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Epson RC520 Manual

Robot controller
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ROBOT CONTROLLER
RC520
Rev.7
EM058C1220F

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  • Page 1 ROBOT CONTROLLER RC520 Rev.7 EM058C1220F...
  • Page 3 ROBOT CONTROLLER RC520 Rev.7 Copyright © 2002-2005 SEIKO EPSON CORPORATION. All rights reserved. RC520 Rev.7...
  • Page 4 FOREWORD Thank you for purchasing our robot products. This manual contains the information necessary for the correct use of the RC520 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.
  • Page 5 Please prepare the following items before you contact us. - Your controller model and its serial number - Your manipulator model and its serial number - Software and its version in your robot system - A description of the problem SERVICE CENTER RC520 Rev.7...
  • Page 6 MANUFACTURER & SUPPLIER Japan & Others SEIKO EPSON CORPORATION Suwa Minami Plant Factory Automation Systems Dept. 1010 Fujimi, Fujimi-machi, Suwa-gun, Nagano, 399-0295 JAPAN TEL: 81-266-61-1802 FAX: 81-266-61-1846 SUPPLIERS North & South America EPSON AMERICA, INC. Factory Automation/Robotics 18300 Central Avenue...

  • Page 7: Before Reading This Manual

    This section describes what you should know before reading this manual. Control System The RC520 Robot Controller can be used with either the EPSON RC+ or SPEL CT systems. For users of each system, the section or chapter to refer in the related manual is indicated as follows in this manual.
  • Page 8 RC520 Rev.7...

  • Page 9: Table Of Contents

    Environmental Requirements ...........29 Power Supply ..............30 3.2.1 Specifications ............30 3.2.2 Power Plug ............31 Cable Connection.............32 3.3.1 Typical Cable Connections (Single Manipulator) ..33 3.3.2 Connecting Drive Unit and Control Unit....36 3.3.3 Connecting a Drive Unit to the Manipulator ..38 Noise Countermeasures...........40 RC520 Rev.7...
  • Page 10 Protected Expansion I/O Board ........64 7.2.1 Jumper Settings ........... 64 7.2.2 Input Circuit............65 7.2.3 Output Circuit ............67 Expansion I/O Board............69 7.3.1 Jumper Settings ........... 69 7.3.2 Input Circuit............69 7.3.3 Output Circuit ............70 viii RC520 Rev.7...
  • Page 11 Expansion I/O Connector Cable ......76 7.5.3 Expansion I/O Connector Cable - Pin Assignments...........77 8. I/O Remote Settings Remote I/O Signal Descriptions (EPSON RC+) ....81 8.1.1 Remote Input Signals ...........82 8.1.2 Remote Output Signals ........84 Remote I/O Signal Descriptions (SPEL CT) .....85 8.2.1...
  • Page 12 Inspection While the Controller is Turned ON ..122 Cleaning the Fan Filter........... 122 Replacing a Lithium Battery on the CPU Board ..... 122 Backup of Data .............. 124 2.5.1 EPSON RC+ ............124 2.5.2 SPEL CT............129 3. Hardware Configuration Control Unit, Drive Unit and Manipulator......133 Optional Boards .............
  • Page 13 Module Functions and Layout ......171 6.3.3 Inspecting the Switching Power Supply Module .172 Motor Driver Module............173 DPB (Drive Power Board)..........173 6.5.1 Layout and Functions .........173 DMB (Drive Main Board) ..........175 6.6.1 Layout and Functions .........175 6.6.2 Replacing the DMB ..........175 RC520 Rev.7...
  • Page 14 7. Verifying Manipulator Operation 8. Recovering the HDD Recovering Windows............185 Configuring Windows ............188 Setting Up EPSON RC+ (For EPSON RC+ User)..189 8.3.1 Installing EPSON RC+ ........189 8.3.2 Reserving Address Resources of EPSON RC+ Options ..............190 Setting Up SPEL CT (For SPEL CT User)......191 8.4.1...

  • Page 15: Setup & Operation

    Setup & Operation This manual contains information for setup and operation of the RC520 Robot Controller.
  • Page 16 Setup & Operation RC520 Rev.7...

  • Page 17: Safety

    Keep this manual handy for easy access at all times. Please read the Safety chapter in User’s Guide to understand safety requirements before installing the robot system. EPSON RC+ :User’s Guide - chapter Safety SPEL CT :User’s Guide Introduction :Safety - 1.
  • Page 18 Controller to the earth terminal of the factory power supply. The equipment must be grounded properly at all times to avoid the risk of electric shock. Always use a power plug and receptacle. Never connect the Controller directly to the factory power supply. (Field wiring) RC520 Rev.7...
  • Page 19 (For EPSON RC+ Users, only the hardware that has been approved by EPSON can be installed on the robot system.) ■ Do not install any other software in the robot system except for the software that was originally installed at ship time.

  • Page 20: Safety Features

    Controller. 1.3 Safety Features The RC520 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.
  • Page 21 The dynamic brake circuit is activated when the Motor Encoder Signal cable (connecting to the Drive Unit) is disconnected. Motor Overload Detection: The dynamic brake circuit is activated when the system detects that the load on the motor has exceeded its capacity. RC520 Rev.7...
  • Page 22 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. RC520 Rev.7...

  • Page 23: Part Names And Functions

    2. Part Names and Functions 2.1 Model Number The RC520 robot controller consists of one Control Unit and Drive Unit(s). Controller Unit and Drive Unit have several models depending on the specifications. The following table shows all the combinations of the Control Unit and Drive Unit, and their differences.
  • Page 24 Example 1 ： One Drive Unit and One Manipulator Robot Manipulator Drive Unit Control Unit Example 2 ： Three Drive Units and Three Manipulators Robot Manipulator Drive Unit Control Unit Robot Manipulator OP500 / OP500RC Drive Unit Robot Manipulator Drive unit RC520 Rev.7...

  • Page 25: Standard Specifications

    Setup & Operation 2.3 Standard Specifications (Part Names and Functions) 2.3 Standard Specifications Item Specification Model RC520 PC compatible computer optimized for RC520: : PentiumIII 850MHz or faster : 20GB or more : 128MB or more Max. 16 Controllable Axes (For the number of controlled axis, refer to the Setup &...
  • Page 26 For the Control Unit, refer to the Setup & Operation 2.4.4 Dimensions. For the Four-axis Drive Unit, Size refer to the Setup & Operation 2.5.6 Dimensions. For the Six-axis Drive Unit, refer to the Setup & Operation 2.6.6 Dimensions. RC520 Rev.7...

  • Page 27: Control Unit

    (For EPSON RC+ Users, only the hardware that has been approved by EPSON can be installed on the robot system.) ■...
  • Page 28 (3) RESET switch: Resets the Control Unit to restart. (4) SYSTEM PANEL: Special system panel for RC520. This has the connectors for operation units and the LED for indicating the status. (5) LED: The LEDs indicate the following status when they turn ON:...
  • Page 29 Connects the optional operation unit or ATTEND (TEACH) Control Device. For details, refer to the Setup & Operation 4. OPTIONAL DEVICE Connector. ■ Do not connect the EPSON RC+ software key to the OPTIONAL DEVICE connector. Connecting the EPSON RC+ software key to the OPTIONAL DEVICE connector while the Control Unit is ON may cause damage to the EPSON RC+ software key.

  • Page 30: Rear Panel

    (1) IEEE-1284 (parallel) connector: Receptacle for printer cable. For EPSON RC+ Users, this connector is for the EPSON RC+ software key. (2) MIB (Motion Interface Board): This board is used for communication between the Control Unit and the Drive Unit.
  • Page 31 Do not lose a PS/2 exchange cable included in the accessories. ■ Connect the mouse and the keyboard properly. If the mouse or keyboard is incorrectly connected, the robot system cannot function properly. CAUTION RC520 Rev.7...

  • Page 32: Dimensions

    CPU and RAM 128MB. Example: When one E2 series Manipulator (SCARA) and one PS3 series Manipulator (Six-Axis) are connected to the RC520, up to six PG axes can be connected. (This example is for the screened box in the table above.) RC520 Rev.7...

  • Page 33: Four-Axis Drive Unit (Rc520Du)

    AC200V or the local equivalent power.) POWER Lights when the four-axis Drive Unit is turned ON. (4) POWER switch: A 15A circuit protector in the four-axis Drive Unit that turns the power to the unit ON and OFF. RC520 Rev.7...

  • Page 34: Locking Out The Four-Axis Drive Unit

    (3) M/C POWER connector: A connector for the Manipulator power source. Connect the dedicated power cable attached to the Manipulator. Protective Earth Terminal: External protective earth terminal (5) AC Power cable: Cable for the AC200V (or the local equivalent) power input RC520 Rev.7...

  • Page 35: Four-Axis Drive Unit - Interior Layout

    Opening the cover(s) of the Controller is extremely hazardous and may result in electric shock even when its main power is OFF because of the high voltage WARNING charge inside the Controller. The figure below shows the interior of a four-axis Drive Unit. RC520 Rev.7...
  • Page 36 The Drive Power Board consists of two circuits: one generates +24V control power and the other distributes the main power source to each motor driver that drives the axes. (8) Motor Power module: This module rectifies AC200V (or the local equivalent) power to output power for the motor. RC520 Rev.7...

  • Page 37: Dimensions

    Setup & Operation 2.5 Four-axis Drive Unit (Part Names and Functions) 2.5.6 Dimensions [Unit: mm] NOTE Do not remove any feet of the four-axis Drive Unit. RC520 Rev.7...

  • Page 38: Six-Axis Drive Unit (Rc520Du6)

    AC200V or the local equivalent power.) POWER Lights when the six-axis Drive Unit is turned ON. (4) POWER switch: A 15A circuit protector in the six-axis Drive Unit that turns the power to the unit ON and OFF. RC520 Rev.7...

  • Page 39: Locking Out The Six-Axis Drive Unit

    Refer to the Setup & Operation 5. EMERGENCY Connector for details. (7) D-I/O connector: This connector is used for connection with input/output devices. There are 16 inputs and 16 outputs. Refer to the Setup & Operation 6. D-I/O Connector for details. RC520 Rev.7...

  • Page 40: Six-Axis Drive Unit - Interior Layout

    Opening the cover(s) of the Controller is extremely hazardous and may result in electric shock even when its main power is OFF because of the high voltage WARNING charge inside the Controller. The photo below shows the interior of a six-axis Drive Unit. RC520 Rev.7...
  • Page 41 The supplied AC200V (or the local equivalent) power is regulated here and is output as +5V. (8) Over-voltage Detection Module or Regeneration Module (For RC520DU6) The installed module is different depending on the Manipulator models. Module Manipulator Over-voltage Detection Module PS3L Regeneration Module (For RC520DU6) PS3LP RC520 Rev.7...

  • Page 42: Dimensions

    Setup & Operation 2.6 Six-axis Drive Unit (Part Names and Functions) 2.6.6 Dimensions 76.1 469.2 [Unit: mm] NOTE Do not remove any feet of the six-axis Drive Unit. RC520 Rev.7...

  • Page 43: Installation

    - There must also be room behind the Controller so that one can attach and remove cables and boards. - Do not block airflow to or from the fan. NOTE The RC520 Controller must be normally placed horizontally. Do not remove any rubber feet of the Control Unit. RC520 Rev.7...

  • Page 44: Power Supply

    If the Drive Unit is connected to the IT power supply system, install an earth leakage circuit breaker between the Drive Unit and the power supply. The power receptacle shall be installed near the equipment and shall be easily accessible. RC520 Rev.7...

  • Page 45: Power Plug

    (for AC Power Source) Green/Yellow (for Protective Earth) Insulator Diameter : 3.5 mm (TYP) UL. Style No. 1015 Braided Shield Braid Density : 70% Color : Black Sheath Diameter : 10.5 mm (TYP) Cable Length : 3.5 m RC520 Rev.7...

  • Page 46: Cable Connection

    Control Unit and the Drive Unit (above the MOTION connector) match. Improper connection between the Control Unit and the Drive Unit may cause malfunction of the robot system and/or serious safety problems as it may make the Manipulator move abnormally. RC520 Rev.7...

  • Page 47: Typical Cable Connections (Single Manipulator)

    (8) Protective Earth Protective Earth Protective earth Terminal Control Unit MOTION Expansion I/O (option) Input/output unit MONITOR Monitor (10) MOUSE Cable MOUSE Mouse (11) KEYBOARD Cable KEYBOARD Keyboard ACIN ATTEND (TEACH) Control Device OPTIONAL DEVICE Operation Unit Dummy Plug RC520 Rev.7...
  • Page 48 For the six-axis Drive Unit, the cable has a D-Sub connector with 37 pins on the Controller-side end and a rectangular connector with 40 pins on the Manipulator-side end. Connect the signal cable to the Manipulator SIGNAL connector and the Controller M/C SIGNAL connector of the Drive Unit. RC520 Rev.7...
  • Page 49 Optional Device Dummy Plug. If neither is connected, the Manipulator will be in the Emergency Stop condition and will not function. For details, refer to the Setup & Operation 4. OPTIONAL DEVICE Connector. (10) Mouse cable (Separate connectors) Cable for a mouse. RC520 Rev.7...

  • Page 50: Connecting Drive Unit And Control Unit

    Control Unit and the Drive Unit (above the MOTION connector) match. Improper connection between the Control Unit and the Drive Unit may cause malfunction of the robot system and/or serious safety problems as it may make the Manipulator move abnormally. RC520 Rev.7...
  • Page 51 Drive Unit’s No. is indicated on the label as shown below. Drive Unit serial number - Identifying proper unit: Drive Unit’s serial number is indicated on the label as shown below. (The following photo is the six-axis Drive Unit.) :RC520DU6 MODEL DRIVE UNIT :00006 SERIAL NO. RC520 Rev.7...

  • Page 52: Connecting A Drive Unit To The Manipulator

    Control Unit, the Drive Unit and the Manipulator correctly. Improper connections between the Drive Unit and the Manipulator and between the Control Unit and the Drive Unit may cause improper function of the robot system CAUTION and also serious safety problems. RC520 Rev.7...
  • Page 53 You can find the serial number of the Manipulator that should be connected to the Drive Unit on your left hand side facing the Drive Unit. The Manipulator’s serial number is indicated on the signature label of the Manipulator. (The following photo is the six-axis Drive Unit.) MANIPULATOR PS3-AS00 00002 Serial number Model RC520 Rev.7...

  • Page 54: Noise Countermeasures

    In selecting a rectifying diode, make sure that it can handle the voltage and current incurred by the induction load. RC520 Rev.7...
  • Page 55 · As they are easily influenced by static electricity or the noise from power source, keep the mouse and keyboard away from peripheral noise sources. NOTE It is sometimes effective in suppressing such noise to wind the keyboard or mouse cables around a ferrite core several times. RC520 Rev.7...
  • Page 56 Setup & Operation 3.4 Noise Countermeasures (Installation) RC520 Rev.7...

  • Page 57: Optional Device Connector

    ATTEND (TEACH) control device that is connected to the OPTIONAL DEVICE connector, be careful not to hit your leg or foot against the front door. ■ Do not connect the EPSON RC+ software key to the OPTIONAL DEVICE CAUTION connector.

  • Page 58: Attend (Teach) Control Device

    4.2 ATTEND (TEACH) Control Device The name of the control device depends on the software used in your Control Unit as shown below: EPSON RC+ : TEACH control device SPEL CT : ATTEND control device To operate the Manipulator at a short distance without any operation unit (option), you should use the ATTEND (TEACH) control device.

  • Page 59: Optioinal Device Dummy Plug

    In this case, however, you cannot operate the Manipulator while the safety door is open. OPTIONAL DEVICE OPTIONAL DEVICE Dummy Plug Connector E_SW11 E_SW21 E_SW12 E_SW22 ENABLE KEY2 Plug Standard D-Sub 25 pin OPTIONAL DEVICE Dummy Plug #4-40 screw RC520 Rev.7...

  • Page 60: Pin Assignments

    Names of each operation mode when ATTEND (TEACH) control device is enabled or NOTE disabled are defined as shown below in EPSON RC+ and SPEL CT. For details on the operation mode, refer to each User’s Guide. ATTEND (TEACH) Control Device...

  • Page 61: Emergency Connector

    The details of safety requirements for this section are described in the Safety chapter in NOTE User’s Guide. Please refer to them to keep the robot system safe. EPSON RC+ :User’s Guide - chapter Safety SPEL CT :User’s Guide Introduction Safety - 1.

  • Page 62: Latch Release Switch

    (1) Turn ON the Control Unit and Drive Unit while the safety door is open in order to boot the Controller. (2) Make sure that "Safety" (EPSON RC+) or “Safety Door” (SPEL CT) is displayed on the status bar on monitor window.

  • Page 63: Emergency Stop Switch

    Emergency Stop at the Drive Unit via the EMERGENCY connector, make sure that the desired equipment is connected to the Emergency Stop output terminals. The relay contacts at the EMERGENCY connector (#5 & #6) (normally closed) will open at the input of Emergency Stop state. RC520 Rev.7...

  • Page 64: Stop Box

    (3) Make sure that “Emergency Stop” is displayed on the status bar on the monitor window. (4) Release the E. STOP box switch. (5) Execute the RESET command. (6) Make sure that “E-STOP” LEDs are turned OFF and the “Emergency Stop” is no longer visible (or dimmed) from the status bar. RC520 Rev.7...

  • Page 65: Pin Assignments

    Latch Release rated input current 10mA/24V input Emergency Stop output relay contact rated +30V 0.5A or under 5-6 pin load NOTE The total electrical resistance of the Emergency Stop switches and their circuit should be 1Ω or less. RC520 Rev.7...

  • Page 66: Circuit Diagrams

    *1: The part indicated with a broken line shows +24V GND Close: latch off the circuit for the four-axis Drive Unit. Open: latch on For the six-axis Drive Unit, there are six motor driver modules in the circuit. RC520 Rev.7...

  • Page 67: Example 2: External Safety Relay Typical

    Safety Door latch release input *2: The part indicated with a broken line shows +24V Close: latch off the circuit for the four-axis Drive Unit. Open: latch on For the six-axis Drive Unit, there are six motor drive modules in the circuit. RC520 Rev.7...

  • Page 68: Multi-Manipulator

    Relay placed on the outside Rated electric current consumption of the coil: 1A or under Minimum applicable load: 10mA or under External +24V GND External +24V External +24V GND Drive Unit 2 External +24V GND Drive Unit 3 External +24V GND RC520 Rev.7...

  • Page 69: D-I/O Connector

    Refer to the Setup & Operation 7. Expansion I/O Board - Optional for the specified model of an expansion I/O Board. For cable wiring, refer to the Setup & Operation 3.4 Noise Countermeasures in order to prevent noise. RC520 Rev.7...

  • Page 70: Input Circuit

    1 Input No. 0 to 3 common 2 Input No. 0 3 Input No. 1 (Same) 4 Input No. 2 (Same) 5 Input No. 3 (Same) 26 Input No. 4 to 7 common 27 Input No. 4 (Same) 28 Input No. 5 (Same) (Omit) RC520 Rev.7...
  • Page 71 1 Input No. 0 to 3 common 2 Input No. 0 3 Input No. 1 (Same) 4 Input No. 2 (Same) 5 Input No. 3 (Same) 26 Input No. 4 to 7 common 27 Input No. 4 (Same) 28 Input No. 5 (Same) (Omit) RC520 Rev.7...

  • Page 72: Output Circuit

    JP4, 5, 9, 10, 14, 15, 19, 20, 24, 25 1-3, 2-4, 5-6 24, 25, 26, 27, and 28 do not JP6, 11, 16, 21, 26 Open exist. Their settings are not JP7, 12, 17, 22, 27 Short required.) JP8, 13, 18, 23, 28 RC520 Rev.7...
  • Page 73 JP4, 5, 9, 10, 14, 15, 19, 20, 24, 25 1-2, 3-5, 4-6 25, 26, 27, and 28 do not exist. Short JP6, 11, 16, 21, 26 Their settings are not required.) JP7, 12, 17, 22, 27 Open JP8, 13, 18, 23, 28 RC520 Rev.7...

  • Page 74: Pin Assignments

    Output No. 15 Not to be used. Not to be used. Not to be used. Not to be used. Not to be used. Not to be used. Not to be used. Connector Standard D-I/O connector Rectangular half-pitch 50-pin M3 screw RC520 Rev.7...

  • Page 75: D-I/O Connector Optional Cable - Pin Assignments

    Output No.9 Input No.10 Output No.10 Input No.11 Output No.11 Input common No. 12 to 15 Output common No. 12 to 15 Input No.12 Output No.12 Input No.13 Output No.13 Input No.14 Output No.14 Input No.15 Output No.15 RC520 Rev.7...

  • Page 76: D-I/O Connector Optional Cable For Usa Specification - Pin Assignments

    Output No. 10 Output No. 14 Output No. 11 Output No. 15 Not to be used. Not to be used. Not to be used. Not to be used. Not to be used. Not to be used. Not to be used. RC520 Rev.7...

  • Page 77: Expansion I/O Board - Optional

    ■ Be sure to wire the output circuit properly. Especially the expansion I/O board has no protection circuitry for short-circuit and reverse-connection. Improper CAUTION wiring may cause malfunction of the parts on the board and then improper function of the robot system. RC520 Rev.7...

  • Page 78: Protected Expansion I/O Board

    For details about software settings, refer to the following manual. EPSON RC+ :User’s Guide - the section ISA I/O Board Software Configuration in the chapter I/O Systems SPEL CT :User’s Guide Setup & Operation - the section 11.3.3 I/O Board...

  • Page 79: Input Circuit

    2.2 kΩ 3 Input No. 48 4 Input No. 49 (Same) 5 Input No. 50 (Same) 6 Input No. 51 (Same) 51 Input No. 52 to 55 common 53 Input No. 52 (Same) 54 Input No. 53 (Same) (Omit) RC520 Rev.7...
  • Page 80 2.2 kΩ 3 Input No. 48 4 Input No. 49 (Same) 5 Input No. 50 (Same) 6 Input No. 51 (Same) 51 Input No. 52 to 55 common 53 Input No. 52 (Same) 54 Input No. 53 (Same) (Omit) RC520 Rev.7...

  • Page 81: Output Circuit

    26 Output No. 48 to 51 common (GND) (Same) 77 Output No. 52 ~ ~ ~ (Omit) : +12V to +24V ±10% Rated Output Voltage Maximum Output current : 250mA/1 output Output Driver : N channel power MOS FET Saturation Voltage : 1.0V or under RC520 Rev.7...
  • Page 82 26 Output No. 48 to 51 common (+DC) 77 Output No. 52 (Same) (Omit) : +12V to +24V ±10% Rated Output Voltage Maximum Output current : 250mA/1 output Output Driver : P channel power MOS FET Saturation Voltage : 1.0V or under RC520 Rev.7...

  • Page 83: Expansion I/O Board

    For details about software settings, refer to the following manual. EPSON RC+ : User’s Guide - the section ISA I/O Board Software Configuration in the chapter I/O Systems SPEL CT : User’s Guide Setup & Operation - the section 11.3.3 I/O Board 7.3.2 Expansion I/O Board : Input Circuit...

  • Page 84: Output Circuit

    The following diagrams illustrate cases where #48 through #79 are assigned to the Expansion I/O’s inputs and outputs. The I/O number assignment depends on the EPSON RC+ settings. Expansion I/O Board I/O Typical Output Circuit Application 1 : Output #48 to #55 (Eight low numbers among thirty-two bit numbers existing in one board are output.)
  • Page 85 32 Output No. 56 to 59 common 83 Output No. 60 (Same) 84 Output No. 61 (Same) (Omit) : +12V to +24V ±10% Rated Output Voltage Maximum Output Current : 100mA/1 output Output Driver : Photo coupler Saturation Voltage : 1.6V or under RC520 Rev.7...

  • Page 86: Expansion I/O Board: Pin Assignments

    Input common G (No. 72 to 75) Output common G (GND: No. 72 to 75) Output No.72 Input No.72 Output No.73 Input No.73 Output No.74 Input No.74 Output No.75 Input No.75 Output common A (+DC: No. 48 to 51) RC520 Rev.7...
  • Page 87 Input common H (No. 76 to 79) Output common H (GND: No. 76 to 79) Output No.76 Input No.76 Output No.77 Input No.77 Output No.78 Input No.78 Output No.79 Input No.79 Output common B (+DC: No. 52 to 55) RC520 Rev.7...

  • Page 88: Pin Assignments (Pnp Type)

    Input common G (No. 72 to 75) Output common G (+DC: No. 72 to 75) Output No.72 Input No.72 Output No.73 Input No.73 Output No.74 Input No.74 Output No.75 Input No.75 Output common A (GND: No. 48 to 51) RC520 Rev.7...
  • Page 89 Input common H (No. 76 to 79) Output common H (+DC: No. 76 to 79) Output No.76 Input No.76 Output No.77 Input No.77 Output No.78 Input No.78 Output No.79 Input No.79 Output common B (GND: No. 52 to 55) RC520 Rev.7...

  • Page 90: Expansion I/O Connector

    7.5.2 Expansion I/O Connector Cable The Expansion I/O connector cable is an optional part. It has a 100-pin connector on one end and two 50-pin connectors on the other end. 100pin 50pin×2 Expansion I/O Board RC520 Rev.7...

  • Page 91: Expansion I/O Connector Cable - Pin Assignments

    23 (61) Input No.62 48 (85) Output No.62 24 (62) Input No.63 49 (86) Output No.63 25 (49) FG 50 (50) FG The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin connector. RC520 Rev.7...
  • Page 92 23 (73) Input No.78 48 (97) Output No.78 24 (74) Input No.79 49 (98) Output No.79 25 (99) FG 50 (100) FG The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin connector. RC520 Rev.7...
  • Page 93 23 (61) Input No.62 48 (85) Output No.62 24 (62) Input No.63 49 (86) Output No.63 25 (49) FG 50 (50) FG The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin connector. RC520 Rev.7...
  • Page 94 23 (73) Input No.78 48 (97) Output No.78 24 (74) Input No.79 49 (98) Output No.79 25 (99) FG 50 (100) FG The number in parentheses in the Pin No. above means the corresponding pin number on the 100-pin connector. RC520 Rev.7...

  • Page 95: I/O Remote Settings

    The user defines the I/O number that a remote function is assigned to using software configuration. For further details, refer to the following manual. EPSON RC+ : User’s Guide - the section Remote Control Software Configuration in the chapter Remote Control SPEL CT : User’s Guide Setup &...

  • Page 96: Remote Input Signals

    * Shuts down the Controller. Disabled when tasks are running. Reboot * Reboots the Controller. Disabled when tasks are running. * The Recover has been supported since EPSON RC+ Ver.4.0 The Shutdown and Reboot have been supported since EPSON RC+ Ver.4.1. RC520 Rev.7...
  • Page 97 SelRobot2 SelRobot3 Manipulator 0 : OFF, 1 : ON (*4) Specify the group number with SelGroup0 - 3 bits as shown in the table below. Specified SelGroup0 SelGroup1 SelGroup2 SelGroup3 Group No. 0 : OFF, 1 : ON RC520 Rev.7...

  • Page 98: Remote Output Signals

    RecoverInCycle * Indicates that recover position is in cycle. * The RecoverReqd and RecoverInCycle have been supported since EPSON RC+ Ver.4.0. (*3) (*4): Refer to the tables in the Setup & Operation 8.1.1 Remote Input Signals.

  • Page 99: Remote I/O Signal Descriptions (Spel Ct)

    (*1) Sel Mnp input is used to define the Manipulator for executing Motor Mode, Motor Status, Power Mode, Power Status, MCALed, HOME, the output of Mnp.No.0 to 3 for remote output and Motor ON, Motor OFF, MCAL, HOME for remote input. RC520 Rev.7...
  • Page 100 0 : OFF, 1 : ON (*4) Specify the group number with Grp. No.0-3/4 bit referring to the table below. Specified Grp No.0 Grp No.1 Grp No. 2 Grp No.3 Group No. 0 : OFF, 1 : ON RC520 Rev.7...

  • Page 101: Remote Output Signals

    Outputs the Emergency Stop status of the Controller E-Stop Outputs the error status of the Controller Error Grp No.0 Grp No.1 Outputs the group number in the project. (*4) Outputs the current selected group number with these bit. Grp No.2 Grp No.3 RC520 Rev.7...
  • Page 102 Outputs the READY status of the Controller (ON in the READY READY and RESET status). WAIT Outputs the WAIT RECOVER status of the Controller. RECOVER Outputs the RECOVER status of the Controller. RECOVER (*3) (*4): Refer to the tables in the Setup & Operation 8.2.1 Remote Input Signals. RC520 Rev.7...

  • Page 103: Timing Specifications (Epson Rc+)

    Setup & Operation 8. I/O Remote Settings 8.3 Timing Specifications (EPSON RC+) 8.3.1 Design Notes for Remote Input Signals The following charts indicate timing sequences for the primary operations of the Controller. The indicated time lapses (time durations) should be referred to only as reference values since the actual timing values may vary depending on the number of Manipulators and the number of tasks running, as well as CPU speed of the Controller.

  • Page 104: Timing Diagram For Program Execution Sequence

    *1: The duration varies depending on the Quick Pause (QP) setting and the program’s operating status at the time of Pause input. *2: The Shutdown input is acceptable after the TasksRunning and CmdRunning outputs are OFF. *3: The Reboot input is acceptable after the TasksRunning and CmdRunning outputs are OFF. RC520 Rev.7...

  • Page 105: Timing Diagram For Safety Door Input Sequence

    Paused Output SafeGuard Output MotorOn Depending on Program Output Safety Input Input Latch Input Input Cont Input [Unit: msec] 8.3.5 Timing Diagram for Emergency Stop Sequence TasksRunning Output MotorOn Output EStopOn Output Emergency Input Reset Input [Unit: msec] RC520 Rev.7...

  • Page 106: Timing Diagram For Recover Sequence

    Setup & Operation 8. I/O Remote Settings 8.3.6 Timing Diagram for RECOVER Sequence (EPSON RC+) Remote Auto Recover Paused Output SafeGuard Output RecoverReqd Output RecoverInCycle Output Safety Input Input Latch Input Input Recover Input Start Input [Unit: msec] RC520 Rev.7...
  • Page 107 Setup & Operation 8. I/O Remote Settings Remote Manual Recover Paused Output SafeGuard Output RecoverReqd Output RecoverInCycle Output Safety Input Input Latch Input Input Recover Input Start Input [Unit: msec] RC520 Rev.7...

  • Page 108: Timing Specifications (Spel Ct)

    8.4 Timing Specifications (SPEL CT) 8.4.1 Design Notes for Input Signal The following charts indicate timing sequences for the primary operations of the RC520. The indicated time lapses (time durations) should be referred to only as reference values since the actual timing values may vary depending on the number of Manipulators and the number of tasks running, as well as CPU speed of the Control Unit.

  • Page 109: Timing Diagram For Program Execution Sequence

    Input (*2) [Unit: msec] *1: The duration varies depending on the Quick Pause (QP) setting and the program’s operating status at the time of Pause input. *2: The SHUTDOWN input is acceptable after the RESET output is ON. RC520 Rev.7...

  • Page 110: Timing Diagram For Safety Door Input Sequence

    Timing Diagram for Safety Door Input Sequence This timing depends on the robot’s operation at the time. START monitor Output In PAUSE Output Safety Door Output WAIT RECOVER Input RECOVER Input Open Safety Door Input Safety Door Latch Release Input START Input [Unit: msec] RC520 Rev.7...

  • Page 111: Timing Diagram For Emergency Stop Sequence

    Power status Output START monitor Output RESET Output Emergency Stop Output RESET Input Emergency Stop Input [Unit: msec] 8.4.6 Timing Diagram for Error Generating Sequence START monitor Output RESET Output Error Output RESET Input Error occurs. [Unit: msec] RC520 Rev.7...

  • Page 112: Timing Diagram For Recover Sequence

    8.4.7 Timing Diagram for RECOVER Sequence (SPEL CT) When the RECOVER is input in WAIT RECOVER status: START monitor Output In PAUSE Output Safety Door Output WAIT RECOVER Output RECOVER Output Safety Input Input Latch Input Input RECOVER Input START Input [Unit: msec] RC520 Rev.7...
  • Page 113 Setup & Operation 8. I/O Remote Settings When the START (Continue) is input in WAIT RECOVER status: START monitor Output In PAUSE Output Safety Door Output WAIT RECOVER Output RECOVER Output Safety Input Input Latch Input Input START Input [Unit: msec] RC520 Rev.7...
  • Page 114 Setup & Operation 8. I/O Remote Settings RC520 Rev.7...

  • Page 115: Rs-232C Settings

    Setup & Operation 9. RS-232C Settings 9. RS-232C Settings The Standard RC520 Control Unit comes with two RS-232C channels to facilitate controlling of the data communication among the host computer and peripheral equipment. 9.1 RS-232C cable RS-232C cables are not included with the standard RC520 Controller.

  • Page 116: Connection Example

    For details on the set-up procedure and communication commands, refer to the following manual. EPSON RC+ : User’s Guide - the section RS-232 Software Configuration in the chapter RS-232 Communications SPEL CT : User’s Guide Setup &...

  • Page 117: Jumper Settings For Mib

    Each time an additional MIB is installed, the software needs to be configured accordingly in addition to the jumper settings. For further details, refer to the following manual. EPSON RC+ : User’s Guide - the section RC520 Drive Unit Software Configuration in the chapter Motion Systems SPEL CT : User’s Guide Setup &...
  • Page 118 Short IRQ15 Short Short: Short-circuit Setup the memory address for MIB on the Controller. Memory address C0000-C7FFF Short Short C8000-CFFFF Short For the third MIB D0000-D7FFF Short For the second MIB D8000-DFFFF For the first MIB Short: Short-circuit RC520 Rev.7...
  • Page 119 Drive Units need to be defined as either master or slave. The normal settings are open for all of them. Setting Master (1ms signal) Short Master (XF signal) Short Slave Short Short: Short-circuit JP9, JP10 Factory -set and fixed Short Short: Short-circuit JP11 The normal settings are open. RC520 Rev.7...
  • Page 120 Setup & Operation 10. Jumper Settings for MIB RC520 Rev.7...

  • Page 121: Stand-Alone Option For Rc520

    Setup & Operation 11. Stand-alone Option for RC520 11. Stand-alone Option for RC520 This section describes a Stand-alone Option that allows you to use the RC520’s Control Unit only. 11.1 Stand-alone Option A Stand-alone Option allows forming the Control Unit own system including the Emergency Stop input and Safety Door input by connecting an Emergency Connector Plate Kit to the Control Unit.

  • Page 122: Power Supply

    Setup & Operation 11. Stand-alone Option for RC520 11.4 Power Supply ■ PC power cable for power source supply from the Drive Unit can not be used when using the Control Unit only. Use the proper PC power cable conforming to the specification of the connecting power source.

  • Page 123: Components Of Emergency Connector Plate Kit

    Setup & Operation 11. Stand-alone Option for RC520 11.5.2 Components of Emergency Connector Plate Kit The Emergency Connector Plate Kit consists of the following parts. Emergency Connector Board : Provides the emergency connector function of the Drive Unit for the Control Unit.

  • Page 124: Pin Assignments

    Setup & Operation 11. Stand-alone Option for RC520 11.5.4 Pin Assignments Pin assignments of the Emergency Connector (Stand-alone option) are as follows: Pin No. Signal Name Function E_SW11 Emergency Stop switch output (1) E_SW12 E.STOP1+ Emergency Stop input 1 (+) E.STOP1-...

  • Page 125: Circuit Diagram

    Setup & Operation 11. Stand-alone Option for RC520 11.5.5 Circuit Diagram Example 1: External emergency stop switch typical application Emergency Stop switches of an operating unit Emergency Stop detection Emergency Stop detection Emergency Stop condition control External +24V Safety Door input 1...
  • Page 126 Setup & Operation 11. Stand-alone Option for RC520 Example 2: External safety relay typical application Emergency Connector Board External+24V Emergency Stop switches Fuse* of an operating unit External +24VGND External +24V External safety relay (The above diagram Emergency is simplified for Stop representation.)

  • Page 127: Mib

    For jumper functions, refer to the Setup & Operation 10. Jumper Settings for MIB. 11.7 Option The options for RC520, such as the Operation Units (JP500 and OP500), Expansion I/O Board and Pulse Generating Board, are available to use even in the Control Unit system only.
  • Page 128 Setup & Operation 11. Stand-alone Option for RC520 RC520 Rev.7...
  • Page 129 Maintenance This manual contains maintenance procedures for the RC520 Robot Controller.
  • Page 130 Maintenance RC520 Rev.7...

  • Page 131: Safety Precautions For Maintenance

    ■ Do not shock, shake, or drop any parts during maintenance. When the parts CAUTION related with data (the CD-ROM drive, FDD, HDD, etc.) are shocked physically, they may be damaged and may also cause data loss during data loading/saving. RC520 Rev.7...
  • Page 132 Manipulator move abnormally. Before performing maintenance on the Controller, all the data must be copied as a backup. NOTE Refer to the Maintenance 2.5 Backup of Data for details. RC520 Rev.7...

  • Page 133: Procedure For Lockout

    The tagout method is attaching a tag or sign plate to the Power switch to prevent any one from turning ON the robot system by mistake while someone else is within the safeguarded area for maintenance or repair. RC520 Rev.7...
  • Page 134 Maintenance 1. Safety Precautions for Maintenance RC520 Rev.7...

  • Page 135: Regular Maintenance Inspection

    5 months (1250 h) 6 months (1500 h) 7 months (1750 h) 8 months (2000 h) 9 months (2250 h) 10 months (2500 h) 11 months (2750 h) 12 months (3000 h) 13 months (3250 h) h = hour RC520 Rev.7...

  • Page 136: Inspection Point

    - Do not allow the positive (+) and negative ( - ) electrodes to short circuit at maintenance. CAUTION - Do not throw batteries into fire or heat them to high temperature. - Do not disassemble or alter batteries. - When discarding batteries, insulate the terminals by wrapping them with tape, etc. RC520 Rev.7...
  • Page 137 3-8. Press the <Esc> key twice. The [BIOS] dialog will appear. 3-9. Press the <F10> key. The message “SAVE to COMS and EXIT (Y/N)?” will appear. 3-10. Press the <Y> key and then <Enter> key. The system will be automatically restarted. RC520 Rev.7...

  • Page 138: Backup Of Data

    For EPSON RC+, you can save and restore the system configuration using the MKVER and SETVER commands. Before servicing the system, you should execute MKVER and store the system configuration on a floppy disk.
  • Page 139 (3) Type in a unique name to identify the system in the [MKVER Name] text box. (4) Select the disk drive where you want to save the information in the [Drive] box. (You can select any drive except for C drive.) (5) Click the <OK> button to save the system configuration. RC520 Rev.7...
  • Page 140 (2) Click the <SETVER> button to open the [SETVER] dialog. (3) Select the drive where the backed-up information is stored in the [Drive] box. (4) Select the system configuration from the [Select MKVER files] list box. (5) Click the <OK> button to restore the system configuration. RC520 Rev.7...
  • Page 141 Backing up / Restoring a Project You can back up the whole of stored project and restore it. You can also move your developing EPSON RC+ applications into another system. Back up a project Follow the steps below to make a backup copy of the current project.
  • Page 142 (4) Select the “C drive” in the [New Project Drive] box. (5) Enter a project name for the [New Project Name] box. (6) Click the <OK> button. NOTE The currently open project is the project stored in the C drive. RC520 Rev.7...

  • Page 143: Spel Ct

    (2) Close the project. (3) Select the [Setup] - [Backup] - [System] commands. (4) Select the folder to backup. Click the <OK> button. Click the <New Folder> button when you make a new folder. RC520 Rev.7...
  • Page 144 “Restoring Projects” in the later part of this section. (2) Be sure of the folder/disk to restore. (3) Close all projects that are open. (4) Select the [Setup] - [Restore] - [System] commands. (5) Select the folder to restore. Click the <OK> button. RC520 Rev.7...
  • Page 145 (3) Select the folder to save the backup file in. Click the <OK> button. Click the <New Folder> button when you make a new folder. The status bar will indicate the project name and progress situation under backup. RC520 Rev.7...
  • Page 146 (3) Select the [Setup] - [Restore] - [All Projects] commands. (4) Select the folder to restore. Click the <OK> button. (5) The following message dialog will appear when the file has been restored. Click the <OK> button. The project has been restored. RC520 Rev.7...

  • Page 147: Hardware Configuration

    Regeneration Regeneration Unmount Module Module Module CTGAIN, Motor CTOFFSET, driver Motor driver wattage wattage M/C SIGNAL Cable Cable length Motor wattage Encoder type (ABS/INC) Manipulator’s (Mnp1) (Mnp2) (Mnp3) (Mnp4) (Mnp5) (Mnp6) axes configuration (Manipulator numbers in sample configuration) RC520 Rev.7...

  • Page 148: Optional Boards

    I/O address) the number of I/O) ....Drivers Input/output Equipment Total Input/output Equipment (input/output included): 128 Input Output :32 Motors of manipulator(s) * One Pulse Generating Board increases the number of controllable axes by four (4) at maximum. RC520 Rev.7...

  • Page 149: Control Unit

    (2) Remove four Top Cover screws on the back of the Control Unit. (3) Disconnect the motion cable from the MIB. (3) Motion Cable (4) Remove the Top Cover from the Control Unit. (5) Remove four mounting screws for the board holder assembly, then remove it. Board Holder Assembly RC520 Rev.7...

  • Page 150: Replacing Cpu Board

    (4) Remove the Top Cover from the Control Unit. (5) Remove the four mounting screws for the board holder assembly and remove it. (6) Disconnect seven cables from the CPU board. (HDD, FDD, Parallel Port, COM1, COM2, USB and Front Panel) RC520 Rev.7...
  • Page 151 (7) Remove the mounting screw for the CPU board on the rear side of the Control Unit and remove the CPU board from the slot. (8) Install the new CPU board in the slot. Then, mount the board with the mounting screw. (9) Connect the cables to the CPU board. RC520 Rev.7...

  • Page 152: Replacing An Optional Board

    ■ Do not shock, shake, or drop any parts during maintenance. When the parts related with data (the CD-ROM drive, FDD, HDD, etc.) are shocked physically, they may be damaged and may also cause data loss during data loading/saving. CAUTION (9) Remove the two FDD mounting screws and remove the FDD. RC520 Rev.7...

  • Page 153: Installation Of The System Panel

    (5) Connect the cable from the System Panel to the MIB. (6) Mount the board holder assembly to the Control Unit. (7) Place the Top Cover of the Control Unit back on and mount it with four screws. RC520 Rev.7...

  • Page 154: Cleaning And Replacing The Fan Filter

    (3) Pull out the filter from the filter case of the fan. Filter (4) Clean or replace the filter. When you clean the filter, vacuum the dust with a vacuum cleaner. (5) Place the clean filter back in the filter case. (6) Secure the fan to the Control Unit. RC520 Rev.7...

  • Page 155: Replacing The Fan

    (4) Remove the fan guard from the top of the fan. Fanguard Bottom Plate (5) Replace the fan with a new one. (6) Place the new fan and fan guard on the bottom plate. Then, secure them with the screws. (7) Secure the fan to the Control Unit. RC520 Rev.7...

  • Page 156: Replacing The Hdd (Hard Disk Drive)

    When replacing an Emergency Connector Plate Kit, refer to the Maintenance 4.2 Replacing the MIB and follow the same procedure. Refer to the figure below and connect the MIB and emergency connector board with the cable. Emergency Connector Junction Cable Emergency Connector Board RC520 Rev.7...

  • Page 157: Four-Axis Drive Unit (Rc520Du)

    Maintenance 5. Four-axis Drive Unit 5. Four-axis Drive Unit (RC520DU) 5.1 Overview The figures below show the rear, top, and front views of the RC520 four-axis Drive Unit. M/C Power Connector Rear Panel M/C Signal Connector Motion Connector Motor Driver Modules...

  • Page 158: Pin Assignments For The System Connectors

    The following tables show the pin assignments for the M/C power connector, M/C signal connector and Motion connector respectively. As for the pin assignments of the connectors not covered in this section, refer to the Setup & Operation. 5.2.1 M/C Power Pin No. Signal Name Pin No. Signal Name SHIELD FGND RC520 Rev.7...

  • Page 159: M/C Signal

    Signal Name 1HOME ENC+5V ENC+5V 4HOME ENC+5V EMB1 +24V HCOM ENC+5V 3HOME ENC+5V ENC+5V EMB2 +24V 2HOME ENC+5V ENC+5V NOTE The Drive Unit and Manipulator’s pin numbering layouts differ: one is lined horizontally and the other is lined vertically. RC520 Rev.7...

  • Page 160: Motion

    EA0+ EIOR - EA0 - ED7+ BANK1+ ED7 - BANK1 - ED5+ RESET+ ED5 - RESET - ED3+ ED3 - ED1+ MWR+ ED1 - MWR - SDEN+ EIOW+ SDEN - EIOW - BIO+ ED6+ BIO - ED6 - RC520 Rev.7...

  • Page 161: Four-Axis Drive Unit

    Maintenance 5. Four-axis Drive Unit 5.3 Four-axis Drive Unit 5.3.1 System Configuration of Four-axis Drive Unit RC520 Rev.7...

  • Page 162: Module Functions And Layout

    DC power to the motor. This module outputs +24V rectified from AC200V Switching Power Supply (or the local equivalent) as the control power source. Main Power Supply Circuit Module AC Power Input Switching Power Supply Module Motor Power Module RC520 Rev.7...

  • Page 163: Inspecting The Switching Power Supply Module

    When this lamp is OFF, either the + 24V or + 5V power output may not be normal, or the NOTE + 24V power voltage may be too low. DRIVE UNIT MOTOR ERROR E-STOP POWER POWER (3) LED (green) (2) POWER LED (green) RC520 Rev.7...

  • Page 164: Motor Driver Module

    Record the CT data to be entered in the Control Unit before placing the Top Cover back on the four-axis Drive Unit when replacing the Motor Driver module. After the replacement, refer to User’s Guide and set up the CT data. RC520 Rev.7...

  • Page 165: Replacing A Motor Driver Module

    (4) Check to make sure that LED # 9 (orange) on the DPB is OFF. Wait until the LED is OFF because the capacitors are not completely discharged if LED # 9 is ON. Remove the two screws from the Motor Driver module as shown below. RC520 Rev.7...
  • Page 166 (11) Secure the Top Cover with the eight screws. (12) Set up the CT data. For details, refer to the following manuals. EPSON RC+ : User’s Guide - the section RC520 Drive Unit Software Configuration in the chapter Motion Systems SPEL CT : User’s Guide Setup &...

  • Page 167: Dpb (Drive Power Board)

    The control to adjust the Encoder Power Supply voltage The control to adjust the +5V voltage (VCC) Jumper (JP1) Condition Description JP1 short If the regeneration module is not installed. JP1 open If the regeneration module is installed. RC520 Rev.7...
  • Page 168 AC200V or the local equivalent power.) LED7 POWER Lights when the four-axis Drive Unit is turned ON. LED8 This LED turns OFF when the +24V voltage drops. LED9 This LED indicates the charge status of the condenser. RC520 Rev.7...

  • Page 169: Adjusting Encoder Voltage

    (5) Repeat step (2) to ensure that the voltage is between 4.9V and 5.2V. (6) If necessary, repeat steps (4) and (5) until the voltage is within the range of 4.9V to 5.2V. (7) When the adjustment has been completed, place the Top Cover back on. RC520 Rev.7...

  • Page 170: Adjusting +5V Voltage

    (8) If necessary, repeat steps (7) and (8) until the voltage is within the range of 4.9V to 5.2V. (9) After the adjustment, re-install the Motor Driver module in. Turn OFF the Drive Unit and re-install the Top Cover. (10) RC520 Rev.7...

  • Page 171: Dmb (Drive Main Board)

    - 5V voltage for the Motor Driver module +24V +24V output voltage of the Switching Power Supply module +5.6V Encoder power supply voltage GND for TP1 through TP5 Description ON while the power for Encoder is output. ON while the Manipulator’s electromagnetic brake is released. RC520 Rev.7...

  • Page 172: Replacing The Dmb

    (7) As shown below, remove the mounting screws on the motor drivers for four axes in the Drive Unit. M4 screws (8) If a Regeneration module is connected, remove it by following the steps, (5) and (6), in the Maintenance 5.8.2 Replacing a Regeneration Module (For RC520DU) . RC520 Rev.7...
  • Page 173 (12) Remove six mounting screws securing the DMB in the four-axis Drive Unit. (13) Remove the old DMB. (14) Install the new DMB and mount it with eight mounting screws loose enough so that it can still be moved around a little for positioning. RC520 Rev.7...
  • Page 174 (7) and (8) described in the Maintenance 5.8.2 Replacing a Regeneration Module (For RC520DU) . (19) Re-install the Motor Drivers and Top Cover. Connect the cables that have been disconnected before the DMB replacement to the (20) back of the four-axis Drive Unit. RC520 Rev.7...

  • Page 175: Cooling Fan

    Be careful not to pull out the front panel too far because the power cable of the fan is still NOTE connected to the DPB. Loosen the top center screw M3 crown washer screws RC520 Rev.7...

  • Page 176: Replacing The Fan

    Be careful not to pull out the front panel too far because the power cable of the fan is still NOTE connected to the DPB. Loosen the top center screw M3 crown washer screws RC520 Rev.7...
  • Page 177 (5) Install a new Cooling Fan, and connect the cable of the fan to the connector on the DPB. (6) Reattach the front panel. Turn ON the four-axis Drive Unit and make sure that the new Cooling Fan runs properly. RC520 Rev.7...

  • Page 178: Regeneration Module (For Rc520Du)

    (4) Make sure that LED # 9 (orange) on the DPB is OFF. The capacitors are not completely discharged if this LED is ON. Wait until the LED goes OFF. (5) Remove the two mounting screws for the Regeneration module (for RC520DU). RC520 Rev.7...
  • Page 179 (7) Connect the J20 connector of a new Regeneration module (for RC520DU) to the DPB. (8) The new Regeneration module (for RC520DU) must be pushed in carefully, while making sure that the J26 connector engages properly. Mount the Regeneration module (for RC520DU) securely. Place the Top Cover back on. RC520 Rev.7...
  • Page 180 Maintenance 5. Four-axis Drive Unit RC520 Rev.7...

  • Page 181: Six-Axis Drive Unit (Rc520Du6)

    Maintenance 6. Six-axis Drive Unit 6. Six-axis Drive Unit (RC520DU6) 6.1 Overview The figures below show the rear, top, and front views of the RC520 six-axis Drive Unit. Rear Panel M/C Power Connector Motion Connector M/C Signal Connector Motor Driver Modules...

  • Page 182: Pin Assignments For The System Connectors

    Setup & Operation. 6.2.1 M/C Power Pin No. Signal Name Pin No. Signal Name – FGND FGND FGND FGND FGND – FGND EMBGND 6EMB 5EMB 4EMB – EMBGND – 3EMB 2EMB 1EMB FGND RC520 Rev.7...

  • Page 183: M/C Signal

    The Drive Unit and Manipulator’s pin numbering layouts differ: one is lined horizontally and the other is lined vertically. 6.2.3 MOTION The pin assignments of the MOTION connector for the six-axis Drive Unit are in common with ones for the four-axis Drive Unit. Refer to the Maintenance 5.2.3 MOTION . RC520 Rev.7...

  • Page 184: Six-Axis Drive Unit

    Maintenance 6. Six-axis Drive Unit 6.3 Six-axis Drive Unit 6.3.1 System Configuration of Six-axis Drive Unit RC520 Rev.7...

  • Page 185: Module Functions And Layout

    (or the local equivalent) as the control power source. This module outputs +24V rectified from AC200V Switching Power Supply (+24V) (or the local equivalent) as the control power source. AC Power Input Switching Power Supply Module (+24V) Switching Power Supply Module (+5V) RC520 Rev.7...

  • Page 186: Inspecting The Switching Power Supply Module

    (2) Check that the six-axis Drive Unit’s front panel POWER LED (green) is ON. NOTE If this LED is either OFF or dim, suspect that the + 24V power output is not normal. DRIVE UNIT MOTOR ERROR E-STOP POWER POWER POWER LED (green) RC520 Rev.7...

  • Page 187: Dpb (Drive Power Board)

    The connector for the SSR (Solid State Relay) J8, J9 The connectors for the Cooling Fans The connector for the interface cable to the DMB CN1 through 6 The connectors to output motor power to the Motor Driver module RC520 Rev.7...
  • Page 188 Lights while the CPU of the six-axis Drive Unit is operating normally. LED6 E-STOP Lights when in the emergency stop condition. LED7 POWER Lights when the six-axis Drive Unit is turned ON. LED8 This LED indicates the charge status of the electrolytic capacitor. RC520 Rev.7...

  • Page 189: Dmb (Drive Main Board)

    (1) Shut down Windows, and turn OFF the Control Unit and six-axis Drive Unit. (2) Disconnect cables connected at the back of the six-axis Drive Unit. (3) Wait for about 1 minute until the high voltage is discharged. (4) Remove the Top Cover by removing the eight screws. RC520 Rev.7...
  • Page 190 (7) As shown below, remove the mounting screws on the motor drivers for six axes in the Drive Unit. M4 screws (8) Lift up the Motor Driver module and disconnect cables from the back. Compress the projections on both sides of the connector to disconnect the cable. 2) Pull out 1) Compress RC520 Rev.7...
  • Page 191 (16) Mount the motor driver module holder on the six-axis Drive Unit. (17) Re-install the Motor Drivers and Top Cover. Connect the cables that have been disconnected before the DMB replacement to the (18) back of the six-axis Drive Unit. RC520 Rev.7...

  • Page 192: Cooling Fan

    Be careful not to pull out the front panel too far because the power cable of the fan is still NOTE connected to the DPB. Loosen the top center screw. M3 crown washer screws RC520 Rev.7...

  • Page 193: Replacing The Fan

    NOTE Be careful not to pull out the front panel too far because the power cable of the fan is still connected to the DPB. Loosen the top center screw. M3 crown washer screws RC520 Rev.7...
  • Page 194 (5) Install a new Cooling Fan, and connect the cable of the fan to the connector on the DPB. (6) Reattach the front panel. Turn ON the six-axis Drive Unit and make sure that the new Cooling Fan runs properly. RC520 Rev.7...

  • Page 195: Regeneration Module And Over-Voltage Detection Module (For Rc520Du6)

    Maintenance 6. Six-axis Drive Unit 6.8 Regeneration Module and Over-voltage Detection Module (For RC520DU6) 6.8.1 Regeneration Module When the Manipulator connected to the RC520 is PS3L, PS3LP, or PS5, the regeneration module is installed in the Drive Unit. LED2 LED3...

  • Page 196: Over-Voltage Detection Module

    Maintenance 6. Six-axis Drive Unit 6.8.2 Over-voltage Detection Module When the Manipulator connected to the RC520 is PS3, the over-voltage detection module is installed in the Drive Unit. The LED and connectors are located at the same position as the regeneration module.

  • Page 197: Verifying Manipulator Operation

    Drive Unit may cause malfunction of the robot system and/or safety problems as it may make the Manipulator move abnormally. (2) Turn ON both the Drive Unit and Control Unit. Boot the Controller. During this process, watch and monitor the LED status as described in the following list: RC520 Rev.7...
  • Page 198 The MOTOR POWER LED on the Drive Unit’s Front Panel turns ON. The Manipulator operates normally, and there is excitation. (4) Execute various motion commands (such as JUMP, etc.). The Manipulator must operate accordingly and normally without vibration or unusual sounds. RC520 Rev.7...

  • Page 199: Recovering The Hdd

    When you accidentally turn ON the RC520 with the recovery CD in its CD-ROM drive, NOTE the RC520 will start from the recovery CD. In this case, turn OFF the Controller before the restore begins. The restore will not begin until you click the <Yes> button in the following procedure (9).
  • Page 200 (8) Click the <Continue> button. NOTE If you click the <Cancel> button, the Easy Restore ends. When you accidentally turned ON the RC520 with the recovery CD in its CD drive, click the <Cancel> button in this window. RC520 Rev.7...
  • Page 201 (9) Check the contents of the [Warning] dialog and click the <Yes> button. NOTE If clicking the <No> button, the Easy Restore ends. When you accidentally turned ON the RC520 with the recovery CD in its CD-ROM drive, click the <No> button in this dialog. (10) The restore starts.

  • Page 202: Configuring Windows

    (16) Windows starts. NOTE If the EPSON RC+ or the SPEL CT is not installed, the [Install the Robot Control Software] dialog appears when the Controller is started. Make sure to install the EPSON RC+ or the SPEL CT. If it is not installed, Windows will automatically shutdown in 30 minutes.

  • Page 203: Setting Up Epson Rc+ (For Epson Rc+ User)

    8.3.1 Installing EPSON RC+ (1) Set the EPSON RC+ Setup CD-ROM in the CD-ROM drive. (2) The [EPSON RC+ Setup] dialog is automatically opened. (When the dialog is not automatically opened, select the [Run] from the [Start] menu and enter “d:\epsonrc\setup.exe”...

  • Page 204: Reserving Address Resources Of Epson Rc+ Options

    (13) Click the <Finish> button in the [Completing the Add/Remove Hardware Wizard] dialog. (14) When you continue reserving address resources of the EPSON RC+ options, click the <No> button in the [System Setting Change] dialog and repeat the same steps from (2) for each option.

  • Page 205: Setting Up Spel Ct (For Spel Ct User)

    (13) After the [Install Wizard Complete] dialog appears, remove the SPEL CT Setup Disk from the FDD. (14) Select the <Yes, I want to restart my computer now.> option button in the dialog. Then, click the <Finish> button. RC520 Rev.7...

  • Page 206: Reserving Address Resources Of Spel Ct Options

    When you finish reserving address resources of the SPEL CT options, click the <Yes> button in the [System Setting Change] dialog and restart Windows. NOTE After setting up SPEL CT, restore the backed-up data. For details, refer to the Maintenance 2.5 Backup of Data. RC520 Rev.7...

  • Page 207: Maintenance Parts List

    Cooling Fan for RC520CU-1 R13A060500500 PC Power Cable R12R500CUP013 OPTIONAL DEVICE Dummy Plug R12R500CUP018 R13A090300700 For EPSON RC+ Ver. 3.4 or 3.5 Software Options Key R13A090301300 For EPSON RC+ Ver. 3.6 or higher PNP type R12R520DIO001 SKP376 Protected Expansion I/O Board...
  • Page 208 Integrated Connector for Mouse and Keyboard 2.5" HDD with Japanese R13B110405 Embedded OS English R13B110406 Installation The code of the 2.5" HDD varies depending on the type of Windows installed in the HDD and the type of CPU board in the Control Unit. RC520 Rev.7...

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