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5. Third Step

RC520 Safety and Installation Rev.2

Controller

ROBOT CONTROLLER RC520

This manual indicates descriptions of the Robot Controller RC520 and Robot

system.

Safety

Specification, Installation, Operation, and Setup

Backup and Restore

Maintenance

Verifying Robot System Operation

Error Codes etc.

Robot

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

manuals for each Robot.

EPSON ProSix PS series (PS3, PS3L/PS3LP, PS5)
EPSON SCARA ROBOT E2 series (E2S/E2L, E2C, E2H)
EZ MODULES X4 series

Safety

Specification, Installation, Setting

Maintenance

Calibration etc.

Содержание RC520

Страница 1: ...RC520 Safety and Installation Read this manual first Rev 2 EM089B1742F ...

Страница 2: ... 2 RC520 Safety and Installation Rev ...

Страница 4: ... Office for warranty period information However customers will be charged for repairs in the following cases even if they occur during the warranty period 1 Damage or malfunction caused by improper use which is not described 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 ...

Страница 5: ...s generically to Windows XP and Windows 2000 NOTICE No part of this manual may be copied or reproduced without authorization The contents of this manual are subject to change without notice Please notify us if you should find any errors in this manual or if you have any comments regarding its contents INQUIRIES Contact the following service center for robot repairs inspections or adjustments If se...

Страница 6: ...AN TEL 81 0 266 61 1802 FAX 81 0 266 61 1846 SUPPLIERS North South America EPSON AMERICA INC Factory Automation Robotics 18300 Central Avenue Carson CA 90746 USA TEL 1 562 290 5900 FAX 1 562 290 5999 E MAIL info robots epson com Europe EPSON DEUTSCHLAND GmbH Factory Automation Division Otto Hahn Str 4 D 40670 Meerbusch Germany TEL 49 0 2159 538 1391 FAX 49 0 2159 538 3170 E MAIL robot infos epson ...

Страница 7: ... connect the followings to OPTIONAL DEVICE Connector of RC520 Connecting to the followings may result in malfunction of the device since the pin assignments are different NOTE Operator Panel OP1 Teach Pendant TP1 Teaching Pendant TP 3 Operating Unit OPU 320 RC Software Key ...

Страница 8: ...packing to Operation of Robot System 17 2 2 Unpacking 18 2 3 Transportation 19 2 4 Manipulator Installation 23 2 5 Controller Installation 27 2 6 Connecting Manipulator and Controller 31 2 7 Connecting Manipulator and Controller 41 2 8 Power on 45 3 First Step 47 3 1 windows XP Setup 47 3 2 Installing EPSON RC Software 48 3 3 Writing your first program 49 4 Second Step 53 4 1 Connection with Exter...

Страница 9: ...nsiderations are indicated throughout the manual by the following symbols Be sure to read the descriptions shown with each symbol WARNING This symbol indicates that a danger of possible serious injury or death exists if the associated instructions are not followed properly WARNING This symbol indicates that a danger of possible harm to people caused by electric shock exists if the associated instr...

Страница 10: ... safety requirements is extremely hazardous and may result in serious bodily injury and or severe equipment damage to the robot system The Manipulator and the Controller must be used within the environmental conditions described in their respective manuals This product has been designed and manufactured strictly for use in a normal indoor environment Using the product in an environment that exceed...

Страница 11: ...aching even when someone is inside the safeguarded area The motion of the Manipulator is always in restricted status low speeds and low power to secure the safety of an operator However operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly WARNING Immediately press the...

Страница 12: ...E2 series The motion range of each arm is shown in the figure below Take all necessary safety precautions Joint 3 Up Down Joint 4 Rotate Arm 1 Arm 2 Shaft Figure of E2C Joint 2 Rotate Joint 1 Rotate 4 RC520 Safety and Installation Rev 2 ...

Страница 13: ...4 J5 J5 J6 J6 Arm J2 Lower Arm Arm J3 Arm J4 Joint J6 Joint J3 Joint J4 Arm J1 Joint J5 Arm J6 Base Joint J2 LED Lamp This lamp lights up while the motors are ON Upper Arm Arms J3 to J6 Arm J5 Arm Motion Arm J1 The whole Manipulator revolves Arm J2 The lower arm swings Arm J3 The upper arm swings Arm J4 The wrist revolves Arm J5 The wrist swings Arm J6 The wrist rotates Figure of PS3 ...

Страница 14: ...lator manual Improper removal of parts or improper maintenance may not only cause improper function of the robot system but also serious safety problems Keep away from the Manipulator while the power is ON if you have not taken the training courses Do not enter the operating area while the power is ON Entering the operating area with the power ON is extremely hazardous and may cause serious safety...

Страница 15: ...not put heavy objects on the cables Do not bend or pull the cables forcibly The unnecessary strain on the cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may result in electric shock and or improper function of the robot system CAUTION Carefully use alcohol liquid gasket and adhesive following...

Страница 16: ...s below If grease gets into your eyes Flush them thoroughly with clean water and then see a doctor immediately If grease gets into your mouth If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water thoroughly If grease gets on your skin Wash the area thoroughly with soap and water 8 RC520 Safety and Installation Rev 2 ...

Страница 17: ...peripheral equipment since the operating trajectory while the robot system stops is different from that in normal operation To place the robot system in emergency mode during normal operation press the Emergency Stop switch when the Manipulator is not moving Refer to the Controller manual for instructions on how to wire the Emergency Stop switch circuit Free running distance in emergency The opera...

Страница 18: ...anipulator safely Do not tear damage or remove the labels Use meticulous care when handling those parts or units to which the following labels are attached as well as the nearby areas Examples of Manipulator Labels E2 series PS3 series All Manipulators NOTE Hazardous voltage exists while the Manipulator is ON To avoid electric shock do not touch any internal electric parts 10 RC520 Safety and Inst...

Страница 19: ...ion you must create an ATTEND TEACH control device and connect it to the OPTIONAL DEVICE connector on the front of the Control Unit in order to operate the Manipulator at a short distance The ATTEND TEACH control device should consist of the Emergency Stop switch 3 position enable switch dead man switch and ATTEND TEACH control device enable disable switch The name of the control device depends on...

Страница 20: ...meone else is in the safeguarded area for maintenance or repairs The procedure for lockout is described in the Maintenance 1 Safety Precautions for Maintenance Low Power Mode The motor power is reduced in this mode A shift into restricted status low power status can be done through the execution of a power status change instruction regardless of the safety door or operation mode This ensures the s...

Страница 21: ...e motor is running at incorrect speed Positioning Overflow Servo Error Detection The dynamic brake circuit is activated when the system detects that the difference between the Manipulator s actual position and commanded position exceeds the margin of error allowed Speed Overflow Servo Error Detection The dynamic brake circuit is activated when the system detects that motor speed has overflowed CPU...

Страница 22: ...c brake circuit is activated when the temperature of the power device inside the Motor Driver module is above the nominal limit Over Voltage Detection The dynamic brake circuit is activated when the voltage of the Controller is above the normal limit When mounting a regeneration module toDU4 or using DU6 ...

Страница 23: ...or axes per Drive Unit are as shown below Each four axis Drive Unit RC520DU Up to four axes Each six axis Drive Unit RC520DU6 Up to six axes Up to three Drive Units are connected to one Control Unit The following table shows available connections of the Drive Units per Control Unit Four axis Drive Units Six axis Drive Units Case 1 3 Drive Units Case 2 2 Drive Units 1 Drive Unit Case 3 2 Drive Unit...

Страница 24: ...One Drive Unit and One Manipulator Control Unit Drive Unit Robot Manipulator 10BExample 2 Three Drive Units and Three Manipulators Control Unit 3rd Robot Manipulator 2nd Robot Manipulator 1st Robot Manipulator 1st Drive Unit 2nd Drive Unit 3rd Drive unit OP500 OP500RC ...

Страница 25: ...Transportation Unpacking Error Installation Power on Yes No Procedures to enable operation of the robot system after turning ON the power Manual information to connect or setup the equipment and options 2 Installation Procedures to install the Robot system and turn ON the power properly 4 Second Step 3 First Step ...

Страница 26: ...rk and operate a crane or forklift When these operations are performed by unauthorized personnel it is extremely hazardous and may result in serious bodily injury and or severe equipment damage to the robot system Vibration at transportation Avoid excessive vibration or shock during Manipulator transporting Excessive vibration or shock may cause equipment damage to and or malfunction of the Manipu...

Страница 27: ...ent damage to the robot system Vibration at transportation Avoid excessive vibration or shock during Manipulator transporting Excessive vibration or shock may cause equipment damage to and or malfunction of the Manipulator Anchor bolt When removing the anchor bolts support the Manipulator to prevent falling Removing the anchor bolts without supporting the Manipulator may get hands fingers or feet ...

Страница 28: ...51 kg Manipulator weight 49 kg 109 lb PS3L Approx 53 kg Manipulator weight 51 kg 113 lb PS3LP Approx 53 kg Manipulator weight 51 kg 113 lb Reference Pulse values at Manipulator transport PS series 0 2621440 3140167 0 1847207 0 E2C E2S E2L To carry the Manipulator have two or more people to work on it and secure the Manipulator to the delivery equipment or hold the areas indicated in gray in the fi...

Страница 29: ...the bottom of the base by hand be very careful not to get hands or fingers caught Threaded holes for eye bolts M12 25 E2H Approx 37 kg 83 lb 15BUsing a Crane To hoist the Manipulator with a crane secure the Manipulator with shipping bolts and jigs and posture the Manipulator as shown in the figures below the posture at shipment from the manufacturer Use a cable threaded through the eyebolts attach...

Страница 30: ...to a pallet with shipping bolts and jigs Insert the forklift claws under the pallet and transport the Manipulator together with the pallet The pallet must have enough strength to bear the weight of the Manipulator Transporting of the Manipulator must be performed slowly in order to avoid overturning or slippage 18 Inset here the forklift claws Pallet Bolt 4 M10 45 Controller Figures of PS3 ...

Страница 31: ...Remove the shipping bolt and jigs PS series The shipping bolts and jigs are attached to the Manipulator as shown the figure below points A B and C for protecting the Manipulator from various external forces during transportation Remove the shipping bolts B A and C in this order The jigs are painted yellow Point A 4 M5 12 hexagon socket head cap bolts with plain washers and disc spring washers Poin...

Страница 32: ...base If the bolt is not removed the motion range of Joint 1 will be limited Be sure to remove the bolt Arm retaining bracket Bolt E2H M12 20 E2S M8 10 E2L M12 20 The figure is E2S E2C 1 Using nippers cut off the wire tie securing Arm 2 2 Unscrew the M4 screw on the end of Arm 2 3 Push Arm 1 slowly in the direction shown with an arrow in the figure on the right Fasten the arm retaining bolt on the ...

Страница 33: ... Before installing and operating the Manipulator make sure that all parts of the Manipulator are in place and have no external defects Missing or defective parts may cause improper operation of the Manipulator Improper operation of the Manipulator is extremely hazardous and may result in serious bodily injury and or severe equipment damage to the robot system Base table A base table for anchoring ...

Страница 34: ... falling If the Manipulator falls it is extremely hazardous and may result in serious bodily injury and or severe equipment damage to the robot system For Protected model Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation The Manipulator without connecting them may result in electric shock and or malfunction of the ro...

Страница 35: ... and cooling Installation procedure Before performing any installation procedure turn OFF the Controller and related equipment and then pull out the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Cable Be sure to connect the cables properly Do not allow unnecessar...

Страница 36: ...he power to the Controller is turned OFF and locked out before connecting or disconnecting any cables Connecting or disconnecting any cables with the power ON is extremely hazardous and may result in electric shock and or malfunction of the Controller Cable Be sure to connect the cables properly Do not allow unnecessary strain on the cables Do not put heavy objects on the cables Do not bend or pul...

Страница 37: ...he Drive Unit may cause malfunction of the robot system and or serious safety problems as it may make the Manipulator move abnormally 20BConnection Check label s at the front of Control Unit There is a Connection Check label for each Drive Unit The same number of labels as Drive Units used in the robot system is attached on the bottom of the inside of the front door Model Serial number DRIVE UNIT ...

Страница 38: ...d Installation Rev 2 30 22BDrive Unit serial number Identifying proper unit Drive Unit s serial number is indicated on the label as shown below The following photo is the six axis Drive Unit MODEL RC520DU6 DRIVE UNIT SERIAL NO 00006 ...

Страница 39: ...tor make sure that the pins are not bent Connecting with the pins bent may damage the connector and result in malfunction of the robot system Four axis Drive Units RC520DU EMERGENCY connector Six axis Drive Units RC520DU6 EMERGENCY connector 23BSafety Door Switch and Latch Release Switch The EMERGENCY connector has input terminals for the Safety Door switch and the Emergency Stop switch Be sure to...

Страница 40: ...r switch to the Safety Door input terminal on the EMERGENCY connector The Safety Door switch has safety features such as temporary hold up of the ｓ program or the operation prohibited status that are activated whenever the Safety Door is opened Observe the following in designing the Safety Door switch and the Safety Door For the Safety Door switch select a switch that opens as the Safety Door open...

Страница 41: ...perating the Manipulator 1 Turn ON the Controller while the safety door is open in order to boot the controller software 2 Make sure that Safety is displayed on the main window status bar 3 Close the safety door and turn ON the switch connecting to the latch release input Make sure that the Safety is dimmed on the status bar The information that the safety door is open can be latched by software b...

Страница 42: ...o Circuit Diagrams indicated later in this section 28BChecking Emergency Stop Switch Operation Once the Emergency Stop switch is connected to the EMERGENCY connector continue the following procedure to make sure that the switch functions properly For the safety of the operator the Manipulator must not be powered ON until the following test is completed 1 Turn ON the Controller to boot the controll...

Страница 43: ...P box is connected to the EMERGENCY connector continue the following procedure to make sure that the E STOP box functions properly For the safety of the operator the Manipulator must not be powered ON until the following test is completed 1 Turn ON the Control Unit and the Drive Unit to boot the Controller while pressing the E STOP box switch 2 Make sure that the E STOP LEDs on the Control Unit s ...

Страница 44: ...put 2 14 E STOP2 Emergency Stop input 2 15 RELEASE 16 RELEASE Latch Release input 17 GUARD21 18 GUARD22 Safety Door input 2 2 19 24V 24V output 20 24VGND 24V GND output 1 The Emergency Stop condition is output via relay contact when it is open it is normally closed 2 A critical error occurs if the input values from Safety Door 1 and Safety Door 2 are different for two or more seconds They must be ...

Страница 45: ...t 3 4 13 14 pin Safety Door rated input voltage range Safety Door rated input current 12V to 24V 10 10mA 24V input 7 8 17 18 pin Latch Release rated input voltage range Latch Release rated input current 12V to 24V 10 10mA 24V input 15 16 pin Emergency Stop output relay contact rated load 30V 0 5A or under 5 6 pin The total electrical resistance of the Emergency Stop switches and their circuit shou...

Страница 46: ...se input 9 Latch release input Close latch off Open latch on Emergency Stop detection Dynamic brake control Emergency Stop switches of an operation unit External 24V GND 19 1 2 11 12 3 13 5 6 4 14 10 20 8 7 18 17 16 15 Control Unit MIB Drive Unit DMB Emergency Stop detection Dynamic brake control Emergency Stop detection 1 1 The part indicated with a broken line shows the circuit for the four axis...

Страница 47: ...ion Emergency Stop detection Dynamic brake control External 24V GND External 24V External 24V GND 1 For the protection of the emergency stop circuit the fuse s capacity should be as follows Meets the capacity of the external safety relay 1A or less External safety relay The above diagram is simplified for representation Safety Door input 1 Latch release input Safety Door latch release input Close ...

Страница 48: ...ernal Emergency Stop switch External 24V Control Unit Drive Unit 1 RC520 Emergency Stop switch at the Jog Pad Operation Pendant External 24V GND Drive Unit 2 External 24V GND Drive Unit 3 External 24V GND External 24V Relay placed on the outside Rated electric current consumption of the coil 1A or under Minimum applicable load 10mA or under 1 11 2 12 3 13 4 14 3 13 4 14 3 13 4 14 ...

Страница 49: ...ric shock and or malfunction of the robot system Cable Be sure to connect the cables properly Do not allow unnecessary strain on the cables Do not put heavy objects on the cables Do not bend or pull the cables forcibly The unnecessary strain on the cables may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous a...

Страница 50: ...gers caught while pushing down the connector lock lever because you should apply strong force to it For Clean model When the Manipulator is a Clean model use it with an exhaust system For details refer to the Manipulator manual For Protected model Connect the power cable connection and the signal cable connector to the Manipulator immediately after the Manipulator installation The Manipulator with...

Страница 51: ...e M C POWER connector on the Drive Unit and the rectangular connector to the POWER connector on the Manipulator 34BM C Signal cable For the four axis Drive Unit the M C Signal cable has rectangular connectors with 68 pins on both ends For the six axis Drive Unit the cable has a D Sub connector with 37 pins on the Controller side end and a rectangular connector with 40 pins on the Manipulator side ...

Страница 52: ...2 Installation RC520 Safety and Installation Rev 2 44 36BPS series and RC520 Connection M C Power Cable M C Signal Cable 37BE2 series and RC520 Connection M C Power Cable M C Signal Cable ...

Страница 53: ...e equipment damage to the robot system as the Manipulator may fall down Manipulator check before installation Before installing and operating the Manipulator make sure that all parts of the Manipulator are in place and have no external defects Missing or defective parts may cause improper operation of the Manipulator Improper operation of the Manipulator is extremely hazardous and may result in se...

Страница 54: ... be OFF 2 The LED must be OFF 8 Boot the Controller During this process watch and monitor the Control Unit LED status as described in the following list E STOP When the main power is turned ON the LED must turn ON momentarily and must go OFF unless there is an emergency stop input If there is an emergency stop input at this time the LED must stay ON This LED turns ON when there is an EMERGENCY STO...

Страница 55: ... NOT start up again and you must execute Windows recovery After a short time after turning ON the Controller Windows XP Setup starts automatically Setup procedure is as follows Follow the instruction in the dialog 1 Welcome to Microsoft Windows XP Click the Next button to continue the setup 2 License Agreement This dialog is for selecting agree or disagree to the displayed agreement When you agree...

Страница 56: ...d to add an option upgrade or re install refer to the section Installing EPSON RC Software in Appendix A for instructions on installing EPSON RC Installing the software options key Included with the EPSON RC Software is a software key device that enables options Without this device the options you have installed will not be enabled All options are enabled on one key Options can also be enabled in ...

Страница 57: ... the upper left corner Now you are ready to start entering your first program 3 Edit the program Type in the following program lines in the Main prg edit window You can use upper or lower case characters Function main Print This is my first program Fend 4 Run the program Press F5 to run the program F5 is the hot key for the Start selection of the Run menu You will see the Status window showing the...

Страница 58: ...mand The MCal button is not enabled if you are using an absolute encoder robot Exit the Robot Control Panel by clicking on the Close button Press the Teach P0 button Jog the robot by pressing the Y jog button Hold the button down to continue jogging Let go when the robot is about half way out in the work envelope Jog the robot down by pressing the Z button Now change the current point to P1 by cli...

Страница 59: ...ou taught 7 Modify the program to change speed of robot motion commands Insert the Power Speed and Accel commands as shown in the program below Function main Print This is my first program Power High Speed 20 Accel 20 20 Jump P1 Jump P2 Jump P0 Fend Run the program by pressing F5 and then click on the Start button on the Run window The robot should jump to each of the points you taught at 20 speed...

Страница 60: ...ernal media such as floppy disks Follow these steps to backup the project and system configuration 1 Insert a blank floppy disk in the floppy drive 2 From the Project menu select Copy 3 Change the Destination Drive to A 4 Click OK The project will be copied to the floppy disk 5 From the Tools menu select Maintenance 6 Click on the MKVER button 7 Enter the MKVER name sample 8 Select the A drive 9 C...

Страница 61: ...PSON RC User s Guide Remote Control ROBOT CONTROLLER RC520 manual Setup Operation 8 I O Remote Set Up I O EPSON RC User s Guide I O Setup ROBOT CONTROLLER RC520 manual Setup Operation 6 I O Connector Setup Operation 7 Expansion I O Board Option Fieldbus I O Option EPSON RC Option Fieldbus I O manual Ethernet I O Option EPSON RC User s Guide Ethernet Communication ROBOT CONTROLLER RC520 manual Setu...

Страница 62: ...onnection and Display Language of Option OP500RC Connection ROBOT CONTROLLER RC520 manual Setup Operation 4 OPTIONAL DEVICE connector EPSON RC Option OP500RC manual 1 6 Installation Changing Display Language EPSON RC Option OP500RC manual 1 9 Setting Language ...

Страница 63: ...m Operation and Configuration Operation of Program Development Software EPSON RC GUI SPEL Language and Application Configuration of Robot I O Communication etc EPSON RC SPEL Language Reference This manual indicates descriptions of the SPEL language for robot program Details of the commands Error Messages etc Option The manuals indicate descriptions of the Option s you purchased There are manuals f...

Страница 64: ...Installation Operation and Setup Backup and Restore Maintenance Verifying Robot System Operation Error Codes etc Robot The manuals indicate descriptions of the Robot s you purchased There are manuals for each Robot EPSON ProSix PS series PS3 PS3L PS3LP PS5 EPSON SCARA ROBOT E2 series E2S E2L E2C E2H EZ MODULES X4 series Safety Specification Installation Setting Maintenance Calibration etc ...

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