Articulated Robot Controller

- GC Series
User Manual

Original Instruction

www.hiwin.tw
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 C24UE101-2004

Warranty Terms and Conditions

The period of warranty shall commence at the received date of HIWIN product
(hereafter called “product”) and shall cover a period of 12 months. The warranty does
not cover any of the damage and failure resulting from:

 The damage caused by using with the production line or the peripheral
equipment not constructed by HIWIN.
 Operating method, environment and storage specifications not
specifically recommended in the product manual.
 The damage caused by changing installation place, changing working
environment, or improper transfer after being installed by the
professional installer.
 Product or peripheral equipment damaged due to collision or accident
caused by improper operation or installation by the unauthorized staff.
 Installing non-genuine HIWIN products.

The following conditions are not covered by the warranty:

 Product serial number or date of manufacture (month and year) cannot
be verified.
 Using non-genuine HIWIN products.
 Adding or removing any components into/out the product without
authorized.
 Any modification of the wiring and the cable of the product.
 Any modification of the appearance of the product; removal of the
components inside the product. e.g., remove the outer cover, product
drilling or cutting.
 Damage caused by any natural disaster. i.e., fire, earthquake, tsunami,
lightning, windstorms and floods, tornado, typhoon, hurricane etc.

HIWIN does not provide any warranty or compensation to all the damage caused
by above-mentioned circumstances unless the user can prove that the product is
defective.

For more information towards warranty terms and conditions, please contact the
technical stuff or the dealer who you purchased with.

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 Improper modification or disassemble the robot might reduce

the robot function, stability or lifespan.
 The end-effector or the cable for devices should be installed
and designed by a professional staff to avoid damaging the
robot and robot malfunction.
 Please contact the technical stuff for special modification
coming from production line set up.
 For the safety reason, any modification for HIWIN product is
strictly prohibited.

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Safety Precautions
1. Safety Information
 Safety Responsibility and Effect
 This chapter explains how to use the robot safely. Be sure to read this
chapter carefully before using the robot.
 The user of the HIWIN industrial robot has responsibility to design and
install the safety device meeting the industrial safety regulations in order
to ensure personal safety.
 In compliance with the safety information on industrial robot described
in this manual can’t guarantee that HIWIN robot will not occur any safety
problems.
 This machine is defined as a partly completed machinery, the associated
hazards must be handled by system integrator in accordance with ISO
102018-1/-2.
 A safety-related part of control system (SRP/CS) should conform to the
requirement of performance level d and category 3 according to ISO
13849-1.
 The installation for emergency functions shall be defined by the system
integrator in accordance with ISO 10218-1/2.

 Safety Operation Principle

 Before connecting the power supply for HIWIN industrial robot
startup assembly procedure, check whether the specification of
factory output voltage matches the specification of input voltage of
the product. If it does not match, ensure to use the corresponding
transformer (HIWIN optional transformer is recommended).
 Emergency Stop button (on Teach Pendant or from external emergency
stop switch) must be pressed before turning off the power, and then
switch off the power switch.
 While connecting to the external I/O or the signal, please operate in
the condition that the power switch is turned off to prevent from a
shortcut caused by mistaken touch in the process, and resulting in
damage.

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2. Description Related to Safety

I. Safety Symbols
 Carefully read the instructions in the user manual prior to robot use. The
following shows the safety symbols used in this user manual.
Symbol Description
Failure to follow instructions with this symbol may result
in serious hazard or personal injury. Please be sure to
comply with these instructions.
Failure to follow instructions with this symbol may result
in personal injury or product damage. Please be sure to
comply with these instructions.
Failure to follow instructions with this symbol may result
in poor product performance. Please be sure to comply with
these instructions.

II. Working Person

 The personnel can be classified as follows
 Operator:
 Turns robot controller ON/OFF
 Starts robot program from operator’s panel
 Reset system alarm
 Programmer or teaching operator:
 Turns robot controller ON/OFF
 Starts robot program from operator’s panel
 Reset system alarm
 Teaches robot
 Maintenance engineer:
 Turns robot controller ON/OFF
 Starts robot program from operator’s panel
 Reset system alarm
 Teaches robot
 Does maintenance, adjustment, replacement

 Programmer and the maintenance engineer must be trained for proper robot
operation.

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3. Precautions
3.1 Common Safety Issues
 All operating procedures should be assessed by
professional and in compliance with related
industrial safety regulations.
 When operating robot, operator needs to wear
safety equipment, such as workwear for working
environment, safety shoes and helmets.
 When encountering danger or other emergency or
abnormal situation, please press the emergency
stop button immediately. After danger is
eliminated, move the robot away with low speed
in manual mode.
 When considering safety of the robot, the robot
and the system must be considered at the same
time. Be sure to install safety fence or other safety
equipment and the operator must stand outside the
safety fence while operating the robot.
 A safety zone should be established around the
robot with an appropriate safety device to stop the
unauthorized personnel from access.
 While installing or removing mechanical
components, be aware of a falling piece which
may cause injury to operator.
 Ensure the weight of workpiece does not exceed
the rated load or allowable load moment at wrist.
Exceeding these values could lead to the driver
alarm or malfunction of the robot.
 Do not climb on manipulator.
 Do not store the machine in the environment with
corrosion and flammable gas or close to the
flammable object.
 Do not operate the machine in the environment
with moisture, water or grease.
 Do not operate the machine at the place where
vibration or the strong impact occurs.
 Do not immerse the electric wires into grease or
water.

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 Do not connect or operate the machine with wet

hands.
 Do not operate the machine in potentially
explosive environment.
 Please ensure the controller is grounded.
Otherwise, unpredictable risks may occur.
 Keep hands away from the inner part of the
controller while it is connecting to the power or
during operating.
 Do not touch the heat sink, regenerative
resistance, the power supply or the computer
inside the controller while it is operating due to its
high temperature.
 Be sure power is disconnected prior to repair and
maintenance, and ensure to operate under the
condition of no electrical shock risk.
 Do not disassembly the controller without
permission. If there’s any issues, please contact
our engineers.
 The personnel installing robot should be trained
and licensed.
 To ensure personal safety, robot installation must
comply with this manual and related industrial
safety regulations.
 The control cabinet should not be placed near high
voltage or machines that generate electromagnetic
fields to prevent interference that could cause the
robot to deviation or malfunction.
 Using non-HIWIN spare parts to repair may cause
robot damage or malfunction.
 Beware of the heat generated by the controller and
servo motor.
 Do not overbend the cable to avoid poor circuit
contact or unexpected damage.
 Do not stand on the controller or put heavy objects
on it.
 Do not block the vent or put foreign objects into
the controller.
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 Please ensure the controller is fixed on the base.

 Do not pull the connector violently or twist the
electric wires excessively.
 Do not frequently switch ON/OFF the power
switch and the control button.
 Please ensure that the robot, the emergency stop
switch and the controller are functioning properly
before performing any work.
 Do not shutdown the power switch during the
operation.
 Do not open, modify, disassemble and maintain
the machine without permission.
 The power must be disconnected when the
machine does not operate in a long time.
 Do not turn off the power of the controller when
modifying the program or parameter. Otherwise,
the data stored in the controller will be damaged.
 After the brake of a servo motor is released, the
robot will be moved due to gravity and it may
injured the operator.
 The industrial robots can be applied for the
different industrial environments.
 When the operating procedures are interrupted,
the special attention should be paid during the
troubleshooting.

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3.2 Operation
 Teaching, jogging or programming should be done
outside of the safety fence. If it is inevitable to
enter the safety fence, press the emergency stop
button before entrance. Operation should be
restricted at low speed and beware of surrounding
safety.
 All operations shall be executed by trained staff.
3.3 Maintenance
 Please contact us if the procedure not specified by
HIWIN is needed.
 Please contact us if the replacement of the
component not specified by HIWIN is needed.
 Be sure to carry out regular maintenance,
otherwise it will affect the service life of the robot
or other unexpected danger.
 Prior to repair and maintenance, please switch off
power supply.
 Maintenance and repair should be performed by a
qualified operator with a complete understanding
of the entire system to avoid risk of robot damage
and personal injury.
 When replacing the components, avoid foreign
object going into the robot.

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3.4 End Effector

The end effector can be classified as two types:
A. Gripper: Used to load and unload, such as pneumatic gripper, electric
gripper and vacuum sucker.
B. Tool: Used to process, such as welding, cutting and surface treatment.

 More attention must be paid to the design of the

end effector to prevent power loss or any other
errors that could lead to workpiece falling or
damage.
 The tool-type end effector is usually equipped
with high voltage, high temperature and active
rotary shaft. Special attention should be paid to the
operating safety.
 The end effector should be mounted firmly on the
robot to avoid workpiece fall during operation
which may cause personal injury or hazard.
 The end effector may be equipped with its own
control unit. During installation, pay attention to
installed location. Ensure that the control unit does
not interfere with robot operation.
 The gripper-type end effector should prevent the
workpiece from dropping or damaging when the
robot experiences a power error or other errors. If
potential dangers or abnormal situations exist
when using end effector, the associated hazards
must be handled by the system integrator in
accordance with the related standards.0
3.5 Pneumatic, Hydraulic System
 When using the pneumatic or hydraulic system,
the gripped workpiece may fall due to insufficient
pressure or gravity.
 The pneumatic or hydraulic system must be
equipped with the relief valve, so that it can be
applied in an emergency.
 More attention should be paid to the pressure
remained in the pneumatic systems after the power
is disconnected.
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 The internal pressure must be released before the

pneumatic systems are maintained.
 More attention should be paid to the pressure in
the pneumatic system as it is several times more
than the atmosphere pressure.
3.6 Emergency Stop Switch
 The robot or other control component should have
at least one device for immediate halt, such as an
emergency stop switch.
 The emergency stop button must be installed in an
easily accessible location for quick stop.
 While executing an emergency stop, power to the
servo motor will be cut, and all movements will be
stopped. And the control system will be shut
down. Emergency stop should be reset if the
restoration of operating procedure is wanted.
 Avoid using emergency stop to replace a normal
stop procedure. This could reduce the lifespan of
the robot.
 The drive power and the control system will be
disconnected to stop all actions during the
emergency stop.
 If you want to restart the procedures, you should
reset the emergency stop switch.
 Emergency stop established an immediate stop:
Immediately stop the robot system, and
disconnect the driver power.
 The emergency stop switch is used for emergency
stop only.
 The HIWIN robot is equipped with two emergency
stop switches, where one is installed on the teach
pendant and the other is directly connected to the
controller via a cable. If additional emergency
stop switches are required, other connecting
method can be applied for the same purpose.
 Based on the relevant industrial safety regulations,
the emergency stop switch is directly connected to
the controller of the robot via the physical wires.
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 If the version of the braking is not applied to the

whole axis, once the emergency stop is executed
and the heavy objects are loaded on the robot end,
the axis without brake will move due to gravity.
This attention must be paid for safety issue.

4. Intended use
HIWIN robots are industrial robots and intended for pick-and-place, handling,
assembling, deburring, grinding and polishing. Use is only permitted under the
specified environment, for more detailed information please see section 2.5
environmental conditions.
Use is not permitted under the following conditions:

 Use in potentially explosive environments

 Use without performing risk assessments

 Transportation of people and animals

 Operation outside the allowed operating parameters

5. Disposal
The disposal of HIWIN robot shall be in accordance with the local environmental
regulations.

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Content
1. Specification........................................................................................................ 15
1.1 Standard Specification ............................................................................. 15
1.2 Description of Model Nam ...................................................................... 17
1.3 Standard and Optional Equipment ........................................................... 18
1.4 Appearance Dimensions .......................................................................... 21
1.5 Appearance Component ........................................................................... 23
1.6 Operating Environment ............................................................................ 24
1.7 Sticker and Label ..................................................................................... 25
2. Installation .......................................................................................................... 27
2.1 Installation Dimensions ........................................................................... 27
2.2 Multifunctional Installation Frame .......................................................... 29
2.3 Overview of industrial robot .................................................................... 31
2.4 Controller Boot/Shutdown Program Description..................................... 33
2.5 Power & Signal Cable Connection (CN2) ............................................... 37
2.6 Emergency Stop Switch Connection (CN3) ............................................ 38
3. External Input / Output..................................................................................... 41
3.1 Function I/O ............................................................................................. 42
3.2 Digital I/O ................................................................................................ 43
3.3 Example of Connection............................................................................ 44
3.4 External I/O Expansion Module .............................................................. 50
3.5 RS-232 Port .............................................................................................. 55
3.6 CC-Link interface card ............................................................................ 60
3.7 PROFINET IO interface card .................................................................. 61
4. Teach Pendant .................................................................................................... 62
4.1. Teach Pendant .................................................................................................. 62
4.2. Teach Pendant Shortcut Connector .................................................................. 64
5. Maintenance ....................................................................................................... 65
5.1. Fan Cotton Filter .............................................................................................. 65
5.2. Fuse .................................................................................................................. 67

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Version Date Product Note

1.0.0 2020.04.15 RCA-GC Preliminary edition

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1. Specification
1.1 Standard Specification
The following table shows the standard specifications of RCA605-GC controller.
Item HIWIN Robot Controller
Model No. RCA605-GC
Controlled Manipulator RA605-710-GC RA605-909-GC
Positioning control PTP(point-to-point) / CP(continuous path)
Joint control AC servo control
Operating system HRSS
Memory Fixed point 5000
capacity Step number 10000
Teaching method Teach pendant
RS232 1
Communication Ethernet 2
interface
USB 2
Emergency stop input Input：1
External I/O Function I/O Input: 8/Output: 8
Digital I/O Input: 24/Output: 24
Input power range
Single-phase 200-240
(VAC)
Power capacity (KVA) 2
Power frequency (Hz) 50/60
Power
Voltage drop (msec) 10 or less
Rating output current
8
(A)
Current leakage (mA) 30
Weight (kg) 29
Protection rating IP23
Temperature range for workplaces (℃) 0-45
Relative humidity for workplaces(%RH) 20-75 (non-condensing)
Storage temperature range (℃) 0~55
Storage relative humidity (%RH) 20-75 (non-condensing)
Bending of Standard CN2 cable Inner diameter>160mm (Static)
Bending of optional CN2 cable for drag
Inner diameter>155mm (Dynamic)
chain application

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The following table shows the standard specifications of RCA610-GC controller.

Item HIWIN Robot Controller

Model No. RCA610-GC
RA610- RA610- RA610- RA610-
Controlled Manipulator
1355-GC 1476-GC 1672-GC 1869-GC
Positioning control PTP(point-to-point) / CP(continuous path)
Joint control AC servo control
Operating system HRSS

Memory Fixed point 5000

capacity Step number 10000
Teaching method Teach pendant
RS232 1
Communi Ethernet 2
cation
interface USB 2
Emergency stop input Input：1
External
Function I/O Input: 8/Output: 8
I/O
Digital I/O Input: 24/Output: 24
Input power range (VAC) Single-phase 200-240
Power capacity (KVA) 4
Power frequency (Hz) 50/60
Power
Voltage drop (msec) 10 or less
Rating output current (A) 18
Current leakage (mA) 30
Weight (kg) 38
Protection rating IP23
Temperature range for workplaces (℃) 0-45
Relative humidity for workplaces (%RH) 20-75 (non-condensing)
Storage temperature range (℃) 0~55
Storage relative humidity (%RH) 20-75 (non-condensing)
Static bending of Standard CN2 cable Inner diameter>200mm
Dynamic bending of Standard CN2 cable
Inner diameter>200mm
for drag chain application

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1.2 Description of Model Nam

Model example

RCA605 – GC

Identification Code
GC Version

Series
RCA605 RA605 Series articulated robot controller
RCA610 RA610 Series articulated robot controller

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1.3 Standard and Optional Equipment

Standard and optional equipment for RCA605-GC robot controller.

Item HIWIN Part No. Standard Optional Remark

Teach Pendant RC600Z001-1 ○ Refer to CH 4

Teach Pendant Shortcut Connector RC600Z001-2 ● ○ Refer to CH 4.2

CN1, Main Power Cable 3M RC600Z001-3 ● ○ Refer to CH 2.3

CN2, Power Signal Cable 3M RC600Z001-4 ● ○ Refer to CH 2.5

CN2, Power Signal Cable 5M RC600Z001-5 ○ Refer to CH 2.5

CN2, Power Signal Cable 10M RC600Z001-6 ○ Refer to CH 2.5

CN2, Power Signal Cable 3M for Drag

RC600Z001-7 ○ Refer to CH 2.5
Chain

CN2, Power Signal Cable 5M for Drag

RC600Z001-8 ○ Refer to CH 2.5
Chain

CN2, Power Signal Cable 10M for Drag

RC600Z001-9 ○ Refer to CH 2.5
Chain

CN3 Emergency Stop Switch Unit 5M RC600Z001-21 ○ Refer to CH 2.6

GC Controller Accessory Kit RC600Z001-12 ● ○ Refer to table 1

External I/O Extension Module (Note 1) RC600Z001-22 ○ Refer to table 2

D-Sub Connector Wiring Set 37P(6M) RC600Z001-26 ○ Refer to table 3

Encoder Expansion Module RC600Z001-27 ○ Refer to table 4

CC-Link interface card RC600Z001-30 ○ Refer to CH 3.7

PROFINET IO interface card RC600Z001-31 ○ Refer to CH 3.8

*Note 1:
Include Expansion card and wiring set.
Maximum Expansion: 16 Input and 16 Output.

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Standard and optional equipment for RCA610-GC robot controller.

Item HIWIN Part No. Standard Optional Remark

Teach Pendant RC600Z001-1 ○ Refer to CH 4

Teach Pendant Shortcut Connector RC600Z001-2 ● ○ Refer to CH 4

CN1, Main Power Cable 3M RC600Z001-3 ● ○ Refer to CH 2.3

CN2, Power Signal Cable 3M RC600Z001-10 ● ○ Refer to CH 2.5

CN2, Power Signal Cable 5M RC600Z001-11 ○ Refer to CH 2.5

CN3 Emergency Stop Switch Unit 5M RC600Z001-21 ○ Refer to CH 2.6

GC Controller Accessory Kit RC600Z001-12 ● ○ Refer to Table 1

External I/O Expansion Module (Note 1) RC600Z001-22 ○ Refer to Table 2

D-Sub Connector Wiring Set 37P(6M) RC600Z001-26 ○ Refer to Table 3

Encoder Expansion Module RC600Z001-27 ○ Refer to Table 4

CC-Link interface card RC600Z001-30 ○ Refer to CH 3.7

PROFINET IO interface card RC600Z001-31 ○ Refer to CH 3.8

*Note 1:
Include Expansion card and wiring set.
Maximum Expansion: 16 Input and 16 Output.

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Table 1: GC Controller accessory kit contents:

Item HIWIN Part No. Quantity Note

D-Sub Connector 15P RC600Z001-13 1 Refer to CH 2.6

Housing of D-Sub Connector 15P RC600Z001-14 1 Refer to CH 2.6

D-Sub Connector 37P RC600Z001-15 3 Refer to CH 3.4

Housing of D-Sub Connector 37P RC600Z001-16 3 Refer to CH 3.4

Cotton Filter RC600Z001-17 4 Refer to CH 5.1

Fuse 15A(Fuse1~3) RC600Z001-18 3 Refer to CH 5.2

Fuse 5A(Fuse4) RC600Z001-19 2 Refer to CH 5.2

Fuse 2A(Fuse5) RC600Z001-20 2 Refer to CH 5.2

Table 2: External I/O Expansion Module contents:

Item HIWIN Part No. Quantity Note

External I/O Extension card RC600Z001-23 1 Refer to CH 3.4

37P Terminal Block RC600Z001-24 1 Refer to CH 3.4

37P cable with D-Sub connector(6M) RC600Z001-25 1 Refer to CH 3.4

Table 3: D-Sub connector wiring set 37P contents:

Item HIWIN Part No. Quantity Note

37P Terminal Block RC600Z001-24 2 Refer to CH 3.4

37P cable with D-Sub connector(6M) RC600Z001-25 2 Refer to CH 3.4

Table 4: Encoder Expansion Module contents:

Item HIWIN Part No. Quantity Note

Encoder Capture Card RC600Z001-29 1 Refer to CH 3.4

37P Terminal Block RC600Z001-24 1 Refer to CH 3.4

37P cable with D-Sub connector(10M) RC600Z001-28 1 Refer to CH 3.4

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1.4 Appearance Dimensions

The following below shows appearance dimensions of RCA605-GC. (unit: mm)

 As a complete installation dimension, some space

needs to be reserved for the cables. Please refer to
CAUTION CH2.1.

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The following below show appearance dimensions of RCA610-GC. (unit: mm)

 As a complete installation dimension, some space

needs to be reserved for the cables. Please refer to
CAUTION CH2.1.

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1.5 Appearance Component

The function of each connector outside the GC series robot controller.

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No. Item Description

1 Power Switch Switch power ON/OFF
2 Main Power Source Inlet single phase AC220V
3 Power & Signal Connect robot controller to the robot
Connector(CN2) manipulator
4 Teach Pendant Connect to teach pendant
Connector(CN4)
5 Emergency Stop Connect to external emergency stop device
Connector(CN3)
6 Network Connector Connect to Ethernet device(Note1)
7 USB Connector Connect to USB device
8 RS232 Connector Connect to RS232 device
9 I/O Connector Connect to I/O device
10 Controller Power Indicator Display ON/OFF status
Green Light
11 Encoder Connector Connect to encoder device (403 series
standard & optional)

 Note1: Not allowed to connector with POE

equipment.
DANGER

1.6 Operating Environment

The robot controller employs the IEC protection rating as IP23. In addition, IP23
indicates the protection from the solid larger than 12mm diameters, and liquid from
60 degrees.
 The controller should not be placed at the environment
with moisture, with high temperature, under direct
sunlight or potentially explosive environment.
 Please keep the controller away from the strong
electric field or the magnetic field.
WARNING  Because the vents are set on the right side of the
controller, please ensure a space 50mm from the right.
 Please place the controller at flat place, and avoid
shaking.

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1.7 Sticker and Label

The following shows the appearance stickers and labels of GC series robot controller.

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o. Illustration Description

1 Controller specification

2 Beware of electric shock

3 Grounding

4 Transport by multiple people

5 Danger: authorized proffesionals only

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2. Installation
2.1 Installation Dimensions
The following shows the RCA605-GC robot controller connector installation space.
Please reserve some space for the connecting wires to avoid interference as they bend.
( unit: mm)

 Please make sure the assembly space is enough as

the drawings.
CAUTION  Please don’t obstruct the air flow.

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The following shows the RCA610-GC robot controller connector installation space.
Please reserve some space for the connecting wires to avoid interference as they bend.
( unit: mm)

 Please make sure the assembly space is enough as

the drawings.
CAUTION  Please don’t obstruct the air flow.

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2.2 Multifunctional Installation Frame

This controller is attached with two groups of multifunctional fixing frame while
delivering (as shown below). The fixing frame can be installed on the controller
with the handle, used for transportation. Or the controller can be fixed on other
machines to use. The assembly method of the fixing frame and the handle is shown
below. The specification of the screws is M6X1PX10L flat-head screw.

Multifunctional fixing frame can be installed on the controller. The assembly

drawing is shown below. The specification of the screws is M6X1PX8L.

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Multifunctional fixing frame can be installed under the controller. The assembly
drawing is shown below. The specification of the screws is M6X1PX8L. This
configuration is convenient for the operator to fix the controller on other machines.

The corresponding dimensions of multifunctional fixing frame

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 C24UE101-2004

2.3 Overview of industrial robot

The picture below is an example of basic connection structure. RCA605, 610 controller
needs to be supplied with single-phase AC200-240V, and the ground connection should
be separated from main power breaker. Instead of connecting the ground by devices or
system ground, the correct way is to connect to power ground directly, and high-quality
wires whose diameters are 14AWG or more must be used. The power can be turned on
and tested after connecting the main components mentioned below. Please make sure
that the grounding of manipulator must connected to the power grounding directly.

No. RCA605-GC series basic connection structure

1 CN1 Main Power Cable
2 CN2 Power & Signal Cable
3 CN3 Emergency Stop Switch
4 CN4 Teach Pendant

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 C24UE101-2004

No. RCA610-GC series basic connection structure

1 CN1 Main Power Cable
2 CN2 Power & Signal Cable
3 CN3 Emergency Stop Switch
4 CN4 Teach Pendant

 Before running for a test, please make sure that the

manipulator is securely installed to prevent from
CAUTION tipping during the motion.

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 C24UE101-2004

2.4 Controller Boot/Shutdown Program Description

Boot – Power on by flipping up the power switch.
Shutdown – HIWIN industrial robot (HRSS version 3.2.12 above, if having
previous version, it is highly recommended to update the newest version) provided
with 2 types of shutdown program. “Software shutdown” and “Digital input control
shutdown” respectively, choose either one to execute:

1. Using software to shutdown-

Procedure for shutting down are as follows:
(1) Stop the motion of the robot manipulator.
(2) Press the emergency stop button.
(3) Press the software shutdown button.

(4) Wait at least 5 seconds before switching off the power. (Switch off the
controller switch or cut off the main power directly)

 Operator must not leave until the power switch is

switched off.
CAUTION
2. Using digital input (DI) to control shutdown –
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 C24UE101-2004

Please set the option of DI/DO in the HRSS software program.

The setting method is as follows:

Step 1:
Enter HRSS function page, click Start-up -> System Setting -> DIO Setting

Step 2:
DI setting DO Setting

Please select the DI pin to be set Please select the DO pin to be set
by the customer. by the customer.

Step 3:
Please press SAVE after setting.

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 C24UE101-2004

Procedure for shutting down are as follows:

(1) Press the emergency stop button.
(2) Two types of method: (select either one to execute)
a. After connecting digital input (DI) to trigger shutdown, wait at least 5 seconds
before switching off the power. (Switch off the controller switch or cut off the
main power directly)
b. After connecting digital input (DI) to trigger shutdown, the controller should
receive the digital output (DO) feedback to switch off the power.
(Automatically generated by the system without additional control)
(Switch off the controller switch or cut off the main power directly)

 Operator must not leave until the power switch is

switched off.
CAUTION

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 C24UE101-2004

Digital Input Shutdown Timing:

 If the above procedure is not completed, please do

not directly switch off the power switch on the
controller or cut off the main power. Improper
shutdown could cause damage to the controller.
 Please wait for 30 seconds to reboot. Do not
reboot immediately after switching off the power
switch.
 If stopping a robot in motion is required, please
WARNING
avoid using emergency button. To stop the
program, press the stop button.
 Please stop the motion of the manipulator before
shutting down. Then perform the shutdown
procedure to avoid unexpected danger when the
power is cut off during the motion.

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 C24UE101-2004

2.5 Power & Signal Cable Connection (CN2)

Description:
Connect the power & signal cable (CN2) of the
manipulator to the controller.
The standard specifications are as follows:
Applicable Model Length HIWIN Part No.
605 Series 3m RC600Z001-4
610 Series 5m RC600Z001-10

Connection method:

The motor connection port on

the controller is CN2 connector
which is designed fool-proofing
function. If it cannot be
plugged in, please rotate and
connect it again. RCA605-GC RCA610-GC

Plug the cable into CN2

connector, and secure the safety
lock indeed.

 Plug the connector in the direction parallel to the

pins to avoid the internal pins being crooked and
deformed.
 According to different operating condition, the
WARNING temperature of the cable would rise slightly.
Remove plastic cover before connection.
 Please avoid severe impact while installation.

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 C24UE101-2004

2.6 Emergency Stop Switch Connection (CN3)

Description:

Connector CN3 is a female DSUB-15 connector for

emergency stop.
Emergency stop switch (optional equipment) is a button box
with a 5m wire. It should be placed at the position, which is
easy to reach. DSUB-15 soldering connector is included in
the connector kit.

Emergency stop switch wiring diagram

Controller emergency stop connector is a dual circuit contact, which should be

connected with an external dual circuit emergency stop device additionally. This
device should be a dry contact (uncharged) switch. Ensure the connector is connected
correctly and the emergency stop device is accessible to the operator before the robot
functions.

 The emergency stop device must be connected with

the controller and be placed at the position accessible
to operator. Wrong method of using can cause a
DANGER
severe damage or loss of life and property.

Please consider that the safety application from HIWIN

from the requirement of the European union regulation:
CAUTION  EMO device, refer to EN 60947-5-1 with positive
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 C24UE101-2004

opening(approved component), dual NC contact, can

be self-latch.
 Safety Door switch with lock or without lock
function, refer to EN 60947-5-1 (approved
component), with positive opening and dual NC
contact.
 All the safety function actuated need to be reset the
control function through “manual reset”.

Connection Method:

The connector of emergency stop

device on controller is CN3 which is
designed fool-proofing function. If it
cannot be plugged in, please rotate
and connect it again.

Plug the connector into CN3 and

secure the screws indeed. The screw
tightening torque is suggested to be
4kg-m.

 Please insert the connector with the parallel

direction to the pins, to prevent the pins from
WARNING
bending.
 Depend on the application situation of Robots,
the temperature on the cables might be raised.
Please remove the external plastic protection

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 C24UE101-2004

bags before connection.

 Please prevent the connector from external
force or impact while disassembly or placing.

 Please ensure this emergency stop switch and

the emergency stop on the teach pendant are
all reset before the robot functions.
 The external device connected to the
CAUTION emergency stop switch circuit should be dry
contact (uncharged) switch. The charged
circuit is forbidden.

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3. External Input / Output

Description:
External Input/ Output consists of two DSUB-37, including FI8/FO8 and DI24/DO24.
An external I/O wiring set (optional equipment) contains connecting wire and terminal
block. Connector kit contains DSUB-37 soldering connector. External I/O expansion
module (optional equipment) can be expanded 16 more input and 16 more output.
There are two types of controller external I/O:
(1) Function I/O (FI/O) specific function I/O
(2) Digital I/O (DI/O) external I/O for customer’s configuration

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 C24UE101-2004

3.1 Function I/O

Description:
Standard equipment has function I/O of 8IN/8OUT, which are all in the D37PIN-1
connector.

Function I/O List

INPUT
Pin Parameter Function
2 START Execute program
3 HOLD Pause program
4 STOP Stop program
5 ENBL Enable Function I/O
6 RSR1/PNS1 Robot service request 1 / program selection 1
7 RSR2/PNS2 Robot service request 2 / program selection 2
8 RSR3/PNS3 Robot service request 3 / program selection 3
9 RSR4/PNS4 Robot service request 4 / program selection 4
OUTPUT
Pin Parameter Function
21 RUN Program running
22 HELD Program pausing
23 FAULT Controller failure
24 READY Controller ready
25 ACK1/SNO1 RSR 1 feedback signal / selection program No. 1
26 ACK2/SNO2 RSR 2 feedback signal / selection program No. 2
27 ACK3/SNO3 RSR 3 feedback signal / selection program No. 3
28 ACK4/SNO4 RSR 4 feedback signal / selection program No. 4

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 C24UE101-2004

3.2 Digital I/O

Description:
Standard equipment has 24IN/24OUT digital I/O, distributed in D37PIN-1 and
D37PIN-2 connectors.

Digital I/O List

D37PIN-1 D37PIN-2
Pin Parameter Pin Parameter Pin Parameter Pin Parameter
10 DI[1] 29 DO[1] 2 DI[9] 21 DO[9]
11 DI[2] 30 DO[2] 3 DI[10] 22 DO[10]
12 DI[3] 31 DO[3] 4 DI[11] 23 DO[11]
13 DI[4] 32 DO[4] 5 DI[12] 24 DO[12]
14 DI[5] 33 DO[5] 6 DI[13] 25 DO[13]
15 DI[6] 34 DO [6] 7 DI[14] 26 DO[14]
16 DI[7] 35 DO [7] 8 DI[15] 27 DO[15]
17 DI[8] 36 DO [8] 9 DI[16] 28 DO[16]
10 DI[17] 29 DO[17]
11 DI[18] 30 DO[18]
12 DI[19] 31 DO[19]
13 DI[20] 32 DO[20]
14 DI[21] 33 DO[21]
15 DI[22] 34 DO[22]
16 DI[23] 35 DO[23]
17 DI[24] 36 DO[24]

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3.3 Example of Connection

1. External OUTPUT are all NPN (current sinking) output and OUTPUT signal is 0V.

Pin20 (0V) and pin37 (24V) are supply voltage for OUTPUT which is supplied by

external power source and the power connection cannot be reversed.

2. External INPUT can be NPN (current sinking) or PNP (current sourcing) input, adjusted

with pin18 (COM). Pin19 (0V) is supply voltage for INPUT which is supplied by

external power source and the power connection cannot be reversed.

 COM→24V: NPN INPUT

 COM→0V: PNP INPUT

3. Pin20 (0V) and pin37 (24V) of OUTPUT in the same DSUB-37 connector are the

supply voltage, which should be connected to the same power supply.

4. Pin 18 (COM) and pin19 (0V) of INPUT in the same DSUB37 connector should be

connected to the same power supply. The COM voltage level, which is the same, cannot

be separated.

5. OUTPUT and INPUT in the same DSUB-37 connector can be connected to different

power supplies to provide reference voltage level.

6. D37PIN-1 and D37PIN-2 can be connected to different power supplies to provide

reference voltage level.

 The maximum current at the single output

supplied by external output is 100mA.
 The OUTPUT supplied by controller is all NPN
output, which cannot be modified. The INPUT
CAUTION
can be modified into NPN or PNP type by
adjusting COM voltage.

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 C24UE101-2004

D37PIN-1
INPUT: NPN OUTPUT: NPN

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 C24UE101-2004

D37PIN-1
INPUT: PNP OUTPUT: NPN

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 C24UE101-2004

D37PIN-2
INPUT: NPN OUTPUT: NPN

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D37PIN-2
INPUT: PNP OUTPUT: NPN

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 C24UE101-2004

Connection method:

There are two I/O connectors

(DSUB-37) on the controller which is
designed fool-proofing function. If it
cannot be plugged in, please rotate
and connect it again.

Plug the connector in and secure the

screw indeed. The screw tightening
torque is suggested to be 4kg-m.

 No signal or power supply should be close to or

in contact with any metal case. Wrong method of
using can cause a severe damage or loss of life
DANGER
and property.

 To prevent the internal component from damage,

any wiring operation must be done only when the
WARNING
controller is disconnected.

 Please make sure the screws on the connector are

secured.
CAUTION

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3.4 External I/O Expansion Module

External I/O expansion module are all digital I/O and the pin assignment is shown
below:

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 C24UE101-2004

Description:
External I/O expansion module has 16IN/16OUT digital I/O, distributed in D37PIN-3
connector.

External Expansion I/O List

D37PIN-3
Pin Parameter Pin Parameter
2 DI[25] 21 DO[25]
3 DI[26] 22 DO[26]
4 DI[27] 23 DO[27]
5 DI[28] 24 DO[28]
6 DI[29] 25 DO[29]
7 DI[30] 26 DO[30]
8 DI[31] 27 DO[31]
9 DI[32] 28 DO[32]
10 DI[33] 29 DO[33]
11 DI[34] 30 DO[34]
12 DI[35] 31 DO[35]
13 DI[36] 32 DO[36]
14 DI[37] 33 DO[37]
15 DI[38] 34 DO[38]
16 DI[39] 35 DO[39]
17 DI[40] 36 DO[40]

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 C24UE101-2004

D37PIN-3
INPUT: NPN OUTPUT: NPN

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 C24UE101-2004

D37PIN-3
INPUT: PNP OUTPUT: NPN

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 C24UE101-2004

Actual Wiring Example

Take OMRON E6B2-CWZ1X as an example, the encoder required extra supply of
5V, CH1 as an input example.
Color Terminal
Brown Power supply(+Vcc)
Blue 0V(common)
Black Output phase A
White Output phase B
Orange Output phase Z
Black/red stripes Output phase A
White/red stripes Output phase B
Orange/red stripes Output phase Z

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3.5 Encoder Expansion Module

Description:
There is 4 channel of encoder signal input, CH1~CH4.
The Latch signal is IDI1~IDI4.
IDICOM can decide the input signal to be NPN or PNP.

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 C24UE101-2004

Encoder channel list:

腳位 參數名 腳位 參數名
1 EGND 20 CH1A-
2 CH1A+ 21 CH1B-
3 CH1B+ 22 CH1Z-
4 CH1Z+ 23 CH2A-
5 CH2A+ 24 CH2B-
6 CH2B+ 25 CH2Z-
7 CH2Z+ 26 CH3A-
8 CH3A+ 27 CH3B-
9 CH3B+ 28 CH3Z-
10 CH3Z+ 29 CH4A-
11 CH4A+ 30 CH4B-
12 CH4B+ 31 CH4Z-
13 CH4Z+ 32 EGND
14 IDICOM 33 IDI2
15 IDI1 34 IDI4
16 IDI3 35 EGND
17 EGND

 The maximum output current is 50mA for all

channel.
CAUTION

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 C24UE101-2004

Example:
Take OMRON E6B2-CWZ1X as an example, the encoder needs an external 5V
power, and the input is CH1.
Color 端子
Brown Power(+Vcc)
Blue 0V
Black Output phase A
White Output phase B
Black/Red Output phase A
White/Red Output phase B

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 C24UE101-2004

3.6 RS-232 Port

Description:
The following figure shows the pin assignment of RS-232 controller.

Pin Description
2 RXD-Receiver
3 TXD-Transmit
5 GND -Ground

The following figure shows the connection method with external device.

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 C24UE101-2004

Connection method:

The I/O connector of controller is

COM1, which is designed fool-
proofing function. If it cannot be
plugged in, please rotate and connect
it again.

Plug the connector in and secure the

screw indeed. Recommended
screwing torque is 4kg-m.

 No signal or power supply should be close to or

in contact with any metal case. Wrong method of
using can cause a severe damage or loss of life
DANGER
and property.

 To prevent the internal component from damage,

any wiring operation must be done only when the
WARNING controller is disconnected.

 Please make sure the screws on the connector are

secured.
CAUTION

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 C24UE101-2004

3.7 CC-Link interface card

CC-Link pin assignment is showed below:

腳位 訊號 意義

1 DA Data A
2 DB Data B
3 DG Data Ground
4 SLD Shield
5 FG Field Ground

Recommended extension card configuration:

Configuration CN5 CN6 CN7
Only CC-Link CC-Link
CC-Link+I/O CC-Link I/O-1 I/O-2
CC-Link+EN EN CC-Link

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3.8 PROFINET IO interface card

PROFINET IO pin assignment is showed below:

腳位 訊號 意義

1 TX+ Transmit Data +

2 TX- Transmit Data -
3 RX+ Receive Data +
4 TERM 1 Connected to each other and
5 TERM 1 terminated to PE through RC circuit

6 RX- Receive Data -

7 TERM 2 Connected to each other and
8 TERM 2 terminated to PE through RC circuit

Recommended extension card configuration:

擴充選擇搭配 CN5 CN6 CN7
僅 PROFINET IO PROFINET IO
PROFINET IO+I/O PROFINET IO I/O-1 I/O-2
PROFINET IO+EN EN PROFINET IO

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4. Teach Pendant

4.1. Teach Pendant

Description:
The Teach Pendant provides the program edit, program management and motion
position teaching etc. In addition, for user’s safety, the Teach Pendant is equipped with
the Emergency Stop Switch and the Enable Switch

Specification:
Item HIWIN Robot Teach Pendant
Model No. TP02
Dimensions 318x245x107 mm3
Weight 2.5kg
Protection Rating IP20
Display 10.2” touch screen
Resolution 1024x768 pixels
Mode Manual, Auto and Lock
Physical Button 20keys＋Enable Switch＋Emergency Stop Switch + Key Switch
Cable Length 5M

 It is forbidden to use Teach Pendant in the high

dust concentration and high grease concentration
environment since its protection rating is IP20.
WARNING  To ensure the Teach Pendant functions normally,
any impact and fall are forbidden.
Names and functions on Teach Pendant

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 C24UE101-2004

Button Definition:
No. Item Function Description
1 Emergency Stop Disable servo and directly stop the robot.
Switch
2 Mode Switch Switch mode among Manu, Auto and Lock
3 XY-Axis T1 Key In the T1 mode, control the movement in XY-axis.
4 Z-Axis T1 Key In the T1 mode, control the movement in Z-axis.
5 Speed Key Adjust the robot speed
6 T1 Key Adjust the value in each axis in the different mode.
When pressing one of the switches, the robot can start
7 Enable Switch(Note 1) to move; the robot will stop directly when releasing this
switch or pressing it to the end.

*Note 1: instruction on enable switch:

In T1 and T2 mode, the enable switch must be held at center position to start the
robot. In Auto mode (AUT) and External Auto mode (EXT), the enable switch
should be held at center position only in the moment it starts, and then release.
The Enable Switch has three positions:
(1) Not pressed The robot can’t move.
(2) Center position The robot can move and teach
(3) Fully pressed The robot can’t move.
In addition, the enable switch on both side has the same function.

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 C24UE101-2004

4.2. Teach Pendant Shortcut Connector

Description:
While using the controller without teach pendant, please insert the Teach
Pendant Shortcut Connector into the CN4 connector.
Please shutdown the controller power when removing the teach pendant and
inserting the shortcut connector.

Please insert the Teach Pendant

Shortcut Connector into the CN4
connector.
Please align the arrow mark and
buckle the safety lock authentically.

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 C24UE101-2004

5. Maintenance

5.1. Cotton Filter of Fans

Every air inlet outside the cabinet contains cotton filter, which has the function of
blocking external foreign matter, enhancing the air convection and aid heat
dissipation. Please decide the frequency of cotton filter replacement according to
working environment.

 Schematic diagram 1.
(1) Remove M4X0.7PX12L Phillips screws on the cover.
(2) Replace internal cotton filter. (HIWIN part number: RC600Z001-17)
(3) Install the cover in order.

 The accumulation of foreign matter causing

internal cotton filter experiencing poor
convection. It may cause the internal occurring
CAUTION
over-temperature and crash.

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 C24UE101-2004

 Schematic diagram 2.
(1) Remove M4X0.7PX12L Phillips screws on the cover.
(2) Replace internal cotton filter. (HIWIN part number: RC600Z001-17)
(3) Install the cover in order.

 Air flow direction:

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 C24UE101-2004

5.2. Fuse
If encountered the following two situations, please try to open the controller cover and
check whether the internal fuse has melted:

RCBCDZ023

RCBCDZ033

1. If unable to start the controller, please follow the steps below to replace the
fuse:
(1)Remove 11 pieces of M4X0.7PX12L Phillips screws on the cover and
remove the cover.
(2)Check FUSE1, FUSE2, FUSE3 on RCBCDZ023.
(3)Remove the protective cover of the fuse, if the fuse is melted, replace a
new fuse.
(4)The specification of FUSE1, FUSE2, FUSE3 are 15A 5*20mm glass fuse.
(5)After replacing a new fuse, cover the fuse with protective cover.
(6)Check FUSE1 on RCBCDZ033, if the fuse is melted, please replace a new
fuse LITTELFUSE 0297005 5A(HIWIN part number: RC600Z001-19)
(7)Close the cover and secure the screws.

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 C24UE101-2004

 When replacing the fuse, it should be replaced

straight up and down, and should not over
expanded the shrapnel.
 Before installation, please press the shrapnel
inwards gently to keep the distance between the
top ends of the shrapnel slightly less than 5mm,
CAUTION and then install the fuse.
 After the fuse is replaced, it is recommended
that the customer use a multimeter to measure
(The both ends of the solder joint of the fuse
base has a resistance value less than 0.5Ω)

RCBCDZ023 FUSE1
FUSE2
FUSE3

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 C24UE101-2004

2. If abnormal sound is produced during the operation of the arm or an error code
02-02-11 appeared during automatic running
(1)Remove 11 pieces of M4X0.7PX12L Phillips screws on the cover and
remove the cover.
(2)Check FUSE5 on RCBCDZ033, if the fuse is melted, please replace a new
fuse LITTELFUSE 0297002 2A (HIWIN Part No.: RC600Z001-20)
(3)Close the cover and secure the screws.

FUSE5 FUSE4
RCBCDZ033

 Make sure the controller is disconnected to the

power supply before replacing the fuse.
 Replacing fuses with different ampere or other
WARNING conductive materials (Iron wire, Iron sheet) are
forbidden.

69
Articulated Robot Controller - GC Series (Original Instruction)
User Manual
Publication Date：April 2020

1. HIWIN is a registered trademark of HIWIN Technologies Corp. For your protection, avoid buying
counterfeit products from unknown sources.
2. Actual products may differ from specifications and photos provided in this catalog. These differences
may be the result of various factors including product improvements.
3. HIWIN website for patented product directory: http://www.hiwin.tw/Products/Products_patents.aspx
4. HIWIN will not sell or export products or processes restricted under the "Foreign Trade Act" or
related regulations. Export of restricted products should be approved by proper authorities in
accordance with relevant laws and shall not be used to manufacture or develop nuclear, biochemical,
missiles or other weapons.

Copyright © HIWIN Technologies Corp.

 Subsidiaries / Research Center

HIWIN GmbH HIWIN Schweiz GmbH HIWIN KOREA HIWIN TECHNOLOGIES CORP.
OFFENBURG, GERMANY JONA, SWITZERLAND SUWON‧CHANGWON, KOREA No. 7, Jingke Road,
www.hiwin.de www.hiwin.ch www.hiwin.kr Taichung Precision Machinery Park,
www.hiwin.eu [email protected] [email protected]
[email protected] Taichung 40852, Taiwan
Tel: +886-4-23594510
Fax: +886-4-23594420
www.hiwin.tw
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TOHOKU‧SHIZUOKA．HOKURIKU‧ www.hiwin.cz www.hiwin.cn
HIROSHIMA‧FUKUOKA‧KUMAMOTO, [email protected] [email protected]
JAPAN
www.hiwin.co.jp
[email protected]

HIWIN USA HIWIN SINGAPORE Mega-Fabs Motion Systems, Ltd.

CHICAGO, U.S.A. SINGAPORE HAIFA, ISRAEL
www.hiwin.com www.hiwin.sg www.mega-fabs.com
[email protected] [email protected] [email protected]

HIWIN Srl
BRUGHERIO, ITALY
www.hiwin.it
[email protected]

Copyright © HIWIN Technologies Corp.

The specifications in this catalog are subject to change without notification. ©2020 FORM C24UE101-2004 (PRINTED IN TAIWAN)