CR800 Series Controller INSTRUCTION MANUAL Controller Setup, Basic Operation, and Maintenance Bfp-A3476d

Mitsubishi Electric Industrial Robot
CR800 Series Controller

INSTRUCTION MANUAL
Controller setup, basic operation, and maintenance
CR800-D
CR800-R
CR800-Q
BFP-A3476-D
Safety Precautions
Always read the following precautions and the separate "Safety
Manual" before starting use of the robot to learn the required
measures to be taken.
CAUTION All teaching work must be carried out by an operator who has received special
training. (This also applies to maintenance work with the power source turned
ON.)
Enforcement of safety training
CAUTION For teaching work, prepare a work plan related to the methods and procedures
of operating the robot, and to the measures to be taken when an error occurs
or when restarting. Carry out work following this plan. (This also applies to
maintenance work with the power source turned ON.)
Preparation of work plan
WARNING Prepare a device that allows operation to be stopped immediately during

teaching work. (This also applies to maintenance work with the power source
turned ON.)
Setting of emergency stop switch
CAUTION During teaching work, place a sign indicating that teaching work is in progress
on the start switch, etc. (This also applies to maintenance work with the power
source turned ON.)
Indication of teaching work in progress
DANGER Provide a fence or enclosure during operation to prevent contact of the

operator and robot.
Installation of safety fence
CAUTION Establish a set signaling method to the related operators for starting work, and
follow this method.
Signaling of operation start
CAUTION As a principle turn the power OFF during maintenance work. Place a sign
indicating that maintenance work is in progress on the start switch, etc.
Indication of maintenance work in progress
CAUTION Before starting work, inspect the robot, emergency stop switch and other
related devices, etc., and confirm that there are no errors.
Inspection before starting work
The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.
DANGER When automatic operation of the robot is performed using multiple control
devices (GOT, programmable controller, push-button switch), the interlocking of
operation rights of the devices, etc. must be designed by the customer.
CAUTION Use the robot within the environment given in the specifications. Failure to do
so could lead to a drop or reliability or faults. (Temperature, humidity,
atmosphere, noise environment, etc.)
CAUTION Transport the robot with the designated transportation posture. Transporting
the robot in a non-designated posture could lead to personal injuries or faults
from dropping.
CAUTION Always use the robot installed on a secure table. Use in an instable posture
could lead to positional deviation and vibration.
CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
CAUTION Do not apply excessive force on the connector or excessively bend the cable.
Failure to observe this could lead to contact defects or wire breakage.
CAUTION Make sure that the workpiece weight, including the hand, does not exceed the
rated load or tolerable torque. Exceeding these values could lead to alarms or
faults.
WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or
flies off during operation.
WARNING Securely ground the robot and controller. Failure to observe this could lead to
malfunctioning by noise or to electric shock accidents.
CAUTION Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
WARNING When carrying out teaching work in the robot's movement range, always secure
the priority right for the robot control. Failure to observe this could lead to
personal injuries or damage if the robot is started with external commands.
CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do
so could lead to interference with the workpiece or peripheral devices.
CAUTION After editing the program, always confirm the operation with step operation
before starting automatic operation. Failure to do so could lead to interference
with peripheral devices because of programming mistakes, etc.
CAUTION Make sure that if the safety fence entrance door is opened during automatic
operation, the door is locked or that the robot will automatically stop. Failure to
do so could lead to personal injuries.
CAUTION Never carry out modifications based on personal judgments, or use non-
designated maintenance parts.
Failure to observe this could lead to faults or failures.
WARNING When the robot arm has to be moved by hand from an external area, do not
place hands or fingers in the openings. Failure to observe this could lead to
hands or fingers catching depending on the posture.
CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's
main power OFF. If the robot controller main power is turned OFF during
automatic operation, the robot accuracy could be adversely affected. Moreover,
it may interfere with the peripheral device by drop or move by inertia of the arm.
CAUTION Do not turn off the main power to the robot controller while rewriting the
internal information of the robot controller such as the program or parameters.
If the main power to the robot controller is turned off while in automatic
operation or rewriting the program or parameters, the internal information of the
robot controller may be damaged.
DANGER Do not connect the Handy GOT when using the GOT direct connection function
of this product. Failure to observe this may result in property damage or bodily
injury because the Handy GOT can automatically operate the robot regardless
of whether the operation rights are enabled or not.
DANGER Do not connect the Handy GOT to a programmable controller when using an iQ
Platform compatible product with the CR800-R/CR800-Q controller. Failure to
observe this may result in property damage or bodily injury because the Handy
GOT can automatically operate the robot regardless of whether the operation
rights are enabled or not.
DANGER Do not remove the SSCNET III cable while power is supplied to the multiple
CPU system or the servo amplifier. Do not look directly at light emitted from
the tip of SSCNET III connectors or SSCNET III cables of the Motion CPU or
the servo amplifier. Eye discomfort may be felt if exposed to the light.
(Reference: SSCNET III employs a Class 1 or equivalent light source as
specified in JIS C 6802 and IEC60825-1 (domestic standards in Japan).)
DANGER Do not remove the SSCNET III cable while power is supplied to the controller.
Do not look directly at light emitted from the tip of SSCNET III connectors or
SSCNET III cables. Eye discomfort may be felt if exposed to the light.
(Reference: SSCNET III employs a Class 1 or equivalent light source as
specified in JIS C 6802 and IEC60825-1 (domestic standards in Japan).)
DANGER Attach the cap to the SSCNET III connector after disconnecting the SSCNET
III cable. If the cap is not attached, dirt or dust may adhere to the connector
pins, resulting in deterioration connector properties, and leading to malfunction.
CAUTION Make sure there are no mistakes in the wiring. Connecting differently to the way
specified in the manual can result in errors, such as the emergency stop not
being released. In order to prevent errors occurring, please be sure to check
that all functions (such as the teaching box emergency stop, customer emer-
gency stop, and door switch) are working properly after the wiring setup is com-
pleted.
CAUTION Use the network equipments (personal computer, USB hub, LAN hub, etc)
confirmed by manufacturer. The thing unsuitable for the FA environment
(related with conformity, temperature or noise) exists in the equipments
connected to USB. When using network equipment, measures against the noise,
such as measures against EMI and the addition of the ferrite core, may be
necessary. Please fully confirm the operation by customer. Guarantee and
maintenance of the equipment on the market (usual office automation
equipment) cannot be performed.
CAUTION To maintain the safety of the robot system against unauthorized access from
external devices via the network, take appropriate measures.
To maintain the safety against unauthorized access via the Internet, take mea-
sures such as installing a firewall.
*CR800 controller
Notes of the basic component are shown.
CAUTION Please install the earth leakage breaker in the primary side power supply of the
controller because of leakage protection.
㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼞㼑㼍㼞

㻭㻯㻞㻜㻜㼂㻭㻯㻞㻜㻜㼂
㻼㼞㼕㼙㼍㼞㼥㻌㼟㼕㼐㼑
Note 1)
㻱㼍㼞㼠㼔㻌㼘㼑㼍㼗㼍㼓㼑㻌㻭㻯㻵㻺㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻭㻯㻵㻺㻌㼏㼍㼎㼘㼑
㼎㼞㼑㼍㼗㼑㼞㻌㻔㻺㼂㻕㻔㼍㼠㼠㼍㼏㼔㼙㼑㼚㼠㻕㻼㻱㻌㻔㼜㼞㼛㼠㼑㼏㼠㼕㼢㼑㻌㼑㼍㼞㼠㼔㻕㻌㼠㼑㼞㼙㼕㼚㼍㼘
㻹㻠㻌㼟㼏㼞㼑㼣
㻿㼑㼏㼛㼚㼐㼞㼥㻌㼟㼕㼐㼑
㻸㻝㻸㻞㻸㻟㻸㻺
㻳㼞㼛㼡㼚㼐㼕㼚㼓㻌㼏㼍㼎㼘㼑
㻼㻱㻌㼠㼑㼞㼙㼕㼚㼍㼘
Note 1) Always use the terminal cover for the earth leakage breaker.
1) Prepare the following items.

Part name Specifications Remarks
Earth leakage breaker The following is recommended product. Prepared by customer.

Single phase: NV30FAU-2P-10A-AC100-240V-30mA
(Terminal cover: TCS-05FA2)
Three phase: NV30FAU-3P-10A-AC100-240V-30mA
Cable for primary power supply AWG14 (2mm2) or above Prepared by customer.
Tightening torque for terminal
fixing screw is 2 ～ 3Nm.
Grounding cable AWG14 (2mm2) or above Prepared by customer.

ACIN cable Terminal: M5, cable length: 3m Supplied with the product.
2) Confirm that the primary power matches the specifications.
3) Confirm that the primary power is OFF and that the earth leakage breaker power switch is OFF.
4) Connect the ACIN cable to the breaker.
Connect the power terminals of the ACIN cable to the secondary side terminals of the earth leakage breaker.
Also, ground the FG terminal of the cable.
5) Connect the ACIN cable to the ACIN connector on the rear of the controller.
6) Connect one end of the grounding cable to the PE (protective earth) terminal on the controller and ground the
other end (2-point grounding) in order to comply with the requirements of EN 61800-5-1 for the touch cur-
rent of 3.5 mA AC or more.
7) Connect the primary power cable to the primary side terminal of the earth leakage breaker.
Revision history
Date of print Specifications No. Details of revisions
2017-04-25 BFP-A3476 ・ First print
2017-09-25 BFP-A3476-A ・ ”4.3.2 Input the serial number” was added.
2017-11-01 BFP-A3476-B ・ Description of countermeasures against unauthorized access was added.

・ Descriptions of CR800-R controller in “4.1.1 Names of each parts” were
supplemented.
2018-03-01 BFP-A3476-C ・ Descriptions of CR800-Q controller were added.
2018-09-01 BFP-A3476-D ・ ”3.1 Installing/removing the Option Card” was modified.

■ Introduction
Thank you for purchasing the Mitsubishi industrial robot.

This instruction manual explains the unpacking methods, installation, basic operation, maintenance and
inspection of the controller.
Always read through this manual before starting use to ensure correct usage of the robot.
The optional equipments and power supply voltage are different according to connecting robot type.
Refer to separate "Standard Specifications Manual" for detail.
The information contained in this document has been written to be accurate as much as possible. Please
interpret that items not described in this document "cannot be performed."
This document explains for CR800 series controller.
Installation of the emergency stop switch

To be able to stop the robot immediately at the time of the abnormalities because of safety, please
install the emergency stop switch in the position which is certainly easy to operate it, and connect with
the controller. Refer to the Page 24, "2.3.6 Connecting the external emergency stop and mode selector
switch" for the connection method.
And, the connection method of the door switch or the mode selector switch is also indicated here.
Please use it together with the emergency stop switch.
Synchronous connection of the addition axis servo power supply

It is building the circuit so that the output point of contact (the contactor control output for addition
axes: AXMC) installed in the controller may be used in use of the addition axis function and the power
supply of the servo amplifier for addition axes may be shut down by opening of this output,The servo
ON/OFF state of the addition axis can be synchronized with the servo ON/OFF state of the robot arm.
With reference to Page 35, "2.3.8 Magnet contactor control connector output (AXMC) for addition
axes", I ask you to have synchronous connection made.
Notice
*ONLY QUALIFIED SERVICE PERSONNEL MAY INSTALL OR SERVICE THE ROBOT SYSTEM.
*ANY PERSON WHO PROGRAM, TEACHES, OPERATE, MAINTENANCE OR REPAIRS THE ROBOT
SYSTEM IS TRAINED AND DEMONSTRATES COMPETENCE TO SAFELY PERFORM THE
ASSIGNED TASK.
*ENSURE COMPLIANCE WITH ALL LOCAL AND NATIONAL SAFETY AND ELECTRICAL CODES
FOR THE INSTALLATION AND OPERATION OF THE ROBOT SYSTEM.
・ No part of this manual may be reproduced by any means or in any form, without prior consent from
Mitsubishi.
・ The details of this manual are subject to change without notice.
・ The information contained in this document has been written to be accurate as much as possible.
Please interpret that items not described in this document "cannot be performed." or "alarm
may occur".
Please contact your nearest dealer if you find any doubtful, wrong or skipped point.
・ This specifications is original.
・ Company names and production names in this document are the trademarks or registered trade-
marks of their respective owners.
Copyright(C) 2017-2018 MITSUBISHI ELECTRIC CORPORATION
For users operating robots that have not been mounted with an operation panel:
Operation of robot programs such as start-up and shutdown are carried out using external signals
(exclusive input/output signals). This instruction manual is based on key operations on the teaching
pendant and operation in the operation screen of the teaching pendant. Using the parameter set-
tings, please assign exclusive input/output signals that correspond with each operation to general
purpose input/output signals, and operate the robot using signal operations.
The following table details exclusive input/output signals that correspond with the key operations of
the operation panel explained in this manual. Please use this as a reference to assign signals and
operate the robot.
For further details regarding parameters please see the separate instruction manual "Detailed expla-
nations of functions and operations".
Table: Dedicated I/O signals corresponding to the teaching pendant (T/B) operations
Parameter Default
T/B operation Class Function
name setting
Start START Input Starts a program. 3,0
In operation
Output Indicates that a program is being executed.
[STOP] key STOP Input Stops a program. 0,-1
Standby
Output Indicates that the program is paused.
[RESET] key ERRRESET Input Releases the error state. 2,2
ERROR lamp
Program reset Output Indicates that an error has occurred.
SLOTINIT Input Cancels the paused status of the program and brings the exe- -1,-1
cuting line to the top. Executing a program reset makes it possi-
ble to select a program.
Output Outputs that in the program selection enabled state.
Program selection PRGSEL Input Selects the value inputted into the signal assigned to the numer- -1,
[OVRD ↑ ] key ical input as a program number.
[OVRD ↓ ] key Output -
Step display
PRGOUT Input Outputs the program number selected to the signal assigned to -1,-1
the numerical output.
Output Indicates outputting the program number to the numerical out-
put.
OVRDSEL Input Sets the value inputted into the signal assigned to the numerical -1,
input as a override.
Output -
OVRDOUT Input Outputs the override value to the signal assigned to the numeri- -1,-1
cal output.
Output Indicates outputting the override value to the numerical output.
LINEOUT Input Outputs the current line number to the signal assigned to the -1,-1
numerical output.
Output Indicates outputting the current line number to the numerical
output.
ERROUT Input Outputs the error number to the signal assigned to the numerical -1,-1
output.
Output Indicates outputting the error number to the numerical output.
IODATA Input Reads the program number and the override value as a binary -1,-1,
value. -1,-1
Output Outputs the program number, line number and override value as
a binary value.
Continuous CYCLE Input Starts the cycle stop. -1,-1
Cycle
Output Outputs that the cycle stop is operating.
[SERVO] key SRVON Input Turns ON the servo power supply. 4,1
SERVO lamp
Output Indicates the servo power supply is ON.
[SERVO] key SRVOFF Input Turns OFF the servo power supply. 1,-1
SERVO lamp
Output This output indicates a status where the servo power supply
cannot be turned ON. (Echo back)
Contents
Page
1 Before starting use .......................................................................................................................... 1-1
1.1 Using the instruction manuals ................................................................................................... 1-1
1.1.1 The details of each instruction manuals ............................................................................... 1-1
1.1.2 Symbols used in instruction manual .................................................................................... 1-2
1.2 Safety Precautions .................................................................................................................... 1-3
1.2.1 Precautions given in the separate Safety Manual ................................................................ 1-4
2 Unpacking to installation .............................................................................................................................................................. 2-6

2.1 Confirming the products ....................................................................................................................................................... 2-6
2.2 Installation .................................................................................................................................................................................. 2-7
2.2.1 Unpacking procedures ................................................................................................................................................... 2-7
2.2.2 Transportation procedures .......................................................................................................................................... 2-7
2.2.3 Installation procedures .................................................................................................................................................. 2-8
2.3 Installation and connection ............................................................................................................................................... 2-10
2.3.1 Installation of the robot CPU unit (CR800-R controller) ............................................................................. 2-10
(1) Notes on the handling .............................................................................................................................................. 2-10
(2) Notes on base unit installation ............................................................................................................................ 2-12
(3) Installation and removal of the unit ................................................................................................................... 2-14
2.3.2 Installation of the robot CPU unit (CR800-Q controller) ............................................................................. 2-16
(1) Notes on the handling .............................................................................................................................................. 2-16
(2) Notes on base unit installation ............................................................................................................................ 2-18
(3) Installation and removal of the unit ................................................................................................................... 2-20
2.3.3 Connecting the power cable and grounding cable ........................................................................................... 2-22
2.3.4 Connection between the robot CPU unit and the drive unit ...................................................................... 2-23
2.3.5 Emergency stop input and output etc. ................................................................................................................. 2-24
2.3.6 Connecting the external emergency stop and mode selector switch ..................................................... 2-24
2.3.7 Examples of safety measures ................................................................................................................................... 2-30
(1) External emergency stop connection [supplementary explanation] .................................................... 2-34
2.3.8 Magnet contactor control connector output (AXMC) for addition axes ................................................ 2-35
(1) Example circuit ........................................................................................................................................................... 2-35
(2) Image of how to connect the controller connector .................................................................................... 2-36
2.3.9 Connecting to the robot arm .................................................................................................................................... 2-37
(1) Connecting a machine cable ................................................................................................................................. 2-37
(2) Removing a machine cable .................................................................................................................................... 2-37
2.4 Confirming the operation .................................................................................................................................................... 2-37
3 Installing the option devices ..................................................................................................................................................... 3-38

3.1 Installing/removing the Option Card ............................................................................................................................. 3-38
3.1.1 Installing the Option Card .......................................................................................................................................... 3-38
3.1.2 Removing the Option Card ........................................................................................................................................ 3-39
3.2 Installing and wiring of the controller protection box (CR800-MB) ................................................................. 3-40
4 Basic operations ............................................................................................................................................................................ 4-42

4.1 Handling the controller ........................................................................................................................................................ 4-43
4.1.1 Names of each parts .................................................................................................................................................... 4-43
4.2 Handling the T/B ................................................................................................................................................................... 4-45
4.2.1 Installing and removing the T/B .............................................................................................................................. 4-45
(1) Installing the T/B ...................................................................................................................................................... 4-45
(2) Removing the T/B .................................................................................................................................................... 4-45
4.2.2 Functions of each key ................................................................................................................................................. 4-46
4.3 Turning the power ON and OFF ...................................................................................................................................... 4-47
4.3.1 Turning the control power ON ................................................................................................................................. 4-47
4.3.2 Input the serial number ............................................................................................................................................... 4-48
4.3.3 Shutting OFF the control power ............................................................................................................................. 4-49
4.3.4 Shutting OFF the controller power ........................................................................................................................ 4-50
4.4 Jog operation .......................................................................................................................................................................... 4-51
i
Contents
Page
4.5 Opening and closing the hand .......................................................................................................................................... 4-52
4.6 Programming ............................................................................................................................................................................ 4-53
(1) Creation procedures ................................................................................................................................................ 4-53
(2) Robot work ................................................................................................................................................................... 4-53
4.6.1 Creating the program ................................................................................................................................................... 4-54
(1) Deciding the operation order ................................................................................................................................ 4-54
(2) Deciding the operation position name .............................................................................................................. 4-55
(3) Describing and creating the program ................................................................................................................ 4-56
(4) Confirming the program .......................................................................................................................................... 4-62
(5) Correcting the program .......................................................................................................................................... 4-63
(6) Saving the program ................................................................................................................................................... 4-66
(7) Start automatic operation. .................................................................................................................................... 4-67
5 Maintenance and Inspection ..................................................................................................................................................... 5-71

5.1 Maintenance and inspection interval ............................................................................................................................. 5-71
5.2 Inspection items ..................................................................................................................................................................... 5-72
5.2.1 Daily inspection items .................................................................................................................................................. 5-72
5.2.2 Periodic inspections ..................................................................................................................................................... 5-72
5.3 Maintenance and inspection procedures ..................................................................................................................... 5-73
5.3.1 Replacing the battery (CR800-Q controller only) ............................................................................................ 5-73
5.3.2 The check of the filter, cleaning, exchange. ....................................................................................................... 5-75
5.4 Maintenance parts ................................................................................................................................................................. 5-76
ii
1Before starting use
1 Before starting use

This chapter explains the details and usage methods of the instruction manuals, the basic terminology and
the safety precautions. Moreover, handling and operation of a teaching pendant (T/B) are described based
on R32TB in instruction manuals. If using other T/B, such as R56TB, refer to a supplied instruction manual
of the T/B.
1.1 Using the instruction manuals

1.1.1 The details of each instruction manuals
The contents and purposes of the documents enclosed with this product are shown below. Use these doc-
uments according to the application.
For special specifications, a separate instruction manual describing the special section may be enclosed.
Manual name Description
Safety Manual Explains the common precautions and safety measures to be taken for robot handling, system design
and manufacture to ensure safety of the operators involved with the robot.
Standard Specifications Explains the product's standard specifications, factory-set special specifications, option configuration
and maintenance parts, etc.
Precautions for safety and technology, when incorporating the robot, are also explained.
Robot Arm Setup & Maintenance Explains the procedures required to operate the robot arm (unpacking, transportation, installation,
confirmation of operation), and the maintenance and inspection procedures.
Controller setup, basic operation, Explains the procedures required to operate the controller (unpacking, transportation, installation,
and maintenance confirmation of operation), basic operation from creating the program to automatic operation, and the
maintenance and inspection procedures.
Detailed explanations of functions Explains details on the functions and operations such as each function and operation, commands used
and operations in the program, connection with the external input/output device, and parameters, etc.
Troubleshooting Explains the causes and remedies to be taken when an error occurs. Explanations are given for each
error No.
Additional axis function Explains the specifications, functions and operations of the additional axis control.
Tracking Function Explains the control function and specifications of conveyor tracking.
GOT Direct Connection Extended Explains the detailed description of data configuration of shared memory, monitoring, and operating
Function procedures about the GOT (standalone type robot).
iQ Platform Supporting Extended Explains the detailed description of data configuration of shared memory, monitoring, and operating
Function procedures about the PLC (iQ Platform compatible type robot).
Ethernet Function Explains the measures to perform communication with personal computers on Ethernet with the
TCP/IP protocol.
Using the instruction manuals 1-1

1.1.2 Symbols used in instruction manual

The symbols and expressions shown in Table 1-1 are used throughout this instruction manual. Learn the
meaning of these symbols before reading this instruction manual.
Table 1-1:Symbols in instruction manual

Terminology Item/Symbol Meaning
iQ Platform compatible type
Controller Indicates the controller which controls the robot arm.
Indicates the CPU unit for the robots which installed to the sequencer
The robot CPU unit or robot CPU base unit of MELSEC iQ-R/MELSEC-Q series. It is connected with
the controller by the dedicated cable.
Item
Multi-CPU system.
The robot CPU system It consists of MELSEC units, such as the sequencer base unit, the
sequencer CPU unit, and the robot CPU unit, etc.
Standalone type
Controller Indicates the controller which controls the robot arm.

Precaution indicating cases where there is a risk of operator fatality or
DANGER serious injury if handling is mistaken. Always observe these precau-
tions to safely use the robot.
Precaution indicating cases where the operator could be subject to

WARNING fatalities or serious injuries if handling is mistaken. Always observe
these precautions to safely use the robot.
Precaution indicating cases where operator could be subject to injury

Symbol CAUTION or physical damage could occur if handling is mistaken. Always
observe these precautions to safely use the robot.
If a word is enclosed in brackets or a box in the text, this refers to a

[JOG]
key on the teaching pendant.
This indicates to press the (B) key while holding down the (A) key.
[RESET] + [EXE]
In this example, the [RESET] key is pressed while holding down the
(A) (B)
[EXE] key.
T/B This indicates the teaching pendant.
Descriptions in this manual are based on R32TB.
1-2 Using the instruction manuals

1.2 Safety Precautions

Always read the following precautions and the separate "Safety Manual" before starting use of the robot to
learn the required measures to be taken.
CAUTION All teaching work must be carried out by an operator who has received special
training. (This also applies to maintenance work with the power source turned ON.)
Enforcement of safety training
CAUTION For teaching work, prepare a work plan related to the methods and procedures of
operating the robot, and to the measures to be taken when an error occurs or when
restarting. Carry out work following this plan. (This also applies to maintenance
work with the power source turned ON.)
Preparation of work plan
WARNING Prepare a device that allows operation to be stopped immediately during teaching
work. (This also applies to maintenance work with the power source turned ON.)
Setting of emergency stop switch
CAUTION During teaching work, place a sign indicating that teaching work is in progress on
the start switch, etc. (This also applies to maintenance work with the power source
turned ON.)
Indication of teaching work in progress
DANGER Provide a fence or enclosure during operation to prevent contact of the operator
and robot.
Installation of safety fence
CAUTION Establish a set signaling method to the related operators for starting work, and fol-
low this method.
Signaling of operation start
CAUTION As a principle turn the power OFF during maintenance work. Place a sign indicating
that maintenance work is in progress on the start switch, etc.
Indication of maintenance work in progress
CAUTION Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
Inspection before starting work
Safety Precautions 1-3

1.2.1 Precautions given in the separate Safety Manual

The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.
DANGER When automatic operation of the robot is performed using multiple control devices
(GOT, programmable controller, push-button switch), the interlocking of operation
rights of the devices, etc. must be designed by the customer.
CAUTION Use the robot within the environment given in the specifications. Failure to do so
could lead to a drop or reliability or faults. (Temperature, humidity, atmosphere,
noise environment, etc.)
CAUTION Transport the robot with the designated transportation posture. Transporting the
robot in a non-designated posture could lead to personal injuries or faults from
dropping.
CAUTION Always use the robot installed on a secure table. Use in an instable posture could
lead to positional deviation and vibration.
CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
CAUTION Do not apply excessive force on the connector or excessively bend the cable.
Failure to observe this could lead to contact defects or wire breakage.
CAUTION Make sure that the workpiece weight, including the hand, does not exceed the
rated load or tolerable torque. Exceeding these values could lead to alarms or
faults.
WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or
flies off during operation.
WARNING Securely ground the robot and controller. Failure to observe this could lead to
malfunctioning by noise or to electric shock accidents.
CAUTION Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
WARNING When carrying out teaching work in the robot's movement range, always secure
the priority right for the robot control. Failure to observe this could lead to personal
injuries or damage if the robot is started with external commands.
CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do
so could lead to interference with the workpiece or peripheral devices.
CAUTION After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with
peripheral devices because of programming mistakes, etc.
CAUTION Make sure that if the safety fence entrance door is opened during automatic oper-
ation, the door is locked or that the robot will automatically stop. Failure to do so
could lead to personal injuries.
CAUTION Never carry out modifications based on personal judgments, or use non-desig-
nated maintenance parts.
Failure to observe this could lead to faults or failures.
WARNING When the robot arm has to be moved by hand from an external area, do not place
hands or fingers in the openings. Failure to observe this could lead to hands or fin-
gers catching depending on the posture.
1-4 Safety Precautions

CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's
main power OFF.
If the robot controller main power is turned OFF during automatic operation, the
robot accuracy could be adversely affected.
CAUTION Do not turn off the main power to the robot controller while rewriting the internal
information of the robot controller such as the program or parameters. If the main
power to the robot controller is turned off while in automatic operation or rewriting
the program or parameters, the internal information of the robot controller may be
damaged.
CAUTION Do not connect the Handy GOT when using the GOT direct connection function of
this product. Failure to observe this may result in property damage or bodily injury
because the Handy GOT can automatically operate the robot regardless of
whether the operation rights are enabled or not.
DANGER Do not connect the Handy GOT to a programmable controller when using an iQ
Platform compatible product with the CR800-R/CR800-Q controller. Failure to
observe this may result in property damage or bodily injury because the Handy
GOT can automatically operate the robot regardless of whether the operation rights
are enabled or not.
DANGER Do not remove the SSCNET III cable while power is supplied to the multiple CPU
system or the servo amplifier. Do not look directly at light emitted from the tip of
SSCNET III connectors or SSCNET III cables of the Motion CPU or the servo
amplifier. Eye discomfort may be felt if exposed to the light. (Reference: SSCNET
III employs a Class 1 or equivalent light source as specified in JIS C 6802 and
IEC60825-1 (domestic standards in Japan).)
DANGER Do not remove the SSCNET III cable while power is supplied to the controller. Do
not look directly at light emitted from the tip of SSCNET III connectors or SSCNET
III cables. Eye discomfort may be felt if exposed to the light. (Reference: SSCNET
III employs a Class 1 or equivalent light source as specified in JIS C 6802 and
IEC60825-1 (domestic standards in Japan).)
DANGER Attach the cap to the SSCNET III connector after disconnecting the SSCNET III
cable. If the cap is not attached, dirt or dust may adhere to the connector pins,
resulting in deterioration connector properties, and leading to malfunction.
specified in the manual can result in failures, such as the emergency stop not
being released. In order to prevent from occurring, please be sure to check that all
functions (such as the teaching box emergency stop, customer emergency stop,
and door switch) are working properly after the wiring setup is completed
CAUTION Use the network equipments (personal computer, USB hub, LAN hub, etc) con-
firmed by manufacturer. The thing unsuitable for the FA environment (related with
conformity, temperature or noise) exists in the equipments connected to USB.
When using network equipment, measures against the noise, such as measures
against EMI and the addition of the ferrite core, may be necessary. Please fully
confirm the operation by customer. Guarantee and maintenance of the equipment
on the market (usual office automation equipment) cannot be performed.
CAUTION To maintain the safety of the robot system against unauthorized access from
external devices via the network, take appropriate measures.
To maintain the safety against unauthorized access via the Internet, take mea-
sures such as installing a firewall.
Safety Precautions 1-5

2Unpacking to installation
2 Unpacking to installation
2.1 Confirming the products
Confirm that the parts shown in the standard configuration of the controller shown in Table 2-1 are enclosed
with the purchased product.
Users who have purchased options should refer to the separate "Standard Specifications". The primary power
supply cable and grounding cable must be prepared by the customer.
Table 2-1 ： Standard configuration

No. Part name Type Qty. Remarks
CR800-D controller
1 Controller CR800-D 1 unit Stand alone type
2 CD-ROM (Instruction manual) 5F-GA01-C00 1 pc.
3 ACIN cable 1 pc. Accessory cable for single phase. The cable is 3m
BKO-FA1006H53
in length.
1 pc. Accessory cable for single phase and three phase.
BKO-FA1006H03
The cable is 3m in length.
4 CNUSR11 connector DFMC-1.5-16-ST- 1 pc. Manufactured by PHOENIX CONTACT
3.5-LR
3.5-LR
6 1.6A fuse (reserves) LM16 1 pc.
7 EU DECLARATION OF CONFORMITY BFP-A5735-29 1 copy
8 QUICK SETUP GUIDE BFP-A3548 1 copy
CR800-R controller
1 Controller CR800-R 1 unit MELSEC iQ-R compatible type
2 Robot CPU unit R16RTCPU 1 unit
3 Robot CPU unit connecting cable 1 pc. The cable is 10m length.
MR-J3BUS10M-A
(SSCNET III cable)
BKO-FA1006H53
in length.
BKO-FA1006H03
3.5-LR
3.5-LR
CR800-Q controller
1 Controller CR800-Q 1 unit MELSEC-Q compatible type
2 Robot CPU unit Q172DSRCPU 1 unit
3 Robot CPU unit connecting cable 1 pc. The cable is 10m length.
MR-J3BUS10M-A
(SSCNET III cable)
BKO-FA1006H53
in length.
BKO-FA1006H03
3.5-LR
3.5-LR
2-6 Confirming the products

2.2 Installation
2.2.1 Unpacking procedures
The controller is shipped from the factory packaged in cardboard.Open the cardboard package and take out the
controller.
2.2.2 Transportation procedures

The following shows how to transport the controller.
Mass
Approx. 12.5kg
Fig. 2-1 ： Transporting controller
1) Slightly tilt the controller and put your hands underneath. Providing steady support with both hands, lift it up
and transport.
Be careful not to trap fingers when transporting the controller.
Installation 2-7
2.2.3 Installation procedures

The installed size is shown as follows.
When installing the controller horizontally, only one controller can be stacked on top of another controller.
㻴㼛㼞㼕㼦㼛㼚㼠㼍㼘㻌㼕㼚㼟㼠㼍㼘㼘㼍㼠㼕㼛㼚
㻭㼕㼞㻌㼕㼚㼠㼍㼗㼑
㻝㻠㻡㼙㼙㻝㻠㻡㼙㼙
㻝㻣㻜㼙㼙㻝㻡㻜㼙㼙
㼂㼑㼞㼠㼕㼏㼍㼘㻌㼕㼚㼟㼠㼍㼘㼘㼍㼠㼕㼛㼚
㻝㻡㻜㼙㼙
㻡㻜㼙㼙㻞㻜㼙㼙
㻝㻡㻜㼙㼙
㻭㼕㼞㻌㼕㼚㼠㼍㼗㼑
Fig.2-2 ： Installation dimensions
CAUTION Fixing installation section sure for prevention from the fall, when using the controller
placing vertically. The reference figure of the metal plate for fixing is shown in Fig. 2-3.
You should install the metal plate for fixation to the controller with M4 x 8 or the shorter
screw. The screw projection length inside the controller (side board thickness is 1.2 mm)
surely makes 6.8 mm or less.
CAUTION When storing the controller in a cabinet, etc., take special care to the heat radiating
properties and ventilation properties so that the ambient temperature remains within the
specification values. And, don't install the controller in the position where direct rays or
the heat of lighting hits. The skin temperature of the controller may rise, and the error
may occur.
2-8 Installation
㻠㻙䃥㻢㻚㻡㻌㼔㼛㼘㼑
㻔㻝㻠㻕
㻠㻙䃥㻝㻜㻌㼔㼛㼘㼑㻠㻙䃥㻠㻚㻡㻌㼔㼛㼘㼑
㻔㻠㻜㻕
㻝㻞㻚㻝
㻝㻞㻜
㻝㻠㻤
㻝㻞㻜㻝㻞㻜㻝㻞㻜㻞㻝㻚㻣
㻡㻝
㻢㻤
㻢㻠
㻢㻚㻡
㻠㻞
㻠㻜
㻝㻠
㻠㻙㻯㻟
㻟㻢㻜㻞㻜
㻔㻝㻜㻕㻠㻜㻜㻝㻜㻔㼠㻞㻕
㻠㻞㻜㻝㻜
Fig.2-3 ： Metal plate for fixation to placing vertically
Installation 2-9
2.3 Installation and connection

2.3.1 Installation of the robot CPU unit (CR800-R controller)
(1) Notes on the handling
Explain notes on the handling of the CPU unit, the input/output unit, the intelligent functional unit, the power
supply unit, the base unit, etc.
1) Please do not drop the unit, the terminal stand connector, and the pin connector, or do not supply a strong
shock.
2) The printed circuit board of the unit should not remove from the case. It becomes the cause of failure.
3) Please carry out bolting of the unit fixing screw and the terminal stand screw in the range shown in the table
below.
Screw Bolting torque range [N ･ m]
Unit fixing screw (M3x12) 0.36 ～ 0.48
Input/output unit terminal stand screw (M3) 0.42 ～ 0.58
Input/output unit terminal stand attachment screw (M3.5) 0.68 ～ 0.92

Terminal screw of the power supply unit (M4) 1.02 ～ 1.38
Terminal screw of the power supply unit (M3.5) 0.66 ～ 0.89

4) The basic base unit should equip with the power supply unit at any cost. If the load of the input/output unit
and intelligent functional unit with which the base unit is equipped is low, it may operate, even if there is no
power supply unit. However, since voltage becomes unstable, operation cannot be guaranteed.
5) Since it may malfunction by vibration if it installs the basic base unit in the plate, please be sure to fix with
the screw for fixing.
CAUTION 1) Please use the robot CPU system in the environment of general specification given in
this manual. If other, it becomes the electric shock, the fire, malfunction, the damage
to the product, or the cause of deterioration.
2) Pressing down the unit lower lever for unit wearing, insert the projection for unit fixing
in the fixing hole of the base unit surely, and install with the unit fixing hole as a
fulcrum. If the unit is not installed correctly, it will become the cause of malfunction,
failure, and drop. If it uses it in the environment with much vibration, fix the unit with
the screw. Please perform bolting of the screw in the regulation torque range. If
bolting of the screw is loose, it will become the cause of drop, the short circuit, and
malfunction. If the screw is tightened too much, it will become the cause of drop by
breakage of the screw or the unit, the short circuit, and malfunction.
3) Please be sure to do the installing and removing of the unit after shutting down all
phase of the external power supply currently used by the system.
4) The installing and removing of the unit and the base may be less than 50 times after
product use. It may become the cause of malfunction if it exceeds 50 times.
5) Please do not touch the electric conduction section or electronic components of the
unit directly. It becomes malfunction of the unit, and the cause of failure.
2-10 Installation and connection

The installation procedure of the base unit is shown in the following.

a) Fix two mounting screws for the upper side of the base unit to the control panel.
b) Place the notch on the right side of the base unit to a screw on the right side of the panel.
When the RQ extension base unit is used, place the bell-shaped hole on the right side of the base unit to
the screw on the right side of the panel.
<Basic base unit, extension base unit> <RQ extension base unit>
c) Place the bell-shaped hole on the left side of the base unit to a screw on the left side of the panel.
d) Fix the mounting screws into the holes at the bottom of the base unit, and retighten all the mounting
screws.
Notes: In the condition that the right end slot is vacated, install the basic base unit in the plate. When you
remove, remove the basic base unit after removing the unit of the right end slot.
Installation and connection 2-11

(2) Notes on base unit installation

If it installs the robot CPU system in the plate etc., please fully take into consideration the operativity,
conservativeness, and environment-proof.
1) Installation position for unit

To improve the airflow and change a module easily, provide clearance between the module top/bottom and
structures/parts as shown below.
㻯㼑㼕㼘㼕㼚㼓㻌㼛㼒㻌㼠㼔㼑㻌㼏㼛㼚㼠㼞㼛㼘㻌㼜㼍㼚㼑㼘㻘㻌㼣㼕㼞㼕㼚㼓㻌㼐㼡㼏㼠㻘㻌㼛㼞㻌㼛㼠㼔㼑㼞㻌㼜㼍㼞㼠㼟
㻾㼛㼎㼛㼠㻌㻯㻼㼁㻌㼡㼚㼕㼠㻠㻜㼙㼙㻌㼛㼞㻌㼙㼛㼞㼑
㻝㻜㻜㼙㼙㻌
㼛㼞㻌㼙㼛㼞㼑㻰㼛㼛㼞
㻝㻜㻜㼙㼙㻌㼛㼞㻌㼙㼛㼞㼑
㻡㼙㼙㻌㼛㼞㻌㼙㼛㼞㼑㻡㼙㼙㻌㼛㼞㻌㼙㼛㼞㼑
Fig. 2-4 ： Installation dimension of the robot CPU unit
2) Unit installation direction

a) Use the robot CPU system in the installation direction of the airy following figure because of heat
dissipation.
b) Don't use it in the installation direction of the following figure.
4) Installation surface
Install the base unit in the flat field. If the installation surface has unevenness, impossible force is applied
to printed circuit board , and it will become the cause of fault.
5) Mixture with other equipment

Mixture with the sources of vibration, such as large-sized magnetic contact and the no fuse breaker, is
avoided, and make it another panel, or detach and install.

6) Distance with other equipment

Because of to avoid the effect of the radiation noise or the heat, please secure the following distance for
the robot CPU system and the equipment (the contactor and relay).
・ Front of the robot CPU system ................100mm or more
・ Horizontal direction of the robot CPU system .........50mm or more
㻔㼎㻕
㻔㼎㻕
㻔㼍㻕

(3) Installation and removal of the unit

The installing-and-removing procedure to base units, such as the power supply unit, the sequencer CPU unit, the
robot CPU unit, the input-and-output unit, and the intelligent functional unit, is shown in the following.
■ Installation
1) When a cap is attached to the unit connector of the base unit, remove it.
2) Place the concave part (a) of an unit onto the guide (b) of the base unit.
㻔㼍㻕
㻔㼎㻕
3) Push in the unit until the module fixing hook (c) snaps into place.
㻔㼏㻕
Check that the unit fixing hook (c) hangs the base unit and the unit is mounted on the base unit securely.
4) Fix the unit on the base unit with the screws.
[Note]
・ Make sure to tighten all the unit fixing screws to prevent the unit from falling.
・ The user needs to prepare the unit fixing screws (M3x12).

■ Removal
1) Remove unit fixing screws.
2) Support the unit with both hands and securely press the unit fixing hook (a) with your finger.
㻔㼍㻕
3) Pull the unit straight supporting it at its bottom while pressing the unit fixing hook (a).
While lifting the unit, remove the concave part (b) from the guide (c) of the base unit.
㻔㼎㻕
㻔㼏㻕
CAUTION When unit fixing screws are used, remove the screws first and unit from the base unit.
Failure to do so may damage the unit.
CAUTION The unit surface temperature may be high immediately after power-off. When the unit is
removed, pay attention to the burn injury.
㻹㼑㼠㼍㼘㻌㼜㼍㼞㼠㼟㻌㼎㼑㼏㼛㼙㼑㻌㼔㼛㼠㻚

2.3.2 Installation of the robot CPU unit (CR800-Q controller)

(1) Notes on the handling
Explain notes on the handling of the CPU unit, the input/output unit, the intelligent functional unit, the power
supply unit, the base unit, etc.
1) Please do not drop the unit, the terminal stand connector, and the pin connector, or do not supply a strong
shock.
2) The printed circuit board of the unit should not remove from the case. It becomes the cause of failure.
3) Please carry out bolting of the unit fixing screw and the terminal stand screw in the range shown in Table 2-
2.
Table 2-2 ： Conclusion torque of the fixing screw

Place of the screw Bolting torque range
Robot CPU unit fixing screw （M3×13） 0.36 ～ 0.48N ･ m
Unit fixing screw （M3×12） 0.36 ～ 0.48N ･ m
Input/output unit terminal stand screw （M3） 0.42 ～ 0.58N ･ m
Input/output unit terminal stand attachment screw 0.68 ～ 0.92N ･ m

（M3.5）
Terminal screw of the power supply unit （M3.5） 0.68 ～ 0.92N ･ m
4) The basic base unit should equip with the power supply unit at any cost. If the load of the input/output unit
and intelligent functional unit with which the base unit is equipped is low, it may operate, even if there is no
power supply unit. However, since voltage becomes unstable, operation cannot be guaranteed.
5) Since it may malfunction by vibration if it installs the basic base unit in the plate, please be sure to fix with
the screw for fixing.
CAUTION 1) Please use the robot CPU system in the environment of general specification given in
this manual. If other, it becomes the electric shock, the fire, malfunction, the damage
to the product, or the cause of deterioration.
2) Pressing down the unit lower lever for unit wearing, insert the projection for unit fixing
in the fixing hole of the base unit surely, and install with the unit fixing hole as a
fulcrum. If the unit is not installed correctly, it will become the cause of malfunction,
failure, and drop. If it uses it in the environment with much vibration, fix the unit with
the screw. Please perform bolting of the screw in the regulation torque range. If
bolting of the screw is loose, it will become the cause of drop, the short circuit, and
malfunction. If the screw is tightened too much, it will become the cause of drop by
breakage of the screw or the unit, the short circuit, and malfunction.
3) Please be sure to do the installing and removing of the unit after shutting down all
phase of the external power supply currently used by the system.
4) The installing and removing of the unit and the base may be less than 50 times after
product use. It may become the cause of malfunction if it exceeds 50 times.
5) Please do not touch the electric conduction section or electronic components of the
unit directly. It becomes malfunction of the unit, and the cause of failure.
CAUTION When a CPU error occurred in the PLC, the robot CPU can operate without error.
When the robot operation is stopped when a CPU error occurred, periodically
communicate between the PLC CPU and robot CPU, and check the operating status in
robot program.
The installation procedure of the basic base unit is shown in the following.

a) Install the two screws for fixing for basic base unit surface to the plate.
Plate
盤
b) Hook the hollow on the right side of the basic base unit on the right side screw.
Plate
盤
c) Hook the long hole on the left side of the basic base unit on the left side screw.
Plate
盤
d) Install the fixing screw in the fixing screw hole of the basic base unit bottom, and retighten all the fixing
screws securely.
Notes: In the condition that the right end slot is vacated, install the basic base unit in the plate. When you
remove, remove the basic base unit after removing the unit of the right end slot.

(2) Notes on base unit installation

If it installs the robot CPU system in the plate etc., please fully take into consideration the operativity,
conservativeness, and environment-proof.
1) Installation dimension
Five fixing screws (M4x14)
5-取付けネジ(M4×14)
OUT
5V
SG
Hs2
H
POWER CPU I/O0 I/O1 I/O2 I/O3 I/O4 I/O5 I/O6 I/O7 I/O8 I/O9 I/O10 II/O11
/O11
FG Q312DB
Hs1
Ws1 Ws2 Ws3
W
Table 2-3 ： Installation dimension

Dimension place Q38DB Q312DB
W 328 439
Ws1 15.5
Ws2 170±0.3
Ws3 138±0.3 249±0.3
H 98
Hs1 7
Hs2 80±0.3
2) Unit installation position

Secure the following distance for the unit up-and-down section, and the structure and the parts, and
breathability and the convertibility of the unit are upgraded.
<Q172DSRCPU>
The position of the ceiling of the plate or the wiring duct section Base unit
Motion CPU unit 40mm Motion CPU unit

or more
MELSEC Q173DCPU QX40 QX40 Q172DEX Q173DPX
Q61P Q03DCPU 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 SY.ENC TREN PLS.A PLS.B TREN
POWER MODE 8 9 A B C D E F 8 9 A B C D E F 1 1 1 1 1
RUN 2 2
2 2 2
ERR. 3 3 3
USER SW
BAT. 1 2
BOOT STOP RUN
CAUTION
EMI
SY.ENC1
PULL
PULSER
I/O11
I/O11
Q312DB
Plate
CN1
USB
PULL
Door
CN2
RS-232
FRONT 100mm
or more
BAT
Q172DEX Q173DPX
123.5mm
100mm
or more
5mm 5mm
or more or more
Fig. 2-5 ： Installing dimensions of the robot CPU unit

3) Unit installation direction

a) Use the robot CPU system in the installation direction of the airy following figure because of heat
dissipation.
b) Don't use it in the installation direction of the following figure.
Vertical
縦取付けinstallation Horizontal
水平取付けinstallation Upside down installation
天地逆取付け
4) Installation surface
Install the base unit in the flat field. If the installation surface has unevenness, impossible force is applied
to printed circuit board , and it will become the cause of fault.
5) Mixture with other equipment

Mixture with the sources of vibration, such as large-sized magnetic contact and the no fuse breaker, is
avoided, and make it another panel, or detach and install.
6) Distance with other equipment

Because of to avoid the effect of the radiation noise or the heat, please secure the following distance for
the robot CPU system and the equipment (the contactor and relay).
・ Front of the robot CPU system ................100mm or more
・ Horizontal direction of the robot CPU system .........50mm or more
50mm
50mm以上
or more
100mm
100mm以上 50mm
50mm以上
or more or more
Contactor or relay, etc

コンタクタ，リレーなど

(3) Installation and removal of the unit

The installing-and-removing procedure to base units, such as the power supply unit, the sequencer CPU unit, the
robot CPU unit, the input-and-output unit, and the intelligent functional unit, is shown in the following.
1) Installing and removing of the unit to the base unit "Q3 □ DB"
a) Installation to "Q3 □ DB"
Base unit Base unit

Insert surely so that the
projection for unit fixing
may not deviate from
the unit fixing hole. Unit
connector
Projection
for unit fixing
P u s h a n d in s ta ll th e u n it
in th e d ire c tio n o f th e Unit installation
a rro w b y u s in g th e u n it Unit lever
fix in g h o le a s th e fu lc ru m Unit fixing hole
Projection
Projection for unit fixing
for unit fixing
C o n firm th a t th e u n it is
Unit fixing hole
in s ta lle d s u re ly .
Unit
installation
lever
Unit fixing hole
If vibration and the shock ＊

are applied to, fix to the
base unit with the screw. Base unit
Base unit
Hook for
unit fixing
Complete
　　
Projection
for unit fixing
Unit fixing hole
*: Please be sure to fix the robot CPU unit to the base unit with the screw.
<Point>
・The unit should insert the projection for unit fixing in the unit fixing hole always. In that case, insert surely
so that the projection for unit fixing may not deviate from the unit fixing hole. If it installs forcibly, without
inserting, the unit connector and the unit will be damaged.
・If it uses it at the place which is applied to of vibration and the shock, fix the unit to the base unit with the
screw. Unit fixing screw: M3x12 (prepare by the customer) Always fix the robot CPU unit to the base unit
with the screw with the attached unit fixing screw (M3x13).
・ The installing and removing of the unit and the base may be less than 50 times after product use. It may
become the cause of malfunction if it exceeds 50 times.
CAUTION Pressing down the unit lower lever for unit wearing, insert the projection for unit fixing in
the fixing hole of the base unit surely, and install with the unit fixing hole as a fulcrum. If
the unit is not installed correctly, it will become the cause of malfunction, failure, and
drop. If it uses it in the environment with much vibration, fix the unit with the screw.
Please perform bolting of the screw in the regulation torque range. If bolting of the screw
is loose, it will become the cause of drop, the short circuit, and malfunction. If the screw
is tightened too much, it will become the cause of drop by breakage of the screw or the
unit, the short circuit, and malfunction.

b) Removing from "Q3 □ DB"

R e m o v e th e s c re w , if th e Push
u n it fix in g s c re w is b e in g
used.
Hook for unit fixing

H o ld th e u n it w ith b o th
h a n d s a n d p u s h th e
u p s id e h o o k fo r fix in g ,
u n til it s to p s .
Base unit
Unit Unit
P u s h th e h o o k fo r u n it connector
fix in g , u s e lo w e r p a rt a s
th e fu lc ru m a n d p u ll it to
th e fro n t. Unit fixing hole
H o ld in g u p th e u n it, a n d
re m o v e th e p ro je c tio n
s e c tio n fo r fix in g fro m Pull to the front Holding up
th e h o le
Complete
<Point>
・Remove the screw, if the unit fixing screw is being used.Next, remove the projection for unit fixing from the
unit fixing hole. If it tries to remove the unit by force, the projection for unit fixing will be damaged.
CAUTION Since the heat dissipation fin of the robot CPU unit may become the high temperature
for a power supply on, and after power supply off, please do not touch. It becomes the
cause of the burn. When you remove the unit, be careful of the handling.

2.3.3 Connecting the power cable and grounding cable

The following shows how to connect the power cables and grounding cables.
CAUTION Please install the earth leakage breaker in the primary side power supply of the
controller because of leakage protection.
㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼞㼑㼍㼞

㻼㼞㼕㼙㼍㼞㼥㻌㼟㼕㼐㼑
Note 1)
㻱㼍㼞㼠㼔㻌㼘㼑㼍㼗㼍㼓㼑㻌㻭㻯㻵㻺㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻭㻯㻵㻺㻌㼏㼍㼎㼘㼑
㼎㼞㼑㼍㼗㼑㼞㻌㻔㻺㼂㻕㻔㼍㼠㼠㼍㼏㼔㼙㼑㼚㼠㻕㻼㻱㻌㻔㼜㼞㼛㼠㼑㼏㼠㼕㼢㼑㻌㼑㼍㼞㼠㼔㻕㻌㼠㼑㼞㼙㼕㼚㼍㼘
㻹㻠㻌㼟㼏㼞㼑㼣
㻿㼑㼏㼛㼚㼐㼞㼥㻌㼟㼕㼐㼑
㻸㻝㻸㻞㻸㻟㻸㻺
㻳㼞㼛㼡㼚㼐㼕㼚㼓㻌㼏㼍㼎㼘㼑
Note 1) Always use the terminal cover for the earth leakage breaker.
1) Prepare the following items.

Part name Specifications Remarks
Earth leakage breaker The following is recommended product. Prepared by customer.
Single phase: NV30FAU-2P-10A-AC100-240V-30mA

Three phase: NV30FAU-3P-10A-AC100-240V-30mA

Cable for primary power supply AWG14 (2mm2) or above Prepared by customer.
Grounding cable AWG14 (2mm2) or above Prepared by customer.

ACIN cable Terminal: M5, cable length: 3m Supplied with the product.
2) Confirm that the primary power matches the specifications.
3) Confirm that the primary power is OFF and that the earth leakage breaker power switch is OFF.
4) Connect the ACIN cable to the breaker.
Connect the power terminals of the ACIN cable to the secondary side terminals of the earth leakage breaker. Also,
ground the FG terminal of the cable.
5) Connect the ACIN cable to the ACIN connector on the rear of the controller.
6) Connect one end of the grounding cable to the PE (protective earth) terminal on the controller and ground the other end
(2-point grounding) in order to comply with the requirements of EN 61800-5-1 for the touch current of 3.5 mA AC or
more.
7) Connect the primary power cable to the primary side terminal of the earth leakage breaker.
Connecting the power cable and grounding cable is completed.

2.3.4 Connection between the robot CPU unit and the drive unit
The connection method of the robot CPU unit and the controller is shown below. Connect with reference to Fig.
2-6.
㻾㼛㼎㼛㼠㻌㻯㻼㼁㻌㼟㼥㼟㼠㼑㼙
㻾㼛㼎㼛㼠㻌㻯㻼㼁㻌㼡㼚㼕㼠
㻯㻾㻤㻜㻜㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞
㻻㻼㼀㻝㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻿㻿㻯㻺㻱㼀㻌㻵㻵㻵㻌㼏㼍㼎㼘㼑㻯㻺㻝㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
Fig. 2-6 ： Connection between the robot CPU system and the controller
CAUTION 1) If the cap is not installed in the SSCNET III connector after removing the SSCNET III
cable, there is a possibility that the characteristic may deteriorate and malfunction by
adhesion of garbage and the dust
2) Don't remove the SSCNET III cable, when the power supply of the robot CPU system or
servo amplifier is turned on. Don't face squarely the light emitted from motion CPU or the
tip of the SSCNET III connector of servo amplifier, and the SSCNET III cable. If light hits
to the eyes, there is a possibility of feeling the sense of incongruity for the eyes. (The light
source of SSCNET III is equivalent to the class 1 specified to JISC6802 and IEC60825-1.)
3) Install the SSCNET III cable in the larger radius than minimum flexed radius shown in the
following sure.
Type Minimum flexed radius [mm]
MR-J3BUS10M-A Reinforcement skin section: 50

Code section: 25

2.3.5 Emergency stop input and output etc.

Do wiring of the external emergency stop, the special stop input, the door switch, and the mode selector switch
from the "special input/output" terminal connector.
Connection of the external emergency stop is explained in "2.3.6Connecting the external emergency stop and
mode selector switch". And about wiring of the others, refer to separate "Standard Specifications Manual".
Table 2-4 ： Special input/output terminal

Item Name Function
Input Emergency stop Applies the emergency stop. Dual emergency line.
Input Special stop input Applies the stop.
(Refer to "Special stop input (SKIP)" in separate "Standard Specifications Manual".)
Input Door switch Servo-off. Dual line, normal close.
(Refer to "Door switch function" in separate "Standard Specifications Manual".)
Input Mode selector switch Changes the mode (MANUAL/AUTOMATIC) of the controller. Dual line.
(Refer to "Enabling device function" in separate "Standard Specifications Manual".)
Output Robot error output Contactor is opening during error occurrence.
Output Emergency stop output The point of contact opens under occurrence of emergency stop of external input signal, emergency
stop of OP, emergency stop of T/B.
Output Mode output MANUAL mode: contactor is opening, AUTOMATIC mode: contactor is closing.
Output Magnet contactor control When an additional axis is used, the servo ON/OFF status of the additional axis can be synchronized
connector output for addi- with the robot arm.
tion axes (Refer to Page 35, "2.3.8 Magnet contactor control connector output (AXMC) for addition axes".)
*At the time of the power supply OFF, the output point of contact is always open.
[Note] The contact capacity of each input/output terminal is DC24V/100mA. Don't connect the equipment
except for this range. The use exceeding contact capacity causes failure.
In the customer's system, do not ground the + side of 24V power supply prepared by customer for connect
to the controller. (related with emergency stop and parallel input/output) If it connects with the controller
under the condition that the + side is grounded, it will lead to failure of controller.
[Note] If a stop signal or servo OFF signal is input simultaneously with a door switch open/emergency stop input,
the error, H056n “Servo sys. error (A/D)” may occur.
When a door switch open/emergency stop is input, the robot turns off the servo after it stops. It is
unnecessary to input a stop signal or servo OFF signal. To input a stop signal or servo OFF signal with a
door switch open/emergency stop input, wait for 100ms or more after a door switch open/emergency stop
input.
2.3.6 Connecting the external emergency stop and mode selector switch
The following shows how to connect the external emergency stop.
For external emergency stop, connect to the connector of the controller (see Fig. 2-7).
The input terminals for the external emergency stop, door switch, and mode selector switch are arranged as
shown in Fig. 2-8. Customers should be sure to prepare the external emergency stop, door switch, and mode
selector switch, etc. and use the robot while these are connected. Connection procedures are shown below.
In addition, refer to "2.3.7Examples of safety measures" for the information on the emergency stop connection
and cautions.
[Caution] The emergency stop circuit is duplicated inside the controller. The emergency stop switch uses a
double contact-type switch, so please be sure to fix both of the contacts to the connector pins as
shown below in order to ensure the wiring is duplicated. An error will continue to occur in the event that
only one of the pins is connected.
1) Please prepare the emergency stop switch, door switch, and mode selector switch.
2) Connect the contacts of each switch to the contacts as shown below:
a) External emergency switch
CNUSR11 connector "between 7 and 23" and "between 14 and 30".
b) Door switch
c) Mode selector switch
2-24 Installation and connectionInstallation

[Caution] Be sure to use a shield cable for the emergency stop wiring cable. And when operating in an
environment that is easily affected by noise, be sure to install the ferrite core (recommended model
name: E04SR301334, manufacturer: Seiwa Electric Mfg. Co., Ltd.). Be sure to place the ferrite core in
300mm or less from the connecting terminal section.
specified in the manual can result in failures, such as the emergency stop not being
released. In order to prevent from occurring, please be sure to check that all functions
(such as the teaching box emergency stop, customer emergency stop, and door switch)
are working properly after the wiring setup is completed.
CAUTION You should always connect doubly connection of the emergency stop, the door switch,
and the mode selector switch. In connection of only one side, if the relay of customer
use should break down, it may not function correctly.
And, the output contacts from the robot controller (robot error output, emergency stop
output, mode output, addition axis contactor control output) are dual contacts (syn-
chronizes). You should connect surely by dual line with the customer's equipment as
well as connection of the emergency stop and the door switch.
CAUTION When using several emergency stop switches, perform wiring carefully to make sure
that each emergency stop switch functions independently. Check and make sure that
the emergency stop does not function under an AND condition (when multiple
emergency stop switches are ON at the same time).
㻯㻺㼁㻿㻾㻝㻝㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
Fig. 2-7 ： Emergency stop cable and mode selector switch connection
Refer to the following for details on the example of external emergency stop connection, arrangement of
connectors for exclusive input/output signals, and pin assignment.
Item Reference
Example of external emergency stop connection Fig. 2-8
Arrangement of connectors for exclusive input/output Fig. 2-9

signals
Pin assignment CNUSR11 connector: Table 2-5

CNUSR12 connector: Table 2-6
Installation and connectionInstallation 2-25

㻵㼚㼠㼑㼞㼚㼍㼘㻌㼏㼕㼞㼏㼡㼕㼠㻌㼟㼠㼞㼡㼏㼠㼡㼞㼑
㻔㻯㼡㼟㼠㼛㼙㼑㼞㻕㻔㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼟㼕㼐㼑㻕㻔㻯㼡㼟㼠㼛㼙㼑㼞㻕
㼀㻛㻮㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜
㻗㻞㻠㼂
㻗㻟㻚㻟㼂㻗㻞㻠㼂
㻗㻟㻚㻟㼂㻯㻺㼁㻿㻾㻝㻝
㻝㻠㻱㼤㼠㼑㼞㼚㼍㼘㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌
㻟㻜㼟㼠㼛㼜㻌㼕㼚㼜㼡㼠
㻖㻝㻕
㻗㻟㻚㻟㼂
㻗㻟㻚㻟㼂
㻯㼛㼚㼠㼞㼛㼘㻌
㼏㼕㼞㼏㼡㼕㼠㻌㻝
㻝㻟
㻰㼛㼛㼞㻌㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻞㻥
㻯㻺㼁㻿㻾㻝㻝
㻝㻝
㻹㼛㼐㼑㻌㼛㼡㼠㼜㼡㼠
㻞㻣㻗㻟㻚㻟㼂
㻗㻞㻠㼂
㻝㻞㻹㼛㼐㼑㻌㼟㼑㼘㼑㼏㼠㼛㼞㻌
㻝㻜㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌
㼛㼡㼠㼜㼡㼠㻞㻤㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻞㻢
㻤
㻾㼛㼎㼛㼠㻌㼑㼞㼞㼛㼞㻌㼛㼡㼠㼜㼡㼠
㻞㻠
㻗㻞㻠㼂
㻣㻱㼤㼠㼑㼞㼚㼍㼘㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌
㻞㻟㼟㼠㼛㼜㻌㼕㼚㼜㼡㼠
㻖㻝㻕
㻗㻟㻚㻟㼂
㻗㻟㻚㻟㼂
㻯㼛㼚㼠㼞㼛㼘㻌
㼏㼕㼞㼏㼡㼕㼠㻌㻞
㻢
㻰㼛㼛㼞㻌㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻞㻞
㻠㻗㻟㻚㻟㼂
㻹㼛㼐㼑㻌㼛㼡㼠㼜㼡㼠㻗㻞㻠㼂
㻞㻜㻡㻹㼛㼐㼑㻌㼟㼑㼘㼑㼏㼠㼛㼞㻌
㻟㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㻞㻝㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻝㻥㼛㼡㼠㼜㼡㼠
㻝
㻾㼛㼎㼛㼠㻌㼑㼞㼞㼛㼞㻌㼛㼡㼠㼜㼡㼠
㻝㻣
㻯㻭㼁㼀㻵㻻㻺㻼㼘㼑㼍㼟㼑㻌㼐㼛㻌㼚㼛㼠㻌㼏㼍㼞㼞㼥㻌㼛㼡㼠㻌㼍㼚㻌㼕㼚㼟㼡㼘㼍㼠㼕㼛㼚㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌㼠㼑㼟㼠㻚㻌㻹㼛㼞㼑㼛㼢㼑㼞㻘㻌
㼕㼠㻌㼎㼑㼏㼛㼙㼑㼟㻌㼠㼔㼑㻌㼏㼍㼡㼟㼑㻌㼛㼒㻌㼒㼍㼕㼘㼡㼞㼑㻌㼕㼒㻌㼕㼠㻌㼏㼛㼚㼚㼑㼏㼠㼟㻌㼕㼚㼏㼛㼞㼞㼑㼏㼠㼘㼥㻚
㻼㼘㼑㼍㼟㼑㻌㼞㼑㼒㼑㼞㻌㼠㼛㻌㼠㼔㼑㻌㼑㼤㼍㼙㼜㼘㼑㻌㼛㼒㻌㼟㼍㼒㼑㼠㼥㻌
㼙㼑㼍㼟㼡㼞㼑㼟㻌㼛㼒㻌㻎㻿㼜㼑㼏㼕㼒㼕㼏㼍㼠㼕㼛㼚㼟㻌㻹㼍㼚㼡㼍㼘㻎㻚
㻖㻝㻕㼀㼔㼑㻌㼠㼑㼞㼙㼕㼚㼍㼘㻌㼏㼍㼚㻌㼎㼑㻌㼡㼟㼑㼐㻌㼛㼚㼘㼥㻌㼒㼛㼞㻌㼠㼔㼑㻌㼑㼤㼠㼑㼞㼚㼍㼘㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼕㼚㼜㼡㼠㻌㼠㼛㻌㼠㼔㼑㻌㼞㼛㼎㼛㼠㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻚㻌㻻㼡㼠㼜㼡㼠㻌㼙㼛㼚㼕㼠㼛㼞㼕㼚㼓㻌
㼕㼟㻌㼜㼑㼞㼒㼛㼞㼙㼑㼐㻌㼣㼕㼠㼔㻌㼠㼑㼟㼠㻌㼜㼡㼘㼟㼑㻚
Fig. 2-8 ： External emergency stop connection
CAUTION Place the emergency stop switch in an easily operable position, and be sure to wire it
to the emergency stop correctly by refer to Page 30, "2.3.7 Examples of safety
measures". This is a necessary measure in order to ensure safe operation so that the
robot can be stopped immediately by pressing the emergency stop switch in the event
that the robot malfunctions.

Arrangement of connectors for exclusive input/output signals are shown in Fig. 2-9. The pin assignments of the
connectors for exclusive input/output signals are shown in Table 2-5 and Table 2-6.
㻯㻺㼁㻿㻾㻝㻞㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
Fig. 2-9 ： Arrangement of connectors for exclusive input/output signals
Table 2-5 ： Pin assignment (CNUSR11)

Pin Pin
Name Function Remarks Name Function Remarks
No. No.
1 ROBOTERR21 Robot error output This pin and pin 17 is a 17 ROBOTERR22 Robot error output This pin and pin 1 is a
pair. pair.
2 AXMC21 Magnet contactor To synchronize an 18 AXMC22 Magnet contactor To synchronize an
control connector additional axis to a control connector additional axis to a
output for robot's servo ON/ output for robot's servo ON/OFF.
additional axes OFF. additional axes This pin and pin 2 is a
This pin and pin 18 is a pair.
pair.
3 EMGOUT21 Emergency stop Confirming the 19 EMGOUT22 Emergency stop Confirming the
output presence/absence of output presence/absence of
an emergency stop. an emergency stop.
This pin and pin 19 is a This pin and pin 3 is a
pair. pair.
4 MODEOUT21 Mode output Confirming the 20 MODEOUT22 Mode output Confirming the
controller operation controller operation
mode. mode.
pair. pair.
5 OPKEY2COM(2 Mode selector Switching an operation 21 OPKEY2 Mode selector Switching an operation
4V) switch input mode of a controller. switch input mode of a controller.
pair. pair.
6 24V2 for DOOR Connection of door Detecting the opening 22 DOOR2 Connection of door Detecting the opening
switch and closing of a door. switch and closing of a door.
pair. pair.
7 EXTEMG21 Construction of Constructing an 23 EXTEMG22 Construction of Constructing an
external external emergency external external emergency
emergency stop stop function. emergency stop stop function.
input circuit input circuit
8 ROBOTERR11 Robot error output This pin and pin 24 is a 24 ROBOTERR12 Robot error output This pin and pin 8 is a
pair. pair.
9 AXMC11 Magnet contactor To synchronize an 25 AXMC12 Magnet contactor To synchronize an
control connector additional axis to a control connector additional axis to a
output for robot's servo ON/ output for robot's servo ON/OFF.
additional axes OFF. additional axes This pin and pin 9 is a
This pin and pin 25 is a pair.
pair.
10 EMGOUT11 Emergency stop Confirming the 26 EMGOUT12 Emergency stop Confirming the
output presence/absence of output presence/absence of
an emergency stop. an emergency stop.
pair. pair.

Pin Pin
No. No.
11 MODEOUT11 Mode output Confirming the 27 MODEOUT12 モード出力 Confirming the
controller operation controller operation
mode. mode.
pair. pair.
12 OPKEY1COM(2 Mode selector Switching an operation 28 OPKEY1 Mode selector Switching an operation
4V) switch input mode of a controller. switch input mode of a controller.
pair. pair.
13 24V1 for DOOR Connection of door Detecting the opening 29 DOOR1 Connection of door Detecting the opening
switch and closing of a door. switch and closing of a door.
pair. pair.
14 EXTEMG11 Construction of Constructing an 30 EXTEMG12 Construction of Constructing an
external external emergency external external emergency
emergency stop stop function. emergency stop stop function.
input circuit input circuit
15 Reserved 31 Reserved
16 Reserved 32 Reserved
Table 2-6 ： Pin assignment (CNUSR12)

Pin Pin
No. No.
1 SKIP41 SKIP41 common This pin and pin 10 is 10 SKIP42 SKIP4 input This pin and pin 1 is a
(COM) a pair. pair.
(COM) a pair. pair.
(COM) a pair. pair.
4 SKIP11 Dedicated stop This pin and pin 13 is 13 SKIP12 Dedicated stop This pin and pin 4 is a
input common a pair. input common pair.
(COM)
5 LBH2 B-phase signal + Encoder input of a 14 LBL2 B-phase signal - Encoder input of a
(plus) side of dif- trucking function (minus) side of dif- trucking function
ferential encoder CH2 ferential encoder CH2
CH2 CH2
6 LAH2 A-phase signal + 15 LAL2 A-phase signal -
(plus) side of dif- (minus) side of dif-
ferential encoder ferential encoder
CH2 CH2
7 ENC5V 5V for encoder 5V input 16 RG GND for encoder GND connection for
signal signal pin 7 power supply
8 LBH1 B-phase signal + Encoder input of a 17 LBL1 B-phase signal - Encoder input of a
(plus) side of dif- trucking function (minus) side of dif- trucking function
ferential encoder CH1 ferential encoder CH1
CH1 CH1
9 LAH1 A-phase signal + 18 LAL1 A-phase signal -
(plus) side of dif- (minus) side of dif-
ferential encoder ferential encoder
CH1 CH1

㻯㻺㼁㻿㻾㻝㻞㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞㻭
㼂㼕㼑㼣㻌㻭㻦㻌㻼㼕㼚㻌㼚㼡㼙㼎㼑㼞㻌㼛㼒㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞㼃㼕㼞㼕㼚㼓㻌㼠㼛㻌㼍㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻝㻝㻢㼁㼟㼑㼞㻌㼣㼕㼞㼕㼚㼓㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻸㼑㼢㼑㼞
㻝㻣㻟㻞
㻣㼙㼙
㻝㻥㻯㼍㼎㼘㼑
㻸㼍㼠㼏㼔㻸㼑㼢㼑㼞
㻝㻜㻝㻤㻯㼍㼎㼘㼑㻌㼕㼚㼟㼑㼞㼠㼕㼛㼚㻌㼔㼛㼘㼑
㻯㻺㼁㻿㻾㻝㻞㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞㻲㼘㼍㼠㼔㼑㼍㼐㻌㼟㼏㼞㼑㼣㼐㼞㼕㼢㼑㼞
Connection procedure
Wire cables to the CNUSR11 and CNUSR12 user wiring connectors (attachment), and fit them into the corresponding
connectors (ports) located on the rear side of the controller.
The customer needs to prepare the following items.
　・ Cable: AWG24 to 16 (0.2 to 1.5mm2)
　・ Flathead screwdriver: The width of the tip is 2.5mm.
1) Prepare the user wiring connector (attachment).

2) Strip off 7 mm of the cable sheath.
3) Insert the cable all the way in the insertion hole while pressing down the latch on the user wiring connector with a
flatblade screwdriver.
4) When all the required wirings have been completed, fit the user wiring connector (CNUSR11/CNUSR12) into the
corresponding connector (CNUSR11/CNUSR12 port) on the controller.
5) When the user wiring connector has properly fitted, the levers on both sides of the connector rise and the
connector is fixed. (To dismount the connector, lower the levers.)
The connection has been completed.
Fig. 2-10 ： Wiring method to the user wiring connector
CAUTION Fully check the number of the cable insertion hole (connector pin number) for incorrect
connection. Incorrect wiring may damage the robot or cause a malfunction.
CAUTION When wiring to the CNUSR11/CNUSR12 connector, pay attention to fraying wires of
the core wires. The fraying wires can come into contact with the adjacent terminal,
causing a short circuit.
Do not apply solder on core wires. Doing so may cause a contact failure.

2.3.7 Examples of safety measures

Two emergency-stop input circuits are prepared on the user wiring terminal block of the controller.
The safety measure examples are shown in Fig. 6-1 to Fig. 6-4. Create a circuit as shown below for safety mea-
sures. In addition, the figure shows the normal state which is not in the emergency stop state.
[Note] ･ In the emergency-stop related wiring by the customer, if the coil (is not the contact points) of the relay
prepared by the customer is connected to the controller, please be sure to implement the measure
against the noise by the customer in the coil section. And, please also take the lifetime of noise sup-
pression parts into consideration.
･ Electric specification of the emergency-stop-related output terminal: 24V DC or less, related current
100mA or less.
･ In the customer's system, do not ground the + side of 24V power supply prepared by customer for con-
nect to the controller. (related with emergency stop and parallel input/output) If it connects with the
controller under the condition that the + side is grounded, it will lead to failure of controller.
<Wiring example 1>: Connect the emergency stop switch of peripheral equipment to the controller.
The power supply for emergency stop input uses the power supply in the controller.
<Operation of the emergency stop>
If the emergency stop switch of peripheral equipment is pushed, the robot will also be in the emergency
stop state.
㻌㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼟㼣㼕㼠㼏㼔
㻔㻞㻙㼏㼛㼚㼠㼍㼏㼠㻌㼠㼥㼜㼑㻕
㼀㻛㻮㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼡㼠㼠㼛㼚㻼㼑㼞㼕㼜㼔㼑㼞㼍㼘㻌
㻗㻞㻠㼂㼑㼝㼡㼕㼜㼜㼙㼑㼚㼠
㻖㻞
㻵㼚㼠㼑㼞㼚㼍㼘㻌㼜㼛㼣㼑㼞㻌㼟㼡㼜㼜㼘㼥㻌㻞㻠㼂㻖㻝
㻗㻞㻠㼂
㻗㻟㻚㻟㼂
㻝㻠㻛㻣
㻟㻜㻛㻞㻟
㻿㼍㼒㼑㼠㼥㻌㼒㼑㼚㼏㼑㻌
㻗㻟㻚㻟㼂㼐㼛㼛㼞
㻗㻟㻚㻟㼂
㻝㻟㻛㻢㻰㼛㼛㼞㻌㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻞㻥㻛㻞㻞
㻹㼛㼐㼑㻌㼟㼑㼘㼑㼏㼠㼛㼞㻌
㻗㻟㻚㻟㼂
㻗㻞㻠㼂
㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻝㻞㻛㻡
㻞㻤㻛㻞㻝
㻵㼚㼠㼑㼞㼚㼍㼘㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼏㼕㼞㼏㼡㼕㼠
㻝㻜㻛㻟
㻞㻢㻛㻝㻥㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼛㼡㼠㼜㼡㼠
㻝㻝㻛㻠
㻞㻣㻛㻞㻜㻹㼛㼐㼑㻌㼛㼡㼠㼜㼡㼠
㻤㻛㻝
㻞㻠㻛㻝㻣㻱㼞㼞㼛㼞㻌㼛㼡㼠㼜㼡㼠
㻖㻝㻕㻌㼀㼔㼑㻌㻯㻺㼁㻿㻾㻝㻝㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞㻌㼕㼟㻌㼍㻌㼠㼣㼛㻙㼘㼑㼢㼑㼘㻌㼠㼑㼞㼙㼕㼚㼍㼘㻌㼎㼘㼛㼏㼗㻘㻌㼕㼚㼐㼕㼏㼍㼠㼕㼚㼓㻌㼠㼔㼍㼠㻌㼠㼔㼑㼞㼑㻌㼍㼞㼑㻌㼠㼣㼛㻌㼏㼕㼞㼏㼡㼕㼠㼟㻌㻔㼏㼔㼍㼚㼚㼑㼘㼟㻕㻚㻌㼀㼣㼛㻌
㼠㼑㼞㼙㼕㼚㼍㼘㼟㻌㻔㼏㼍㼎㼘㼑㻌㼕㼚㼟㼑㼞㼠㼕㼛㼚㻌㼔㼛㼘㼑㼟㻕㻌㼚㼑㼑㼐㻌㼠㼛㻌㼎㼑㻌㼡㼟㼑㼐㻌㼒㼛㼞㻌㼛㼚㼑㻌㼏㼕㼞㼏㼡㼕㼠㻚
㻖㻞㻕㻌㼀㼔㼑㻌㼀㻛㻮㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼡㼠㼠㼛㼚㻌㼏㼛㼚㼚㼑㼏㼠㼑㼐㻌㼣㼕㼠㼔㻌㼠㼔㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻚
Fig.2-11 ： Example of safety measures (wiring example 1）

<Wiring example 2>: Connect the emergency stop switch, and door switch of peripheral equipment to the controller.
The power supply for emergency stop input uses the power supply in the controller. Monitor the
emergency stop state by the peripheral equipment side.
If the emergency stop switch of peripheral equipment is pushed, the robot will also be in the emergency
stop state.
When the controller power is OFF, the peripheral devices are in the emergency stop state.
㻌㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼟㼣㼕㼠㼏㼔
㻔㻞㻙㼏㼛㼚㼠㼍㼏㼠㻌㼠㼥㼜㼑㻕
㼀㻛㻮㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼡㼠㼠㼛㼚㻼㼑㼞㼕㼜㼔㼑㼞㼍㼘㻌
㻗㻞㻠㼂㼑㼝㼡㼕㼜㼜㼙㼑㼚㼠
㻖㻞
㻗㻞㻠㼂
㻗㻟㻚㻟㼂
㻝㻠㻛㻣
㻟㻜㻛㻞㻟
㻿㼍㼒㼑㼠㼥㻌㼒㼑㼚㼏㼑㻌㻯㼕㼞㼏㼡㼕㼠
㻗㻟㻚㻟㼂
㻞㻥㻛㻞㻞
㻹㼛㼚㼕㼠㼛㼞
㻗㻟㻚㻟㼂
㻗㻞㻠㼂
㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠㻹㼛㼚㼕㼠㼛㼞
㻝㻞㻛㻡
㻞㻤㻛㻞㻝
㻝㻜㻛㻟㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼛㼡㼠㼜㼡㼠
㻞㻢㻛㻝㻥
㻝㻝㻛㻠
㻤㻛㻝

<Wiring example 3>: Connect the emergency stop switch of peripheral equipment, and the door switch to two controllers, and it
interlocks. The power supply for emergency stop input uses the power supply of peripheral equipment.
Monitor the emergency stop state by the peripheral equipment side.
If the emergency stop switch of peripheral equipment is pushed, the robot will also be in the emergency stop state.
When the controller power is OFF, the peripheral devices are in the emergency stop state.
㼀㻛㻮㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼎㼡㼠㼠㼛㼚
㻗㻞㻠㼂
㻖㻞
㻗㻟㻚㻟㼂
㻗㻞㻠㼂㻯㻺㼁㻿㻾㻝㻝
㻗㻟㻚㻟㼂
㻝㻠㻛㻣
㻟㻜㻛㻞㻟
㻿㼍㼒㼑㼠㼥㻌㼒㼑㼚㼏㼑㻌㻯㼕㼞㼏㼡㼕㼠
㻗㻟㻚㻟㼂
㻞㻥㻛㻞㻞
㻹㼛㼚㼕㼠㼛㼞
㻗㻟㻚㻟㼂
㻗㻞㻠㼂
㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻝㻞㻛㻡
㻞㻤㻛㻞㻝
㻞㻢㻛㻝㻥㻹㼛㼚㼕㼠㼛㼞
㻝㻝㻛㻠
㻤㻛㻝
㻗㻞㻠㼂
㻖㻞
㻗㻟㻚㻟㼂
㻗㻞㻠㼂㻯㻺㼁㻿㻾㻝㻝
㻗㻟㻚㻟㼂
㻝㻠㻛㻣
㻟㻜㻛㻞㻟
㻗㻟㻚㻟㼂
㻗㻟㻚㻟㼂
㻞㻥㻛㻞㻞
㻗㻟㻚㻟㼂㼟㼣㼕㼠㼏㼔㻌㼕㼚㼜㼡㼠
㻗㻞㻠㼂
㻝㻞㻛㻡
㻞㻤㻛㻞㻝
㻞㻢㻛㻝㻥㻹㼛㼚㼕㼠㼛㼞
㻝㻝㻛㻠
㻤㻛㻝

<Wiring example 4>: Connect the controller to the safety relay

Use the controller’s emergency stop button to input safety relay.
㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻯㼡㼟㼠㼛㼙㼑㼞㻌㼑㼝㼡㼕㼜㼙㼑㼚㼠
㻗㻞㻠㼂
㻱㼤㼠㼑㼞㼚㼍㼘㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌
㻗㻟㻚㻟㼂㻿㼍㼒㼑㼠㼥㻌㼞㼑㼘㼍㼥
㻝㻠㼟㼠㼛㼜㻌㼟㼣㼕㼠㼏㼔
㻱㼤㼍㼙㼜㼘㼑䠅
㻟㻜
㻽㻿㻥㻜㻿㻾㻞㻿㻼㻌㻔㻹㼕㼠㼟㼡㼎㼕㼟㼔㼕㻌
㻗㻟㻚㻟㼂㻱㼘㼑㼏㼠㼞㼕㼏㻌㻯㼛㼞㼜㼛㼞㼍㼠㼕㼛㼚㻕
㻗㻟㻚㻟㼂
㻺㼛㻌㼏㼛㼚㼚㼑㼏㼠㼕㼛㼚㻯㻻㻹㻜
㻵㼚㼠㼑㼞㼚㼍㼘㻌㻿㼍㼒㼑㼠㼥㻌㼕㼚㼜㼡㼠㻌㻝
㼄㻜
㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌
㼟㼠㼕㼜㻌㼕㼚㼜㼡㼠㻌
㻝㻝㻜
㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㻞㻠㼂㻌㻰㻯
㼛㼡㼠㼜㼡㼠㻞㻢
㻺㼛㻌㼏㼛㼚㼚㼑㼏㼠㼕㼛㼚㻯㻻㻹㻝
㻿㼍㼒㼑㼠㼥㻌㼕㼚㼜㼡㼠㻌㻞
㼄㻝
㻗㻞㻠㼂
㻗㻟㻚㻟㼂㻗㻞㻠㼂㻗㻞㻠㼂㻞㻠㻳

㻱㼤㼠㼑㼞㼚㼍㼘㻌㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌
㻗㻟㻚㻟㼂㼟㼠㼛㼜㻌㼟㼣㼕㼠㼏㼔
㻣
㻞㻟
㻞㻠㼂㻌㻰㻯㻞㻠㼂㻌㻳
㻗㻟㻚㻟㼂
㻯㼡㼟㼠㼛㼙㼑㼞㻌㼜㼛㼣㼑㼞㻌㼟㼡㼜㼜㼘㼥㻌
㻗㻟㻚㻟㼂㻔㻰㻯㻌㻞㻠㼂㻕
㻵㼚㼠㼑㼞㼚㼍㼘㻌
㼑㼙㼑㼞㼓㼑㼚㼏㼥㻌
㼟㼠㼕㼜㻌㼕㼚㼜㼡㼠㻌
㻞㻟
㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㻞㻠㼂㻌㻰㻯
㻝㻥
㼛㼡㼠㼜㼡㼠
[Caution]
1)The performance of this product must be compliant with the requirements of ISO 13849-1 Category 4. The product
cannot be used in the condition comparable to Category 3.
2) Setup a safety relay on the user equipment, and when using to input the emergency stop button on the controller,
please only use a safety relay that functions when connecting the input to the one end of the 2 systems (i.e.
QS90SR2SP (Manufacture: Mitsubishi Electric Corporation)).
3) When connecting emergency stop button output to an exterior safety relay, please take note of the polarity and make
sure that the electrical current flows in the same direction as indicated by the dotted arrows in the two places in the
diagram. If the polarity is setup incorrectly this function will not operate correctly. Please connect 3 and 10 terminal of
CNUSR11 connector to 24V.

(1) External emergency stop connection [supplementary explanation]
(1) Use a 2-contact type switch for all switches.

(2) Install a limit switch on the safety fence's door. With a constantly open contact (normal open), wire to the
door switch input terminal so that the switch turns ON (is conducted) when the door is closed, and turns OFF
(is opened) when the door is open.
(3) Use a manual-return type of normal close which have two lines for the emergency stop button.
(4) Classify the faults into minor faults (faults that are easily restored and that do not have a great effect) and
major faults (faults that cause the entire system to stop immediately, and that require care in restoration),
and wire accordingly.
[Caution] The emergency stop input (terminal block) on the user wiring in the controller can be used for safety
measures as shown in figure above. Note that there are limits to the No. of switch contacts, capacity
and cable length, so refer to the following and install.
・ Switch contact.......Prepare a 2-contact type.*1)
・ Switch contact capacityRelated current of 24 VDC or higher for a no-voltage contact. *1)
・ Cable length ............The length of the wire between the switch and terminal block must be max. 15m
or less. Please use the shield line, in case of the cable may receive the
noise etc. by other equipment, such as servo amplifier. And, if it is
necessary, please fix a ferrite core (recommended model name:
E04SR301334, manufacturer: Seiwa Electric Mfg. Co., Ltd.) to the
shielded cable.
The size of the wire that fits to use is shown below.
CNUSR11 connector: AWG24 to 16 (0.2 to 1.25mm2)
Electric specification of the emergency stop related output circuit is 100mA/24V or less. Don't connect
the equipment except for this range.
CAUTION Be sure to perform wiring correctly. If there are mistakes in the wiring, the robot may
not stop when the emergency stop button is pressed and there will be a risk of damage
or personal injury occurring.
After wiring, be sure to press each of the installed emergency stop switches and check
whether the emergency stop circuit works properly.
CAUTION Be sure to duplicate connection of the emergency stop, door switch and mode selector
switch. If not duplicated, these functions may fail due to a broken relay used by
customer, etc.
*1) The minimum load electric current of the switch is more than 5mA/24V.

2.3.8 Magnet contactor control connector output (AXMC) for addition axes
When an additional axis is used, the servo ON/OFF status of the additional axis can be synchronized with the
servo ON/OFF status of the robot itself by using the output contact (AXMC) provided on the rear or inside of the
controller and configuring a circuit so that the power to the servo amplifier for the additional axis can be turned
off when this output is open.
An example circuit is shown in Page 35, "(1) Example circuit". An image of how to connect the connector is shown
in Page 36, "(2) Image of how to connect the controller connector".
When you are using an additional axis, please perform appropriate circuit connections by referring to these draw-
ings.
Refer to the separate "Additional axis interface Instruction Manual" for details on the additional axis function.
Note1) You use the addition axis function as a user mechanism who became independent of the robot arm,
please do not connect this output signal. Servo-on of the user mechanism.
(1) Example circuit
1) Get the power supply for the controller from the secondary terminal
of short circuit breaker (NV) built in the addition axis amplifier box.
１）付加軸アンプボックス内蔵漏電遮断器（NV）の２次側より、コントローラ電源を取り出す。
Amplifier
アンプ
2) Get ２）お客様ご準備の漏電遮断器（NV）の２次側から、MC同期用電源を
the power supply for the MC synchronization from the secondary NV
terminal of short circuit breaker (NV) prepared by the customer.
取り出す。 MC MC1 MC2 88
Note1)
注1) DC24V
CNUSR connector
CNUSRコネクタ
NV
Note2)
To the internal
内部回路へ AXMC11
注2)
circuit AXMC12
Note2)
注2)
AXMC21 <Addition axis amplifier box>
<走行軸（付加軸）アンプボックス>
AXMC22
AXMC is output
内部サーボ電源用 Note1) Connector and pin number
from the contact
コンタクタ接点より
for internal servo
power supplies.
AXMC出力 Signal Connector Pin number
<Controller>
<コントローラ> AXMC11 9
CNUSR11
AXMC12 25
AXMC21 2
CNUSR11
AXMC22 18
Note2) This output is opened, if the robot turns off the servo by occurrence of alarm etc.
<Electric specification>
DC24V/10mA to 100mA
[Note] In the customer's system, do not ground the + side of 24V power supply prepared by customer for connect to the con-
troller. (related with emergency stop and parallel input/output) If it connects with the controller under the condition that
the + side is grounded, it will lead to failure of controller.
Fig. 2-15 ： Example of circuit for addition axes of Magnet contactor control output

(2) Image of how to connect the controller connector
* Refer to Page 29 "Fig. 2-10: Wiring method to the user wiring connector" for more details about how to wire a connector.
Fig. 2-16 ： AXMC terminal connector

2.3.9 Connecting to the robot arm

Use a machine cable to connect a robot arm with a controller.
(1) Connecting a machine cable

Refer to the separate manual "Robot arm setup and maintenance", and connect the controller and robot arm with
machine cables.
(2) Removing a machine cable

When removing the machine cable from a controller, push the fixation hook of the machine cable connector and
unlock the connector.
㻲㼕㼤㼍㼠㼕㼛㼚㻌㼔㼛㼛㼗
If the fixation hook is too stuck to release the connector, use a flathead screwdriver to release the connector as
shown below.
㻲㼕㼤㼍㼠㼕㼛㼚㻌㼔㼛㼛㼗
㻵㼚㼟㼑㼞㼠㻹㼛㼢㼑
㻲㼘㼍㼠㼔㼑㼍㼐㻌㼐㼞㼕㼢㼑㼞
[Note]
A flathead driver will possibly damage the connector and fixation hook by scratching it. Please use
a waste cloth to prevent damage to the connector and fixation hook.
2.4 Confirming the operation

Refer to the separate manual "Robot arm setup and maintenance", and confirm the robot operation with jog
operation.

3Installing the option devices
3 Installing the option devices

Refer to Page 45, "4.2.1 Installing and removing the T/B" for installing method of T/B. Refer to the separate
"Standard Specifications" or each option's manual for the optional devices other than those described in this
manual.
3.1 Installing/removing the Option Card
CAUTION When installing or removing the interface card, it is required to keep the interface card
in parallel with the controller.
㻷㼑㼑㼜㻌㼕㼚㻌㼜㼍㼞㼍㼘㼘㼑㼘㻌
㼣㼕㼠㼔㻌㼠㼔㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻚
㻵㼚㼠㼑㼞㼒㼍㼏㼑㻌㼏㼍㼞㼐
㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞
3.1.1 Installing the Option Card

The following describes where and how to install the interface card.
㻿㻸㻻㼀㻝
㻿㻸㻻㼀㻞
㻵㼚㼠㼑㼞㼒㼍㼏㼑㻌㼏㼛㼢㼑㼞㻌㻵㼚㼠㼑㼞㼒㼍㼏㼑㻌㼏㼛㼢㼑㼞
㼞㼑㼙㼛㼢㼍㼎㼘㼑㻌㼘㼑㼢㼑㼞
㻵㼚㼠㼑㼞㼒㼍㼏㼑㻌㼏㼍㼞㼐
㻯㼛㼚㼚㼑㼏㼠㼕㼚㼓㻌
㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻴㼍㼚㼐㼘㼑
㻾㼑㼙㼛㼢㼍㼎㼘㼑㻌㼘㼑㼢㼑㼞
㻔㻻㼠㼔㼑㼞㻌㼟㼕㼐㼑㻕
Fig. 3-1 ： Installation of the interface card
1) Turn off the power.

2) Pick the interface cover removal lever and pull up the interface cover.
3) Insert the interface card in SLOT1 or SLOT2.
Insert the card as both ends of the card may fit into the guide of slot (SLOT1 or SLOT2 showed in Fig. 3-
1).
4) Insert the connection connector securely to the back until the removal lever is locked with the sound.
The installation of the interface card is completed.
3-38 Installing/removing the Option Card

3.1.2 Removing the Option Card

The following describes how to remove the interface card.
㻾㼑㼙㼛㼢㼍㼘㻌㼘㼑㼢㼑㼞
㻴㼍㼚㼐㼘㼑
Fig. 3-2 ： Removing of the interface card
1) Turn off the power.

2) Remove the interface card with the removal lever pushed up. Hold the handle of the interface card and pull
out the interface card in parallel with the controller.
The removing of the interface card is completed.
Installing/removing the Option Card 3-39

3.2 Installing and wiring of the controller protection box (CR800-MB)

Method of installing and wiring with CR800-MB is as follows.
1) Release the metal fittings (4 pcs.) of CR800-MB and remove the top plate.
2) Copy the serial number of a controller to a transcription label, and put it to the front of CR800-MB. After
that, put a transparent label on to a transcription label.
3) Remove the fixing plate (screw x 4pcs.) in CR800-MB (left side), fix it to the left side of a controller by 4
screws (attached).
4) Connect the power supply terminal of the ACIN cable (controller attachment parts) to the terminal base of
CR800-MB. And connect the FG terminal of the ACIN cable to the earth terminal of CR800-MB.
5) Put a controller into CR800-MB and fix it by 4 screws which are removed in process "3)".
6) Connect the ACIN cable to the ACIN connector on the backside of a controller. And store the ACIN cable in
the bottom space of CR800-MB.
㻱㼍㼞㼠㼔㻌㼠㼑㼞㼙㼕㼚㼍㼘㻌㻔㻹㻠㻌㼟㼏㼞㼑㼣㻕㻭㻯㻵㻺㻌㼏㼍㼎㼘㼑㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞

㻔㼍㼠㼠㼍㼏㼔㼑㼐㻌㼠㼛㻌㼠㼔㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻕㻹㼑㼠㼍㼘㻌㼒㼕㼠㼠㼕㼚㼓㼟
㼀㼑㼞㼙㼕㼚㼍㼘㻌㼎㼍㼟㼑
㻔㻹㻠㻌㼟㼏㼞㼑㼣㻕
㻯㼍㼎㼘㼑㻌㼏㼛㼢㼑㼞㻌㼟㼠㼞㼍㼜㻌
㻔㼍㼠㼠㼍㼏㼔㼑㼐㻕
㻲㼞㼛㼚㼠
㻼㼛㼣㼑㼞㻌㼟㼡㼜㼜㼘㼥㻌㼏㼍㼎㼘㼑
㻱㼍㼞㼠㼔㻌㼏㼍㼎㼘㼑
㻔㼁㼟㼑㼞㻌㼜㼞㼑㼜㼍㼞㼍㼠㼕㼛㼚㻕
㻱㼙㼑㼞㼓㼑㼚㼏㼥㻌㼟㼠㼛㼜㻌㼣㼕㼞㼕㼚㼓
㻹㼍㼏㼔㼕㼚㼑㻌㼏㼍㼎㼘㼑
㻔㻯㻺㻝㻕
㻲㼕㼤㼕㼚㼓㻌㼜㼘㼍㼠㼑
㻸㼍㼎㼑㼘㻌㼒㼛㼞㻌㼟㼑㼞㼕㼍㼘㻌㼚㼡㼙㼎㼑㼞㻌㻔㼍㼠㼠㼍㼏㼔㼑㼐㻕㻌㻗㻌
㼀㼞㼍㼚㼟㼜㼍㼞㼑㼚㼠㻌㼟㼑㼍㼘㻌㻔㼍㼠㼠㼍㼏㼔㼑㼐㻕㻲㻭㻺㼀㻛㻮㻌㼏㼛㼚㼚㼑㼏㼠㼕㼚㼓㻌㼏㼍㼎㼘㼑
㻲㼞㼛㼚㼠㻌㼢㼕㼑㼣㻿㼕㼐㼑㻌㼢㼕㼑㼣
㻨㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻪㻨㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻪
㼀㼑㼞㼙㼕㼚㼍㼘㻌㼎㼍㼟㼑㻭㻯㻵㻺㻌㼏㼍㼎㼘㼑㻌㼒㼛㼞㻌㼟㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑
㻔㻹㻠㻌㼟㼏㼞㼑㼣㻕㻔㼍㼠㼠㼍㼏㼔㼑㼐㻌㼠㼛㻌㼠㼔㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻕㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㼀㼑㼞㼙㼕㼚㼍㼘㻌㼎㼍㼟㼑㻭㻯㻵㻺㻌㼏㼍㼎㼘㼑㻌㼒㼛㼞㻌㼠㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞
㻔㻹㻠㻌㼟㼏㼞㼑㼣㻕㻔㼍㼠㼠㼍㼏㼔㼑㼐㻌㼠㼛㻌㼠㼔㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻕
㻼㼛㼣㼑㼞㻌㼟㼡㼜㼜㼘㼥㻌㼏㼍㼎㼘㼑㻘
㻱㼍㼞㼠㼔㻌㼏㼍㼎㼘㼑
㻲㻭㻺
㻱㼍㼞㼠㼔㻌㼠㼑㼞㼙㼕㼚㼍㼘㻌㻔㻹㻠㻌㼟㼏㼞㼑㼣㻕㻱㼍㼞㼠㼔㻌㼠㼑㼞㼙㼕㼚㼍㼘㻌㻔㻹㻠㻌㼟㼏㼞㼑㼣㻕
㻼㼛㼣㼑㼞㻌㼟㼡㼜㼜㼘㼥㻌㼏㼍㼎㼘㼑㻘㻲㻭㻺
㻱㼍㼞㼠㼔㻌㼏㼍㼎㼘㼑㻼㼞㼛㼠㼑㼏㼠㼕㼛㼚㻌㼎㼛㼤㻌㻔㻯㻾㻤㻜㻜㻙㻹㻮㻕
Note) The wiring diagram differs form an actual internal placement of the protection box.
Fig. 3-3 ： Internal structure and wiring diagram
7) Prepare a power supply cable and an earth cable, and connect them to the terminal base and the earth
terminal in CR800-MB.
8) For safety, absolutely prepare an external emergency stop equipment. Refer to Page 24, "2.3.6 Connecting
the external emergency stop and mode selector switch" for connecting the external emergency stop.
9) Connect the machine cable to a controller and package all the cable covers with cable ties (attached).
10) Connect T/B connecting cable installed in the front inside of CR800-MB to T/B connector of a controller.
3-40 Installing and wiring of the controller protection box (CR800-MB)

11) Fix the top plate with metal fittings (4 pcs.) of CR800-MB.
CAUTION When you do not connect T/B to CR800-MB, be sure to connect T/B cap to TB
connector.
CAUTION Install a controller option before combining a controller and CR800-MB.
CAUTION When CR800-MB is used vertically, exchange for the screws of the left side the rubber
legs attached to the bottom.
CAUTION Always transport CR800-MB by two people or more. (Mass of CR800-MB: 20kg)
㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼒㼕㼤㼕㼚㼓㻌㼜㼘㼍㼠㼑
㻿㼏㼞㼑㼣㻌㼔㼛㼘㼑㻌㻔㻠㻌㼜㼘㼍㼏㼑㼟㻕
㻼㼞㼛㼠㼑㼏㼠㼕㼛㼚㻌㼎㼛㼤
Fig. 3-4 ： Controller installation drawing
Installing and wiring of CR800-MB is completed.
Installing and wiring of the controller protection box (CR800-MB) 3-41

4Basic operations
4 Basic operations
In this chapter, the following items will be explained regarding the basic operations for handling the robot.
Handling the controller The functions of the various keys on the controller are
explained.
Handling the teaching pendant The methods of installing/removing the T/B, and the
functions of the various keys are explained.
Turning the power ON/OFF The items to confirm before turning on the controller
power, and the methods of turning the power ON and
OFF are explained.
Operating the robot with jog operation The methods for manually operating the robot arm using
the teaching pendant are explained. This is mainly used
for teaching work.
Opening and closing the hand The methods of opening and closing the hand using the
teaching pendant are explained.
Program creation to automatic operation The procedures of creating the program are explained in
order.
4-42
4Basic operations
4.1 Handling the controller

4.1.1 Names of each parts
㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼒㼞㼛㼚㼠
㻭㼕㼞㻌㼕㼚㼠㼍㼗㼑㻌㼒㼛㼞㻌㼒㼍㼚㻨㻝㻤㻪㻨㻢㻪㻨㻝㻥㻪㻨㻞㻜㻪
㻨㻞㻝㻪
㻨㻣㻪㻨㻤㻪㻨㻥㻪㻨㻝㻜㻪㻨㻝㻝㻪㻨㻝㻞㻪㻨㻝㻟㻪㻨㻝㻠㻪㻨㻝㻡㻪㻨㻝㻢㻪㻨㻝㻣㻪
㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼞㼑㼍㼞
㻨㻝㻪㻨㻟㻪㻭㼕㼞㻌㼑㼤㼔㼍㼡㼟㼠
㻨㻞㻪㻭㼕㼞㻌㼑㼤㼔㼍㼡㼟㼠㻺㻻㻌㼁㻿㻱㻨㻡㻪㻨㻠㻪
Fig. 4-1 ： Names of controller parts
<1> ACIN connector.......................................Supplied ACIN cable connector (input voltage: AC200V).

Number of
ACIN cable
phase
Single phase
㻸㻌㻔㻮㼘㼍㼏㼗㻕
㻺㻌㻔㼃㼔㼕㼠㼑㻕
㻲㻳㻌㻔㻳㼞㼑㼑㼚㻕
Terminal: M5, cable length: 3m
Three phase
㻸㻝㻌㻔㻮㼘㼍㼏㼗㻕
㻸㻞㻌㻔㼃㼔㼕㼠㼑㻕
㻸㻟㻌㻔㻾㼑㼐㻕
㻲㻳㻌㻔㻳㼞㼑㼑㼚㻕
Terminal: M5, cable length: 3m
<2> PE terminal ................................................Terminals for grounding (M4 screw x 2).
<3> CN1 cable...................................................Machine cable connector.
<4> <5> CNUSR connector .........................Robot I/O cable connectors.
<4>: CNUSR11, <5>: CNUSR12
<6> TB connector............................................Dedicated connector for connecting T/B.
Handling the controller 4-43

4Basic operations
<7> LED ...............................................................Four LEDs indicating the controller status.

LED Details
POWER Indicates the control power status.

On: Control power ON
Off: Control power OFF
AUTO Indicates the controller mode.

On: AUTOMATIC mode
Off: MANUAL mode
ERROR Indicates the error status.
On: Error occurred.
Rapid flashing: High-level error occurred.
Off: Normal operation
READY Indicates the operation status.

On: ON (ready)
Slow flashing: During operation
Rapid flashing: Operation suspended.
<8> HAND FUSE ..............................................Fuse for the hand.
<9> EXT1 .............................................................Connector for function extension.
<10> RIO..............................................................Parallel I/O extension connector.
<11> OPT1..........................................................Connector for communication with another controller or the robot CPU.
<12> OPT2..........................................................Connector for communication with another controller.
<13> AXIS ...........................................................Connector for additional axis connection.
<14> PC ...............................................................Connector for communication with a personal computer. This connector
cannot be used in CR800-R/CR800-Q controller.
<15> EXT2...........................................................Connector for function extension. This connector cannot be used in
CR800-R/CR800-Q controller.
<16> LAN.............................................................Connector for Ethernet communication. This connector cannot be used in
CR800-R/CR800-Q controller.
<17> SD CARD .................................................SD memory card slot. This connector cannot be used in CR800-R/CR800-
Q controller.
<18> Filter cover..............................................Dustproof dust filter cover. An air filter is provided inside the filter cover.
<19> <20>Option slot .....................................Option card slots (must be covered when not used).
<19> SLOT1, <20> SLOT2
<21> FG terminal..............................................Option card cable terminals for grounding (M4 screw x 2).
CAUTION Use the network equipments (personal computer, USB hub, LAN hub, etc) confirmed by
manufacturer. The thing unsuitable for the FA environment (related with conformity,
temperature or noise) exists in the equipments connected to USB. When using network
equipment, measures against the noise, such as measures against EMI and
the addition of the ferrite core, may be necessary. Please fully confirm the operation
by customer. Guarantee and maintenance of the equipment on the market (usual office
automation equipment) cannot be performed.
CAUTION For USB connection between the RT ToolBox3 and the robot controller, noise may
cause the instability in data communication.
As a solution, switching communication method to LAN connection is recommended.
◇◆◇ What are the operation rights? ◇◆◇

Even when multiple devices, such as a T/B and personal computer, are connected to the controller, the
operation at one time is limited to one device. This limited device (has the operation rights)
◇◆◇ What operations require the operation rights? ◇◆◇

Operations that start the robot, such as program start and alarm reset, and operations that can cause starting
require the operation rights. Conversely, operation that stop the robot, such as stopping and servo OFF, can be
used without the operation rights for safety purposes. Refer to the separate manual "Explanation of functions
and operations" for details on the functions related to operation rights.
4-44 Handling the controller

4Basic operations
4.2 Handling the T/B

4.2.1 Installing and removing the T/B
Installing and removing the T/B, with turning off the controller power. If T/B is installed and removed in the
state of control source ON, emergency stop alarm will be occurred.
However, it allows you to remove the T/B from the controller without occurrence of alarm by pulling out the T/
B connector within five seconds while the 3-position enable switch of the T/B is being pulled up lightly (in the
position 2).
CAUTION Please do not pull the cable of T/B strongly or do not bend it too much.
It becomes the breaking of a wire of the cable and the cause of breakage of the
connector. Please installing and removing so that stress does not start the cable
with the connector itself.
㼀㼑㼍㼏㼔㼕㼚㼓㻌㼜㼑㼚㼍㼐㼚㼠㻌㻔㼀㻛㻮㻕
㻰㼑㼠㼍㼕㼘㼟㻌㼛㼒㻌㼠㼔㼑㻌㻭㻌㼟㼑㼏㼠㼕㼛㼚
㻸㼛㼏㼗㻌㼘㼑㼢㼑㼞
㻮㻌
㼃㼔㼑㼚㻌㼞㼑㼙㼛㼢㼕㼚㼓㻌㼠㼔㼑㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞㻌㼒㼛㼞㻌㼀㻛㻮㻌
㼏㼛㼚㼚㼑㼏㼠㼕㼛㼚㻘㻌㼡㼟㼑㻌㼘㼛㼏㼗㻌㼞㼑㼘㼑㼍㼟㼑㻌㻔㼟㼠㼍㼠㼑㻌
㼣㼔㼕㼏㼔㻌㼞㼍㼕㼟㼑㼐㻌㼠㼔㼑㻌㼘㼛㼏㼗㻌㼘㼑㼢㼑㼞㻌㼠㼛㻌㼠㼔㼑㻌㼡㼜㻌
㼟㼕㼐㼑㻕㻘㻌㼙㼍㼗㼑㻌㼠㼔㼑㻌㼏㼍㼟㼑㻌㼛㼒㻌㼠㼔㼑㻌㻮㻌㼟㼑㼏㼠㼕㼛㼚㻌
㼟㼘㼕㼐㼑㻌㼠㼛㻌㼠㼔㼑㻌㼒㼞㼛㼚㼠㻘㻌㼍㼚㼐㻌㼞㼑㼙㼛㼢㼑㻌㼍㼚㼐㻌㼜㼡㼘㼘㻌
㼡㼜㻌㼛㼡㼠㻌㼠㼔㼑㻌㼘㼍㼠㼏㼔㻚
㼀㻮㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
㼀㻛㻮㻌㼏㼛㼚㼚㼑㼏㼠㼕㼛㼚㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞
Fig. 4-2 ： Installing and removing the T/B
(1) Installing the T/B

Explain the installation method of T/B below.
1) Check that the power supply of the robot controller is OFF.

2) Refer to Fig. 4-2, connects T/B connector to the robot controller. Use as the upper surface the lock lever,
and push in until there is sound.
The installation of T/B is finished.
(2) Removing the T/B

Explain the removing method of T/B below.
■ In MANUAL mode
1) Check that the power supply of the robot controller is OFF.
2) Refer to Fig. 4-2, raise up the lock lever in the connector upper part , and pull up the connector.
Please install the dummy connector, if you use the robot, without connecting T/B.
The removing of T/B is finished.
■ In AUTOMATIC mode
1) Pull up lightly (in the position 2) the 3-position enable switch of the T/B.
2) Pull out the T/B connector within five seconds while 1). Refer to Fig. 4-2, raise up the lock lever in the
connector upper part , and pull up the connector.
Please install the dummy connector, if you use the robot, without connecting T/B.
The removing of T/B is finished.
Handling the T/B 4-45

4Basic operations
4.2.2 Functions of each key
②
④
①
③
⑤ ⑤
⑥ ⑥
⑦ ⑧
⑨ ⑩
⑪ ⑰
⑫
⑬ ⑱
⑭
⑲
⑮
⑯
⑳
Fig. 4-3 ： Teaching pendant
① [Emergency stop] switch.................The robot servo turns OFF and the operation stops immediately. The release of
the emergency stop turns the switch to the right, or pulls it.
② [Enable/Disable] switch...................This switch changes the T/B key operation between enable and disable.
③ [Enable] switch ....................................When the [Enable/Disable] switch is available, the servo will be turned off, if this
switch is release or it pushes strongly. And the robot will stop immediately.
④ LCD display panel...............................The robot status and various menus are displayed.
⑤ Status display lamp............................Display the state of the robot or T/B.
⑥ [F1], [F2], [F3], [F4] ..........................Execute the function corresponding to each function currently displayed on
LCD.
⑦ [FUNCTION] .........................................Change the function display of LCD.
⑧ [STOP] key ...........................................This stops the program and decelerates the robot to a stop.
⑨ [OVRD ↑ ][OVRD ↓ ] key............Change moving speed. Speed goes up by [OVRD ↑ ] key. Speed goes down by
[OVRD ↓ ] key
⑩ [JOG] operation key .........................Move the robot according to jog mode. And, input the numerical value.
⑪ [SERVO] key ........................................Press this key with holding AA key lightly, then servo power will turn on.
⑫ [MONITOR] key...................................It becomes monitor mode and display the monitor menu.
⑬ [JOG] key ..............................................It becomes jog mode and display the jog operation.
⑭ [HAND] key ...........................................It becomes hand mode and display the hand operation.
⑮ [CHAR] key ...........................................This changes the edit screen, and changes between numbers and alphabetic
characters.
⑯ [RESET] key .........................................This resets the error. The program reset will execute, if this key and the EXE
key are pressed.
⑰ [ ↑ ][ ↓ ][ ← ][ → ] key ................Moves the cursor each direction .
⑱ [CLEAR] key.........................................Erase the one character on the cursor position .
⑲ [EXE] key ...............................................Input operation is fixed. And, while pressing this key, the robot moves when
direct mode.
⑳ Number/Character key ....................Erase the one character on the cursor position . And, inputs the number or
character
◇◆◇ Remove the protection seal of the teaching pendant before using ◇◆◇
Installed the protection seal on the teaching pendant to prevent the damage of the display LCD and the key
seat when shipping. Remove the protection seal when using. The operation of the key and the confirmation of
the display is possible without removing the protection seal, however the adhesive may be left on the teaching
pendant as the time passes.
4-46 Handling the T/B

4Basic operations
4.3 Turning the power ON and OFF

4.3.1 Turning the control power ON
CAUTION Always confirm the following items before turning the controller power ON.
1) Make sure that there are no operators in the robot operation range.
2) Make sure that the controller and robot arm are securely connected with the
machine cable.
3) Make sure that the external emergency stop switch is connected to the controller.
4) Make sure that the controller power cable and grounding cable are correctly
connected.
5) Make sure that the grounding cable is connected to the robot arm.
6) Make sure that there are no obstacles, such as tools, in the robot operation range.
㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑
㻿㼣㼕㼠㼏㼔
㻱㼍㼞㼠㼔㻌㼘㼑㼍㼗㼍㼓㼑
㼎㼞㼍㼗㼑㼞㻌㻔㻺㼂㻕
■ CR800-D controller
Operate the earth leakage breaker of installation outside to do the controller's power supply ON/OFF.
Turns ON the switch of the earth leakage breaker of installation outside. The controller power turn on, and the
power lamp lights up.
■ CR800-R/CR800-Q controller
Operate the earth leakage breaker of installation outside to do the controller's power supply ON/OFF.
Turns ON the switch of the earth leakage breaker of installation outside. The controller power turn on, and the
power lamp lights up Then, the robot CPU unit power on.
Turning the power ON and OFF 4-47

4Basic operations
4.3.2 Input the serial number

If error C0152 (unmatched robot serial number) occurs after purchasing the robot, please input the serial
number of the robot arm into parameter RBSERIAL.
The serial number is printed to the rating name board on base section of the robot arm.
1) Press the [RESET] key of T/B and cancel the error of T/B.
2) Press the [EXE] key of T/B and display the menu panel.
MELFA CR800-D Ver. S3 <MENU>　　　

RH-3FRH5515-D
1.FILE/EDIT 2.RUN
COPYRIGHT (C) 2011 MITSUBISHI ELEC 3.PARAM. 4.ORIGIN/BRK
TRIC CORPORATION ALL RIGHTS RESE 5.SET/INIT. 6.ENHANCED
RVED
　 123 CLOSE
3) Press the [3] key of T/B and display the parameter.
<MENU>　　　 <PARAMETER> NAME( )

ELE( )
1.FILE/EDIT 2.RUN DATA
3.PARAM. 4.ORIGIN/BRK (　　　　　　　　　　　　　　　)
5.SET/INIT. 6.ENHANCED
　 123 CLOSE DATA Prev 123 Next CLOSE
4) Input "RBSERIAL" into the name.

<PARAMETER> NAME( ) <PARAMETER> NAME(RBSERIAL )
ELE( ) ELE( )
DATA DATA
(　　　　　　　　　　　　　　　) (　　　　　　　　　　　　　　　)
DATA Prev 123 Next CLOSE DATA Prev 123 Next CLOSE
5) Press the function key ([F1]) corresponding to the "data", and input the serial number of the robot arm. The
serial number stored in the robot arm is automatically displayed.
Serial number Press the [EXE] key to input the
displayed serial number.
<PARAMETER> NAME(RBSERIAL ) <PARAMETER> (RBSERIAL ) ( )

ELE( )
DATA XXXXXXXXXX　
(XXXXXXXXXX 　　　　　　　　　)
DATA Prev 123 Next CLOSE DATA Prev 123 Next CLOSE
Setting the data [F1] Execute [EXE]

(Operation will be canceled if the [F4] key is pressed.)
Press the [EXE] key, and fix the value with sound, and return to the parameter screen.
◇◆◇ The input of the number/character ◇◆◇

Each time the [CHARACTER] key is pressed, the number input mode and the character input mode change.
The current input mode is displayed in the center under the screen, and the display of "123" shows that the
number input mode and "ABC" is the character input mode.
For details, please refer to "INSTRUCTION MANUAL/ Detailed explanations of functions and operations" of the
separate volume.
4-48 Turning the power ON and OFF

4Basic operations
4.3.3 Shutting OFF the control power

■ CR800-D controller
1) If the robot is operating, stop the robot.
2) After the robot has stopped, turn the servo OFF.
3) Turn OFF the switch of the earth leakage breaker installed outside.
■ CR800-R/CR800-Q controller
1) If the robot is operating, stop the robot.
2) After the robot has stopped, turn the servo OFF.
3) Turns off the robot CPU system.
4) Turn OFF the switch of the earth leakage breaker installed outside.
Turning the power ON and OFF 4-49

4Basic operations
4.3.4 Shutting OFF the controller power

If the controller power is shut off while the robot CPU system is ON, the errors shown in Table 4-1 occurs. To
recover from the error, reset the error after turning on the controller power. Error resetting operation requires
about 60 seconds.
When the robot CPU system was turned off, turn on the robot CPU system after turning on the controller. Refer
to Page 47, "4.3.1 Turning the control power ON" for details.
Table 4-1 ： List of errors

Error No. Error message
H8751 CR800 communication error
4-50 Turning the power ON and OFF

4Basic operations
4.4 Jog operation

Refer to the separate manual "Robot arm setup and maintenance" when carrying out jog operation.
The following jog operation modes are available. Use these according to the purpose.
Table 4-2 ： Jog modes

Jog mode Main application Explanation
JOINT JOG ・ Moves each joint.

・ Moves the robot arm largely.
・ Changes the robot posture.
XYZ JOG ・ Accurately sets the teaching position.
・ Moves the axis straight along the XYZ coordinate system.
・ Moves the axis straight while maintaining the robot posture.
・ Changes the posture while maintaining the hand position.
TOOL JOG ・ Accurately sets the teaching position.

・ Moves the axis straight along the hand direction.
・ Changes the posture while maintaining the hand position.
Separate manual "Robot arm
・ Rotates the hand while maintaining the hand position.
setup and maintenance"
3-AXIS XYZ JOG ・ When the axis cannot be moved with XYZ JOG that maintains the posture. Separate manual "Detailed
・ When the tip is to be moved linearly but the posture is to be changed. explanations of functions and
operations"
CYLINDER JOG ・ Moves in a cylindrical shape centering on the Z axis while maintaining the posture.
・ Moves linearly in a radial shape centering on the Z axis while maintaining the posture.
WORK JOG ・ Accurately sets the teaching position.

(Work jog mode) ・ Moves the axis straight along the coordinates system (work coordinates system)
defined in accordance with a workpiece, pallet, etc.
・ Changes the posture along the work coordinates system.
WORK JOG ・ Accurately sets the teaching position.

(Ex-T jog mode) ・ Moves the axis straight along the work coordinates system (Ex-T coordinates
system) defined in accordance with an installed grinder, dispenser, etc.
・ Changes the posture along the work coordinates system (Ex-T coordinates system).
Jog operation 4-51

4Basic operations
4.5 Opening and closing the hand

Hands 1 to 6 can be opened and closed with the T/B.
<HAND> ±C : HAND1 ±Z : HAND4

±B : HAND2 ±Y : HAND5
±A : HAND3 ±X : HAND6
76543210 76543210
OUT-900□□□□□□ IN-900□□□□□□
SAFE ALIGN HND CLOSE
Press the [HAND] key, and display the hand screen.
Opening and closing hand 1

Open: Press [+C ] key
[-C]] Close: Press [-C ] key
Open: Press [+B ] key
Close: Press [-B ] key
[+C]] Opening and closing hand 3
Open: Press [+A ] key
Open Close Close: Press [-A ] key
Open: Press [+Z ] key
Close: Press [-Z ] key
Open: Press [+Y ] key
Close: Press [-Y ] key
Open: Press [+X ] key
Close: Press [-X ] key
4-52 Opening and closing the hand

4Basic operations
4.6 Programming
The procedures from creating the program to automatic operation are explained in order using a simple procedure
as an example.
MELFA-BASIC VI commands are used in the program examples.
(1) Creation procedures
Start
Decide the robot operation order, operation path

Deciding the operation order (necessity of linear movement), and the work at each
operation position (hand open/close, etc).
Teach the robot operation position in the position

Deciding the operation position name
variables.
Decide the position variable name.
Based on the decided operation order and operation

Describing and creating the program
position name, convert the robot operations and work
into commands. Describe the commands in the program
and save in the controller.
Move the robot to each operation position with jog

Teaching the operation position operation, and teach each position in the position
variables.
Execute the program saved in the controller line by line,

Confirmation of program and operation position and confirm that the program and operation positions
are correctly saved.
Yes
Judgment: OK?
No
If any mistakes were found in the robot operation or

Correcting the program
work during the program confirmation, correct the
program.
If any mistakes were found in the robot operation

Correcting the position position during the program confirmation, correct the
taught position.
Automatically execute the completed program.

Automatic operation
End
Fig.4-4 ： Program creation procedures
(2) Robot work

Assume that the robot is going to carry the workpiece from the left to the right.
Workpiece Carry the workpiece
Fig.4-5 ： Example of work
Programming 4-53
4Basic operations
4.6.1 Creating the program

(1) Deciding the operation order
(1) ：Joint movement

Wait position
：Linear movement
：Teaching position
(10
(2) )
Upward position to (6) Upward position to
grasping workpiece release workpiece
(3) (7)
20mm
(4) Hand close (8) Hand open

(5) (9) Position to release workpiece
Position to grasp workpiece
Start
(1) Move to wait position (joint movement).
(2) Move to 20mm upward workpiece (joint movement).
(3) Move to position to grasp workpiece (linear movement).
(4) Grasp workpiece (hand close).
(5) Move 20mm upward (linear movement).
(6) Move to 20mm upward position to release workpiece
(joint movement).
(7) Move to position to release workpiece (linear movement).
(8) Release workpiece (hand open).
(9) Move 20mm upward (linear movement).
(10) Move to wait position (joint movement).
End
Fig.4-6 ： Deciding the operation order
◇◆◇ Joint movement and linear movement ◇◆◇

The operation for which the robot movement path is not designated in particular is the "joint movement". The
operation for which the movement path is designated as linear is "linear movement".
If the robot could interfere with the peripheral devices, such as the workpiece, when moving to grasp or release
the workpiece, designate "linear movement" to prevent any interference.
4-54 Programming
4Basic operations
(2) Deciding the operation position name
Wait position
(ＰＷＡＩＴ)
Upward position to Upward position to

Position to release
20mm
Position to grasp workpiece workpiece

(ＰＧＥＴ) (ＰＰＵＴ)
Position variable
Name Teaching Remarks
name
Wait position PWAIT Required
Upward position to grasping － Not required Designate with commands.

workpiece
Position to grasp workpiece PGET Required

Upward position to release workpiece － Not required Designate with commands.
Position to release workpiece PPUT Required
Position variable name ････ Designate a random character string starting with "P".
Up to eight characters can be designated. (For MELFA-BASIC VI
commands)
Fig.4-7 ： Deciding the operation position name
◇◆◇ Teaching the operation position ◇◆◇

The operation position does not necessarily need to be taught.
The positions shown with white circles in Fig. 4-7 can be designated with commands as "position 20mm away
from target position". Refer to Page 56, "(3) Describing and creating the program".
CAUTION The designation of the direction separated from the target position differs according to the
robot type.
The position is along the Z axis of the TOOL coordinate system, and the direction is
designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Instruction Manual/
Robot arm setup and maintenance", and confirm the Z axis direction of the TOOL
coordinate system. Then, designate the correct sign (direction) that matches the robot
being used.
Designating the reverse direction could lead to interference with the peripheral devices and
damage.
Generally (in the default state), the hand retract direction is the "-" sign with the vertical
articulate type robot, and the "+" sign is the robot's upward direction with the other robots.
Programming 4-55
4Basic operations
(3) Describing and creating the program

■ Convert the target robot operations and work into commands.
Refer to the separate manual "Instruction Manual: Detailed explanations of functions and operations" for details
on the commands.
Table 4-3 ： Commands used (For MELFA-BASIC VI commands)
Target operation and work Command Example of designation
Joint movement Mov Move to position variable PWAIT Mov PWAIT

Move to 20mm upward position variable Note)
Mov PGET,+20
PGET
Linear movement Mvs Move to position variable PGET Mvs PGET
Move to 20mm upward position variable Note)
Mvs PGET,+20
PGET
Hand open Hopen Open hand 1 Hopen 1
Hand close Hclose Close hand 1 Hclose 1
Wait Dly Wait 1 second Dly 1.0
End End End the program End
Note) Upward movement is designated at a position along the Z axis of the TOOL coordinate system, and the
direction is designated with the + and - signs. Confirm the Z axis direction of the TOOL coordinate system.
Then, designate the correct sign (direction) that matches the robot being used. The example of designation
above is an example using a horizontal multiple-joint type robot.
■ Program the converted commands

Wait position
(ＰＷＡＩＴ)
Upward position to Upward position to

Position to release
20mm
Position to grasp workpiece workpiece

(ＰＧＥＴ) (ＰＰＵＴ)
Start
(1) Move to wait position (joint movement) ...................................................................1 Mov PWAIT
Note)
(2) Move to 20mm upward workpiece (joint movement)...........................................2 Mov PGET,+20
(3) Move to position to grasp workpiece (linear movement)...................................3 MVS PGET
(4) Grasp workpiece (hand close).......................................................................................4 HClose 1
(5) Waits for 1 seconds...........................................................................................................5 Dly 1.0
(6) Move 20mm upward (linear movement).....................................................................6 MVS PGET,+20 Note)
(7) Move to 20mm upward position to release workpiece (joint movement) ...7 Mov PPUT,+20 Note)
(8) Move to position to place workpiece (linear movement) ...................................8 MVS PPUT
(9) Release workpiece (hand open)....................................................................................9 HOpen 1
(10) Waits for 1 seconds ........................................................................................................10 Dly 1.0
Note)
(11) Move 20mm upward (linear movement) ..................................................................11 MVS PPUT,+20
(12) Move to wait position (joint movement) .................................................................12 Mov PWAIT
End...................................................................................................................................................13 End
Hand ････ Up to four hands can be installed. However, in the above program, the 1st hand connected to
hand 1 is the target.
Fig. 4-8 ： Describing the program
4-56 Programming
4Basic operations
CAUTION Note) Upward movement is designated at a position along the Z axis of the TOOL
coordinate system, and the direction is designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Installation
Manual/ Robot arm setup and maintenance", and confirm the Z axis direction of
the TOOL coordinate system. Then, designate the correct sign (direction) that
matches the robot being used.
Designating the reverse direction could lead to interference with the peripheral
devices and damage.
Generally (in the default state), the hand retract direction is the "-" sign with the
vertical articulate type robot, and the "+" sign is the robot's upward direction with
the other robots. "+20" in the command line is a example in horizontal multiple-
jointed type robot.
◇◆◇ Program format ◇◆◇

The program format is configured of the "step No. command parameter affixed to command" as shown in Fig. 4-8.
Example) １ＭｏｖＰＷＡＩＴ
step No. Command Parameter affixed to command
The program is executed in order from the step No. with the smallest number.
Programming 4-57
4Basic operations
■ Input the described program into the controller.

The T/B is used for this operation.
1) Set the controller’s mode to “MANUAL” .

Preparing the T/B
2) Set the T/B [ENABLE] switch to "ENABLE".
Up ：DISABLE
Down：ENABLE
*Lighting
Rear of T/B
<MENU> 3) In the <MENU> screen, press the arrow keys

(" ↑ ", " ↓ ", " ← ", " → ") and move the
1.FILE/EDIT 2.RUN
3.PARAM. 4.ORIGIN/BRK ～ cursor to "1. Management and edit", and
5.SET/INIT. 6.ENHANCED then press the [EXE] key. The <Management
CLOSE
and edit> screen will appear.
123
<FILE/EDIT> 1/20 Rem 136320

4) Press the [F3](New) key, and display the new
1 08-04-24 17:20:32 22490 program screen.
2 08-04-24 14:56:08 694
A1 08-04-24 13:05:54 2208
B1 08-04-24 13:05:54 1851
EDIT POSI. 123 NEW COPY ⇒
<NEW PROGRAM> 5) Press [1], [EXE] key, and display the edit
　　　 screen of program No1.
PROGRAM NAME
( 1_ )
　 ABC CLOSE
<PROGRAM> 1 100%
EDIT DELETE 123 INSERT TEACH ⇒
◇◆◇ Using the T/B ◇◆◇

Set the controller’s mode to "MANUAL" and the T/B [ENABLE] switch to "ENABLE". While the T/B is
enabled, you can only use the T/B to command operations. The external signals cannot be used to command
operations.
◇◆◇ Inputting numbers ◇◆◇
The current input mode is displayed in the center under the screen, and the display of "123" shows that the
number input mode. The number currently written to the lower left of each key in this state can be inputted.
◇◆◇ Correcting incorrect numbers ◇◆◇

Press the [CLREAR] key to delete the character, and then input it again. And, if the long pushing [CLEAR] key,
all the data in the parenthesis can be deleted.
If the cursor is returned by pressing the [ ← ] key, and a character is input, it will be inserted.
4-58 Programming
4Basic operations
<PROGRAM> 1 100%
6) Press the [F3] key.
＿
The cursor will move to the command editing
line.
EDIT DELETE 123 INSERT CLOSE

7) Confirm that the number input mode and
<PROGRAM> 1
press the [1] key.
1＿ "1" of the step number is inputted.
123 CLOSE
<PROGRAM> 1 Ins
8) Press the [CHARACTER] key, and set to
1MOV＿ the character input mode, then press ［SP］
, ［MNO］ key. Display the space and "M."
SPACE
123 CLOSE
<PROGRAM> 1 Ins 9) Press the [ → ] key, and the cursor is

1MOV＿ moved. Then press the ［MNO］ key 3
times, and input "o".
123 CLOSE
10) Press the [TUV］ key 3 times, and input "v".

<PROGRAM> 1 Ins
1MOV＿
123 CLOSE
◇◆◇ Inputting characters and space ◇◆◇

The current input mode is displayed in the center under the screen, and the display of "ABC" shows that the
character input mode. The character currently written to the lower right of each key in this state can be
inputted. When you continue and input the character in the same key, once press the [->] key and advance the
cursor. The space is assigned to the [SP] key.
◇◆◇ The input method of the mark ◇◆◇

It comes out to input the character which is not displayed on the key. The character currently assigned to the
key is shown below.
a) [ ’ ( ) ] key .................... ' → ( → ) → " → ＾→ ： → ； → ￥ →？
b) [ @ = ] key.................... ＠ → ＝ → ＋ → － → ＊→ ／ → ＜ → ＞
c) [ ， % ] key ..................... ，→ ％ → ＃ → ＄ → ！→ ＆ → ＿ → ．
Programming 4-59
4Basic operations
<PROGRAM> 1 Ins 11) Press the [SP], [PQRS] key, and input the
1MOV P1＿ space and "P".
123 CLOSE SPACE
12) Press the [WXYZ] key, and input the space

<PROGRAM> 1 Ins and "W".
1MOV PWAIT＿
123 CLOSE
<PROGRAM> 1 Ins 13) Input "A", "I" and "T" in the same manner.
1MOV PWAIT＿
123 CLOSE
14) Press the [EXE] key.
"1 Mov PWAIT" will be set.
<PROGRAM> 1 Ins
1 MOV PWAIT＿
123 CLOSE 15) Input the program from step 2 to line 13 in

the same manner.
<PROGRAM> 1 Ins
1 MOV PWAIT＿
123 CLOSE
The inputting of the program is completed.
◇◆◇ Displaying the previous and next command step ◇◆◇

Display the four lines on the screen of T/B. For moving the cursor to the front line, the [ ↑ ] key is pressed, for
moving the cursor to the next line, press the [ ↓ ] key, and select.
◇◆◇ Displaying a specific line ◇◆◇

Press the [FUNCTION] key, and change the function display, and press the [F2] key. The display changes to the
JUNP screen. The specification line can be displayed, if the step number to display in the parenthesis is
inputted and the [EXE] key is pressed.
4-60 Programming
4Basic operations
■ Teach the robot operation position.

Set the position with jog operation (Teaching PGET)
1) Move the robot with jog operation, and set
Hand
ハンド
the end of the hand to the position for grasping
the workpiece. When the position has been set,
open and close the hand to confirm that the
workpiece can be grasped.
Work
ワーク Refer to Page 51, "4.4 Jog operation"for details
on the jog operation, and section Page 52, "4.5
Opening and closing the hand" for detains on
opening and closing the hand.
◇◆◇ Effective use of jog mode ◇◆◇

When the robot's current position is greatly separate from the target position, move the robot in axis units with
the "JOINT JOG mode", to approach the position.
If the target position is nearby, move linearly with the "XYZ JOG mode", and finely adjust the position. The
position can be set accurately by delaying the override (operation speed) at this time.
<PROGRAM> 1 Ins
2) In the program edit screen, press the
10 Dly 1.0 [FUNCTION] key twice and change the
11 Mvs PPUT, +20
12 Mov PWAIT function display. [F2](change) Press the key
13 End and display the position edit screen.
[FUNCTION] key
FWD JUMP 123 BWD
DIRECT CHANGE 123 CLOSE
3) Press the [F3](Next) or the [F4](Prev) key,
and display "PGET" on the screen upper
<POS.> JNT 100% PGET
X:＋128.56 A:＋180.00 right.
Y: ＋0.00 B: ＋90.00 The current registration coordinate value of
Z:＋845.23 C:－180.00
L1: L2: the position variable name PGET is
FL1: 7 FL2: 0 displayed.
MOVE TEACH 123 Prev Next ⇒
4) Press the [F2] (teaching) key.
<PROGRAM> 1 The teaching confirmation screen is
PGET displayed.
RECORD CURRENT POSITION.
OK?
5) Press the [F1] (being) key and register the
Yes 123 No
position.
<POS.> JNT 100% PPUT 6) Teach PPUT (position to place workpiece)

X:＋128.56 A:＋180.00 and PWAIT (wait position) in the same
Y: ＋0.00 B: ＋90.00
Z:＋845.23 C:－180.00 manner.
L1: L2:
FL1: 7 FL2: 0
Teaching of the robot operation positions is completed.
◇◆◇ Changing between the command editing screen and position editing screen. ◇◆◇
The commands are edited on the command editing screen, and the positions are edited on the position editing
screen.
To change from the command editing screen to the position editing screen, press the [F3] (Cange) keys.
To change from the position editing screen to the command editing screen, press the [F2] (Cange) keys.
To change the screen, use the [FUNCTION] keys.
Programming 4-61
4Basic operations
(4) Confirming the program

Using the T/B execute the program line by line (step operation), and confirm the operation.
Following operations are operated with lightly pressing the enabling switch on the T/B.
<POS.> JNT 100% PWAIT
X:＋128.56 A:＋180.00 1) Press the [FUNCTION] key and change the
Y: ＋0.00 B: ＋90.00
Z:＋845.23 C:－180.00 function display. Press the [F3](change) and
L1: L2: display the command edit screen.
FL1: 7 FL2: 0
[FUNCTION] key
DELET TEACH
MOVE NAME Prev
CHANGE Next
CLOSE
2) Press the [FUNCTION] key and change the

<PROGRAM> 1 Ins
function display. Pressing the [F1] (FWD)
10 Dly 1.0 key is kept, and the robot will start moving.
11 Mvs PPUT, +20
12 Mov PWAIT
13 End When the execution of one line is completed,
EDIT DELETE 123 INSERT CLOSE the robot will stop, and the next line will
[FUNCTION] key appear on the screen.
FWD JUMP 123 BWD If [F1] (FWD) is released during this step, the
DIRECT CHANGE 123 CLOSE robot will stop.
<PROGRAM> 1 Ins
3) By the same operation as the above-
10 Dly 1.0 mentioned, carry out step operation to the
11 Mvs PPUT, +20
12 Mov PWAIT END command of the 13 lines, and confirm
13 End movement.
EDIT DELETE 123 INSERT CLOSE If movement of the robot and the position are
[FUNCTION] key wrong, correct with reference to the
FWD JUMP 123 BWD following operations.
CAUTION Take special care to the robot movements during operation. If any abnormality occurs,
such as interference with the peripheral devices, release the [F1] (FWD) key and stop
the robot.
◇◆◇ Step operation ◇◆◇

"Step operation" executes the program line by line. The operation speed is slow, and the robot stops after each
line, so the program and operation position can be confirmed.
◇◆◇ Immediately stopping the robot during operation ◇◆◇

・ Press the [EMG.STOP] (emergency stop) switch.
The servo will turn OFF, and the moving robot will immediately stop.
To resume operation, reset the alarm, turn the servo ON, and start step operation.
・ Release or forcibly press the "enable" switch.
The servo will turn OFF, and the moving robot will immediately stop.
To resume operation, lightly press the "enable" switch, and start step operation.
・ Release the [F1] (FWD)key.
The step execution will be stopped. The servo will not turn OFF.
To resume operation, press the [F1] (FWD)key.
4-62 Programming
4Basic operations
(5) Correcting the program

■ Correcting the commands
As an example, the joint movement at line No.7 will be changed to linear movement.
(Change 7 Mov PPUT, +20 to 7 Mvs PPUT, +20) Note)
<PROGRAM> 1 Ins
1 Mov pwait
2 Mov PGET +20 1) Press the [FUNCTION] key and change the
3 Mvs PGET function display. Press the [F2](Jump) key
4 Hclose 1
and display the command edit screen.
[FUNCTION] key
FWD JUMP 123 BWD
2) Press the [7], [EXE] key and display the 7th

<PROGRAM> 1 50% step.
STEP ( 7 )
123 CLOSE
<PROGRAM> 1 Ins
7 Mov PPUT, +20
8 Mvs PPUT
9 Hopen 1
10 Dly 1.0
CAUTION Note) Upward movement is designated at a position along the Z axis of the TOOL
coordinate system, and the direction is designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Installation
Manual/ Robot arm setup and maintenance", and confirm the Z axis direction of
the TOOL coordinate system. Then, designate the correct sign (direction) that
matches the robot being used.
Designating the reverse direction could lead to interference with the peripheral
devices and damage.
Generally (in the default state), the hand retract direction is the "-" sign with the
vertical articulate type robot, and the "+" sign is the robot's upward direction
with the other robots.
◇◆◇ Displaying a specific line ◇◆◇

Press the [FUNCTION] key, and change the function display, and press the [F2] key. The display changes to the
JUNP screen. The specification line can be displayed, if the step number to display in the parenthesis is
inputted and the [EXE] key is pressed.
◇◆◇ Displaying the previous and next command step ◇◆◇

Display the four lines on the screen of T/B. For moving the cursor to the front line, the [ ↑ ] key is pressed, for
moving the cursor to the next line, press the [ ↓ ] key, and select.
Programming 4-63
4Basic operations
<PROGRAM> 1 Ins
3) Press the [F1] (Edit) key and display
command edit screen.
7 Mov PPUT, +20
8 Mvs PPUT
9 Hopen 1
10 Dly 1.0
<PROGRAM> 1 Ins 4) Press the [→] key 3 times. Move the cursor
7 Mov PPUT, +20
to "o."
123 CLOSE
<PROGRAM> 1 Ins
5) Press the [CLEAR] key twice and delete
7 M PPUT, +20 "ov". Leave "M."
123 CLOSE
<PROGRAM> 1 Ins
7 Mvs PPUT, +20 6) Press the [CHARCTER] key and set to the
character input mode. Press the [TUV] key 3
times (input "v"), the [→] key, the [PQRS]
123 CLOSE key 4 times (input "s").
7) Press the [EXE] key and the 7th step is

<PROGRAM> 1 Ins fixed. It returns to the program edit screen of
7 Mvs PPUT, +20 the four-line display.
8 Mvs PPUT
9 Hopen 1
10 Dly 1.0
Step No. 7 has been changed to linear movement with the above operation.
◇◆◇ Correcting incorrect numbers ◇◆◇

Press the [CLREAR] key to delete the character, and then input it again. And, if the long pushing [CLEAR] key,
all the data in the parenthesis can be deleted.
If the cursor is returned by pressing the [ ← ] key, and a character is input, it will be inserted.
◇◆◇ After correcting a program ◇◆◇

After correcting the program, carry out step operation, and confirm that the program has been corrected.
◇◆◇ Inputting characters and space ◇◆◇

The current input mode is displayed in the center under the screen, and the display of "ABC" shows that the
character input mode. The character currently written to the lower right of each key in this state can be
inputted. When you continue and input the character in the same key, once press the [→] key and advance the
cursor. The space is assigned to the [SP] key.
4-64 Programming
4Basic operations
■ Correcting the taught position

As an example, the wait position (PWAIT) will be corrected.
New wait position

(ＰＷＡＩＴ)
Change
<PROGRAM> 1 Ins
1 Mov pwait
2 Mov PGET +20 1) In the program edit screen, press the
3 Mvs PGET [FUNCTION] key twice and change the
4 Hclose 1 function display. [F2](change) Press the key
EDIT DELETE 123 INSERT CLOSE and display the position edit screen.
[FUNCTION] key
FWD JUMP 123 BWD
2) Press the [F3](Next) or the [F4](Prev) key,

<POS.> XYZ 100% PWAIT and display "PWAIT" on the screen upper
X:＋128.56 A:＋180.00
Y: ＋0.00 B: ＋90.00 right. The current registration coordinate
Z:＋845.23 C:－180.00 value of the position variable name PWAIT is
L1: L2:
FL1: 7 FL2: 0 displayed.
<POS.> XYZ 100% PWAIT 3) Move the robot to the new standby position
X:＋128.56 A:＋180.00 by jog operation.
Y: ＋0.00 B: ＋90.00
Z:＋845.23 C:－180.00
L1: L2: Refer to Page 51, "4.4 Jog operation"for
FL1: 7 FL2: 0
details on the jog operation, and section
Page 52, "4.5 Opening and closing the hand"
for detains on opening and closing the hand.
◇◆◇ Calling out a position variable ◇◆◇

The displayed position variable can be scrolled up or down by pressing the [F3] (Next) or [F4] (Prev) key.
Programming 4-65
4Basic operations
<POS.> XYZ 100% PWAIT

X:＋128.56 A:＋180.00 4) Press the [F2] (Teaching) key.
Y: ＋0.00 B: ＋90.00
Z:＋845.23 C:－180.00 The teaching confirmation screen is
L1: L2: displayed.
FL1: 7 FL2: 0
<POS.EDIT> 1
PWAIT 5) Press the [F1] (Yes) key and register the

RECORD CURRENT POSITION. position.
OK?
Yes 123 No
<POS.> XYZ 100% PWAIT

X:＋128.56 A:＋180.00
Y: ＋0.00 B: ＋90.00
Z:＋845.23 C:－180.00
L1: L2:
FL1: 7 FL2: 0
Correction of the standby position is completed.
◇◆◇ After correcting a program ◇◆◇

After correcting the program, carry out step operation, and confirm that the program has been corrected.
(6) Saving the program
If creation of the program or correction finishes, the program will certainly be saved.
If the [F4 (close)] key is pressed in the command edit screen or the position edit screen, the confirmation
message "the program was saved" is displayed and the details of edit are saved.
◇◆◇ Attention about the edit save ◇◆◇

Please keep in mind that the details of edit including teaching data will be canceled if the power supply is shut
down with the program edit screen.
4-66 Programming
4Basic operations
(7) Start automatic operation.
Operations are carried out from the <OPERATION> screen opened by selecting <MENU> → <RUN>.
CAUTION The T/B has the operation rights while displaying the <OPERATION> screen. (The T/
B’s status display lamp [ENABLE] blinks)
Note that operations which require external signal to have operation rights cannot be
executed.
The functions which can be executed from the T/B <OPERATION> screen and the operations which can be
executed while the <OPERATION> is displayed are shown below.
Operations from <OPERATION> screen (Each function key)

<1> Selecting a program............................................................"CHOOSE"
<2> Turning servo ON/OFF....................................................."SV. ON” / ”SV. OFF"
(When the controller mode sets "AUTOMATIC", the
ENABLE switch does not need to be turned ON.)
<3> Executing automatic operation ......................................"START"
<4> Changing operation mode (continuous/cycle)........."CONT./CYCLE"
<5> Resetting a program ..........................................................."RESET"
Other key operations

<1> Changing the movement speed ....................[OVRD ↑ ] / [OVRD ↓ ] key
Note) When the controller (drive unit) mode is set to "AUTOMATIC", the robot moves at the regular
speed. When set to "MANUAL", the robot moves at low speed (to confirm movement). Set the
controller (drive unit) to the required mode.
<2> Turning servo ON ...............................................[SERVO] key
(When the controller mode sets "AUTOMATIC", the ENABLE
switch does not need to be turned ON.)
<3> Resetting the alarm ...........................................[RESET] key
* The robot can be stopped at any time with the [EMG. STOP] switch or [STOP] key.
Operations using the [JOG], [HAND] or [MONITOR] key will be invalid.
The methods for starting automatic operation from the T/B are explained in this section.
1) Set the T/B [ENABLE] switch to "DISABLE".

Up ：DISABLE
Down：ENABLE
*Lighting
Rear of T/B
2) Set the controller’s mode to "AUTOMATIC".

3) Press [2] key while the <MENU> screen is displayed. The <RUN> screen appears.
<MENU>　　　 <RUN>　　　
1.FILE/EDIT 2.RUN 1.CHECK 2.TEST RUN
3.PARAM. 4.ORIGIN/BRK 3.OPERATION
5.SET/INIT. 6.ENHANCED
　 123 CLOSE 　 123 CLOSE
RUN menu selection [2]
Programming 4-67
4Basic operations
4) Press [3] key while the <RUN> screen is displayed. The <OPERATION> screen appears.
<RUN>　　　 <OPERATION> 100% Auto
1.CHECK 2.TEST RUN PROGRAM NAME: STEP:

3.OPERATION PRG1 00001
STATUS: STOP MODE: CONT.

　 123 CLOSE START CYCLE 123 RESET CHOOSE ⇒
OPERATION
CAUTION Before starting automatic operation, always confirm the following items. Starting
automatic operation without confirming these items could lead to property damage or
physical injury.
・ Make sure that there are no operators near the robot.
・ Make sure that the safety fence is locked, and operators cannot enter
unintentionally.
・ Make sure that there are no unnecessary items, such as tools, inside the robot
operation range.
・ Make sure that the workpiece is correctly placed at the designated position.
・ Confirm that the program operates correctly with step operation.
Explanation of <OPERATION> screen

Note 1) Note 2)
Currently selected program name Setting speed Controller (drive unit) mode
Note 3)
<OPERATION> 100% Auto
Line No. currently being executed
<OPERATION>
PROGRAM NAME: 100%
STEP: Auto
Indication of program
PRG1 00001
execution status PROGRAM NAME: STEP:
・ RUN PRG1 00001 Indication of operation mode
・ READY ・ CONT.
START STATUS:
CYCLE RUN CHOOSE ⇒
123 RESET MODE: CONT. ・ CYCLE
・ STOP
SV.ON SV.OFF 123 CLOSE ⇒
"START" ...................................................... Starts program execution / restarts from stopped state.

"CONT." / "CYCLE." ............................. Switches over the operation mode
"RESET"....................................................... Cancels program’s halted state, and executes program reset.
Resets alarm if alarm is occurring.
"CHOOSE" .................................................. Selects the program to start. Opens the <PROGRAM CHOICE>
screen.
"SV. ON" / "SV. OFF" .......................... Turns the servo power ON/OFF
"CLOSE" ...................................................... Ends the <OPERATION> screen (Ends the operation started from
the T/B.)
Note 1) If the controller mode is "MANUAL", low speed movement will take place even if the set speed is 100%. (To confirm the
movements)
Note 2) When the controller mode is “AUTOMATIC”, the T/B’s status display lamp [ENABLE] will blink to indicate that the T/B is enabled.
The T/B is disabled when the <OPERATION> screen is ended.
Note 3) The [JOG], [HAND] and [MONITOR] keys are disabled while the <OPERATION> screen is opened.
5) Press the function key [F4] assigned to "CHOOSE" while the <OPERATION> screen is displayed. The
<PROGRAM CHOICE> screen opens.
<OPERATION> 100% Auto <PROGRAM CHOICE>　　　
PROGRAM NAME: STEP: PROGRAM NAME

PRG1 00001
( PRG1 )
START CYCLE 123 RESET CHOOSE ⇒ 　 123 CLOSE
Program selection [F4] Name of the currently selected program is displayed.
4-68 Programming
4Basic operations
6) Enter the name of the program into the Program Name brackets, and press the [EXE] key.
The program will be newly selected, and the display will return to the <OPERATION> screen.
<PROGRAM CHOICE>　　　 <OPERATION> 100% Auto
PROGRAM NAME PROGRAM NAME: STEP:

PRG2 00001
( PRG2 )
　 123 CLOSE START CYCLE 123 RESET CHOOSE ⇒
Enter the program name and press [EXE] key The figure shows an example of changing program
name to “PRG2”.
7) Press the function key [F1] assigned to "SV. ON" to turn the servo power ON. (Press the [FUNCTION] key
if the "SV. ON" function is not displayed.)
<OPERATION> 100% Auto <OPERATION> 100% Auto
PROGRAM NAME: STEP: PROGRAM NAME: STEP:

PRG2 00001 PRG2 00001
STATUS: STOP MODE: CONT. STATUS: STOP MODE: CONT.

SV.ON SV.OFF 123 CLOSE ⇒ SV.ON SV.OFF 123 CLOSE ⇒
Servo ON [F1]
CAUTION Before starting automatic operation, always confirm that the target program No. is
selected.
CAUTION Take special care to the robot movements during automatic operation. If any
abnormality occurs, press the [EMG. STOP] switch and immediately stop the robot.
CAUTION When beginning automatic operation, move at low speed at first, and you should
gather speed slowly with being careful of interference with peripheral equipment. The
movement speed can be changed with the [OVRD ↑ ] and [OVRD ↓ ] keys on the
T/B.
8) Press the function key [F1] assigned to "START" to open the CHECK screen.
<OPERATION> 100% Auto <STARTING PROGRAM>
PROGRAM NAME: STEP: PRG2

PRG2 00001 START THE PROGRAM.
OK?
START CYCLE 123 RESET CHOOSE ⇒ Yes 123 No
Start [F1]
9) Press the function key [F1] assigned to “YES”. Automatic operation of the currently selected program will
start.
The screen will return to the <OPERATION> screen.
<STARTING PROGRAM> <OPERATION> 100% Auto
PRG2 PROGRAM NAME: STEP:
START THE PROGRAM. PRG2 00001
OK?
STATUS: RUN MODE: CONT.
Yes 123 No START CYCLE 123 RESET CHOOSE ⇒
Yes [F1]
Programming 4-69
4Basic operations
10) The operation mode follows the mode displayed on the screen.
Change the mode if necessary.
<OPERATION> 100% Auto <OPERATION> 100% Auto
PROGRAM NAME: STEP: PROGRAM NAME: STEP:

PRG2 00001 PRG2 00001
STATUS: RUN MODE: CONT. STATUS: RUN MODE: CYCLE

START CYCLE 123 RESET CHOOSE ⇒ START CONT. 123 RESET CHOOSE ⇒
Change operation mode [F2] The figure shows an example of changing from
"CONT." to "CYCLE".
The starting of automatic operation from the T/B is completed.
4-70 Programming
5Maintenance and Inspection
5 Maintenance and Inspection

The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are
described in this chapter. The types and replacement methods of consumable parts are also explained.
5.1 Maintenance and inspection interval

Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carry
out at set intervals. Always carry these out to prevent unforeseen trouble, to maintain the product for a long time,
and to secure safety.
(1) Inspection schedule
0 Hr
Monthly inspection
Monthly inspection
500 Hr Monthly inspection
Monthly inspection
Monthly inspection
Daily inspection
Monthly inspection
Monthly inspection
Monthly inspection
Monthly inspection
Operating time
<Guideline for inspection period>

For one shift
8 Hr/day x 20 days/month x 12 months = approx. 1800 Hr
For two shifts
[Caution] According to the schedule on the above, when using the double shift, you should
make the inspections at half the regular intervals.
Fig. 5-1 ： Inspection schedule
Maintenance and inspection interval 5-71

5.2 Inspection items

The controller inspection items are shown below.
Refer to section "Maintenance and Inspection" in the separate manual "Robot arm setup and maintenance",
and inspect the robot arm at the same time.
5.2.1 Daily inspection items

Carry out daily inspections following the procedures given in Table 5-1.
Table 5-1 ： Daily inspection items (details)

Procedure Inspection items (details) Remedies
Before turning the power ON (Check the following inspection items before turning the power ON.)
1 Is the power cable securely connected? Securely connect.

(Visual)
2 Are the machine cables between the robot arm and controller securely Securely connect.
connected?
(Visual)
3 Is the controller cover cracked, has any foreign matter adhered, or is Replace with a new part, or take remedial measures.
there any interference?
After turning the power ON (Turn the power ON while monitoring the robot.)
1 Is there any abnormal movement or noise when the power was turned Refer to the Troubleshooting section and remedy.
ON?
During operation (Try moving with an original program.)
1 Check that the operation point is not deviated. If deviated, check the Refer to the Troubleshooting section and remedy.
following items.
1) Are any of the installation bolts loose?
2) Are the bolts at the hand installation section loose?
3) Is the position of the jigs, other than the robot, deviated?
4) If the positional deviation cannot be eliminated, refer to
"Troubleshooting", and remedy.
2 Is there any abnormal movement or noise? Refer to the Troubleshooting section and remedy.
(Visual)
5.2.2 Periodic inspections

Carry out periodic inspections following the procedures given in Table 5-2.
Table 5-2 ： Periodic inspection items (details)

Procedure Inspection items (details) Remedies
Monthly inspection items

1 Are any of the connector fixing screws or terminal block terminal Securely tighten the screws.
screws loose?
2 Is the controller filter dirty? Clean or replace with a new part.

Inspect, clean and replace the filter by refer to
(Visual) Page 75, "5.3.2 The check of the filter, cleaning,
exchange.".
5-72 Inspection items

5.3 Maintenance and inspection procedures

The procedures for carrying out periodic maintenance and inspection are described below. Thoroughly
comprehend the procedures, and follow the instructions. This work can be commissioned to the Mitsubishi Service
Dept. for a fee. (Never disassemble, etc., any of the parts not described in this section.)
The maintenance parts required for the maintenance and inspection are shown in Page 76, "5.4 Maintenance
parts". Contact your dealer for these parts when required.
5.3.1 Replacing the battery (CR800-Q controller only)

In the CR800-Q controller, while power of controller is turned off, the programs must be saved by the backup
battery. The robot arm also uses backup batteries to save the position data of an encoder. The batteries are
installed when the robot is shipped from the factory, but as these are consumable parts, they must be replaced
periodically by the customer.
The guideline for replacing the lithium battery is one year, but this will differ according to the robot's usage state.
There are the kind of the errors about the battery shown in Table 5-3. If error 7500 occurs, please exchange the
batteries of the robot arm and the robot CPU unit (CR800-Q controller only).
Table 5-3 ： The error about the battery

Error number Description Measure
7510 Encoder battery voltage low Replace the battery as soon as pos-
7500 No encoder battery voltage sible.
The backup data cannot be

112nNote1) Encoder ABS position data lost
guaranteed if this error occurs.
Replace the battery as soon as pos-
7451Note2) Robot CPU unit battery voltage low
sible.
The backup data cannot be
7450Note2) No robot CPU unit battery voltage
guaranteed if this error occurs.
Note1) “n” indicates the axis number
Note2) This error occurs in CR800-Q controller only.
The method of replacing the battery of the CR800-Q controller is shown below.
Refer to the separate "ROBOT ARM SETUP & MAINTENANCE" about robot arm's battery.
About the purchase of the battery, refers to Page 76, "5.4 Maintenance parts".
CAUTION If error No. 7500 or 112n occurs, the program data and other data in the controller
is lost and it becomes necessary to load the data again.
CAUTION If error 7450 occurs, the program data and other data in the controller is lost and it
becomes necessary to load the data such as program and origin data again.
Maintenance and inspection procedures 5-73

"+" side
Battery lead connector
Do not hold lead wire Battery connector
Q6BAT
Battery lead wire

Battery holder
Fig. 5-2 ： Exchange of the battery
1) Turn on the robot CPU system power supply for 10 minutes or longer.
2) Turn off the robot CPU system power supply.
3) Disconnect the lead connector from the battery connector. Remove the old battery from its holder.
4) Install a new battery into the holder in the correct direction. Connect the lead connector to the connector
(BATTERY). Complete the work within 3 minutes after removing the old battery.
5) Turn on the robot CPU system power supply.
[Caution] If the old battery is replaced because it has been used up, it is necessary to operate the robot type
resetting. Refer to the separate "Detailed Explanation of Functions and Operations" and operate the
robot type resetting.
This completes the replacement of the battery.
5-74 Maintenance and inspection procedures

5.3.2 The check of the filter, cleaning, exchange.

The filter is installed in the controller.
The following shows the procedure for inspecting, cleaning and replacing the filter:
1) Loosen the M4 x 6 screws and remove the filter cover from the front of the controller. Remove the claw on
the left side of the filter cover as it is inserted in the front face of the controller.
2) Remove the filter from the filter cover and remove dust and other dirt that has built up on it.
* If the filter is particularly dirty then wash it in water and detergent and then dry fully before re-fixing. In
the event that the surface of the washed filter has become fluffy, please replace it with a new filter.
3) Attach the cleaned or new filter to the controller, and install the filter cover to controller with the M4 x 6
screw.
㻯㼘㼍㼣
㻲㼕㼘㼠㼑㼞
㻲㼕㼘㼠㼑㼞㻌㼏㼛㼢㼑㼞
㻹㻠㼤㻢㻌㼟㼏㼞㼑㼣
Fig. 5-3 ： Cleaning, exchanging the filter
The inspection, cleaning and replace of the filter for the controller is completed.
Maintenance and inspection procedures 5-75

5.4 Maintenance parts

The consumable parts that must be replaced periodically are shown in Table 5-4, and spare parts that may be
required during repairs are shown in Table 5-5. Purchase these parts from the dealer when required. Some
Mitsubishi-designated parts differ from the maker's standard parts. Thus, confirm the part name, robot arm and
controller serial No. and purchase the parts from the dealer.
Table 5-4 ： Controller consumable parts list

No. Part name Note1) Qty. Usage section Maker
Type
1 Filter BKOFA0773H42 1 Inside the filter cover Mitsubishi Electric Co.
2 Lithium battery Q6BAT 1 Robot CPU unit: For

Q172DSRCPU Mitsubishi Electric Co.
(CR800-Q controller only)
Note1) Confirm the robot arm serial No., and contact the dealer or service branch of Mitsubishi Electric Co., for
the type.
Table 5-5 ： Controller spare parts list

No. Part name TypeNote1) Qty. Usage section Maker
1 1.6A fuse LM16 1 HAND FUSE (front of the control-

Mitsubishi Electric Co.
ler)
Note1) Confirm the robot arm serial No., and contact the dealer or service branch of Mitsubishi Electric Co., for
the type.
5-76 Maintenance parts

HEAD OFFICE: TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
NAGOYA WORKS: 5-1-14, YADA-MINAMI, HIGASHI-KU NAGOYA 461-8670, JAPAN
Authorised representative:
Mitsubishi Electric Europe B.V. FA - European Business Group
Mitsubishi-Electric-Platz 1, D-40882 Ratingen, Germany
Tel: +49(0)2102-4860
Sep., 2018 MEE Printed in Japan on recycled paper. Specifications are subject to change without notice.

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Mitsubishi Electric Industrial Robot

CR800 Series Controller

WARNING Prepare a device that allows operation to be stopped immediately during

DANGER Provide a fence or enclosure during operation to prevent contact of the

Notes of the basic component are shown.

㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑 㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑 㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼞㼑㼍㼞

1) Prepare the following items.

Earth leakage breaker The following is recommended product. Prepared by customer.

Grounding cable AWG14 (2mm2) or above Prepared by customer.

2017-04-25 BFP-A3476 ・ First print

2017-09-25 BFP-A3476-A ・ ”4.3.2 Input the serial number” was added.

2017-11-01 BFP-A3476-B ・ Description of countermeasures against unauthorized access was added.

2018-03-01 BFP-A3476-C ・ Descriptions of CR800-Q controller were added.

2018-09-01 BFP-A3476-D ・ ”3.1 Installing/removing the Option Card” was modified.

Thank you for purchasing the Mitsubishi industrial robot.

This document explains for CR800 series controller.

Installation of the emergency stop switch

Synchronous connection of the addition axis servo power supply

2 Unpacking to installation .............................................................................................................................................................. 2-6

3 Installing the option devices ..................................................................................................................................................... 3-38

4 Basic operations ............................................................................................................................................................................ 4-42

5 Maintenance and Inspection ..................................................................................................................................................... 5-71

1 Before starting use

1.1 Using the instruction manuals

Manual name Description

Using the instruction manuals 1-1

1.1.2 Symbols used in instruction manual

Table 1-1:Symbols in instruction manual

iQ Platform compatible type

Controller Indicates the controller which controls the robot arm.

Controller Indicates the controller which controls the robot arm.

Precaution indicating cases where the operator could be subject to

Precaution indicating cases where operator could be subject to injury

If a word is enclosed in brackets or a box in the text, this refers to a

1-2 Using the instruction manuals

1.2 Safety Precautions

Safety Precautions 1-3

1.2.1 Precautions given in the separate Safety Manual

1-4 Safety Precautions

Safety Precautions 1-5

Table 2-1 ： Standard configuration

2-6 Confirming the products

2.2.2 Transportation procedures

Fig. 2-1 ： Transporting controller

2.2.3 Installation procedures

Fig.2-2 ： Installation dimensions

Fig.2-3 ： Metal plate for fixation to placing vertically

2.3 Installation and connection

Input/output unit terminal stand screw (M3) 0.42 ～ 0.58

Input/output unit terminal stand attachment screw (M3.5) 0.68 ～ 0.92

Terminal screw of the power supply unit (M3.5) 0.66 ～ 0.89

2-10 Installation and connection

The installation procedure of the base unit is shown in the following.

Installation and connection 2-11

(2) Notes on base unit installation

1) Installation position for unit

Fig. 2-4 ： Installation dimension of the robot CPU unit

2) Unit installation direction

b) Don't use it in the installation direction of the following figure.

㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼞㼑㼍㼞

㼀㼔㼞㼑㼑㻌㼜㼔㼍㼟㼑㻿㼕㼚㼓㼘㼑㻌㼜㼔㼍㼟㼑㻯㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌㼞㼑㼍㼞