key EMERGENCY port connector 1 set I/O connector 1 set PS/2 cable 1 cable IDE cable *1 1 cable

Power cable (3 m) 1 cable EPSON RC+ 6.0 installer 1 DVD Manual installer *2 1 CD

*1 Required to connect IDE device. Be careful not to lose. *2 Attached when the manual(s) in the EPSON RC+ 6.0 installer DVD is revised.

(If the DVD drive is installed, the wiring is already arranged.)

3.2 Environmental Requirements

WARNING

In order to optimize the robot system’s performance for safety, the Controller must be placed in an environment that satisfies the following conditions: The Controller is not designed for clean-room specification. If it must be installed in a clean room, be sure to install it in a proper enclosure with adequate ventilation and cooling.

Install Controller in a location that allows easy connection / disconnection of cables.

Ambient temperature 5 to 40 deg.C (with minimal variation) Ambient relative

humidity First transient burst noise 2 kV or less (Power supply wire)

Electrostatic noise 4 kV or less Base table

eeds the conditions m a y not only shorten the life cycle of the product but also

3.2.1 Environment

20% to 80% (with no condensation)

1 kV or les (Signal wire)

Placing the Controller directly on the floor could allow dust penetration leading to malfunction.

designed and manufactured

. Using the product in the environment

24 RC620 Rev.8

Setup & Operation 3. Installation

If the Controller must be used in an environment that does not fulfill the conditions mentioned above, take adequate countermeasures. For example, the Controller may be enclosed in a cabinet with adequate ventilation and cooling.

- Install indoors only.

- Place in a well-ventilated area.

- Keep away from direct sunlight and radiation heat.

- Keep away from dust, oily mist, oil, salinity, metal powder or other contaminants.

- Keep away from water.

- Keep away from shocks or vibrations.

- Keep away from sources of electronic noise

- Prevent the occurrence of strong electric or magnetic field.

3.2.2 Installation

The controller can be placed vertically and horizontally. When you place it vertically, place the left side (from front side view) down. Also, put the rubber feet on the bottom to the left side. Use the same screws for securing the rubber feet.

Position of set screws for rubber feet

Make sure to keep the controller away from the peripherals for the air supply and exhaust. Controller Front side: 100 mm // Rear side: 150 mm

The rear side exhausts the hot air (approx. 10 deg C higher than ambient temperature). Therefore, make sure that heat sensitive devices are not placed near the outlet.

There must be room in front of the Controller so that the entire Controller can be pulled outward.

There must also be room behind the Controller so that one can attach and remove cables.

Use a base table that is at least 100 mm off the floor. Placing the Controller dire ctly on the floor could allow dust penetration leading to malfunction.

RC620 Rev.8 25

Setup & Operation 3. Installation

For approximate power consumption of each model, refer to

Peak Current

When power is turned ON : approx. 80 A (2 msec.)

3.3 Power Supply

3.3.1 Specifications

Ensure that the available power meets following specifications.

Item Specification

Voltage AC 200 V to AC 240 V Phase Single phase Frequency 50/60 Hz Momentary Power

Interrupt Power Consumption Max. 2.5 kVA

10 msec. Or less

Actual consumption depends on the model, motion, and load of the Manipulator.

the followings.

C3 : 1.2 kVA G1 : 0.5 kVA G3 : 1.1 kVA G6 : 1.5 kVA G10 : 2.4 kVA G20 : 2.4 kVA RS3 : 1.2 kVA RS4 : 1.4 kVA

Refer to Manipulator manual for Manipulator rated consumption.

Rated power consumption of X5 varies depending on the manipulator model. For details, please contact us.

When motor is ON : approx. 50 A (5 msec.) Leakage Current Max. 10 mA Ground Resistance

Install an earth leakage circuit breaker or a circuit breaker in the AC power cable line at 15 A or less rated electric current. Bo th should be a two-pole disconnect type. If you install an earth leakage circuit breaker, make sure to use an inverter type that does not operate by induction of a 10 kHz or more leakage current. If you install a circuit breaker, please select one that will handle the above mentioned “peak current”.

The power receptacle shall be installed near the equipment and shall be easily accessible.

100 Ω or less

26 RC620 Rev.8

■

Make sure that cable manufacturing and connection are done by a qualified personal. When proceeding, b green/yellow equipment must be groun ded properly at all times to avoid the risk of electric shock. Always use a power plug

. Never connect

the Controll

Plug (Set by the users)

To controller

The previous connection

M4 Ring solderless termina l (RC620-UL: M5 Ring solderless terminal)

AC power wire (2 cables)

Black

■

Branch Circuit protec tion (R ated current: 15 A or less) shall be installed i n the ex ternal AC power supplying side in accordance with the National Electrical Code. A disconnecting means shall be installed in accordance with the National Electrical Code and provide the ability for lockout and tagout.

■

Make sure that the power to the Controller is turned OFF and the power plug is disconnected

Connecting or disconnecting electric shock and ma

■

Be sure to connect (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on th e cables may result in damage to the c ables, disconnection, and/or contac hazardous and may result in electric shock and/or improper function of the system.

■

The serial number of the Manipulator that should be connected is indicated on the Connection Check Label correctly. not only improper function of the robot system but also safety problems.

■

Before connecting t he connector, make sure with system.

WARNING

Setup & Operation 3. Installation

3.3.2 AC Power Cable

e sure to connect the earth wire of the AC power cable colored

on the Contro ller to the earth ter minal of the factor y power supply. The

and receptacle f or power connecting cabl e

er directly to the factory power supply. (Fi eld wiri ng)

The AC plug in not attached to the AC power cable delivered at shipment. Refer to the wire connection specification and attach a proper plug to the cable that is suitable for the factory power supply. (A plug is prepared as option.)

Cable Wire Connection Specification

Purpose Color

Ground wire Green / Yellow

Cable length : 3 m (Standard)

For RC620-UL

WARNING

3.4 Cable Connection

an y cables with the power ON is extrem ely hazardous and may res ult in

WARNING

t failure. Damaged cables, d isconnecti on, or contact f ailure is extrem ely

Improper connection between the Controller and the Manipulator may cause

CAUTION

the pins bent may damage the connector and result in malfunction of the robot

before connecting or disconnecting any cables.

lfunction of the Controller.

the cables properly. Do not allow unnecessary strain on the cables.

on the Controller. Connect the Controller and the Manipulator

that the pins are not bent. Connecting

RC620 Rev.8 27

Setup & Operation 3. Installation

Manipulator

Input/Output Device

Additional axis

Ethernet Device

Controller

AC200V

-240V

Emergency Stop Safety Door, etc.

Teach Pendant

Disconnectable connector Cable attached at delivery Cable prepared by users

(1)AC Power Cable

(2) M/C Power Cable

(3) M/C Signal Cable

(2) M/C Power Cable

(3) M/C Signal Cable

(4) EMERGENCY

Cable

(7) P/S2 cable

Keyboard

Mouse

Display

(8) VGA cable

(5) I/O Cable

(9) TP cable

(6) LAN Cable

(1)

AC Power cable

(2)

M/C Power cable

(3)

M/C Signal cable

(4)

EMERGENCY cable

3.4.1 Typical Cable Connection

Cable for AC 200V power input to the Controller.

Connect the motor power signals between the Manipulator and Controller. Insert

the connectors on the Controller until you hear a “click”.

Connect the encoder signals between the Manipulator and the Controller.

Secure this cable to the Controller for sure using the set screws on both sides of the Controller.

The EMERGENCY connector has inputs to connect the Emergency Stop switch and

the Safe Giard switch. For safety reasons, connect proper switches for these input devices. For details, refer to the Setup & Operation 8. EMERGENCY.

28 RC620 Rev.8

Setup & Operation 3. Installation

(5)

I/O cable

(6)

LAN (EtherNet) cable

(7)

PS/2 cable

Dual-head cable for the connection of keyboard and mouse.

(8)

VGA cable

(7)

TP cable

■

Make sure that the power to the Control disconnecting an y cables. is extremely Controller

■

Be sure to connect the cables properly. Do (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 cabl es, disconnection, and/or contact failure. Dam aged cable hazardous and may result in electric shock and/or improper function of the system.

■

The serial number of the Manipulator that should be connected is indicated on the Controller. Connect the Controller and the Manipulator correctly. connection between th e Controller and the Manipulator m ay cause not only improper function of the robot system but also

■

When connecting t wo manipulators to the Control ler, number

NOTE

This connector is used for external input/output devices.

For details, refer to the Setup & Operation 9. I/O Connector.

Connect the EtherNet device.

For details, refer to the Setup & Operation 6. LAN (Ethernet Communication) Port.

Use the cable attached to the product. Check the mark of mouse and keyboard on the tip of the PS/2 cable and connect it correctly.

Connect the Display.

Connect the option Teach Pendant.

For details, refer to the Setup & Operation 7.TP Port.

3.4.2 Connecting Manipulator to Controller

Connect the Manipulator to the Controller by using the Power cable and the Signal cable.

WARNING

CAUTION

label and connect them correctly.

The Manipulator’s serial number is indicated on the signature label on the back of the Manipulator.

ler is turned OFF before connecting or

Connecting or disconnecting any cables with the power ON

hazardous and may result in electric shock and malfunction of the

not allow unnecessary strain on the cables.

s, disconnection, or contac t failure is extr emely

Improper

serious safety problems.

make sure to ref er to the serial

RC620 Rev.8 29

Setup & Operation 3. Installation

t run AC power lines and DC power lines in the same wiring duct, and separate them by at least 200 mm. For example, separate the AC motor

200 mm from the sensor or valve I/O lines; and do

other, they should cross perpendicularly. The preferable example is shown in the right figure.

AC Line duct

DC line duct

200 mm or more

3.5 Noise Countermeasures

To minimize electrical noise conditions, the following items must be observed in the system’s cable wiring:

To minimize electrical noise condition, be sure of followings for wiring.

- T he earth wire of the power supply should be grounded. (Ground resistance: 100 Ω or less) It is important to ground the frame of Controller not only for prevention from electric shock, but also for reducing the influence of electric noise around the Controller. Therefore, be sure to connect the earth wire (yellow/green) of the Controller’s power cable to the ground terminal of the factory power supply. For details about the plug and AC power cable, refer to the Setup & Operation 3.3 Power Supply.

- D o not tap power from a power line that connects to any equipment which may cause noise.

- When you tap power for the Controller and the single-phase AC motor from the same power line, change the phase of one or the other. Ensure that they will not be the same phase.

- Use a twisted pair motor power line.

- D o no

power line and the Controller power line by at least

not bundle both sets of wiring with the same cable tie. If more than one duct/cable must cross each

- Wire as short as possible to the I/O connector and EMERGENCY connector. Use a shielded cable and clamp the shield to the attached connector interior. Make sure to keep away from the peripheral noise source as far as possible.

- Make sure that the induction elements used to connect to the Controller’s I/O (such as relays and solenoid valves) have surge suppressors. If an induction element without a surge suppressor is used, make sure to connect a rectifying diode located at the induction element in parallel with it. In selecting a rectifying diode, make sure that it can handle the voltage and current incurred by the induction load.

- To start and change revolutions of the conveyer’s (or the like’s) AC motor (ex: an induction motor or three-phase induction motor) regularly or abruptly, make sure to install a spark suppressor between the wires. The spark suppressor is more effective when placed closer to the motor.

- As they are easily influenced by static electricity or the noise from power source, keep cable such as USB, Ethernet, RS-232C, or fieldbus away from peripheral noise sources.

30 RC620 Rev.8

Setup & Operation 4. Operation Mode (TEACH/AUTO)

Controller

TEACH mode

AUTO mode

Program mode

Auto mode

This mode enables point data teaching and checking close to the

This mode cannot operate the Robots or run programs with the Safety Door open.

release input signal for AUTO mode.

4. Operation Mode (TEACH/AUTO)

4.1 Overview

The Robot system has two operation modes TEACH mode and AUTO mode.

TEACH mode

Robot using the Teach Pendant. In this mode the Robot operates in Low power status.

AUTO mode

This mode enables automatic operation (program execution) of the Robot system for the manufacturing operation, and also programming, debug, adjustment, and maintenance of the Robot system.

4.2 Switch Operation Mode

Change the operation mode using the mode selector key switch on the Teach Pendant.

TEACH mode

AUTO mode

Turn the mode selector key switch to “Teach” for TEACH mode. Switching to TEACH mode pauses the program if it was running. Only the background tasks continue running. The operating Robot stops by Quick Pause.

Turn the mode selector key switch to “Auto” and turn on the latch

RC620 Rev.8 31

Setup & Operation 4. Operation Mode (TEACH/AUTO)

(2)

(5)

(3)

(4)

4.3 Program Mode (AUTO)

4.3.1 What is Program Mode (AUTO)?

Program mode is for programming, debug, adjustment, and maintenance of the Robot system. Procedures for switching to the Program mode are the followings.

Set the start mode of the EPSON RC+ 6.0 to “Program” and start up the Controller.

4.3.2 Setup from EPSON RC+ 6.0

Switch the start mode to Program mode from the EPSON RC+ 6.0.

(1) Select EPSON RC+ 6.0 menu | Setup | Sys tem Configuration to display the [System

Configuration] dialog.

(2) Select [Startup]. (3) Select [Start mode]-<Program> button. (4) Click the <Apply> button. (5) Click the <Close> button.

32 RC620 Rev.8

(2)

(5)

(3)

(4)

NOTE

4.4 Auto Mode (AUTO)

4.4.1 What is Auto mode (AUTO)?

Auto mode (AUTO) is for automatic operation of the Robot system. Procedures for switching to the Auto mode (AUTO) are the followings.

A : Set the start mode of the EPSON RC+ 6.0 to “Auto” and start the Controller. B : Set the Controller to the Independent mode.

Execute and stop the program from the control device specified by the EPSON RC+ 6.0. (Refer to 4.4.3 Setup Control Device.)

4.4.2 Setup EPSON RC+ 6.0

Switch the Start mode to Auto mode (AUTO).

(1) Select EPSON RC+ 6.0 menu | Setup | System Configuration to display the [System

Configuration] dialog.

Setup & Operation 4. Operation Mode (TEACH/AUTO)

(2) Select [Startup]. (3) Select [Start Mode]-<Auto> button. (4) Click the <Apply> button. (5) Click the <Close> button.

RC620 Rev.8 33

Setup & Operation 4. Operation Mode (TEACH/AUTO)

(2)

(5)

(3)

(4)

Set the Controller to Independent mode. (1) Select EPSON RC+ 6.0 menu | Setup | System Configuration to display the [System

Configuration] dialog.

(2) Select SPEL Controller Board | Preference.

(3) Check [Independent Mode] check box. (4) Click the <Apply> button. (5) Click the <Close> button.

For the details of Independent mode, refer to the EPSON RC+6.0 Users Guide: 4.2.1 Startup Sequence – Cooperat ive mode and Indepen dent mode .

34 RC620 Rev.8

Setup & Operation 4. Operation Mode (TEACH/AUTO)

(2)

(5)

(3)

(4)

4.4.3 Setup from Control Device

Set the control device from EPSON RC+ 6.0.

(1) Select EPSON RC+ 6.0 menu | Setup | System Configuration to display the [System

Configuration] dialog.

(1) Select SPEL Controller Board | Configuration. (2) Select Setup Controller | Control Device to select the control device from the

following two types.

Self Remote (I/O)

(3) Click the <Apply> button. (4) Click the <Close> button.

RC620 Rev.8 35

Setup & Operation 5. Memory Port

■

Controller status storage function is available at any status after starting the Cont r ol ler. However, operations form the console including stop and pause are not while executing this funct i on. Also,

the robot cycle time and the communication with

.0. Other than only when it is necessary, do not execute this

function when operating t he r obot .

5. Memory Port

Connect a commercial USB memory to the Controller memory port for following functions.

- Function for Controller status storage to the USB memory.

- Function for read & write to the USB memory from the SPEL

For the file operation of the USB memory, refer to the SPEL manual or Online Help - ChDisk or ROpen.

 Security support for the USB memory

Make sure the USB memory is not infected with virus when connecting to the Controller.

CAUTION

 If you power on the Controller with the USB memory inserted, the Controller

cannot start up normally. Make sure the USB memory is not inserted before you power on the Controller.

program.

Language Reference

5.1 What is Controller Status Storage Function?

This function saves various kinds of Controller data with one push to the USB memory. Data saved in USB memory is loaded to EPSON RC+ 6.0 to get the status of the Controller and the program simply and accurately. The saved data can also be used for restoring the Controller. For details, refer to Maintenance 4.4 Restore.

5.2 Before Using Controller Status Storage Function

5.2.1 Precautions

time and in any Controller

CAUTION

this function influences

PSON RC+ 6

- Make sure that the USB port is used only for USB memory even though the port on the

Controller is a universal USB port.

- Insert the USB memo ry directl y into the Controller memory port. Connection with

cables or hubs between the Controller and the USB memory is not assured.

- Make sure that the USB memory is inserted or removed slowly.

- Do not edit the saved files with an editor. O peration of the robot system after data

restoration to the Controller is not assured.

available

36 RC620 Rev.8

5.2.2 Adoptable USB Memory

- Status Backup

-Status Backup

-OKBackup OK

-NGBackup Failed

NOTE

Use USB memory that meets the following conditions.

- USB2.0, USB1.1 supported

- Without security function

USB memory with password input function cannot be used.

- No installation of a driver or software is necessary for Windows.

- Without encryption protection or security software.

Note that the conditions above are no guarantee of your USB memory availability with the Controller. The Controller cannot recognize some types of the USB memory.

5.3 Controller Status Storage Function

5.3.1 Controller Status Storage with Trigger Button

Use this procedure to save the status of the Controller to USB memory. (1) Insert the USB memory into the memory port.

Setup & Operation 5. Memory Port

(2) Wait approximately 10 seconds for USB memory recognition. (3) Press the trigger button on the Controller.

The LCD displays the following repeatedly during the data transfer.

Wait for the display to turn back to the normal. (Data transfer time depends on the project size, etc..)

(4) When the storage has been completed, LCD displays as below for two seconds.

When the storage has failed, LCD displays as below for two seconds.

(5) Remove the USB memory from the Controller.

- USB memory with LED is recommended to check the status changes in procedure (2).

- When storage is executed during Motor ON status, it may fail to store the status. Use another USB memory or execute the storage during Motor OFF status.

RC620 Rev.8 37

Setup & Operation 5. Memory Port

5.3.2 Controller Status Storage with Teach Pendant (Option)

Use this procedure to save the status of the Controller to the USB memory. (1) Insert the USB memory into the Controller.

(2) In the [Main Menu] screen, move the cursor to [Controller States...], and press the <OK>

key. The following screen appears.

(3) Select a folder to save the data.

The root directory is selected by default.

(4) Press the <OK> key to save the status.

5.3.3 Load Data with EPSON RC+ 6.0

The following shows the procedure to read the data stored in the USB memory by EPSON RC+ 6.0 and display the Controller status.

(1) Insert the USB memory into the PC with EPSON RC+ 6.0. (2) Make use that the following folder is indicated in the USB memory.

S_ serial number_data status was saved → Exmaple: S_12345_200608074410

(3) Copy the folder confirmed in procedure (2) to the “\EpsonRC60\Status” folder. (4) Select the EPSON RC+ 6.0 menu | Tools | Controller to display the [Controller Tools]

dialog.

(5) Click the <Export Controller Status…> button.

38 RC620 Rev.8

Setup & Operation 5. Memory Port

NOTE

(6) [Browse For Folder] dialog appears. Select the folder copied in procedure (3) and

click the <OK> button.

(7) [Controller Status Viewer] dialog appears to confirm the Controller status.

For details, refer to View Controller Sta tus in EPSON RC+ 6.0 User’s Guide 5.11.7 Controller Command (Tools Menu).

5.3.4 Transfer with E-mail

Follow this procedure to transfer the data by e-mail that was saved to the USB memory. (1) Insert the USB memory to a PC that supports sending of e-mail. (2) Make sure that the USB memory has following folders.

S_serial number_data status was saved → Example: S_12345_200608074410

(3) Send all the folders by e-mail.

- Delete files that do not relate to the project before transfer.

- This function is used to send the data to the system director and EPSON from the end

users for problem analysis.

RC620 Rev.8 39

Setup & Operation 5. Memory Port

File Name

Outline

for restore

CurrentMnp16.PRM

CurrentStatus.txt

Save status

Saves program and I/O status.

ErrorHistory.csv

Error history

InitFileSrc.txt

Initial setting

Saves various settings of the Controller.

MCSys16.MCD

information

Prg file is not included.

GlobalPreserves.dat variables

VXDWORK.bin

Includes program files.

VisHWConfig.dat

file is stored.

stored.

5.4 Details of Data

The following data files are created by the Controller status storage function.

Backup.txt Information file

CurrentMnp01.PRM :

MCSys01.MCD :

SrcmcStat.txt Hardware

ProjectName.obj OBJ file Result of project build.

MCSRAM.bin MCSYSTEMIO.bin MCTABLE.bin MDATA.bin

Robot parameter Saves information such as ToolSet.

Robot setting Saves information of connected robot.

Global Preserve

Inner information of Robot operation

File with information for Controller restore.

(for each robot)

Saves installation information of hardware.

Saves values of Global Preserve variables.

All files related to project except ProjectName.obj

ProjectName.vis

RCSam.dat RC+ When the Security option is used, the file is

Project When [Include project files when status

exported] check box is checked in EPSON RC+ 6.0 menu | Setup | System Configuration | Controller | Preference, the project file is stored.

Vision When the Vision Guide option is used, the

40 RC620 Rev.8

Setup & Operation 6. LAN (Ethernet Communication) Port

Controller

Ethernet

Smart Camera

LAN-1

LAN-2

NOTE

6. LAN (Ethernet Communication) Port

- For Ethernet (TCP/IP) communication with robot application software, refer to EPSON

RC+ 6.0 Online Help or User’s Guide 12. TCP/IP Communications.

- Refer to EPSON RC+6.0 option Vision Guide 6.0 manual for other details of connection

of the Controller and the Smart Camera.

- This port is not used for EtherNet/IP. Use the port for fieldbusI/O board. For other

CAUTION

details, refer to

 Security support for the network connection

The network connecting function (Ethernet) on our products assumes the use in the local network such as the factory LAN network. Do not connect to the external network such as Internet. In addition, please take security measure such as for the virus from the network connection by installing the antivirus software.

Robot Controller RC620 option Fieldbus I/O manual.

6.1 About the LAN (Ethernet Communication) Port

The RC620 Controller has two ports: LAN-1 and LAN-2. Both are Ethernet communication ports and support 100BASE-TX / 10 BASE-T. These two ports are used for the following purposes.

LAN-1 port (SPEL+ dedicated Ethernet port)

Connection with other Cont r oll er or PC

This port can be used as an Ethernet (TCP/IP) communication port to communicate between multiple controllers from robot application software.

Connection with Smart Camera (when the progr am starts running)

This port can be used for connection of the Controller and the Smart Camera when you execute commands such as VRun from the robot application software.

LAN-2 port (General Ethernet port)

General Ethernet connect i on from the application on t he Windows

This port can be used for the general-use Ethernet connection from the application on the Windows or OS.

Connection with the Smar t Camera (when creating the seq uence)

This port can be used for the connection of the Controller and the Smart Camera when you create the Smart camera sequence or display the live image.

When using the Smart Camera, the both LAN-1 and LAN-2 must be connected.

RC620 Rev.8 41

Setup & Operation 6. LAN (Ethernet Comm unication) Port

NOTE

6.2 IP Address

Set the proper IP address or subnet mask depending on the Controller configuration to use the LAN port.

Use an address from the following Private Address List in the closed network environment such as P2P or production line. Also, make sure the address is not redundantly assigned inside the closed network.

In other cases, check with the network administrator.

Private Address List

10.0.0.1 to 10.255.255.254

172.16.0.1 to 172.31.255.254

192.168.0.1 to 192.168.255.254

Configuration of the controller at shipment:

LAN-1 port

IP Address : 192.168.0.1 IP Mask : 255.255.255.0 IP Gateway : 0.0.0.0

* LAN-1 port cannot automatically acquire the IP address (not support DHCP).

LAN-2 port

This port can acquire the IP address automatically.

6.3 Changing IP Address

6.3.1 LAN-1 port

Change the IP address of LAN-1 port.

(1) Select the EPSON RC+ 6.0 menu | Setup | Controller to display the [Setup Controller]

dialog.

(2) Enter the proper IP address and subnet mask and click the <Apply> button. (3) Click the <Close> button. The Controller reboots automatically.

IP address configuration is completed and the Controller reboot dialog disappears.

(4) Connect the Ethernet cable to the Controller LAN-1 port.

42 RC620 Rev.8

LAN-1 port cannot automatically acquire the IP address (not support DHCP).

Setup & Operation 6. LAN (Ethernet Communication) Port

6.3.2 LAN-2 port

The IP address of LAN-2 port can be changed in the normal steps of Windows.

RC620 Rev.8 43

Setup & Operation 7. TP Port

Controller

TP Cable

Teach

Pendant

Conversion Kit CK1

Controller

TP Cable

Teach

Pendant

NOTE

7. TP Port

The TP port connects the Teach Pendant to the Controller. For the details, refer to Setup & Operation

Example

When nothing is connected to the TP port, Emergency Stop status occurs in the Controller. When the Teach Pendant is not connected, connect the TP/OP bypass plug.

Typical cable connection

A: TP Cable A

The shape of the cable connector used in connection A differs to connection B. TP Cable A : Circular connector to connect to the conversion kit CK1. TP Cable B : D-sub connector to connect directly to the Controller.

- Do not connect TP1 to the following Robot Controllers. Connecting to the following Robot Controllers may result in malfunction of the device since the pin assignments are different. RC420 / RC520 / SRC5** / SRC-3** / SRC-2**

- Do not connect the following devices to the TP port of RC620. Connecting these devices may result in malfunction of the device since the pin assignments are different.

OPTIONAL DEVICE dummy plug Operation Pendant OP500 Jog Pad JP500 Operator Pendant OP500RC

- Be careful of the operating instructions of the TP1 when connecting it to the Robot Controller RC180/RC170, it is different from the explanation in this manual Setup & operation 13. Option: Teach Pendant. When using the TP1 with the RC180/RC170, refer to the RC170 / RC180 Option Teach Pendant.

Teach Pendant Connect io n

(1) Make sure the Controller and manipulator are surely connected.

13. Option: Teach Pendant.

B: TP Cable B

Teaching Pendant TP-3**

44 RC620 Rev.8

(2) Connect the Teach Pendant connector to the TP port on RC620 Controller . (3) Turn on the RC620 Controller.

Teach Pendant connection and disconnection from the Controller are allowed when the Controller power is ON.

When the Teach Pendant connector is removed from the Controller with the mode selector key switch of the Teach Pendant in the “Teach” position, the operation mode will remain in the TEACH mode. The operation mode cannot be switched to AUTO mode. Be sure to remove the Teach Pendant after switching the operation mode to “Auto” mode.

Before connecting the connector, make sure

the pins are not bent.

Connecting with

connector and result in

malfunction of

EMERGENCY connector

NOTE

8. EMERGENCY

The details of safety requirements for this section are described in the Users Guide 2. Safety. Please refer to them to keep the robot system safe.

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

■

WARNING

Setup & Operation 8. EMERGENCY

that

the pins bent may damage the

the robot system.

RC620 Rev.8 45

Setup & Operation 8. EMERGENCY

■

The interlock of the Safety Door must be functioning when the operated. be turned ON/OFF (e. system when the switch is not may intended function

8.1 Safety 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

D-sub 25 male pin

Mounting style #4 - 40

WARNING

EMERGENCY connector

(Controller side)

* The E-STOP BOX, connector cable, terminal block, and connector kit are offered as

options.

8.1.1 Safety Door Switch

Do not operate the system under the condition that the switch cannot

g. The tape is put around the switch.). Operating the robot

functioning properly i s extremely hazardous and

cause serious safety problems as the Safety Door input cannot fulfill its

robot system is

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

Observe the followings 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.

- 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.

46 RC620 Rev.8

Setup & Operation 8. EMERGENCY

Safety

NOTE

8.1.2 Latch Release Switch

The controller software latches these conditions:

- The safety door is open.

- The operation mode is set to “TEACH”.

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 “TEACH”. Closed : The latch release switch releases the latched conditions. When the latched TEACH mode 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.

8.1.3 Checking 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 the Controller LCD displays the one of the following.

(3) Make sure that “Safety” is displayed on the main window status bar. (4) 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 the condition that the safety door is open.

To cancel the condition, close the safety door, and then close the safety door

latch release input.

RC620 Rev.8 47

Closed : The latch release switch does not latch the condition that the safety door is open.

The latch release input also functions to acknowledge the change of to TEACH mode. In order to change the latched condition of TEACH mode, turn the mode selector key switch on the Teach Pendant to “Auto”. Then, close the latch release input.

Setup & Operation 8. EMERGENCY

Estop

NOTE

8.2 Emergency Stop Switch Connection

8.2.1 Emergency Stop Switch

If it is desired to add an external Emergency Stop switch(es) in addition to the Emergency Stop on the Teach Pendant and Operator Panel, be 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 the Setup & Operation 8.4 Circuit Diagrams.

8.2.2 Checking 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.

(2) Make sure that the Controller LCD displays the one of the following.

(3) Make sure that “E.Stop” is displayed on the status bar on the main window. (4) Release the Emergency Stop Switch. (5) Execute the RESET command. (6) Make sure that LCD display in step (2) is turned off and that “E-Stop” is dimmed on

the main window status bar.

8.2.3 Recovery from Emergency Stop

To recover from the emergency stop condition, follow the procedure of safety check as required by the system.

After safety check, the operations below are required to recover from the emergency stop condition.

- Release the Emergency Stop Switch

- Execute the RESET command

48 RC620 Rev.8

Setup & Operation 8. EMERGENCY

NOTE

8.3 Pin Assignments

The EMERGENCY connector pin assignments are as follows:

Pin No. Signal Function Pin No. Signal Function

1 ESW11 Emergency Stop switch contact (1) *3 14 ESW21 Emergency Stop switch contact (2) *3 2 ESW12 Emergency Stop switch contact (1) *3 15 ESW22 Emergency Stop switch contact (2) *3 3 ESTOP1+ Emergency Stop circuit 1 (+) 16 ESTOP2+ Emergency Stop circuit 2 (+) 4

ESTOP1− 5 NC 6 NC 7 SD11 Safety Door input (1) *2 20 SD21 Safety Door input (2) *2 8 SD12 Safety Door input (1) *2 21 SD22 Safety Door input (2) *2 9 24V +24V output 22 24V +24V output

10 24V +24V output 23 24V +24V output 11 24VGND +24V GND output 24 24VGND +24V GND output 12 24VGND +24V GND output 25 24VGND +24V GND output 13 NC

Emergency Stop circuit 1 (

18 SDLATCH1 Safety Door Latch Release 19 SDLATCH2 Safety Door Latch Release

)

ESTOP2−

Emergency Stop circuit 2 (-)

*1 Do not connect anything to these pins. *2 A critical error occurs if the input values from the 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 A critical error occurs if the input values from the Emergency Stop switch contact 1

and Emergency Stop switch contact 2 are different for two or more seconds. T hey must be connected the same switch with two sets of contacts.

Emergency Stop switch output rated load +30 V 0.3 A or under 1-2, 14-15 pin 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

+24 V ±10%

47.5mA +24 V input +24 V ±10%

10 mA/+24 V input +24 V ±10%

10 mA/+24 V input

3-4, 16-17 pin

7-8, 20-21 pin

18-19 pin

The total electrical resistance of the Emergency Stop switches and their circuit should be 1 Ω or less.

RC620 Rev.8 49

Setup & Operation 8. EMERGENCY

+24V

+5V

Safety Door input 1

External +24V

Safety Door input

Latch release input

Latch release input Close :Latch off

Open :Latch on

Main Circuit

Control

AC Input

Emergency Stop switch of an Operation Unit (TP)

External +24V GND

External Emergency

Stop switches

Motor Driver

Controller

9 10 22

2 14 15

3 16

4 17

12 24

8 20

21 18

Emergency

Stop detection

NOTE:+24V GND

+ 5V GND

8.4 Circuit Diagrams

8.4.1 Example 1: External emergency stop switch typical application

50 RC620 Rev.8

Setup & Operation 8. EMERGENCY

* For the protection of the

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

- Meets the capacity of the external safety relay

- 0.4A or less

External safety relay

(The above diagram

is simplified for representation.)

External +24V GND

+24V

+5V

Safety Door input 1

Safety Door input 2

Latch Release input

AC Input

Motor Driver

External +24V

Fuse

−

External +24V

Controller

9 10 22 23

2 14 15

3 16

11 12

24 25

8 20

21 18

Main Circuit

Control

Emergency Stop switch of an Operation Unit (TP)

Emergency

Stop detection

External +24V

Latch release input Close :Latch off

Open :Latch on

External +24V GND

NOTE:+24V GND

+ 5V GND

External +24V GND

8.4.2 Example 2: External safety relay typical application

RC620 Rev.8 51

Setup & Operation 9. I/O Connector

Pins

Bit number

Input

0 to 23

Output

0 to 15

Input

32 to 55

Output

32 to 47

Input

256 to 279

Output

256 to 271

9. I/O Connector

The I/O connector is for connecting your input/output equipment to the system.

Control Unit

Drive Unit 1

Drive Unit 2

For details of the expanded I/O to be installed to the Special slot, refer to Setup & Operation 11.2. Expansion I/O Board. For cable wiring, refer to the Setup & Operation 3.5 Noise Countermeasures in order to prevent noise.

9.1 Input Circuit

Input Voltage Range : +12 to 24 V ±10% ON Voltage : +10.8 V (min.) OFF Voltage : +5 V (max.) Input Current : 10 mA (TYP) at +24 V input

Two types of wiring are available for use with the two-way photo coupler in the input circuit.

52 RC620 Rev.8

Setup & Operation 9. I/O Connector

1 Input No.0 to 7 common

2 Input No.0 3 Input No.1 4

Input No.2 5 Input No.3 6 Input No.4 7 Input No.5 8 Input No.6 9 Input No.7

I/O-1

(Same)

Omit

GND +DC

18 Input No.8 to 15 common 19 Input No.8

20 Input No.9

(Same)

1 Input No.0 to 7 common

2 Input No.0 3 Input No.1 4 Input No.2 5 Input No.3 6 Input No.4 7 Input No.5 8 Input No.6 9 Input No.7

I/O-1

(Same)

Omit

GND +DC

18 Input No.8 to 15 common 19 Input No.8

20 Input No.9

(Same)

Typical Input Circuit Appl i c at ion 1

Typical Input Circuit Appl i c at ion 2

RC620 Rev.8 53

Setup & Operation 9. I/O Connector

9.2 Output Circuit

Rated Output Voltage : +12 V to 24 V ±10% Maximum Output Current : TYP 100 mA/1 output Output Driver : PhotoMOS Relay On-State Resistance (average) : 23.5 Ω or less

Two types of wiring are available for use with the nonpolar photoMOS relay in the output circuit.

54 RC620 Rev.8

Setup & Operation 9. I/O Connector

10 Output No.0

I/O-1

(Same)

Omit

+DC

11 Output No.1

Load

GND

33 Output No.8 to 15 common (GND)

(Same)

10 Output No.0

I/O-1

(Same)

Omit

+DC

29 Output No.8 30 Output No.9

11 Output No.1 12 Output No.2

13 Output No.3 14 Output No.4 15 Output No.5

Output No.6

28 Output No.7 17 Output No.0 to 7 com mon (+DC)

Load

GND

33 Output No.8 to 15 common (+DC)

(Same)

Typical Output Circuit Application 1

12 Output No.2 13 Output No.3 14 Output No.4 15 Output No.5

27 Output No.6 28 Output No.7

17 Output No.0 to 7 com mon (GND)

29 Output No.8 30 Output No.9

Typical Output Circuit Application 2

RC620 Rev.8 55

Setup & Operation 9. I/O Connector

No.

Pin No.

No.

9.3 Pin Assignments

Signal Name

1 Input common No. 0 to 7 18 Input commo n No. 8 to 15 34 I nput common No. 16 to 23 2 Input No. 0 19 Input No. 8 35 I nput No. 16 3 Input No. 1 20 Input No. 9 36 I nput No. 17 4 Input No. 2 21 Input No. 10 37 I nput No. 18 5 Input No. 3 22 Input No. 11 38 I nput No. 19 6 Input No. 4 23 Input No. 12 39 Input No. 20 7 Input No. 5 24 Input No. 13 40 Input No. 21 8 Input No. 6 25 Input No. 14 41 Input No. 22

9 Input No. 7 26 Input No. 15 42 I nput No. 23 10 Output No. 0 27 Output No. 6 43 Output No.11 11 Output No. 1 28 Output No. 7 44 Output No.12 12 Output No. 2 29 Output No. 8 45 Output No.13 13 Output No. 3 30 Output No. 9 46 Output No.14 14 Output No. 4 31 Output No.10 47 Output No.15 15 Output No. 5 32 NC 48 NC 16 NC 33 Output common No. 8 to 15 49 NC 17 Output common No. 0 to 7 50 NC

Signal Name

Connector Standard

I/O Connector (Controller side)

D-sub 50 male pin

Mounting style #4 - 40

* The I/O connector, I/O connector cable, terminal block, and I/O connector kit are offered as options.

56 RC620 Rev.8

When using remote I/O, always make sure of the following. Using the robot system under

conditions may cause malfunction of the system

and/or safety problems.

NOTE

10. I/O Remote Settings

This section describes the functions of input and output signals. For details, refer to the EPSON RC+ Users Guide 10. Remote Control. The remote functions may be assigned to your standard I/O board(s), expansion I/O

board(s), or fieldbus I/O board(s) to enhance robot system control - either from an operational unit of your choice or a sequencer.

Remote function is not initially assigned. To accept external remote inputs, assign the remote function and the control device is

remote. The user can defines the I/O number that a remote function is assigned to using software

configuration. For details about I/O cable connection, refer to sections on Setup & Operation 9. I/O

Connector, 11.2. Expansion I/O Board (Option), 11.3 Fieldbus I/O Board (Option), and Robot Controller RC620 opti on Fieldbus I/O manual .

Setup & Operation 10. I/O Remote Settings

CAUTION

■ unsatisfactory

- Assign remote functions to inputs/outputs correctly and wire correctly when setting up remote I/O signals.

- Make sure that the functions correspond to the correct input/output signals before turning ON the system.

- When verifying the robot system operation, prepare for failures with initial settings or wiring. If the Manipulator functions unusually by t he failures with initial settings or wiring, press the Emergency Stop switch immediately to stop the Manipulator.

- Remote function is available when virtual I/O is enabled.

- When you set up a remote I/O signal, please either keep a written record of the settings or store the data in a file for later reference.

- When you set up a fieldbus I/O signal to the remote function, response depends on the baud rate of the fieldbus. For details of fieldbus response, refer to Robot Controller RC620 option Fieldbus I/O manual..

RC620 Rev.8 57

Setup & Operation 11. R-I/O Connector

Pins

Bit number

Control Unit

Input

24,25

Drive Unit 1

Input

56,57

Drive Unit 2

Input

280,281

R-I/O

INPUT No.24-1

INPUT No.24-2

INPUT

No.25-1

INPUT

No.25-2

GND +24V

11. R-I/O Connector

This function is available with the controller (Serial No. 01-05001 or later / 02-05001 or later).

The R-I/O connector is for connecting the input signals of the real time I/O function.

By inputting trigger signals to the R-I/O, you can keep and get the operating robot position when trigger is detected. If you use this function with Vision, you can create an application of parts pickup, alignment, and assembly by robots without stopping.

For details, refer to EPSON RC+6.0 Users Guide - Real time I/O. In the case of 6-axis robot, this function can not be used.

11.1 Input Circuit

Input Voltage Range : +24 V ±10% Input Current : 10 mA (TYP) at +24 V input

The following two types of wiring are available in the input circuit.

Typical Input Circuit Appl i c at ion 1

58 RC620 Rev.8

R-I/O

INPUT No.24-1

INPUT No.24-2

INPUT No.25-1

INPUT No.25-2

GND +24V

No.

INPUT No25-2

Typical Input Circuit Appl i c at ion 2

11.2 Pin Assignments

Setup & Operation 11. R-I/O Connector

Signal Name

1 INPUT No24-1 2 INPUT No24-2 3 INPUT No25-1

5 to 15* NC

* For the pins 5 to 15, do not connect anything.

Connector Standard

I/O Connector (Controller side)

D-sub 50 male pin

Mounting style #4 - 40

 When using R-I/O connector, be careful of the following points. If you use the

R-I/O connector without meeting the necessary conditions, it may cause the system failure and/or safety problems.

CAUTION

- Use a shielded cable and route the cables as far from the surrounding noise sources as possible. For details, refer to Setup & Operation: 3.5

Noise Countermeasures.

- Make sure to check the cable routing before turning on the power supply.

RC620 Rev.8 59

Setup & Operation 12. Option Slots

Special slots

PCI

slots

NOTE

12. Option Slots

12.1 What are Option slots?

The RC620 Co ntroller has Special slots for the option board and PCI slots for the PCI board.

Max. 4 option boards can be installed to the Special slots. As the option board, the following 4 types are provided.

- Expanded I/O board

- RS-232C board

- Fieldbus I/O slave board (Refer to the RC620 Option Fieldbus I/O manual.)

- Pulse generator board (Refer to the RC620 OptionPG Motion system manual.)

Max. 3 PCI boards can be installed to the PCI slots. As the option board, the following 2 types are provided.

- Frame grabber board (Refer to the EPSON RC+ 6.0 Option Vision Guide 6.0 manual.)

- Fieldbus I/O master board (Refer to the RC620 Option Fieldbus I/O manual.)

Of the PCI slots, a slot next to the CPU board has to limit the hei ght of parts on the board to avoid the interference with the CPU board. Available height is less tha n 10 mm.

To set the screw for securing the PCI board in the PCI slot, apply the torque described below. If you set the screw too tight, the screw hole will b e broken. Tightenin g torque: approx. 1 N⋅m

60 RC620 Rev.8

Input Bit #

Output Bit #

Applicable Hardware

0 to 23

0 to 15

STANDARD I/O

64 to 95

The 1st Expansion I/O board

96 to 127

The 2nd Expansion I/O board

128 to 159

The 3rd Expansion I/O board

160 to 191

The 4th Expansion I/O board

CN1

CN2

DSW2

DSW1

CN4

Setup the DSW1 and DSW2. CN4 is all open.

1st board

2nd board

3rd board

4th board

SW4 SW3 SW2 SW1

DSW2

SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

DSW1 CN4

SW4 SW3 SW2 SW1

DSW2

SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

DSW1 CN4

SW4 SW3 SW2 SW1

DSW2

SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

DSW1 CN4

SW4 SW3 SW2 SW1

DSW2

SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

DSW1 CN4

12.2 Expansion I/O Board

12.2.1 About Expansion I/O Board

Each additional expansion I/O board provides 32 inputs and 32 outputs. CN1: 16 inputs / 16 outputs CN2: 16 inputs / 16 outputs

The number of I/Os that can be expanded is maximum 4 boards and 128 inputs and outputs. The input and output bit numbers are assigned as follows. (Bit number is assigned from CN1.)

12.2.2 Board Configuration (Expansion I/O)

Setup & Operation 12. Option Slots

Board Appearance Switch and Jumper Configuration

RC620 Rev.8 61

Setup & Operation 12. Option Slots

12.2.3 Confirmation of Operation Using EPSON RC+ 6.0

When an expansion I/O board is mounted to the option unit, the Controller software automatically identifies the expansion I/O board. Therefore, no software configuration is needed.

Correct identification can be confirmed from EPSON RC+ 6.0.

(1) Select the EPSON RC+ 6.0 menu-[Setup]-[System Configuration] to display the

[System Configuration] dialog.

(2) Select the [Inputs / Outputs].

(3) Make sure that “Yes” is displayed in the Installed column.

The expansion I/O board is identified by the Controller software. Corresponding Input and Output is available.

12.2.4 Input Circuit

Input Voltage Range : + 12 V to 24 V ±10% ON Voltage : + 10.8 V (Min.) OFF Voltage : + 5 V (Max.) Input Current : 10 mA (TYP) at + 24 V input

Two types of wiring are available for use with the two-way photo coupler in the input circuit.

62 RC620 Rev.8

Setup & Operation 12. Option Slots

1 Input No.64 to 71 common

2 Input No.64 3 Input No.65 4 Input No.66 5 Input No.67 6 Input No.68 7 Input No.69 8 Input No.70 9 Input No.71

Expansion I/O board-1

(Same)

Omit

GND +DC

Input No.72 to 79 common

19 Input No.72 20 Input No.73

(Same)

1 Input No.64 to 71 common

2 Input No.64 3 Input No.65 4 Input No.66 5 Input No.67 6 Input No.68 7 Input No.69 8 Input No.70 9 Input No.71

Expansion I/O board -1

(Same)

Omit

GND +DC

18 Input No.72 to 79 common 19 Input No.72

20 Input No.73

(Same)

Protected Expansion I/O Board Typical Input Circuit Appl i c at ion 1

Protected Expansion I/O Board Typical Input Circuit Appl i c at ion 2

RC620 Rev.8 63

Setup & Operation 12. Option Slots

10 Output No.64

11 Output No.65 12 Output No.66

13 Output No.67 14 Output No.68

15 Output No.69 27 Output No.70 28 Output No.71

17 Output No.64 to 71 common (GND)

Expansion I/O-

(Same)

Omit

+DC

29 Output No.72

30 Output No.73

33 Output No.72 to 79 common (GND)

Load

GND

(Same)

12.2.5 Output Circuit

Rated Output Voltage : +12 V to 24 V ±10% Maximum Output Current : TYP 100 mA/1 output Output Driver : PhotoMOS Relay

On-State Resistance (average) : 23.5 Ω or less

Two types of wiring are available for use with the nonpolar photoMOS relay in the output circuit.

Protected Expansion I/O Board Typical Output Circuit Application 1

64 RC620 Rev.8

Setup & Operation 12. Option Slots

10 Output No.64

11 Output No.65 12 Output No.66

13 Output No.67 14 Output No.68 15 Output No.69

27 Output No.70 28 Output No.71

Output No.64 to 71 common

Expansion I/O-1

(Same)

Omit

+DC

29 Output

No.72

30 Output No.73

33 Output No.72 to 79 com mon

Load

GND

(Same)

Protected Expansion I/O Board Typical Output Circuit Application 2

RC620 Rev.8 65

Setup & Operation 12. Option Slots

Output No.65

Output No.71

Output No.76

Output No.68

Output No.74

Output No.79

D-sub 50 male pin

12.2.6 Pin Assignments

Pin Assignment table of the 1st Expansion I/O board.

Connector 1 Pin Assignments

Pin No.

Input common No.64 to 71 Input No.64

Input No.65

Input No.66 5 Input No.67 22 Input No.75 38 NC 6 Input No.68 23 Input No.76 39 NC 7 Input No.69 24 Input No.77 40 NC 8 Input No.70 25 Input No.78 41 NC 9 Input No.71 26 Input No.79 42 NC

10 Output No.64 27 Output No.70 43 Output No.75

Signal Name

No.

Input common No.72 to 79 Input No.72

Input No.73

Input No.74

Signal Name

No.

36 37

Signal Name

NC NC NC NC

12 Output No.66 29 Output No.72 45 Output No.77 13 Output No.67 30 Output No.73 46 Output No.78

Output No.69

Output common No.64 to 71

Connector Standard

I/O Connector (Controller side)

* The I/O connector, I/O connector cable, terminal block, and I/O connector kit are offered as options.

Output common No.72 to 79

NC NC

Mounting style #4 - 40

66 RC620 Rev.8

Setup & Operation 12. Option Slots

Output No.81

Output No.87

Output No.92

Output No.84

Output No.90

Output No.95

D-sub 50 male pin

Connector 2 Pin Assignments

Pin No.

Input common No.80 to 87

Signal Name

Input No.80

Input No.81

Input No.82

No.

Input common No.88 to 95

Signal Name

Input No.88

Input No.89

Input No.90

No.

36 37

Signal Name

NC NC NC

NC 5 Input No.83 22 Input No.91 38 NC 6 Input No.84 23 Input No.92 39 NC 7 Input No.85 24 Input No.93 40 NC 8 Input No.86 25 Input No.94 41 NC 9 Input No.87 26 Input No.95 42 NC

10 Output No.80 27 Output No.86 43 Output No.91

12 Output No.82 29 Output No.88 45 Output No.93 13 Output No.83 30 Output No.89 46 Output No.94

Output No.85

NC Output common No.80 to 87

Output common No.88 to 95

48 49

Connector Standard

I/O Connector (Controller side)

Mounting style #4 - 40

* The I/O connector, I/O connector cable, terminal block, and I/O connector kit are offered as options.

12.3 Fieldbus I/O Board

The Fieldbus I/O board has the following 2 types.

- Fieldbus I/O master board

- Fieldbus I/O slave board

For the details, refer to the RC620 Controller Option Fieldbus I/O manual.

RC620 Rev.8 67

Setup & Operation 12. Option Slots

Board Appearance

Switch and Jumper Configuration

CN1

CN2

CN3

CN4

JMP1

DSW2

DSW1

CN6

CN6 is all open.

1st board

2nd board

SW4 SW3 SW2 SW1

DSW2

SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

12345678

DSW1

IRQ15 IRQ11 IRQ10 IRQ7 IRQ5

JMP1

JP5 JP4 JP3 JP2 JP1

1 2

CN6

SW4 SW3 SW2 SW1

DSW2

SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1

12345678

DSW1

IRQ15 IRQ11 IRQ10 IRQ7 IRQ5

JMP1

JP5 JP4 JP3 JP2 JP1

1 2

CN6

12.4 RS-232C Board

12.4.1 About the RS-232C Board

The RS-232C option accepts four ports expansion per board. A maximum of two boards, eight ports expansion is available for RS-232C board.

Port numbers are assigned as follows.

Port No. Supported hardware

#1 to #4 First RS-232C board #5 to #8 Second RS-232C board

12.4.2 Board Setup (RS-232C)

Set DSW1, DSW2 and JMP1.

68 RC620 Rev.8

Setup & Operation 12. Option Slots

NOTE

12.4.3 Verify with EPSON RC+ 6.0 (RS-232C)

When an RS-232C board is mounted in as option slot, the Controller software automatically identifies the RS-232C board. Therefore, no software configuration is needed.

Correct identification can be confirmed from EPSON RC+ 6.0. (1) Select the EPSON RC+ 6.0 menu-[Setup]-[System Configuration] to display the

[System Configuration] dialog.

(2) Select the [RS-232C].

RC620 controller has one or two communication ports as standard. When using the communication ports, you should enable the port #1001 and #1002 by checking the [Enabled] check box.

If no RS-232C board is installed, controller of the RS-232C will not be displayed. RS-232C is automatically recognized by the controller software. Communication with

external equipment is available.

RC620 Rev.8 69

Setup & Operation 12. Option Slots

Item

Specification

14400, 19200, 38400, 57600, 115200

Data bit length

7, 8

Stop bit length

1, 2

Parity

Odd, even, NA

Terminator

CR, LF, CRLF

Connector

Standard

NOTE

12.4.4 RS-232C Software Communication Setup (RS-232C)

Available communication settings are as follows.

Baud Rates 110, 300, 600, 1200, 2400, 4800, 9600,

Refer to EPSON RC+ 6.0 Online Help or 11. RS-232C Communications for RS-232C communication from the Robot application.

12.4.5 Communication Cable (RS-232C)

Prepare a communication cable as described in this section.

Use twisted pair cable for shielded wire. Clamp the shield to the hood for noise prevention.

Pin assign of the RS-232C connector is as follows.

Pin No Signal Function Signa l Direc t i on

12.5 PG Board

RS-232C Connector

(Controller side)

1 DCD Data carrier detect Input 2 RXD Receive data Input 3 TXD Send data Output 4 DTR Terminal ready Output 5 GND Signal ground 6 DSR Data set ready Input 7 RTS Request to send Output 8 CTS Clear to send Input 9 RI Ring indicator Input

D-sub 9 male pin

Mounting style #4 - 40

The PG board is used in the following 2 methods. For the details, refer to the each manual.

- When used as the conveyor encoder Refer to the EPSON RC+ 6.0 Users Guide 15. Conveyor Tracking.

- When used as the PG motion system Refer to the RC620 Robot Controller option PG Motion System manual.

70 RC620 Rev.8

Utilize the UPS only for protecting the data from damages caused by failure or power intentionally while Windows is operating, the life cycle of UPS battery will be shortened and the UPS may perform insuffici ent ly.

Complete the shutdown of Windows down within the battery backup t ime of the UPS, the data may be damaged.

13. UPS

Setup & Operation 13. UPS

The UPS (Uninterruptible Power Supply) protects the hard disk data (including Windows and applications) from being damaged by power failure or power-off without shutdown.

CAUTION

■

-off without shutdown. If the UPS is turned OFF over and over

■

The UPS consists of the battery and the ATX power inside the Controller. The UPS provides backup power only for the 3.3V, 5V, and 12V power supplies that are necessary to operate the CPU, hard disk, and the control board. The UPS does not back up the power supply of Manipulator or Encoder Power Supply. Therefore, when a power failure or power-off without shutdown occurs while the Manipulator is operating, an error such as an encoder communication error occurs and the Manipulator makes an emergency stop.

within two minutes. If Windows is not shut

power

Normal Shutdown of Robot System

Exit EPSON RC+ 6.0 and shut down Windows. After the Windows shutdown, make sure the LCD panel is turned OFF and then turn OFF the power switch of the Controller.

Automatic Shutdown by UPS service in Robot System

For R C620, the UPS service of the Windows functions and automatically shuts down the system when a power failure or power-off without shutdown occurs.

■While Windows is starting up

A power failure or voltage drop occurs and the power does not r ecover. The power switch is turned OFF accidentally and the switch is left OFF.

→ Windows starts up and then it is shut down automatically.

A power failure or voltage drop occurs and the power r ecovers promptly. The power switch is turned OFF accidentally and the switch is turned ON.

→ Windows，EPSON RC+ start up normally.

 When W ind ows is hung, e ve n if you t urn OFF the Con tr o lle r , W ind o ws r e mai ns hun g

until the AT X powe r battery is completely discharged. In this case, turn OFF the

CAUTION

UPS ON/OFF switch. Then, press the SHUTDOWN switch on the front of Controller for more than 5 seconds. The ATX power output will be turned OFF.

RC620 Rev.8 71

Setup & Operation 13. UPS

■

When precautions for safe use.

CAUTION

■After Wind ows starts up (in normal status)

A power failure or voltage drop occurs. The power switch is turned OFF accidentally.

→ The UPS automatically shuts down EPSON RC+ and Windows when detecting

power-off. After Windows is shut down, the ATX power output is turned off and the LCD panel of the Controller lights.

UPS Battery

handling the UPS battery (nickel hydride battery), observe the following

- Be sure to use the battery supplied as the maintenance parts from EPSON.

(Refer to Maintenance 9. Maintenance Parts List.)

- Do not allow the positive (+) and negative (-) electrodes to short circuit.

- Do not discard batteries into fire or heat the m to high temperature.

- Do not disassemble or alter batteries.

- Do not apply a strong shock to the battery.

- Stop using the battery if you se e any sign s of chang e of color or dama ge to the

battery.

Recycling of Battery

Dispose of the used battery appropriately in accordance with the laws and acts of your national or local government. If you cannot dispose of a used battery properly, please inquire of your EPSON robot supplier how to dispose of it.

Charging Battery

Turning ON the Controller will automatically charge the UPS battery. To completely charge a discharged UPS battery, turn ON the Controller and keep it energized for at least 2 hours after the backup operation.

Life Cycle of Battery

The battery is expendable. T o maintain the Controller function, make sure to replace the battery regularly and appropriately for the use condition. The life cycle of the battery depends on the ambient temperature, number of backup cycles, and backup time. To prolong the life cycle of the battery, complete the shutdown of Windows within 2 minutes.

Relation between the life cycle of battery and the ambient temperature: When the ambient temperature is 20 deg.C: approx. 10 years When the ambient temperature is 25 deg.C: approx. 8 years When the ambient temperature is 30 deg.C: approx. 5 years and 7 months When the ambient temperature is 35 deg.C: approx. 4 years When the ambient temperature is 40 deg.C: approx. 2 years and 9 months

Note that the life cycle above is for the reference and it does not guarantee the backup in this period. Also, the battery must be replaced before 10 years in any circumstances.

72 RC620 Rev.8

Setup & Operation 14. Option : Teach Pend ant TP1

Only trained personnel should design and install the robot system. personnel are defined as those who have taken robot system training and maintenance training classes 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 thos e who have comp courses.

Only authorized personne l who hav e ta ken t he safet y tr aining shou ld be a llow ed t o execute teaching or calibration of The safety training is t he program for industrial robot operator that follows the laws an acquire knowledge of indu st r ial robots (operations, teaching, etc.). The personnel who have completed the robot system manufacturer, dealer, or loc robot system.

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. The

training and

training classes held by the manufacturer, dealer, or locally

14. Option : Teach pendant TP1

Here describes the functions and operating instructions of the Teach Pendant TP1 – Option fo r the Robot controller.

14.1 Function

14.1.1 Safety

For details of Safety, refer to Safety Chapter in the User’s Guide. Please read and understand the chapter before using the robot system.

WARNING



leted the training



the robot system.

d regulations of each n ation. The personnel who have taken the s afety t raining

-training class held by the

ally-incorporated company are allowed to maintain the

Only authorized personnel who hav e ta ken the safet y tr aining should be a llowe d to



maintain the robot system . The safety training is t he pr ogra m for i ndustr ial robot operator that follows the laws

Trained

personnel who have completed the robot systemmaintenanceincorporated company ar e allowed to maintain the robot system.

RC620 Rev.8 73

Setup & Operation 14. Option : Teach Pend ant TP1

Teach Pendant is not

is extremely hazardous and may cause serious safety

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,

amaged cables, disconnection, or

Immediately press the EMERGENCY STOP switch whenever you suspect any



danger. The Teach Pendant is equipped with an EMERGENCY STOP switch. Before operating the Teach Pendant, make sure that the EMERGENCY STOP switch on the Teach Pendant functions properly. Operating the Teach Pendant when the switch does not function properly is extremely hazardous and may result in serious bodily injury and/or serious damage to the equipment, as the switch cannot fulfill its intended funct ion in an emergency.

WARNING

When nothing appears on its display window, the connected with the Co nt r oller. In this case, the EMERGENCY STOP switch on the Teach Pendant will no t function.

If the Teach Pendant is not connected to the controller, DO NOT place it within



easy reach during operation. You might press the EMERGENCY STOP switch on the unconnected Teach Pendant by mistake to stop the robot system in an emergency. Pressing the EMERGENCY STOP switch on the disconnected Teach Pendant in an em ergency is extremely haz ardous an d may cause serio us safety problems.

When entering the safeguarded area for teaching, change the mode of the



Teach Pendant to TEAC H and take out the key for the mode selector key switch and then enter the sa feg uar ded ar ea w ith the key. Leaving the key in the mode

WARNING

selector key switch problems as someone else may inadv ertent ly chang e t he mode to t he auto mat ic operation.

Be sure to connect the cables between the Controller and the Teach Pendant



properly. Do not allow unnecessary strain on the cables. (Do not put heavy

WARNING

CAUTION

disconnection, and/or contact failure. D contact failure is extremely hazardous and may result in electric shock and/or improper function of the s ystem. Do not use the cables near heat or fire.

Do not shock the Teach Pendant physically or place any object on Teach



Pendant. A liquid crystal display is used for the Teach Pendant display. If the display is damaged, liquid crystal may leak out. Liquid crystal is harmful. If it sticks on your skin or clothes, immediately wash your skin and clothes thoroughly with clean water and soap immediately.

74 RC620 Rev.8

Teach Pendant by yourself.

Teach Pendant is not

CAUTION

WARNING

Setup & Operation 14. Option : Teach Pend ant TP1

The Teach Pendant must be us ed w ithi n the env iron mental con ditions de scri bed



in this manual. This product has been designed and manufactured strictly for use in a normal indoor environment. Using this product in the environment that exceeds the conditions may not only shorten the l ife cy cle of the produ ct but also cause serious safety problems.

Do not disassemble, repair, or modify the



Improper disassembly, repair, or modification of the Teach Pendant may cause not only improper function of t he robot system but also serious safety problems.

EMERGENCY STOP

Immediately press the EMERGENCY STOP switch whenever you suspect any



When the EMERGENCY STOP switch is pushed, stops the programs execution and halts the robot excitation. Programs and point data will not be damaged. When pushed, the EMERGENCY STOP switch mechanically holds that state and electrically holds the emergency stop state.

Reset EMERGENCY STOP

Follow these steps to reset Emergency Stop condition.

(1) Remove the cause of the Emergency Stop and verify that it is safe to operate the robot

again.

(2) Release the EMERGENCY STOP switch. To release the mechanical latch, turn the

EMERGENCY STOP switch to the right.

(3) Turn the Teach Pendant mode selector key switch to “Teach”.

RC620 Rev.8 75

Setup & Operation 14. Option : Teach Pend ant TP1

(4) Press the <Reset> key on the operation panel to reset the Emergency Stop.

E-STOP Lamp

<Reset> Key

(5) Make sure that the E

operation

panel is OFF.

-STOP lamp on the

Mode Selector Key Switch

The mode selector key switch is used to select TEACH or AUTO operation mode. For safety, if the mode is changed during program execution, all tasks except the background tasks will be stopped.

Mode switching during tas k execution AUTO→TEACH

(1) Press the <Stop> button to stop all tasks normally. (2) Turn the mode selector key switch to “Teach”.

TEACH→AUTO Turn the mode selector key switch to “Auto” and close the latch release input.

Using Teach Pendant in Safeguarded Area

When the mode selector switch of the Teach Pendant is switched to “Teach” mode, the operator can jog and move the robot to predefined points in slow speed when the enable switch is gripped and the safeguard is open. Personnel that will be using the Teach Pendant should be thoroughly trained on how to use it. Follow these guidelines when using the Teach Pendant in the safeguarded area:

(1) Before entering the safeguarded area to use the Teach Pendant, turn the mode selector

key switch to “Teach”.

(2) Enter the safeguarded area and perform the teaching operations. (3) Leave the safeguarded area and close the safeguard. (4) Return the mode selector key switch to “Auto”. (5) Close the latch release input.

(For details on the pin assignments of the EMERGENCY connector, refer to Setup & Operation 9.3 Pin Assignments in the RC620 controller manual.)

76 RC620 Rev.8

Setup & Operation 14. Option : Teach Pend ant TP1

Front view

(3)

(2)

(1)

(5)

(4)

Back view

(6)

(7)

14.1.2 Specifications

Part Names and Functions

(1) Mode Selector Key switch

The mode selector key switch is used to change the operation mode between TEACH and AUTO. The mode can be fixed by pulling out the key. When the mode is switched while a program is executing, the program will be stopped. Close the latch when switching the mode from TEACH to AUTO. For the procedure to switch the mode, refer to Operation: 14.1.1 Safety - Mode Selector Key Switch.

(2) EMERGENCY STOP switch

When this switch is pushed, the Emergency Stop state is held both mechanically and electrically. Pushing the switch stops the program, removes power to robot motors and stops the manipulator motion immediately. To cancel the Emergency Stop state, first turn the EMERGEN CY STOP switch to the right to release the mechanical latch. Switch the mode selector key switch to “Teach”.

Press the <Reset> key to reset the electrically held Emergency Stop state. The E-STOP lamp goes OFF. For the procedure to reset the Emergency Stop state, refer to Operation: 14.1.1 Safety - EMERGENCY STOP.

(3) Display

Displays various kinds of information.

(4) Operation Panel

Teaching operation, automatic operation and data input are available.

(5) Connection Cable

This is a cable to connect the Teach Pendant and the Controller. The connector is attached at the end of the cable.

RC620 Rev.8 77

Setup & Operation 14. Option : Teach Pend ant TP1

Item

Specification

Rated voltage

DC24 V

Electric power consumpti on

6 W or less

mode selector key switch, excluding cables)

Display element

F-STN type Black and white LCD

Contrast

8-level (Gray scale)

Back light

LED (Color : White)

specifications

240

（Unit：mm）

251.9

8°

NOTE

(6) Enable switch

This is a three-position switch. Motion and I/O output commands are available while the switch is gripped when the Teach Pendant is operated in TEACH mode. The switch turns ON when it is at the midpoint, and it turns OFF when it is fully gripped or released.

(7) Handle

Use this part as the hand strap while operating the Teach Pendant。

Standard Specification s

General

specifications

Weight

1075 g (include EMERGANCY STOP switch and the

Display

specifications

Serial interface

Electrical characteristics Compliant with RS-422A standard

Outer Dimensions

Use the installation metal in the attachment when attaching the Teach Pendant to a panel, or the like.

78 RC620 Rev.8

Setup & Operation 14. Option : Teach Pend ant TP1

Item

Condition

Keep away from dust, oily smoke, salinity, metal powder

flammable or corrosive solvents and

. The touch panel is made of glass. Therefore, if

14.1.3 Installation

TP1 (with cables) : 1 unit Mode selector key : 2 units

Environmental Conditions

The Teach Pendant must be used in an environment that conforms to the following requirements to ensure safe and reliable operation.

Ambient temperature 0 to 50 deg C (with minimal variation)

CAUTION

Ambient relative

5 to 95%

temperature Protection structure IP65 (excluding the connector) Environment -

and other contaminants.

- Keep away from gases.

Operating Precautions

Do not drop the Teach Pendant or hit hard against other objects to av oid damage, as



the case of the Teach Pendant may be damaged since the main body is made of resin.

Use the hand strap to prevent dropping the Teach Pendant during operation.



Do not hit the touch panel of the Teach Pendant against a hard object or put



excessive pressure on it excessive pressure is put on it, it may be damaged.

Do not press or rub the surface of the front panel push buttons with a hard object



such as a tool. The surface of the buttons may be damaged as they are easily scratched.

Wipe the dirt and oils adhering to the surface of the Teach Pendant di splay with a



soft cloth dampened with a neut r al d etergent or an alcohol solvent.

If using the mounting bracket, check that the bracket and screws are not bent or



loosened.

RC620 Rev.8 79

Setup & Operation 14. Option : Teach Pend ant TP1

result in damage to the cables, disconnection, and/or contact failure. Damaged the connector with the pin bent may cause malfunction and result in improper

ay cause malfunction and result in improper

Controller

TP Cable

Teach

Pendant

Conversion Kit CK1

Controller

TP Cable

Teach

Pendant

NOTE

Connection

This section indicates the connection of the Controller and the Teach Pendant.

Be sure to connect the cables of Controller and Teach Pendant 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

cables, disconnection, or contact failure is extremely hazardous and may result in improper function of the s ystem.

Make sure that the pins are not bent when connecting the connector. Connecting



function of the system.

CAUTION

The connector connected to the end of the cable is a general-purpose type



connector. When connecting the connector, note that the wat er pr oof e f fi ci ency and dustproof efficiency of the connector do not comply w it h I P65.

When connecting the Teach Pendant TP1 to t he TP port, be careful of the connector



inserting direction (up/down). It m function of the system.

Typical cable connection

The Teach Pendant is connected to TP port of controller RC620.

- When nothing is connected to the TP port, Emergency Stop status occurs to the Controller. When the Teach Pendant is not connected, connect the TP/OP bypass plug.

Example

A: TP cable A

B: TP cable B

- The shape of the cable connector used in connection A differs to connection B. TP Cable A : Circular connector to connect to the conversion kit CK1. TP Cable B : D-sub connector to connect directly to the Controller.

- Be careful of the operating instructions of the TP1 when connecting it to the Robot Controller RC180/RC170, it is different from the explanation in this manual. When using the TP1 with the RC180/RC170, refer to the RC170 / RC180 Option Teach Pendant TP1.

80 RC620 Rev.8

Setup & Operation 14. Option : Teach Pend ant TP1

NOTE

Connection to the Contro ller

(1) Make sure that the Controller and the Robot is connected properly. (2) Connect the connector of the Teach Pendant cable to the TP port of Controller RC620. (3) Turn ON the controller RC620.

- Teach Pendant insert and removal from the Controller RC620 are available when the Controller power is ON.

- When Teach Pendant connector is removed from the Controller RC620 with the mode selector key switch of Teach Pendant that is in “Teach” position, the operation mode will remain in TEACH mode. The operation mode cannot be switched to AUTO mode. Make sure to remove the Teach Pendant after switching the operation mode to “Auto” mode.

Power Supply

The power of the Teach Pendant is supplied via the TP port on the Controller RC620. The Controller and the Teach Pendant communication, the following screen will appear on the display of the Teach Pendant.

TEACH mode

AUTO mode

RC620 Rev.8 81

Setup & Operation 14. Option : Teach Pend ant TP1

Hook A

Hook B

201.4

31.4

100

118

56.2

100

226

39.6

392.9

Detail : J

Detail : K

Front View

Back View

Side View

[Unit :mm]

Wall Bracket (Option)

Outer Dimension

82 RC620 Rev.8

Setup & Operation 14. Option : Teach Pend ant TP1

Teach Pendant

Cable

Mount and Use

Mount the Teach Pendant with the wall bracket in the following procedures. (1) Secure the wall bracket to the wall with three screws (positions are indicated by

dotted line in the Outer Dimension).

(2) Hang the handle of the Teach Pendant to Hook A. (3) Hang the cable of the Teach Pendant to Hook B.

RC620 Rev.8 83

Setup & Operation 14. Option : Teach Pend ant TP1

This mode enables point data teaching and check close from the

(program execution) of the

Robot system at the manufacture operation, besides, programming,

This mode cannot operate Robots or run program with the Safety Door open.

TEACH

mode

Jog & Teach

13.3.1 Jog & Teach

Point Editor

13.3.2 Point Editor

Robot

13.3.3 Robot

Motion Command

13.3.4 Motion Command

I/O Command

13.3.5 I/O Command

Jog Distance

13.3.6 Jog Distance

Free Joints

13.3.7 Free Joints

Brake

13.3.8 Brake (For 6-axis robot)

F1-F8 : Function key

Name : Screen name

: Reference se ctio n

NOTE

14.1.4 Operation Mode（TEACH/AUTO）

A coordinate point including the arm pose is defined as “position (point),” and the data is called “point data.”

Outline

Robot system has two operation modes TEACH mode and AUTO mode.

TEACH mode

AUTO mode

Robot using the Teach Pendant. Robot operates in Low power status.

This mode enables automatic operation

debug, adjustment, and maintenance of the Robot system.

84 RC620 Rev.8

Epson RC620 CU, RC620 Series, RC620 DU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

WARRANTY

TRADEMARKS

TRADEMARK NOTATION IN THIS MANUAL

NOTICE

INQUIRIES

SERVICE CENTER

MANUFACTURER

SUPPLIERS

Before Reading This Manual

Security support for the network connection

Security support for the USB memory

Table of Contents

Safety

1. Safety 3

2. Conventions 3

3. Safety Precautions 4

Setup & Operation

1. Specifications 9

2. Part Names and Functions 14

3. Installation 24

4. Operation Mode (TEACH/AUTO) 31

5. Memory Port 36

6. LAN (Ethernet Communication) Port 41

7. TP Port 44

8. EMERGENCY 45

9. I/O Connector 52

10. I/O Remote Settings 57

11. R-I/O Connector 58

12. Option Units 60

13. UPS 71

14. Option : Teach Pendant TP1 73

15. Option : RAID 117

Maintenance

1. Safety Precautions on Maintenance 123

2. Regular Maintenance Inspection 125

3. Controller Structure 127

4. Backup and Restore 134

5. Firmware Update 139

6. Maintenance Parts Replacement Procedures 145

7. Recovering the HDD 201

8. Troubleshooting 208

9. Maintenance Parts List 209

Safety

1. Safety

2. Conventions

3. Safety Precautions

Setup & Operation

1. Specifications

1.1 System Example

1.2 Standard Specifications

1.3 Outer Dimensions

2. Part Names and Functions

2.1 Part Names

2.2 Functions

2.3 LED and LCD

LED and LCD

Particular Status Display

2.4 Safety Features

3. Installation

3.1 Unpacking

3.2 Environmental Requirements

3.2.1 Environment

3.2.2 Installation

3.3 Power Supply

3.3.1 Specifications

3.3.2 AC Power Cable

3.4 Cable Connection

3.4.1 Typical Cable Connection

3.4.2 Connecting Manipulator to Controller

3.5 Noise Countermeasures

4. Operation Mode (TEACH/AUTO)

4.1 Overview

4.2 Switch Operation Mode

4.3 Program Mode (AUTO)

4.3.1 What is Program Mode (AUTO)?