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: RC620 CU (Control Unit) RC620 DU (Drive Unit)
WARRANTY The robot system and its optional parts are shipped to our customers only after being subjected to the strictest quality controls, tests, and inspections to certify its compliance with our high performance standards. Product malfunctions resulting from normal handling or operation will be repaired free of charge during the normal warranty period.
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®...
Table of Contents 3. Drive unit Structure 3.1 Location of Parts ..................50 3.2 Diagram of Cable Connections ............... 52 3.3 Connector Pin Assignment ..............55 3.3.1 M/C Power Connector ..............55 3.3.2 M/C Signal Connector ..............56 4. Maintenance Parts Replacement Procedures 4.1 Fan and Fan Filter ...................
Safety This section contains information for safety of the Robot System.
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. Read the Safety chapter in EPSON RC+ 5.0 User’s Guide and confirm Safety-related requirements. Conventions Important safety considerations are indicated throughout the manual by the following symbols.
Safety 3. Safety Precautions 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.
Safety 3. Safety Precautions Do not open the cover(s) of the Drive unit except while maintaining it. Opening the cover(s) of the Drive unit is extremely hazardous and may result in electric shock even when its main power is OFF because of the high voltage charge inside the Drive unit.
Setup & Operation 1. Specifications Specifications 1.1 System Example RC620CU Control Unit RC620DU C3 series Drive Unit ProSix Standard Installation Driver Unit ･EMERGENCY ・Standard I/O ・Remote I/O X5 series G series RS series * Controls one of the robots. Drive Unit is the auxiliary unit connected with the control unit using the special cable. NOTE ...
Setup & Operation 1. Specifications 1.2 Drive Unit Standard Specifications Item Specification Drive Unit RC620DU Model (UL specification: RC620DU-UL) Controllable axes Up to six (6) connectable AC servo motors Input : 24 External input/output Standard I/O per Drive Unit signals (standard) Output : 16 Drive Unit connect 2 channel...
Setup & Operation 1. Specifications 1.3 Outer Dimensions [Unit : mm] Base Unit (Four-axis robot construction) 130.5 170.5 Base Unit + ProSix Driver Unit (Six-axis robot construction) 130.5 170.5 NOTE Dimension of RC620DU-UL is the same as RC620DU. RC620DU Rev.5...
Setup & Operation 2. Part Names and Functions 2.2 Functions (1) 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.
Setup & Operation 2. Part Names and Functions (11) Thumb Head screw This is two of the four screws used to attach the front cover of the Drive Unit. Use these screws to pull out the Motor Driver module and SMB unit. NOTE - A spacer is attached to the thumb head screw.
Setup & Operation 2. Part Names and Functions 2.3 LED Three LEDs are mounted on Drive Unit. They have the following status patterns. Color Status Green ON / Flashing / OFF AUTO Green ON / OFF ERR/E-STOP ON / Flashing / OFF From applying current to Drive Unit to completing startup DU IN DU LED...
Setup & Operation 2. Part Names and Functions 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 safety functions is highly dangerous.
Setup & Operation 2. Part Names and Functions Irregular Motor Torque (out-of-control manipulator) Detection The dynamic brake circuit is activated when irregularity with motor torque (motor output) is detected (in which case the Manipulator is out of control). Motor Speed Error Detection The dynamic brake circuit is activated when the system detects that the motor is running at incorrect speed.
Setup & Operation 3. Installation Installation 3.1 Unpacking Controller mounting metal hasp (S) 1 set Controller mounting metal hasp (L) 1 set EMERGENCY port connector 1 set Connecting cable for RC620DU 1 cable 3.2 Environmental Requirements ■ The Manipulator and the Drive Unit must be used within the environmental conditions described in their manuals.
Setup & Operation 3. Installation 3.2.2 Installation - Mount the Drive Unit mounting screws with 80 to 110 Ncm torque. - Install the Drive Unit on a flat surface such as wall, floor, and Drive Unit box in the direction shown from (A) to (D). Fixture L Base Table Fixture L...
Setup & Operation 3. Installation For Drive Unit installation to the Drive Unit box or the base table, process screw hole drilling as follows. Unit [mm] When mounting direction is (A) or (B) Drive unit Drive unit only + ProSix Driver Unit When mounting direction is (C) (Front Side) (Front Side)
Setup & Operation 3. Installation 3.2.3 Install inside a Cabinet When installing the Drive Unit inside a Cabinet, make sure to satisfy the condition indicated in 3.2.1 Environment, 3.2.2 Installation and also the following conditions. - The distance from the mounting surface and the inside of the door must be 220 mm or more (190 mm when using the option I/O connector).
Setup & Operation 3. Installation 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 10 msec. Or less Interrupt Power Consumption Max.
Setup & Operation 3. Installation 3.3.2 AC Power Cable ■ Make sure that cable manufacturing and connection are done by a qualified personal. When proceeding, be sure to connect the earth wire of the AC power cable colored green/yellow on the Drive Unit to the earth terminal of the factory power supply. The equipment must be grounded properly at all times to avoid the risk of electric WARNING shock.
Setup & Operation 3. Installation (4) EMERGENCY The EMERGENCY connector has inputs to connect the Emergency Stop switch and the Safety Door switch. For safety reasons, connect proper switches for these input devices. For details, refer to the Setup & Operation 6. EMERGENCY. (5) I/O connector This connector is used for input/output devices of the user.
Setup & Operation 3. Installation 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. - The earth wire of the power supply should be grounded. (Ground resistance: 100 Ω or less) It is important to ground the frame of Drive Unit not only for prevention from electric shock, but also for reducing the influence of electric noise around the Drive Unit.
Setup & Operation 4. Motion Network Port Drive Unit Connection Drive Unit is connected to the Control Unit using the attached connection cable. Up to two Drive Units can be connected to the Control Unit. DU OUT DU IN DU OUT Drive Unit RC620DU Control Unit RC620CU A: Control Unit and 1...
Setup & Operation 5. Drive Unit Configuration Drive Unit Confirmation To confirm 1 or 2 Drive Unit, use the following methods. With DU number label: Check the label attached on Drive Unit. DU1 : 1 Drive Unit DU2 : 2 Drive Unit With SMB: The DIP switch is equipped in SMB to configure 1...
Setup & Operation 6. EMERGENCY EMERGENCY The details of safety requirements for this section are described in EPSON RC+ 5.0 2. NOTE Safety. Please refer to them to keep the robot system safe. Connect a safeguard switch or Emergency Stop switch to the Drive Unit EMERGENCY connector for safety.
Setup & Operation 6. EMERGENCY 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.
Setup & Operation 6. EMERGENCY 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.
Setup & Operation 6. EMERGENCY 6.2 Emergency Stop Switch Connection 6.2.1 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, be sure to connect such Emergency Stop switch(es) to the Emergency Stop input terminal on the EMERGENCY connector.
Setup & Operation 6. EMERGENCY 6.4.2 Wiring Example for Emergency Stop 184.108.40.206 External emergency stop switch typical application Emergency stop switch Emergency stop switch of an Operation unit (TP) Terminal block NOTE - The Emergency cable, Emergency cable kit, and Terminal block are offered as options. ...
Setup & Operation 6. EMERGENCY 220.127.116.11 External safety relay typical application Drive unit Emergency Stop switch External +24V Fuse * External safety relay External +24V External +24V External +24V External +24V Terminal block * Fuse For the protection of the emergency stop circuit, the fuse’s capacity should be as follows: - Meets the capacity of the external - 0.4A or less...
Setup & Operation 6. EMERGENCY 6.4.3 Wiring Example for Safety Door Input / Latch Release Input External Safety Door input 1 Safety Door input 2 Latch release input Latch release input Close :Latch off Open :Latch on Safety Door input 1 Safety Door input 2 Latch release input Safety Door input 1...
Setup & Operation 7. I/O Connector I/O Connector The I/O connector is for connecting your input/output equipment to the system. Pins Bit number Input 0 to 23 Control Unit Output 0 to 15 Input 32 to 55 Drive Unit 1 Output 32 to 47 Input...
Setup & Operation 7. I/O Connector 7.2 Output Circuit : +12 V to 24 V ±10% Rated Output Voltage 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.
Setup & Operation 7. I/O Connector 7.3 Pin Assignments Signal Name Signal Name Signal Name Input common No. 0 to 7 Input common No. 8 to 15 Input common No. 16 to 23 Input No. 0 Input No. 8 Input No. 16 Input No.
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.
Maintenance 1. Safety Precautions on Maintenance Safety Precautions on Maintenance 1.1 Safety Precautions ■ Only authorized personnel who have taken the safety training should be allowed to execute teaching or calibration of the robot system. The safety training is the program for industrial robot operator that follows the laws and regulations of each nation.
Maintenance 1. Safety Precautions on Maintenance ■ Do not lose the screws removed at maintenance. When the screw is dropped into the Drive unit, be sure to take it out. Leaving the screw in the Drive unit may cause short circuit and may result in equipment damage to the parts and/or robot system.
Maintenance 2. Regular Maintenance Inspection Regular Maintenance Inspection Performing regular maintenance inspection properly is essential for preventing trouble and maintaining safety. This chapter describes the schedules for maintenance inspection and procedures. Be sure to perform the maintenance inspections in accordance with the schedules. 2.1 Schedule for Maintenance Inspection Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and annual.
Maintenance 3. Drive unit Structure Drive unit Structure 3.1 Location of Parts AC Terminal Block This area contains high voltage. Turn OFF and unplug the power supply during the procedure. Motor Driver ：Axis 1 ：Axis 2 ：Axis 3 ：Axis 4 (1) Thumb Head screws These are two of the four screws used to mount the front cover of the Derive unit.
Maintenance 3. Drive unit Structure 15V Switching Power Supply Module Regeneration Module Encoder I/F Board Be careful of the regeneration module resistor high temperature. 24V Switching Power Supply Module Be careful of the regeneration module resistor high temperature. 5V Switching Power Supply Module SMB Board NOTE...
Maintenance 3. Drive unit Structure 3.2 Diagram of Cable Connections For the electrical connections of the Drive unit, refer to the following diagram. Motor Driver Motor Driver 5 axis 6 axis Resistor AC200 Switching -240V Power Supply (5V) AC200 Switching -240V Power Supply (5V)
Maintenance 3. Drive unit Structure Cable Layout Drawing For cable connections inside the Drive unit, refer to the following figure. M/C POWER Encoder I/F Board Regeneration Board Switching Power Supply (15V) (11) (10) to Noise Filter (13) Switching Power Supply (24V) Switching Power Supply (5V) (12) (14)
Maintenance 3. Drive unit Structure Cable List Cable Connector Pin Wire Connector Pin Connection Connection Note Quantity Quantity Quantity − Noise Filter Switching Power Supply (5V) Switching Power Supply (24V) Switching Power Supply (15V) 26<F> 25(D-SUB) EMERGENCY Switching Power Supply (24V) ProSix Driver Unit I/F Board Regeneration Board Regeneration...
Maintenance 3. Drive unit Structure 3.3 Connector Pin Assignment Pin assignments differ depending on the manipulator type. The following tables show the pin assignments for the M/C power connector and M/C signal connector. For EMERGENCY , refer to Setup & Operation. 3.3.1 M/C Power Connector G / RS / X5 series C3 series...
Maintenance 4. Maintenance Parts Replacement Procedures Maintenance Parts Replacement Procedures ■ Before performing any maintenance procedure, always make sure that the main power of the Drive unit is turned OFF and that the high voltage charged area is completely discharged. Performing any maintenance procedure while the main power is ON or the high voltage charged area is not discharged completely is extremely hazardous and may result in electric shock and/or cause serious safety problems.
Maintenance 4. Maintenance Parts Replacement Procedures 4.1 Fan and Fan Filter Inspect the fan filter periodically and clean it when needed. The temperature inside the Drive unit may get too high and the Drive unit may not operate properly if the filter is not kept clean.
Maintenance 4. Maintenance Parts Replacement Procedures 4.1.2 Replacing the Fan Unit Fan Unit (1) Turn OFF the Drive unit. Remove (2) Pull out the two plastic fasteners and remove the inlet plate. (3) Remove the four screws on the fan unit. (4) Remove the fan unit.
Maintenance 4. Maintenance Parts Replacement Procedures Fan Unit (1) Mount a new fan filter in the fan unit. Mount NOTE When an Option Unit is mounted, no fan filter is necessary. (2) Connect the two fan cable connectors to the CPU board. Refer : Maintenance 3.2 Diagram of Cable Connections - Cable Layout Drawing (3) Hold down the fan cable protection tube...
Maintenance 4. Maintenance Parts Replacement Procedures 4.2 Motor Driver 4.2.1 Part Names Main Circuit Connector Heat Sink Input/ Output Signal Connector Signature Plate 750W (With cable for dynamic brake resistor) 50W, 100W, 200W, 400W The wattage of the motor driver can be determined by the type code indicated on the signature plate.
Maintenance 4. Maintenance Parts Replacement Procedures (4) Loosen the two screws on the side of the front side. (5) Open the front cover and hold it open. Motor Driver 1: Axis 1 2: Axis 2 3: Axis 3 4: Axis 4 (6) Open the clamp for the front cover support bar.
Maintenance 4. Maintenance Parts Replacement Procedures (8) Remove the five screws from the Motor Driver mounting bracket. Motor Driver Mounting Bracket Connected to the G10 or G20 series manipulator Refer to Remove step (9) and remove the connector. Connected to the G1, G3, G6, C3 , RS or X5 series manipulator Go on to Remove step (10).
Maintenance 4. Maintenance Parts Replacement Procedures Connected to the G10 or G20 series manipulator Motor Driver Start from Mount step (1). (Axis 1 to 4) Connected to the G1, G3, G6, C3 , RS or X5 series manipulator Mount Start from Mount step (3). (1) When replacing the first or the second Cement motor driver, insert the connector...
Maintenance 4. Maintenance Parts Replacement Procedures (10) Connect the following cables if they were previously connected to the front of the Drive unit. M/C Power Cable M/C Signal Cable EMERGENCY Cable (11) Plug in the power connector. Turn ON the Drive unit and make sure that the Drive unit starts properly without any vibration or abnormal noise.
Maintenance 4. Maintenance Parts Replacement Procedures 4.2.3 Replacing Motor Driver (Axis 5 and 6) Motor Driver (1) Turn OFF the Drive unit and unplug the power connector. (Axis 5 and 6) (2) Open the front cover. Remove Refer : Maintenance 4.2.2 Replacing Motor Driver (Axis 1 to 4) Removing procedure from (2) to (7) (3) Remove the four screws shown to remove the top cover of the ProSix...
Maintenance 4. Maintenance Parts Replacement Procedures Motor Driver (2) Insert the Motor Driver along the guide (Axis 5 and 6) rails until the surface height differences Mount of the Motor Driver comes to 5 mm or Top Surface less. of Motor Drive (3) Push the Motor Driver securely into the two Motor Driver connectors.
Maintenance 4. Maintenance Parts Replacement Procedures 4.3 SMB Unit NOTE The Drive unit differs by the using manipulator. Different procedures are instructed for each Drive unit as follows. Follow the corresponding procedure. Connected to the C3 series manipulator Connected to the G, RS or X5 series manipulator SMB Unit (1) Turn OFF the Drive unit and unplug the power connector.
Maintenance 4. Maintenance Parts Replacement Procedures (6) Slide the ProSix Driver Unit approximately 20 mm in direction (A) and then slowly slide it approximately 10 mm in direction (B). NOTE The ProSix Driver Unit cable is connected to the main chassis. Be sure to remove it slowly.
Maintenance 4. Maintenance Parts Replacement Procedures SMB Unit (1) Connect the four CPU board connectors. Mount Refer : Maintenance 3.2 Diagram of Cable Connections - Cable Layout Drawing (2) Carefully insert the SMB by pushing it straight in. - Make sure that connector CN2 of the SMB and the NOTE ...
Maintenance 5. Maintenance Parts List Maintenance Parts List Part Name Code Note Fan Unit R13B060501 R13B060502 Fan Filter For Base Unit R13B070101 Motor Driver 50 W R13B070102 100 W R13B070103 200 W R13B070104 400 W R13B070105 750 W R13B060401 Fuse For DPB R13B040008 SMB Unit...
Maintenance . Maintenance Parts List RC620DU Rev.5...