Epson RC700DU, RC700DU-A User Manual
Rev.11 EM208C4461F
ROBOT CONTROLLER / Drive Unit
RC700DU /
RC700DU-A
ROBOT CONTROLLER / Drive Unit RC700DU / RC700DU-A Rev.11
ii
ROBOT CONTROLLER / DRIVE UNIT
RC700DU / RC700DU-A
Rev.11
Copyright © 2014-2020 SEIKO EPSON CORPORATION. All rights reserved.
RC700DU / RC700DU-A Rev.11 i
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the Robot Controller
and the Drive Unit.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
RC700 / RC700-A robot Controller consists of the following:
This manual contains the information for the RC700 DU / RC700DU-A (Drive Unit).
For RC700 CU / RC700CU-A (Control Unit), refer to the RC700 / RC700-A Robot
Controller manual.
The information for the Robot Controller is describes as below, indicating both RC700 CU
/ RC700CU-A and RC700 DU / RC700DU-A:
The information for the either unit (CU or DU) is described as below:
RC700 CU / RC700CU-A (Control Unit)
RC700 DU / RC700DU-A (Drive Unit)
Robot Controller
Controller
RC700
RC700CU / RC700CU-A Control Unit
RC700DU / RC700DU-A Drive Unit
ii RC700DU / RC700DU-A Rev.11
WARRANTY
1. Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2. Malfunctions caused by customers’ unauthorized disassembly.
3. Damage due to improper adjustments or unauthorized repair attempts.
4.
Damage caused by natural disasters such as earthquake, flood, etc.
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.
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 contact the supplier of your region for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
Warnings, Cautions, Usage:
robot system
specifications described in the manuals, this warranty is void.
RC700DU / RC700DU-A Rev.11 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® 8 Operating system
Microsoft® Windows® 10 Operating system
Throughout this manual, Windows 8 and Windows 10 refer to above respective operating
systems. In some cases, Windows refers generically to Windows 8 and Windows 10.
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.
MANUFACTURER
CONTACT INFORMATION
Contact information is described in “SUPPLIERS” in the first pages of the following
manual:
Robot System Safety and Installation Read this manual first
iv RC700DU / RC700DU-A Rev.11
Safety
1. Safety 3
2. Conventions 3
3. Safety Precautions 4
Setup & Operation
1. Specifications 9
1.1 System Example ....................................................................................... 9
1.2 Drive Unit Standard Specifications ......................................................... 11
1.3 Outer Dimensions ................................................................................... 12
Table of Contents
2. Part Names and Functions 13
2.1 LED ......................................................................................................... 15
2.2 Safety Features ....................................................................................... 16
3. Installation 18
3.1 Unpacking .................................................................................................. 18
3.2 Environmental Requirements ................................................................. 18
3.2.1 Environment ................................................................................ 18
3.2.2 Installation ................................................................................... 19
3.2.3 Wall Mounting Option .................................................................. 20
3.3 Power Supply .......................................................................................... 21
3.3.1 Specifications .............................................................................. 21
3.3.2 AC Power Cable .......................................................................... 22
3.4 Cable Connection ................................................................................... 23
3.4.1 Typical Cable Connection ........................................................... 24
3.4.2 Connecting Manipulator to Drive Unit ......................................... 26
3.5 Noise Countermeasures ......................................................................... 27
4. Drive Unit Connection 28
5. Drive Unit Setup 29
RC700DU / RC700DU-A Rev.11 v
Table of Contents
6. EMERGENCY 32
6.1 Safety Door Switch and Latch Release Switch ...................................... 32
6.1.1 Safety Door Switch ..................................................................... 32
6.1.2 Latch Release Switch ................................................................. 33
6.1.3 Checking Latch Release Switch Operation ................................ 33
6.2 Emergency Stop Switch Connection ...................................................... 34
6.2.1 Emergency Stop Switch .............................................................. 34
6.2.2 Checking Emergency Stop Switch Operation ............................ 34
6.2.3 Recovery from Emergency Stop ................................................. 34
6.3 Pin Assignments ..................................................................................... 35
6.4 Circuit and Wiring ................................................................................... 36
6.4.1 Circuit Diagram ........................................................................... 36
6.4.2 Wiring Example for Emergency Stop .......................................... 37
6.4.3 Wiring Example for Safety Door Input / Latch Release Input ..... 39
Maintenance
7. I/O Connector 40
7.1 Input Circuit ............................................................................................. 40
7.2 Output Circuit .......................................................................................... 43
7.3 Pin Assignments ..................................................................................... 45
8. R-I/O Connector 46
8.1 Input Circuit ............................................................................................... 46
8.2 Pin Assignments ..................................................................................... 47
1. Safety Precautions on Maintenance 51
2. Regular Maintenance Inspection 53
3. Drive Unit Structure 54
3.1 Location of Parts ..................................................................................... 54
3.1.1 RC700DU .................................................................................... 54
3.1.2 RC700DU-A ................................................................................ 54
3.2 Diagram of Cable Connections .............................................................. 55
3.2.1 RC700DU .................................................................................... 55
3.2.2 RC700DU-A ................................................................................ 56
vi RC700DU / RC700DU-A Rev.11
Table of Contents
4. Maintenance Parts Replacement Procedures 57
4.1 Fan Filter ................................................................................................. 57
4.2 Fan .......................................................................................................... 58
4.2.1 Front Fan ..................................................................................... 58
4.2.2 Fan 2 (RC700DU-A only) ............................................................ 59
4.3 MDB ........................................................................................................ 61
4.4 DMB ........................................................................................................ 65
4.5 DMB-SUB Board ..................................................................................... 67
4.6 DMB-LED Board ..................................................................................... 68
4.6.1 DMB-LED Board (RC700DU) ..................................................... 68
4.6.2 DMB-LED Board (RC700DU-A) .................................................. 69
4.7 DPB ......................................................................................................... 70
5. Verifying Robot System Operation 72
6. Troubleshooting 73
6.1 Error Code Table .................................................................................... 73
7. Maintenance Parts List 74
RC700DU / RC700DU-A Rev.11 vii
Table of Contents
viii RC700DU / RC700DU-A Rev.11
Safety
This section contains information for safety of the Robot System.
WARNING
properly.
WARNING
This symbol indicates that a danger of possible harm to people
not followed properly.
CAUTION
instructions are not followed properly.
1. Safety
Installation and transportation of Manipulators 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 serious injury or
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 exists if the associated
RC700DU / RC700DU-A Rev.11 3
Safety 3. Safety Precautions
Personnel
read the Safety chapter in User
before designing and/or constructing the robot system. Designing and/or
constructing the robot system withou
extremely hazardous, may result in serious bodily injury and/or severe equipment
damage to the robot system, and may cause serious safety problems.
The Manipulator and the
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 enviro
conditions may not only shorten the life cycle of the
serious safety problems.
The
the manuals.
may
problem
The interlock of the Safety Door must be functioning when the
operated.
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
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 that the Emergency Stop switch in the
always functions. (Refer to the typical application diagram in
6
3. Safety Precautions
Only trained personnel should design and install the robot system.
Trained personnel are defined as those who have taken robot system training class held by
the manufacturer, dealer, or local representative company, or those who understand the
manuals thoroughly and have the same knowledge and skill level as those who have
completed the training courses.
The following items are safety precautions for qualified design or installation
personnel:
WARNING
who design and/or construct the robot system with this product must
’s Guide to understand the safety requirements
t understanding the safety requirements is
Drive Unit
product but may also cause
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 serious safety
s.
robot system is
Do not operate the system under the condition that the switch cannot
nmental
functioning properly is extremely hazardous and
cause serious safety problem
.
.4 Circuit and Wiring.)
4 RC700DU / RC700DU-A Rev.11
whole system
Setup & Operation
Safety 3. Safety Precautions
Do not open the cover(s) of the
the cover(s) of the
shock
the
Make sure that the power to the
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
cables, disconnection, and/or contact failure. Damaged cables, disconnection,
or a contact failure is extremely hazardous and may result in electric shock and/or
improper function of the system.
When
by qualified personnel. When connecting the plug,
wire of the AC power cable colored green/yellow
terminal of the factory power supply.
at all times to avoid the risk of electric shock.
receptacle
(Field wiring)
The serial number of the
Connection Check Label
nit and the
Manipulator correctly.
nit and the
Manipulator may cause improper function of the rob
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.
-
-
input/output signals
- When verifying the robot system operation, prepare for failures with initial
WARNING
even when its main power is OFF because of the high voltage charge inside
Drive Unit.
is extremely hazardous and may result in electric shock and/or
lfunction of the Drive Unit.
connecting the plug to fit the outlet in your factory, make sure that it is done
. Never connect the Drive Unit directly to the factory power supply.
Drive Unit except while maintaining it. Opening
Drive Unit is extremely hazardous and may result in electric
Drive Unit is turned OFF before connecting or
Connecting or disconnecting
result in damage to the
be sure to connect the earth
on the Drive Unit to the earth
The equipment must be grounded properly
Always use a power plug and
Manipulator that should be connected is indicated on the
on the Drive Unit. Connect the Drive U
Improper connection between the Drive U
unsatisfactory
CAUTION
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
before turning ON the system.
settings or wiring. If the Manipulator functions unusually by the failures with
initial settings or wiring, press the Emergency Stop switch immediately to stop
the Manipulator.
ot system and also safety
RC700DU / RC700DU-A Rev.11 5
Safety 3. Safety Precautions
The interlock of the Safety Door must be functioning when the
operated.
be turned ON/OFF. (I.E. the condition where the switch is disabled)
(Example: Tape is put around
system when the switch is not
may
s as the Safety Door input cannot fulfill its
intended function
Do not open the
the cover(s) of the
shock
the
The following items are safety precautions for qualified operator personnel:
WARNING
WARNING
robot system is
Do not operate the system under the condition that the switch cannot
the switch to hold it closed.) Operating the robot
functioning properly is extremely hazardous and
cause serious safety problem
.
cover(s) of the Drive Unit except while maintaining it. Opening
Drive Unit is extremely hazardous and may result in electric
even when its main power is OFF because of the high voltage charge inside
Drive Unit.
6 RC700DU / RC700DU-A Rev.11
Setup & Operation
This section contains information for setup and operation of the Drive Unit.
RC700 / RC700-A
RC700DU / RC700DU-A
・EMERGENCY
・Standard I/O
・Remote I/O
・R-I/O
Standard Installation
C4 series
C8 series
G series
RS series
* 2
* 1
X5
N6 series
C4
C8
C12 G RS
N2
N6
X5
RC700DU
- - - - - - - RC700DU-A
-
-
1. Specifications
1.1 System Example
Setup & Operation 1. Specifications
*1 Control Unit
For details, refer to the following manual.
*2 Any one of the Manipulators can be controlled.
Available combinations are as follows. (: connectable)
Robot Controller RC700 / RC700-A
RC700DU / RC700DU-A Rev.11 9
Setup & Operation 1. Specifications
DU2
B
A
DU IN
DU1 CU
DU IN
DU OUT
DU OUT
DU3
C
DU IN
DU OUT
NOTE
Drive Unit is the auxiliary unit connected with the control unit using the special cable.
Drive Unit cannot operate alone.
Up to three Drive Units can be used per robot system.
A: Control Unit and 1st Drive Unit (CU-DU1)
st
B: 1
Drive Unit and 2nd Drive Unit (DU1-DU2)
nd
C: 2
Drive Unit and 3rd Drive Unit (DU2-DU3)
10 RC700DU / RC700DU-A Rev.11
Item
Specification
Model
Drive Unit RC700DU / RC700DU-A
Controllable axes
Up to six (6) connectable AC servo motors
1.2 Drive Unit Standard Specifications
Setup & Operation 1. Specifications
External input/output
signals (standard)
Drive Unit connect interface
(standard)
Safety features
Standard I/O
2 channel
- Emergency stop switch
- Safety door input
- Low power mode
- Dynamic brake
- 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
Input : 24
Output : 16
per Drive Unit
Power Source
Maximum Rated Capacity 2.5 kVA (Depending on the Manipulator model)
Insulation Resistance 100 MΩ or more
Rated Ambient
Temperature
Rated Relative Humidity 20 to 80% (with no condensation)
Weight *1 9 kg
Degree of protection IP20
*1 Weight of the unit is indicated on the Drive Unit 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.
200 to 240 VAC
Single phase 50/60 Hz
5 to 40 deg.
RC700DU / RC700DU-A Rev.11 11
Setup & Operation 1. Specifications
1.3 Outer Dimensions
[Unit : mm]
12 RC700DU / RC700DU-A Rev.11
Setup & Operation 2. Part Names and Functions
(2)
(3)
(1)
(Left side)
(4)
(5)
(7) (8)
(6)
(10)
(13)
(14)
(15)
(16)
(11)(12)
(9)
The details of the Manipulator to be connected are recorded
Manipulator model and Manipulator serial number.
MANIPULATOR
00001 C4-A600S
2. Part Names and Functions
(1) Signature label (top panel)
The serial number of the Drive Unit and other information are shown.
(2) LED
The LED indicates current operation mode (RUN, AUTO, ERROR/E-STOP).
For details, refer to Setup & Operation 2.1 LED.
(3) M/C POWER connector
A connector for the Manipulator power source.
Connect the dedicated power cable attached to the Manipulator.
(4) 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 Drive Unit.
For inspection, cleaning, and replacement, refer to the Maintenance 4.1 Fan Filter, 4.2
Fan.
(5) POWER switch
Turns ON or OFF the Drive Unit.
(6) Connection Check label
on the label as shown in the right. The label indicates the
(7) EMERGENCY connector
This connector is used for input/output from/to Emergency Stop and Safety Door
switches. For details, refer to the Setup & Operation 6. EMERGENCY.
RC700DU / RC700DU-A Rev.11 13
Setup & Operation 2. Part Names and Functions
Switch
M/C Cable Length
1
3 m 2 5 m
3
10 m
4
15, 20 m
(8) Encoder Voltage Adjustment Switch
Use this switch to adjust voltage according to length of M/C cable. (adjusted as a
factory default)
Wrong setting may result in Robot system malfunction. Do not change the switch.
(9) M/C SIGNAL connector
This connector is used for signals such as the Manipulator’s motor encoders, etc.
Connect the Manipulator’s dedicated signal cable.
(10) R-I/O connector
This connector is for the input signals used for the real time I/O function.
(11) RC700DU: DU OUT Connector / RC700DU-A: OUT Connector
To connect the 2
nd
Drive Unit:
Use the cable attached for Drive Unit and connect with the DU IN connector of the
nd
Drive Unit.
2
To connect the 3
rd
Drive Unit:
Use the cable attached for Drive Unit and connect with the DU IN connector of the
rd
Drive Unit.
3
(12) RC700DU: DU IN Connector / RC700DU-A: IN Connector
st
For the 1
Drive Unit:
Use the cable attached for Drive Unit and connect with the DU OUT connector of
the Control Unit.
nd
For the 2
Drive Unit:
Use the cable attached for Drive Unit and connect with the DU OUT connector of
st
Control Unit.
the 1
rd
For the 3
Drive Unit:
Use the cable attached for Drive Unit and connect with the DU OUT connector of
nd
Control Unit.
the 2
(13) RC700DU / RC700DU-A No. Setting Switch
This switch indicated the Drive Unit number.
For details, refer to the Setup & Operation
(14) I/O connector
This connector is used for input/output device. There are 24 inputs and 16 outputs.
For details, refer to Setup & Operation 7. I/O Connector.
(15) AC IN
The cable for 200VAC power input.
For details, refer to Setup & Operation 3.3.2 AC Power Cable.
(16) Drive Unit Number label
The serial number of the Drive Unit is indicated.
5. Drive Unit Setup.
14 RC700DU / RC700DU-A Rev.11
LED
Color
Status
RUN
Green
ON / Flashing / OFF
AUTO
Green
ON / OFF
ERR/E-STOP
Red
ON / Flashing / OFF
DU IN
connector
RUN
AUTO
ERR/E-STOP
LINK (Green)
Power OFF
OFF
OFF
OFF
OFF
Power ON
Flashing
OFF
OFF
OFF
Establishing
the connection
Normally operating
ON
OFF
OFF
Flashing rapidly
LED
Status
Auto mode
ON
ON
-
Flashing rapidly
Program mode
Teach mode
Robot error
ON
-
Flashing
Flashing rapidly
Emergency stop
ON - ON
Flashing rapidly
NOTE
2.1 LED
Setup & Operation 2. Part Names and Functions
Three LEDs are mounted on Drive Unit. They have the following status patterns.
From applying current to Drive Unit to completing startup
Drive Unit LED
Flashing OFF OFF Flashing rapidly
After the connection to Drive Unit is completed
The error information is displayed on the seven-segment display of the Control Unit.
For details, refer to the RC700 / RC700-A Robot Controller manual: Setup & Operation 2.1
LED and Seven-segment LED .
ON OFF - Flashing rapidly
RC700DU / RC700DU-A Rev.11 15
Setup & Operation 2. Part Names and Functions
2.2 Safety Features
The robot control system supports safety features described below. However, the user is
recommended to strictly follow the proper usage of the robot system by thoroughly reading
the attached manuals before using the system. Failure to read and understand the proper
usage of the safety functions is highly dangerous.
Among the following safety features, the Emergency Stop Switch and Safety Door Input are
particularly important. Make sure that these and other features function properly before
operating the robot system.
For details, refer to the Setup & Operation 6. EMERGENCY.
Emergency Stop Switch
The EMERGENCY connector on the Drive Unit 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.
Stop category of Emergency Stop input: Category 0 (refer to Safety Standard IEC60204-1)
Safety Door Input
Low Power Mode
Dynamic Brake
In order to activate this feature, make sure that the Safety Door Input switch is connected to
the EMERGENCY connector at the Drive Unit.
When the safety door is opened, normally the Manipulator immediately stops the current
operation, and the status of Manipulator power is operation-prohibited until the safety door
is closed and the latched condition is released. In order to execute the Manipulator
operation while the safety door is open, you must change the mode selector key switch on
the Teach Pendant to the “Teach” mode. Manipulator operation is available only when the
enable switch is on. In this case, the Manipulator is operated in low power status.
Stop category of Safety door input: Category 1 (refer to Safety Standard IEC60204-1)
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 ensures the safety of the operator and reduces the possibility of peripheral equipment
destruction or damage caused by careless operation.
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.
Motor Overload Detection
The dynamic brake circuit is activated when the system detects the overload status of the
motor.
Irregular Motor Torque (out-of-control Manipulator) Detection
The dynamic brake circuit is activated when irregular motor torque (motor output) is
detected.
16 RC700DU / RC700DU-A Rev.11
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