Motoman JRC Installation - Maintenace Guide

YASKAWA
JRC
INSTALLATION & MAINTENANCE GUIDE
Upon receipt of the product and prior to initial operation,read these instructions thoroughly,and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-□□□INSTRUCTIONS
JRC BEGINNER’S GUIDE
JRC SETTING-UP MANUAL
JRC INSTALLATION ＆ MAINTENANCE GUIDE
JRC WINCAPSⅡGUIDE
JRC PROGRAMMER’S MANUAL
JRC ERROR CODE TABLES
Do not submit this electronic data to the customer.
THIS MATERIAL IS FOR STUDY PURPOSE ONLY.

YOU MUST READ THE MANUAL WHICH ENCLOSED
WITH A ROBOT.
MANUAL NO. RE-CTO-A206

Preface
Thank you for purchasing this high-speed, high-accuracy handling robot.
Before operating your robot, read this manual carefully to safely get the maximum benefit from your robot
in your assembling operations.
Important
To ensure operator safety, be sure to read the precautions and instructions in "SAFETY PRECAUTIONS,"
pages 1 through 8.
i
How the documentation set is organized
The documentation set consists of the following six books. If you are unfamiliar with this robot series,
please read all six books and understand them fully before operating your robot.
BEGINNER'S GUIDE
Introduces you to the robot. Taking an equipment setup example, this book guides you through
running your robot with the teach pendant, making a program in WINCAPSII, and running your
robot automatically.
INSTALLATION & MAINTENANCE GUIDE - this book -

Provides an explanation of the robot outline, instructions for installing the robot components,
and maintenance & inspection procedures.
SETTING-UP MANUAL
Describes how to set-up or teach your robot with the teach pendant or operating panel.
WINCAPSII GUIDE (that comes with WINCAPSII)

Provides instructions on how to use the teaching system installed on the PC, connected to the
robot and its controller, for developing and managing programs.
PROGRAMMER'S MANUAL
Describes the PAC programming language, steps to develop programs in PAC, and command
specifications.
ERROR CODE TABLES

List error codes that will appear on the teach pendant, operating panel, or PC screen if an error
occurs in the robot series or WINCAPSII. These tables provide detailed description and
recovery ways.
ii
How this book is organized
This book is just one part of the documentation set. This book consists of SAFETY PRECAUTIONS,
chapters one through six, and appendix.
SAFETY PRECAUTIONS
Defines safety terms and related symbols and provides precautions that should be observed. Be sure to
read this section before operating your robot.
Chapter 1 General Information about Robot

This chapter describes the components and specifications of the robot. Read this chapter before
installing and operating the robot to familiarize yourself with the robot.
Chapter 2 Installing Robot Components

This chapter describes the procedures and precautions for transporting the robot during installation, and
for designing end-effectors.
Chapter 3 Optional Devices

This chapter describes the configurations and functions of the optional devices. Consult this chapter
according to the optional device to be used.
The optional devices include an operating panel, a teach pendant, the PC teaching system “WINCAPSII,”
a floppy disk drive, µVision board, Ethernet board, and DeviceNet board.
Chapter 4 Customizing Your Robot

This chapter describes how to customize your robot.
Chapter 5 Robot Controller Interface

This chapter describes the connections between the robot controller and other devices and precautions
for connecting them.
Chapter 6 Maintenance and Inspections

This chapter describes the regular maintenance and inspections necessary for maintaining the
performance and functions of the robot.
Appendix
iii
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Be sure to observe all of the following safety precautions.
Strict observance of these warning and caution indications are a MUST for preventing accidents, which
could result in bodily injury and substantial property damage. Make sure you fully understand all
definitions of these terms and related symbols given below, before you proceed to the text itself.
WARNING Alerts you to those conditions, which could result

in serious bodily injury or death if the instructions
are not followed correctly.
CAUTION Alerts you to those conditions, which could result

in minor bodily injury or substantial property
damage if the instructions are not followed
correctly.
Terminology and Definitions

Maximum space: Refers to the volume of space encompassing the maximum designed movements of
all robot parts including the end-effector, workpiece and attachments. (Quoted from the RIA* Committee
Draft.)
Restricted space: Refers to the portion of the maximum space to which a robot is restricted by limiting
devices (i.e., mechanical stops). The maximum distance that the robot, end-effector, and workpiece can
travel after the limiting device is actuated defines the boundaries of the restricted space of the robot.
(Quoted from the RIA Committee Draft.)
Motion space: Refers to the portion of the restricted space to which a robot is restricted by software
motion limits. The maximum distance that the robot, end-effector, and workpiece can travel after the
software motion limits are set defines the boundaries of the motion space of the robot.
Operating space: Refers to the portion of the restricted space that is actually used by the robot while
performing its task program. (Quoted from the RIA Committee Draft.)
Task program: Refers to a set of instructions for motion and auxiliary functions that define the specific
intended task of the robot system. (Quoted from the RIA Committee Draft.)
(*RIA: Robotic Industries Association)
1
1. Introduction This section provides safety precautions to be observed during
installation, teaching, inspection, adjustment, and maintenance
of the robot.
2. Installation Precautions
2.1 Insuring the proper The robot and the robot controller have not been designed to
installation withstand explosions, dust-proof, nor are they splash-proof.
environment Therefore, they should not be installed in any environment
where:
(1) there are flammable gases or liquids,
(2) there are any shavings from metal processing or other
conductive material flying about,
(3) there are any acidic, alkaline or other corrosive gases,
(4) there is cutting or grinding oil mist,
(5) it may likely be submerged in fluid,
(6) there is sulfuric cutting or grinding oil mist, or
(7) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other
sources of electrical noise.
When using the robot controller in an environment exposed to

mist, put it in an optional protective box.
2.2 Service space The robot and peripheral equipment should be installed so that
sufficient service space is maintained for safe teaching,
maintenance, and inspection.
2.3 Control devices The robot controller, teach pendant, and operating panel should
outside the robot's be installed outside the robot's restricted space and in a place
where you can observe all of the robot’s movements when
restricted space
operating the robot controller, teach pendant, or operating panel.
2.4 Positioning of gauges Pressure gauges, oil pressure gauges and other gauges should
be installed in an easy-to-check location.
2.5 Protection of electrical If there is any possibility of the electrical wiring or

wiring and hydraulic/pneumatic piping being damaged, protect them with a
cover or similar item.
hydraulic/pneumatic
piping
2
SAFETY PRECAUTIONS
2.6 Positioning of Emergency stop switches should be provided in a position where

emergency stop they can be reached easily should it be necessary to stop the
robot immediately.
switches
(1) The emergency stop switches should be red.
(2) Emergency stop switches should be designed so that they
will not be released after pressed, automatically or
mistakenly by any other person.
(3) Emergency stop switches should be separate from the
power switch.
2.7 Positioning of Operating status indicators should be positioned in such a way

operating status where workers can easily see whether the robot is on temporary
halt or on an emergency or abnormal stop.
indicators
2.8 Setting-up the safety A safety fence or enclosure should be set up so that no one can
fence or enclosure easily enter the robot's restricted space. If it is impossible, utilize
other protectors as described in Section 2.9.
(1) The fence or enclosure should be constructed so that it
cannot be easily moved or removed.
(2) The fence or enclosure should be constructed so that it
cannot be easily damaged or deformed through external
force.
(3) Establish the exit/entrance to the fence or enclosure.
Construct the fence or enclosure so that no one can easily
get past it by climbing over the fence or enclosure.
(4) The fence or enclosure should be constructed to ensure that
it is not possible for hands or any other parts of the body to
get through it.
(5) Take any one of the following protections for the entrance/
exit of the fence or enclosure:
1) Place a door, rope or chain across the entrance/exit of
the fence or enclosure, and fit it with an interlock that
ensures the emergency stop device operates
automatically if it is opened or removed.
2) Post a warning notice at the entrance/exit of the fence or
enclosure stating "In operation--Entry forbidden" or
"Work in progress--Do not operate" and ensure that
workers follow these instructions at all times.
When making a test run, before setting up the fence or
enclosure, place an overseer in a position outside the
robot’s restricted space and one in which he/she can see
all of the robot’s movements. The overseer should
prevent workers from entering the robot's restricted
space and be devoted solely to that task.
3
2.9 Positioning of rope or If it is not possible to set up the safety fence or enclosure
chain described in Section 2.8, hang a rope or chain around the
perimeter of the robot’s restricted space to ensure that no one
can enter the restricted space.
(1) Ensure the support posts cannot be moved easily.
(2) Ensure that the rope or chain’s color or material can easily
be discerned from the surrounds.
(3) Post a warning notice in a position where it is easy to see
stating "In operation--Entry forbidden" or "Work in progress
--Do not operate" and ensure that workers follow these
instructions at all times.
(4) Set the exit/entrance, and follow the instructions given in
Section 2.8, (3) through (5).
2.10 Setting the robot's The area required for the robot to work is called the robot's
motion space operating space.
If the robot’s motion space is greater than the operating space, it
is recommended that you set a smaller motion space to prevent
the robot from interfering or disrupting other equipment.
Refer to the "INSTALLATION & MAINTENANCE GUIDE"
Chapter 4.
2.11 No robot modification Never modify the robot unit, robot controller, teach pendant or
allowed other devices.
2.12 Cleaning of tools If your robot uses welding guns, paint spray nozzles, or other
end-effectors requiring cleaning, it is recommended that the
cleaning process be carried out automatically.
2.13 Lighting Sufficient illumination should be assured for safe robot

operation.
2.14 Protection from objects If there is any risk of workers being injured in the event that the
thrown by the end- object being held by the end-effector is dropped or thrown by the
end-effector, consider the size, weight, temperature and
effector
chemical nature of the object and take appropriate safeguards to
ensure safety.
4
SAFETY PRECAUTIONS
3. Precautions
while robot is Touching the robot while it is in operation can lead to
Warning seriousinjury. Please ensure the following conditions are
running maintainedand that the cautions listed from Section 3.1
onwards are followed when any work is being performed.
1) Do not enter the robot's restricted space when the robot
is in operation or when the motor power is on.
2) As a precaution against malfunction, ensure that an
emergency stop device is activated to cut the power to
the robot motor upon entry into the robot's restricted
space.
3) When it is necessary to enter the robot's restricted space
to perform teaching or maintenance work while the robot
is running, ensure that the steps described in Section 3.3
"Ensuring safety of workers performing jobs within the
robot's restricted space" are taken.
3.1 Creation of working When entering the robot’s restricted space to perform teaching
regulations and or maintenance inspections, set "working regulations" for the
following items and ensure workers adhere to them.
assuring worker
adherence (1) Operating procedures required to run the robot.
(2) Robot speed when performing teaching.
(3) Signaling methods to be used when more than one worker is
to perform work.
(4) Steps that must be taken by the worker in the event of a
malfunction, according to the contents of the malfunction.
(5) The necessary steps for checking release and safety of the
malfunction status, in order to restart the robot after robot
movement has been stopped due to activation of the
emergency stop device
(6) Apart from the above, any steps below necessary to prevent
danger from unexpected robot movement or malfunction of
the robot.
1) Display of the control panel (See Section 3.2 on the
following page)
2) Assuring the safety of workers performing jobs within the
robot's restricted space (See Section 3.3 on the following
page)
3) Maintaining worker position and stance
Position and stance that enables the worker to confirm
normal robot operation and to take immediate refuge if a
malfunction occurs.
5
4) Implementation of measures for noise prevention
5) Signaling methods for workers of related equipment
6) Types of malfunctions and how to distinguish them
Please ensure "working regulations" are appropriate to the robot
type, the place of installation and to the content of the work.
Be sure to consult the opinions of related workers, engineers at
the equipment manufacturer and that of a labor safety consultant
when creating these "working regulations".
3.2 Display of operation To prevent anyone other than the worker from accessing the
panel start switch or the changeover switch by accident during
operation, display something to indicate it is in operation on the
operating panel or teach pendant. Take any other steps as
appropriate, such as locking the cover.
3.3 Ensuring safety of When performing jobs within the robot’s restricted space, take
workers performing any of the following steps to ensure that robot operation can be
stopped immediately upon a malfunction.
jobs within the robot's
restricted space (1) Ensure an overseer is placed in a position outside the
robot’s restricted space and one in which he/she can see all
robot movements, and that he/she is devoted solely to that
task.
c An emergency stop device should be activated
immediately upon a malfunction.
d Do not permit anyone other than the worker engaged for
that job to enter the robot’s restricted space.
(2) Ensure a worker within the robot's restricted space carries
the portable emergency stop switch so he/she can press it
(the robot stop button on the teach pendant) immediately if it
should be necessary to do so.
3.4 Inspections before Before starting work such as teaching, inspect the following
commencing work items, carry out any repairs immediately upon detection of a
malfunction and perform any other necessary measures.
such as teaching
(1) Check for any damage to the sheath or cover of the external
wiring or to the external devices.
(2) Check that the robot is functioning normally or not (any
unusual noise or vibration during operation).
(3) Check the functioning of the emergency stop device.
(4) Check there is no leakage of air or oil from any pipes.
(5) Check there are no obstructive objects in or near the robot’s
restricted space.
3.5 Release of residual air Before disassembling or replacing pneumatic parts, first release
pressure any residual air pressure in the drive cylinder.
6
SAFETY PRECAUTIONS
3.6 Precautions for test Whenever possible, have the worker stay outside of the robot's
runs restricted space when performing test runs.
3.7 Precautions for (1) At start-up

automatic operation Before the robot is to be started up, first check the following
items as well as setting the signals to be used and perform
signaling practice with all related workers.
1) Check that there is no one inside the robot’s restricted
space.
2) Check that the teach pendant and tools are in their
designated places.
3) Check that no lamps indicating a malfunction on the
robot or related equipment are lit.
(2) Check that the display lamp indicating automatic operation
is lit during automatic operation.
(3) Steps to be taken when a malfunction occurs
Should a malfunction occur with the robot or related
equipment and it is necessary to enter the robot's restricted
space to perform emergency maintenance, stop the robot’s
operation by activating the emergency stop device. Take
any necessary steps such as placing a display on the starter
switch to indicate work is in progress to prevent anyone from
accessing the robot.
3.8 Precautions in repairs (1) Do not perform repairs outside of the designated range.
(2) Under no circumstances should the interlock mechanism be
removed.
(3) When opening the robot controller's cover for battery
replacement or any other reasons, always turn the robot
controller power off and disconnect the power cable.
(4) Use only spare tools authorized by YASKAWA.
4. Daily and periodical (1) Be sure to perform daily and periodical inspections. Before
starting jobs, always check that there is no problem with the
inspections robot and related equipment. If any problems are found,
take any necessary measures to correct them.
(2) When carrying out periodical inspections or any repairs,
maintain records and keep them for at least 3 years.
7
5. Management of (1) After finishing teaching or making any changes, always save
the programs and data onto floppy disks.
floppy disks
Making back-ups will help you recover if data stored in the
robot controller is lost due to the expired life of the back-up
battery.
(2) Write the names of each of the floppy disks used for storing
task programs to prevent incorrect disks from loading into
the robot controller.
(3) Store the floppy disks where they will not be exposed to
dust, humidity and magnetic field, which could corrupt the
disks or data stored on them.
8
CONTENTS
Preface.........................................................................................................................................i
i
How the documentation set is organized ..............................................................................ii
ii
How this book is organized................................................................................................... iii
SAFETY PRECAUTIONS ............................................................................................................1
1
Chapter1 General Information about Robot

1.1 Items contained in the Package .................................................................................. 1-1
1.1.1 Standard Items......................................................................................................... 1-1
1.2 Robot Configuration..................................................................................................... 1-2
1.2.1 Robot System........................................................................................................... 1-2
1.2.2 Names of the Robot Controller Components........................................................... 1-3
1.3 Robot Controller Specifications.................................................................................. 1-5
1.4 Warranty....................................................................................................................... 1-10
Chapter2 Installing Robot Components

2.1 Preparing a Proper Environment for Installation ...................................................... 2-1
2.1.1 Installation Environments......................................................................................... 2-1
2.1.2 Ambient Temperature and Humidity ........................................................................ 2-2
2.1.3 Vibration ................................................................................................................... 2-2
2.1.4 Connecting the Robot Unit and Robot Controller .................................................... 2-2
2.2 Installing the Robot Controller.................................................................................... 2-3
2.2.1 Securing the Robot Controller to the Controller Mounting Panel ............................ 2-3
2.2.2 Installing the Robot Controller.................................................................................. 2-5
Chapter3 Optional Devices

3.1 Operating Panel ............................................................................................................ 3-1
3.1.1 Operating Panel Functions ...................................................................................... 3-1
3.1.2 Names of Operating Panel Components ................................................................. 3-2
3.1.3 Operating Panel Specifications................................................................................ 3-3
3.1.4 Mounting and Connecting the Operating Panel....................................................... 3-4
3.2 Teach Pendant............................................................................................................... 3-5
3.2.1 Teach Pendant Functions ........................................................................................ 3-5
3.2.2 Names of Teach Pendant Components ................................................................... 3-6
3.2.3 Teach Pendant Specifications.................................................................................. 3-7
3.3 PC Teaching System Software, "WINCAPSII" ......................................................... 3-12
3.3.1 Functions in WINCAPSII........................................................................................ 3-12
3.3.2 Operating Environment Required .......................................................................... 3-13
3.3.3 Communication Cable............................................................................................ 3-14
3.4 Floppy Disk Drive ....................................................................................................... 3-15
3.4.1 Floppy Disk Drive Functions .................................................................................. 3-15
3.4.2 Floppy Disk Drive Specifications ........................................................................... 3-15
3.4.3 Location of the Floppy Disk Drive and its Component Names.............................. 3-16
3.4.4 Mounting the Floppy Disk Drive ............................................................................. 3-17
3.5 μVision Board ........................................................................................................... 3-22
3.5.1 μVision Board Specifications ............................................................................... 3-22
3.5.2 Peripheral Devices ................................................................................................. 3-27
3.6 Ethernet Board............................................................................................................ 3-30
3.6.1 Ethernet Board Position and Connector Names.................................................... 3-30
3.7 DeviceNet Board ......................................................................................................... 3-32
3.7.1 Overview ................................................................................................................ 3-32
3.7.2 Product Specifications ........................................................................................... 3-33
3.7.3 Assignment of Serial I/O Data................................................................................ 3-38
3.7.4 Parameter Entry Procedure ................................................................................... 3-40
3.7.5 Error Code Table .................................................................................................... 3-44
3.8 Mounting Extension Boards...................................................................................... 3-47
3.9 Controller Protective Box .......................................................................................... 3-54
3.9.1 Components in Package........................................................................................ 3-54
3.9.2 Names of the Components .................................................................................... 3-54
3.9.3 Setting up the Controller Protective Box................................................................ 3-55
3.9.4 Precautions ............................................................................................................ 3-56
Chapter4 Specifying Your Robot

4.1 Modifying Software Motion Limits to Define New Motion Space ............................ 4-1
4.1.1 What Is a Software Motion Limit? ............................................................................ 4-1
4.1.2 Changing Software Motion Limits ............................................................................ 4-2
4.1.3 Precautions When Changing the Software Motion Limits ....................................... 4-3
4.1.4 Procedure for Changing the Software Motion Limits............................................... 4-3
4.1.5 Changing the Software Motion Limit Temporarily .................................................... 4-6
4.2 CALSET.......................................................................................................................... 4-8
4.2.1 What Is CALSET? ................................................................................................... 4-8
4.2.2 CALSET Procedure.................................................................................................. 4-8
4.2.3 Procedure for Performing CALSET ......................................................................... 4-9
4.3 Setting Control Set of Motion Optimization............................................................. 4-15
4.4 Setting Robot Installation Conditions ...................................................................... 4-17
4.5 Recovery Procedure After Encoder Reference Position Error.............................. 4-18
4.5.1 Purpose of the Encoder Reference Position Error ................................................ 4-18
4.5.2 Operation Limitation When Encoder Reference Position Error............................. 4-20
4.5.3 Setting the Encoder Reference Position................................................................ 4-21
4.5.4 Recovery Procedure After Encoder Reference Position Error .............................. 4-24
4.5.5 Moving the Robot to the Encoder Reference Position .......................................... 4-26
4.5.6 Displaying the Current Status ................................................................................ 4-26
Chapter5 Robot Controller Interface

5.1 General Information about the Interface .................................................................... 5-1
5.1.1 Standard Mode and Special Mode .......................................................................... 5-1
5.1.2 Robot Controller Appearance and Connector Names............................................5-11
5.1.3 Example of Control System Configuration............................................................. 5-12
5.1.4 Types and General Information about I/O Signals ................................................ 5-13
5.2 Using User I/O Signals ............................................................................................... 5-15
5.2.1 I/O Type Variable Declaration ................................................................................ 5-15
5.2.2 User Input Commands ........................................................................................... 5-15
5.2.3 User Output Commands ........................................................................................ 5-16
5.3 System I/O Signals Standard Mode.......................................................................... 5-17
5.3.1 Types and Functions of System Output Signals (Standard Mode) ...................... 5-17
5.3.2 Usage of System Output Signals (Standard Mode) ............................................. 5-18
5.3.3 Types and Functions of System Input Signals (Standard Mode) ......................... 5-27
5.3.4 Usage of System Input Signals (Standard Mode) ................................................ 5-28
5.4 Command Execution I/O Signals Dedicated to Standard Mode............................ 5-34
5.4.1 General Information about Commands.................................................................. 5-34
5.4.2 Processing I/O Commands .................................................................................... 5-35
5.4.3 I/O Commands Details........................................................................................... 5-41
5.4.4 Example of Using System I/O Signals in Standard Mode ..................................... 5-53
5.5 System I/O Signals Special Mode ............................................................................. 5-57
5.5.1 Types and Functions of System Output Signals(Special Mode) .......................... 5-57
5.5.2 Usage of System Output Signals in the Special Mode.......................................... 5-58
5.5.3 Types and Functions of System Input Signals (Special Mode) ............................. 5-73
5.5.4 Usage of System Input Signals in Special Mode................................................... 5-74
5.5.5 Example of Using System I/O Signals in Special Mode ........................................ 5-93
5.6 I/O Circuits and Connectors (PNP type).................................................................. 5-97
5.6.1 I/O Signal Connector Pin Layout ........................................................................... 5-97
5.6.2 Robot Controller I/O Circuits ................................................................................ 5-103
5.6.3 Precautions When Wiring the Robot Controller I/O Connectors ..........................5-112
5.7 I/O Wiring ................................................................................................................... 5-114
5.7.1 Multi-core Cables with Connectors .......................................................................5-114
5.7.2 Wiring ....................................................................................................................5-115
Chapter6 Maintenance and Inspection

6.1 Maintenance & Inspection Intervals and Purposes .................................................. 6-1
6.2 Daily Inspections .......................................................................................................... 6-2
6.2.1 Check Items ............................................................................................................. 6-2
6.3 Quarterly Inspections................................................................................................... 6-4
6.3.1 Check Items ............................................................................................................. 6-4
6.3.2 Cleaning the Cooling Fan Filters in the Robot Controller ........................................ 6-5
6.4 Biennial Inspections..................................................................................................... 6-9
6.4.1 Battery Replacement and Check Items ................................................................... 6-9
6.4.2 Replacing the Memory Backup Battery ................................................................. 6-10
6.4.3 Setting the Next Battery Replacement Date.......................................................... 6-14
6.5 Supplies ....................................................................................................................... 6-15
6.5.1 Supplies.................................................................................................................. 6-15
6.6 Replacing Fuses ......................................................................................................... 6-16
6.6.1 Replacing Fuses .................................................................................................... 6-18
6.7 Replacing the Output ICs........................................................................................... 6-22
6.7.1 Replacing an Output IC.......................................................................................... 6-24
6.8 Checking the Odometer and Trip Meter ................................................................... 6-27
6.8.1 Displaying the Odometer, Trip Meter, and Oil Change Intervals ........................... 6-27
6.8.2 Resetting the Trip Meter to Zero ............................................................................ 6-29
6.9 Checking the Controller ON-Time and the Robot Running Time and Resetting
their User Counters .................................................................................................... 6-31
6.9.1 Displaying the Controller ON-time and the Robot Running Time.......................... 6-31
6.9.2 Resetting the User Counters of the Controller ON-Time and the Robot Running
Time ....................................................................................................................... 6-33
Appendix
1.1 I/O Signal Connector Pin Layout...................................................................Appendix-1
1.1.1 Connector Pin Layout Common to Both Modes ......................................... Appendix-1
1.1.2 Connector Pin Layout for Standard Mode .................................................. Appendix-3
1.1.3 Connector Pin Layout for Compatible Mode............................................... Appendix-5
1.2 Robot Controller I/O Circuits.........................................................................Appendix-7
1.2.1 User-Input, System-Input and Hand-Input Circuits..................................... Appendix-7
1.2.2 Robot Stop Input and Enable Auto Input Circuits ....................................... Appendix-9
1.2.3 User-Output, System-Output, and Hand-Output Circuits ......................... Appendix-10
1.2.4 Emergency Stop Output Circuit ................................................................ Appendix-13
1.2.5 I/O Power Connector ................................................................................ Appendix-14
1.3 Precautions When Wiring the Robot Controller I/O Connectors ............Appendix-16
Chapter 1
General Information
about Robot
This chapter touches on general information

about the specifications and configuration of the
robot.
Contents

1.1 Items Contained in the Package ................................................................................................ 1-1
1.1.1 Standard Items ............................................................................................................................ 1-1
1.2 Robot Configuration.................................................................................................................... 1-2

1.2.1 Robot System .............................................................................................................................. 1-2
1.2.2 Names of the Robot Controller Components .............................................................................. 1-3
1.3 Robot Controller Specifications ................................................................................................ 1-5

[ 1 ] Specifications................................................................................................................... 1-5
[ 2 ] Outer Dimensions ............................................................................................................ 1-7
[ 3 ] Controller Setting Table ................................................................................................... 1-8
1.4 Warranty ..................................................................................................................................... 1-10
1.1 Items Contained in the Package

1.1.1 Standard Items
The items listed in Table 1-1 are contained in the product package.
Table 1-1 Standard Items
No. Item Qty.
(1) Robot controller 1
(2) Manuals
1) BEGINNER'S GUIDE
2) INSTALLATION & MAINTENANCE GUIDE
1 each
3) SETTING-UP MANUAL
4) PROGRAMMER'S MANUAL
5) ERROR CODE TABLES
(3) Spare fuse for robot controller 3
(4) Pendantless connector (Dummy connector) 1
(5) Spare output IC for robot controller 1
(6) Connector for primary power supply 1
1-1
1.2 Robot Configuration
1.2.1 Robot System
Figure 1-1 shows the entire configuration of the robot system.
Controller Sequencer (prepared

protective box by customer)
(option)
Vision camera
Robot unit (option)
I/O cable Monitor

(option) (option)
RS-232C
cable
(prepared by
Floppy disk drive
customer)
(option)
Personal
computer
(prepared by
customer) (1) Robot
controller
Printer cable Power cable (200 Ethernet board

(prepared by customer) (4) Pendantless VAC)(prepared by (option)
connector (Note 2) customer)
Power connector for I/O Teach pendant µVision board

Printer (prepared by customer) (option)
(prepared (option)
by customer)
Personal computer system

teaching software
(CD-ROM or FD) (option) µVision board DeviceNet board
(for Europe) (slave station)
(option) (option)
Operating panel
(option)
(2) Owner’s Manuals
(3) Spare fuses for robot (5) Spare output IC for robot
controller controller
Power connector for I/O
Note 1: Items (1) to (5) are the standard components listed in Table 1-1.
Note 2: The pendantless connector is attached to the robot controller connector when no teach
pendant is connected.
Note 3: The components illustrated above are typical models or parts.
Figure 1-1 Robot Components
1-2
1.2.2 Names of the Robot Controller Components

Figure 1-2 and Table 1-2 show the names of the robot controller components.
<Front>
Floppy disk drive (option)
FG terminal
Robot stop button
Memory backup
battery holder
Pilot lamp
Fuse box
Transistor array box Power switch
<Left side> <Right side>
Radiating fin
Filters (exhaust)
Filters (air intake)
Figure 1-2 Names of Robot Controller Components
1-3
Table 1-2 Connector Names
Connector Marking Name Connector Marking Name

No. No.
CN1 RS232C Serial interface CN8 INPUT Connector for user input
connector or system input
CN2 CRT CRT connector CN9 HAND I/O Connector for end-
effector I/O
CN3 KEYBD Keyboard connector CN10 OUTPUT Connector for user output
or system output
CN4 MOUSE Connector for PS/2 CN11 INPUT AC Power connector
mouse
CN5 PENDANT Connector for teach CN12 MOTOR Motor connector
pendant
CN6 PRINTER Printer connector CN13 ENCODER Encoder connector
CN7 I/O Power connector for

POWER I/O
Caution: The robot controller connectors are of a screw-lock type or

ring-lock type. Lock the connectors securely. If even one of
the connectors is not locked, weak contact may result thereby
causing an error.
Be sure to turn the robot controller OFF before connecting/
disconnecting the power connector or motor connector.
Otherwise, the internal circuits of the robot controller may be
damaged.
1-4
1.3 Robot Controller Specifications

[ 1 ] Specifications
Table 1-3 lists the robot controller specifications.
Table 1-3 Robot Controller Specifications
Item Specification
Applicable robot Small-sized, vertical articulated type
Model ERCJ-UPJ3, ERCJ-SV3
Control system PTP, CP 3-dimensional linear, 3-dimensional circular
No. of controllable axes Up to eight axes simultaneously
Drive system All axes: all digital AC servo
Memory capacity 1.25 MB (equivalent to 5000 steps, 13,000 points)
Language used SLIM Based Robot Language (PAC)
Teaching system 1) Remote teaching 2) Numerical input (MDI)
Input
External 20 user open points (PLC 12, hand input 8) + 36 fixed system points
signal
signals
(I/O) Output
32 user open points (PLC 24, hand output 8) + 33 fixed system points
signal
External RS-232C:1 line

communication Ethernet:1 line (option)
Timer function 0.02 to 10 sec.(in units of 1/60 sec.)
Self-diagnosis
Overrun, servo error, memory error, input error, etc.
function
Error codes will be displayed on the external I/O or the operating panel (option).
Error display
Error messages will be displayed in English on the teach pendant (option).
3-phase, 200 VAC-15% to 230 VAC+10%, 50/60 Hz, 0.8 kVA

Power source
Single-phase, 200 VAC-10% to 230 VAC+10%, 50/60 Hz, 0.8 kVA
Environmental conditions Temperature: 0 to 40°C

(in operation) Humidity: 90% RH or less (no condensation allowed)
Degree of protection IP20
Weight Approx. 17 kg (excluding attached cables)
1-5
CAUTION
⋅ DO NOT touch fins. Hot surface may cause severe burns.
⋅ DO NOT insert fingers or foreign objects into opening, or
personal injury may occur.
⋅ DO NOT touch inside of controller before turning off power
switch, disconnecting cable from controller and waiting 3
minutes or more, or you can receive electric shock.
⋅ DO NOT attach or detach connectors while power switch is
on.
Improper operation may cause electric shock or controller
failure.
CAUTION IN INSTALLATION
⋅ This controller does not meet dust-proof, splash-proof or
explosion-proof specifications.
⋅ Read operation manual before installation.
⋅ Do not place anything on the controller.
1-6
[ 2 ] Outer Dimensions
Figure 1-3 shows the outer dimensions of the robot controller.
ERCJ-UPJ3 Name plate (Example)
ERCJ-UPJ3
YASKAWA
Figure 1-3 Outer Dimensions of Robot Controller
1-7
[ 3 ] Controller Setting Table
The controller setting table given on the next page is attached on the controller. It
shows the parameters that are set before delivery of the robot, as well as the
next replacement dates of the memory backup battery and encoder backup
battery.
• Parameters (c in Figure)
Shows only parameters changed from typical values. Blanks indicate that the
typical values are set.
For further information about parameters, see Chapter 4 "Robot Specification
Changes."
• Main software Ver. (d in Figure)
Shows the version of the main software for the controller.
• Sub software Ver. (e in Figure)
Shows the version of the control software.
• Battery replacement date (f in Figure)
Shows the next battery replacement date.
• SER No. (g in Figure)
Shows the serial number of the robot.
• TYPE (h in Figure)
Shows the model of the robot system. Its coding system is described below:
1-8
Figure 1-4 Controller Setting Table
1-9
1.4 Warranty
YASKAWA MOTOMAN manufactures robots under strict quality control. In case
of failure, we warranty the robot under the following conditions:
Warranty Period
The warranty shall be effective for one year from the date of purchase.
Warranty Coverage
YASKAWA MOTOMAN shall repair the robot free of charge when a failure
occurs and is attributable to the design, manufacture or material of the robot
within the warranty period in spite of proper use.
Items Not Covered

Failures, which arise from one of the following, shall not be covered by the
warranty even if the robot is under warranty:
(1) Failures caused by improper repair, modification, transfer or handling by you
or a third party;
(2) Failures caused by the use of a part or oil/fat other than those specified by
YASKAWA MOTOMAN;
(3) Failures caused by a fire, salt damage, earthquake, storm/flood or other acts
of God;
(4) Failures caused by the use of the robot in an environment other than the
environment specified by YASKAWA MOTOMAN, such as dust and water
ingress;
(5) Failures caused by a worn-out consumable, such as a fan filter;
(6) Failures caused by improper performance or non-performance of
maintenance or inspections stated in this owner's manual; and
(7) Damages other than the robot repair costs.
1-10
Chapter 2
Installing Robot
Controller
This chapter describes the installation of the robot

controller.
For safe operation of the robot, read "SAFETY

PRECAUTIONS, 2. Installation Precautions."
Contents

2.1 Preparing a Proper Environment for Installation..................................................................... 2-1
2.1.1 Installation Environments ............................................................................................................ 2-1
2.1.2 Ambient Temperature and Humidity ............................................................................................ 2-2
2.1.3 Vibration....................................................................................................................................... 2-2
2.1.4 Connecting the Robot Unit and Robot Controller........................................................................ 2-2
2.2 Installing the Robot Controller................................................................................................... 2-3

2.2.1 Securing the Robot Controller to the Controller Mounting Panel................................................ 2-3
2.2.2 Installing the Robot Controller ..................................................................................................... 2-5
[ 1 ] Stand-alone...................................................................................................................... 2-5
[ 2 ] Wall-mounted................................................................................................................... 2-6
2.1 Preparing a Proper Environment for

Installation
Before installing the robot unit and robot controller, confirm that the operating
environment is in conformity with each item of "SAFETY PRECAUTIONS, 2.
Installation Precautions," and that the surrounding environment of the location
where the robot is to be used meets the specifications as described below. Also,
take proper measures to protect the components from vibration.
In an inappropriate environment, the robot will not operate to its full capacity or
performance, components may not last long, and unexpected failure may result.
2.1.1 Installation Environments
The robot is not explosion-proof, dust-proof or splash-proof, so it should not be

installed in any environment where:
(1) there are flammable gases or liquids,
(2) there are any shavings from metal processing or other conductive material
flying about,
(3) there are any acidic, alkaline or other corrosive gases,
(4) there is cutting or grinding oil mist,
(5) there is sulfuric cutting or grinding oil mist, or
(6) there are any large-sized inverters, high output/high frequency transmitters,
large contactors, welders, or other sources of electrical noise.
2-1
2.1.2 Ambient Temperature and Humidity
Keep the ambient temperature between 0°C and 40°C during operation.
Keep the ambient humidity at 90% or below to prevent dew condensation.
2.1.3 Vibration
Do not install the robot in an environment where it will be exposed to excessive
vibration or impact.
2.1.4 Connecting the Robot Unit and Robot Controller
Caution: Confirm that the robot unit and the robot controller have the
same order number.
For the position of the order number, see “ 1.2 Checking the
Order Number ” in the MOTOMAN Instructions.
Special care must be taken when more than one manipulator is
to be installed.
If the numbers do not match, manipulators may not perform as

expected and cause injury or damage.
2-2
2.2 Installing the Robot Controller

Before installing the robot controller to the target position, you need to secure the
robot controller to the controller mounting panel as described in Subsection
2.2.1.
The robot controller supported by the mounting panel may be either stand-alone
or wall-mounted.
For installing the robot unit, refer to MOTOMAN Instructions.
Caution: When using the robot controller in any environment where

there is mist, put the controller in an optional robot controller
protective box. The robot controller is not dust-proof,
splash-proof, or explosion-proof.
2.2.1 Securing the Robot Controller to the Controller Mounting

Panel
(1) Figure 2-10 shows the bottom view of the robot controller. Marked with "{,"
the M4-nut welded holes may be used for securing the robot controller to the
mounting panel.
(2) Prepare a mounting panel large enough to mount the robot controller.
Secure the robot controller to the mounting panel at six nut-welded holes
marked with "{" in Figure 2-1, using six M4 screws.
Caution (1) The controller mounting screws must not be more than
the thickness of the mounting panel plus 5 mm in length.
If they exceed 5 mm, the nut welded holes may be
damaged.
(2) Fix the robot controller at all of the six nut-welded holes.
2-3
Robot controller M4 nut weld
bottom plate
{: Screw tightening position
Mounting (Controller mounting panel)
plate
Screw 5
Front of robot controller
Figure 2-1 Location of Mounting Screw Holes

(on the bottom of the robot controller)
2-4
2.2.2 Installing the Robot Controller

The robot controller may be installed stand-alone or on the wall.
[ 1 ] Stand-alone
Install the robot controller as shown in Figure 2-2.
Caution: Do not place anything within 200 mm from the air inlet and air
outlet of the robot controller.
(Left panel)
Air inlet
(Right panel)
Air outlet
Controller mounting panel
Figure 2-2 Stand-alone Installation
2-5
[ 2 ] Wall-mounted
Install the robot controller as shown in Figure 2-3.
Caution: Do not place anything within 200 mm from the air inlet and
air outlet on the robot controller.
Figure 2-3 Wall-mounted Installation
Radiating fin
Top
Air inlet
Air outlet
Controller
mounting
panel
Bottom
Air outlet
Air outlet
Radiating
fin Top
Controller
mounting
panel
Air inlet
2-6
Chapter 3
Optional Devices
This chapter describes the configurations and

functions of these optional devices--operating
panel, teach pendant, PC teaching system
"WINCAPSII," floppy disk drive, µVision board,
Ethernet board, and DeviceNet board.
Contents

3.1 Operating Panel ........................................................................................................................... 3-1
3.1.1 Operating Panel Functions.......................................................................................................... 3-1
3.1.2 Names of Operating Panel Components .................................................................................... 3-2
3.1.3 Operating Panel Specifications ................................................................................................... 3-3
3.1.4 Mounting and Connecting the Operating Panel .......................................................................... 3-4
3.2 Teach Pendant ............................................................................................................................. 3-5

3.2.1 Teach Pendant Functions ............................................................................................................ 3-5
3.2.2 Names of Teach Pendant Components ...................................................................................... 3-6
3.2.3 Teach Pendant Specifications ..................................................................................................... 3-7
[ 1 ] Specifications ...................................................................................................................... 3-7
[ 2 ] Outer Dimensions................................................................................................................ 3-8
[ 3 ] Pendantless State ............................................................................................................... 3-9
[ 4 ] Connecting and Disconnecting Operating Panel and Teach Pendant.............................. 3-10
3.3 PC Teaching System Software, "WINCAPSII" ........................................................................ 3-12

3.3.1 Functions in WINCAPSII ........................................................................................................... 3-12
3.3.2 Operating Environment Required.............................................................................................. 3-13
3.3.3 Communication Cable ............................................................................................................... 3-14
3.4 Floppy Disk Drive ...................................................................................................................... 3-15

3.4.1 Floppy Disk Drive Functions...................................................................................................... 3-15
3.4.2 Floppy Disk Drive Specifications ............................................................................................... 3-15
3.4.3 Location of the Floppy Disk Drive and its Component Names ................................................. 3-16
3.4.4 Mounting the Floppy Disk Drive ................................................................................................ 3-17
3.5 µVision Board ............................................................................................................................ 3-22

3.5.1 µVision Board Specifications..................................................................................................... 3-22
[ 1 ] Location of the µVision Board and Names of Connectors ................................................ 3-24
[ 2 ] Block Diagram and Internal Configuration of µVision Board ............................................ 3-25
3.5.2 Peripheral Devices .................................................................................................................... 3-27
[ 1 ] General Information about the Camera ............................................................................ 3-27
[ 2 ] General Information about the Monitor ............................................................................. 3-29
3.6 Ethernet Board........................................................................................................................... 3-30

3.6.1 Ethernet Board Position and Connector Names ....................................................................... 3-30
3.7 DeviceNet Board........................................................................................................................ 3-32

3.7.1 Overview.................................................................................................................................... 3-32
[ 1 ] Features............................................................................................................................. 3-32
[ 2 ] Typical Network ................................................................................................................. 3-32
3.7.2 Product Specifications ............................................................................................................... 3-33
[ 1 ] Components and Functions .............................................................................................. 3-34
[ 2 ] General Specifications ...................................................................................................... 3-37
3.7.3 Assignment of Serial I/O Data ................................................................................................... 3-38
[ 1 ] Standard Assignment Mode .............................................................................................. 3-38
[ 2 ] Special Assignment Mode................................................................................................. 3-39
3.7.4 Parameter Entry Procedure....................................................................................................... 3-40
[ 1 ] Entering the Number of Input/Output Slots ....................................................................... 3-40
[ 2 ] Quick Reference Table for the Number of Input/Output Slots .......................................... 3-43
3.7.5 Error Code Table ....................................................................................................................... 3-44
3.8 Mounting Extension Boards..................................................................................................... 3-47
3.9 Controller Protective Box ......................................................................................................... 3-54

3.9.1 Components in Package ........................................................................................................... 3-54
3.9.2 Names of the Components........................................................................................................ 3-54
3.9.3 Setting up the Controller Protective Box ................................................................................... 3-55
3.9.4 Precautions................................................................................................................................ 3-56
3.1 Operating Panel

The operating panel is a operation console that allows you to recover the robot
from a stop due to problems caused by peripheral units, etc, and it is a simple
teach pendant for teaching. Therefore, the panel has minimum necessary
teaching/operating functions.
To the operating panel you may connect a teach pendant which is designed for
teaching and other fine operations.
The ROBOT STOP button and the STOP key on the operating panel and the
teach pendant are available anytime. For other functions, you may select the
operating panel or teach pendant. To switch between the operating panel and
teach pendant, use the mode selector switch on the operating panel.
3.1.1 Operating Panel Functions

Operating
The operating panel provides these functions--motor power ON/OFF, CAL
execution, program selection, speed change, automatic operation start/stop and
manual operation. For further information, see the SETTING-UP MANUAL.
Display
The operating panel has an LCD capable of displaying 2 lines of 16 characters. It
displays the current robot position, ongoing program number, error code when
an error occurs, and related information in alphanumerical characters.
Connecting the Teach Pendant

A teach pendant can be connected to the TP terminal at the bottom of the
operating panel. The robot can be operated from the teach pendant by setting
the mode selector switch on the operating panel to TP.
When the mode selector switch is set to MANUAL or AUTO, the robot is
operated from the operating panel.
3-1
3.1.2 Names of Operating Panel Components
Figure 3-1 shows the names of the operating panel components.
Mode selector switch
ROBOT STOP button
SHIFT key
M-MOD key
STOP key
R-SEL key
MOTOMAN
Cancel key
MOTOR key
OK key
Arm traverse keys
Deadman switch
Figure 3-1 Names of Operating Panel Components
3-2
3.1.3 Operating Panel Specifications

Table 3-1 lists the operating panel specifications.
Table 3-1 Operating Panel Specifications
Item Specifications
Model ERCJ-OP-1
Display Liquid crystal display with backlight, 16 characters × 2 lines
Power source 24 VDC (supplied from robot controller)
23 flat key switches, Emergency STOP button,

Operation
mode selector switch, deadman switch
Temperature: 0 to 40°C
Installation
conditions Humidity: 90% RH or less (Dew condensation shall not be
allowed.)
Dimensions
140 × 100 × 40 mm (See Note 1)
(H x W x D)
Weight Approx. 0.7 kg
Cable length 4 m or 8 m
Equipped with a socket for connecting the teach pendant

Others
(See Note 2)
(Note 1) Projections caused by switches are not included in these measurements.
(Note 2) When no teach pendant is connected, a pendantless connector should be
connected to the TP socket.
Caution: The operating panel is a fixed type operation console. Be

sure to secure it to the equipment.
3-3
3.1.4 Mounting and Connecting the Operating Panel
Connecting the operating panel
As shown in Figure 3-2, the operating panel can be connected to the robot
controller. A teach pendant can also be connected to the operating panel.
Connection type 1: Operating panel only
Operating panel
Robot controller
Mode switch
Turn this switch to
the MANUAL or
AUTO position.
Pendantless connector
NOTE: Be sure to secure the operating panel to a safe place such as equipment.
NOTE: When using the operating panel without the teach pendant connected, always
insert the pendantless connector into the TP socket on the operating panel.
Connection type 2: Operating panel connected with the teach pendant

Mode switch
To use the teach pendant, turn this switch to the TP position.
To use the operating panel, turn this switch to the MANUAL or
Operating panel AUTO position.
Teach pendant
Robot controller
Figure 3-2 Connecting the Operating Panel and Robot Controller
3-4
3.2 Teach Pendant

The teach pendant is a entry/operation device for creating programs and
teaching. The teach pendant can perform all operations except automatic
external operation.
3.2.1 Teach Pendant Functions

For instructions on how to operate the teach pendant, refer to the SETTING-UP
MANUAL.
Programming and teaching

This function allows you:
- to enter commands and store the robot arm position. You may specify a
program and enter program steps one by one,
- to modify, delete, or copy those commands and robot arm positions, and
- to check edited programs in running them in Teach check mode.
Operating the robot

This function turns power to the motor ON/OFF, starts and stops automatic
operation, and performs manual operation.
Displaying
This function displays the contents of programs, the progress of running
programs, ongoing step number, current robot position or error messages.
3-5
3.2.2 Names of Teach Pendant Components
Figure 3-3 shows the names of the teach pendant components.
R-SEL (Robot selection) switch

LOCK key
M-MOD (Motion mode) key
MOTOR key SPEED key
Mode selector switch ROBOT stop button
Jog dial
STOP key
Cancel key
Hand strap
OK key
Cursor keys
Hand strap
MOTOMAN
Arm traverse keys

LCD screen
SHIFT key Function keys
Deadman switch
Deadman switch
Back of teach pendant
Figure 3-3 Names of Teach Pendant Components
3-6
3.2.3 Teach Pendant Specifications
[ 1 ] Specifications
Table 3-2 lists the teach pendant specifications.
Table 3-2 Teach Pendant Specifications
Item Specifications
Model ERCJ-TP-1
Display Liquid crystal display with backlight, 640 × 480 pixels
Power source 24 VDC (supplied from robot controller)
Emergency Stop button, deadman switch, jog dial, motor

power ON/OFF key, AUTO/MANUAL selector switch,
Operation function keys, arm traverse keys, LOCK key
R-SEL key, M-MOD key, SPEED key cursor keys,
STOP key, OK key, Cancel key
Installation conditions Humidity: 90% RH or less
(Dew condensation shall not be allowed.)
Outside dimensions 260 × 186 × 60 mm (excluding projections)
Weight 1 kg
Cable length 4 m, 8 m, 12 m
3-7
[ 2 ] Outer Dimensions
Figure 3-4 shows the outer dimensions of the teach pendant.
MOTOMAN
Figure 3-4 Outer Dimensions of the Teach Pendant
3-8
[ 3 ] Pendantless State
What is Pendantless State?
The state without having connected the operating panel and the teach pendant
to the robot controller is called a pendantless state.
Setting the Pendantless State

As described below, there are four ways to set the pendantless state:
(1) Turning ON the power to the robot controller without the operating panel and
the teach pendant.
(2) Disconnecting the connected teach pendant.
(3) Disconnecting the connected operating panel.
(4) Disconnecting the connected operating panel and teach pendant.
Caution: Refer to the operation procedures described in "[ 4 ]

Connecting and Disconnecting Operating Panel and Teach
Pendant" on the next page when connecting or disconnecting
the operating panel and the teach pendant with the power to the
robot controller ON.
Pendantless State Precautions

Since no teach pendant is connected in the Pendantless state, the robot cannot
enter the manual operation mode or the teach check mode.
The robot is therefore in the Auto mode whenever the Enable Auto input is free.
The external mode cannot be switched, and the program cannot start to run.
When operating the robot in the Pendantless state perform the following steps:
(1) Set the robot not to start to operate when the Enable Auto input is free.
(2) Enable Auto input free state and automatic mode output. Refer to "5.3.2.2
Auto Mode (Output) and 5.5.2.2 Auto Mode (Output)".
Set the equipment to make an emergency stop in an AND state.
Add (1) and (2) above with the external sequence circuit.
3-9
[ 4 ] Connecting and Disconnecting Operating Panel and Teach Pendant
The operating panel and the teach pendant can be connected or disconnected
with the power to the robot controller ON. Connect or disconnect them according
to the procedure described below.
Table 3-3 shows the state of change resulting from connecting or disconnecting
the operating panel and/or the teach pendant.
Each letter in the table represents the appropriate connecting and disconnecting
procedure (×: no procedure applicable).
Table 3-3 Table Showing Change of State by Connection and Disconnection
Before
change
Pendantless OP and TP
OP connected TP connected
mode connected
After
change
Pendantless
× (A) (B) (A)
mode
OP connected (D) × × (C)
TP connected (D) × × ×
OP and TP
(D) (D) × ×
connected
Caution: The operating panel and the teach pendant cannot be connected
or disconnected while a program is being executed.
3-10
Table 3-4 Connection and Disconnection Procedures
Procedure Steps
Step 1 Select the AUTO mode, and activate an emergency stop.

Step 2 Disconnect the connector from CN5 on the robot controller.
(A) Step 3 Connect the connector used for pendantless operation to
CN5 of the robot controller.
Step 4 Error 2187 occurs. Clear it from the external device.
Step 1 Select the AUTO mode, and activate an emergency stop.
Step 2 Perform disconnection. See the SETTING-UP MANUAL,
Section 5.9, "Preparing the Robot Controller to Unplug the
Teach Pendant."
(B)
Step 3 Disconnect the connector from CN5 on the robot controller
within 15 seconds.
Step 4 Connect the connector for Pendantless operation to CN5 on
Step 1 Set the mode selector switch on the operating panel to TP.
Step 2 Set the mode selector switch on the teach pendant to AUTO,
and activate an emergency stop.
Step 3 Perform disconnection. See the SETTING-UP MANUAL,
Section 5.9, "Preparing the Robot Controller to Unplug the
Teach Pendant."
(C)
Step 4 Disconnect the teach pendant from the operating panel
within 15 seconds.
Step 5 Connect the connector used for Pendantless operation to
the operating panel.
Step 6 Set the mode selector switch on the operating panel to
MANUAL.
Step 1 Disconnect the connector used for pendantless operation
from CN5 on the robot controller.
(D)
Step 2 Connect the operating panel or teach pendant to CN5 on the robot
controller.
3-11
3.3 PC Teaching System Software,
"WINCAPSII"
The PC teaching system facilitates the creation and editing of robot programs.
Use this system to improve creation and/or robot management programs. For
further information about how to use this teaching system, refer to the
WINCAPSII GUIDE.
3.3.1 Functions in WINCAPSII

WINCAPSII has the following functions:
Entering and editing robot programs

Robot programs can be entered or edited.
New programs can be created by making use of the programs supplied as a
library or with existing programs.
Reading/writing data
Programs, variables, coordinate values, CALSET data, log data, and other such
data can be read from the robot controller to and displayed on the personal
computer or written from the personal computer to the robot controller.
Caution: To use this function, the robot controller and the personal
computer must be connected to each other with a
communication cable.
Save
Programs, CALSET data, log data, etc. can be stored onto the hard disk or a
floppy disk. Data stored on the hard disk or a floppy disk can be read, reedited or
written to the robot controller.
Print
If a printer is connected to a personal computer the program’s CALSET data, log
data, and related data can be printed.
Simulation
Robot movements can be checked by simulating the movements of the robot in
animation, on the personal computer display.
A simulation can be performed with the robot body connected to the robot
controller.
When the robot is in automatic operation or manual operation mode, using the
teach pendant, the simulated image movements correspond to the actual
movement of the robot.
3-12
3.3.2 Operating Environment Required

The PC teaching system software requires the operating environments listed in
Table 3-5.
Table 3-5 Operating Environments for the PC Teaching System Software
PC having an i486DX4 CPU or higher and

Personal computer
capable of running Windows 95 or later
Operating system Windows 95 (Note) or later version
Recommended capacity: 32 MB or more (at least
Memory capacity
16 MB required)
Free area of 30 MB or more should be available at
Hard disk
installation.
Monitor resolution 640 × 480 or higher
Note: The teaching system cannot run properly on an older version of

Windows 95.
The version of Windows 95 can be checked with [Control Panel -
System – Information]. If A, B or C is not displayed (no symbol)
at the end of the version information (4.00, 95B), update
Windows 95 with the Windows 95 Service Pack 1, available from
Microsoft’s web site.
3-13
3.3.3 Communication Cable
To enable the personal computer and the robot controller to communicate with
each other, they must be connected with a communication cable. Use the
appropriate RS-232C for cross cable wiring, as shown in Figures 3-5 and 3-6.
Robot controller Personal computer (IBM PC compatible)

CN1 (RS-232C) connector
(9-pin D-SUB female) (9-pin D-SUB female)
2 2
RXD RXD
3 3
TXD TXD
4 4
DTR DTR
6 6
DSR DSR
7 7
RTS RTS
8 8
CTS CTS
5 5
SG SG
Frame Frame
Shield
Figure 3-5 RS-232C Communication Cable Wiring Diagram (IBM PC compatible)
Robot controller Personal computer (PC-98)

CN1 (RS-232C) connector
(9-pin D-SUB female) (25-pin D-SUB male)
1 1
DCD
2 2
RXD TXD
3 3
TXD RXD
4 4
DTR RTS
5 5
SG CTS
6 6
DSR DSR
7 7
RTS SG
8 8
CTS DCD
9 1
R1
20
DTR
22
R1
Frame Frame
Shield
Figure 3-6 RS-232C Communication Cable Wiring Diagram (PC-98)
3-14
3.4 Floppy Disk Drive

The floppy disk drive is an optional storage device that stores or reads data,
such as robot programs, to/from a floppy disk and is incorporated in the robot
controller.
3.4.1 Floppy Disk Drive Functions

The floppy disk drive has the following functions:
Format
This function initializes a floppy disk so that it can store data. You need to
initialize a new floppy disk before using it.
Floppy disks will be initialized in MS-DOS format.
Save
This function stores programs, CALSET data, etc. from the robot controller onto
a floppy disk.
Load
This function reads programs, CALSET data, etc. from a floppy disk to the robot
controller.
Caution NEVER load the CALSET data prepared for other robots. If
loaded, the robot will malfunction. It is DANGEROUS.
3.4.2 Floppy Disk Drive Specifications

Table 3-6 lists the specifications of the built-in floppy disk drive.
Table 3-6 Built-in Floppy Disk Drive Specifications
Item Specification
Power source 5 VDC (supplied from the robot controller)
Temperature : 5 to 40°C
Environmental conditions
Humidity : 20% to 80% (without dew condensation)
Weight 155 g (body alone)
Type 2HD, 3.5-inch floppy disk

Applicable floppy disk Storage
1.44 MB
capacity
3-15
3.4.3 Location of the Floppy Disk Drive and its Component
Names
Floppy disk
insertion slot
Eject button
Indicator
Figure 3-7 Location of the Floppy Disk Drive and its Component Names
Insert a floppy disk through this slot.

Floppy disk insertion slot
(see Figure 3-8).
Eject button Push this button to eject the floppy disk.
This lamp remains ON while the floppy disk is

Indicator
accessed.
Notch
Inserting direction
Figure 3-8 Inserting a Floppy Disk
Caution: Do not eject the floppy disk when the indicator is lit. Doing so
will damage or destroy data stored on the floppy disk.
3-16
3.4.4 Mounting the Floppy Disk Drive

Mount the floppy disk drive in the robot controller, according to the following
procedure:
Remove the eight screws from the controller top cover.

4STEP 1
Lift and remove the top cover from the robot controller.
4STEP 2
3-17
Remove the four screws from the upper plate and take off the upper
4STEP 3 plate.
Push the two pins of the blind plate outwards and remove the blind
4STEP 4 plate.
3-18
Mount the floppy disk drive in the appropriate position of the robot
4STEP 5 controller.
The floppy disk drive is secured to a disk drive mounting plate.
Tighten the two screws used to fasten the front panel of the floppy disk
4STEP 6 drive.
3-19
Tighten the four screws on the floppy disk drive mounting plate.
4STEP 7
Connector J6 FDD 26P on the printed circuit board has a cable lock.
4STEP 8 If the connector is locked, lift and unlock it. The lock is made of resin.
Do not apply excessive force to it or the lock may be damaged. Handle
it with extreme care.
Insert the flat cable of the floppy disk drives completely into connector
J6 FDD 26P on the circuit board. If the flat cable is inserted
completely, the blue line marked on the connecting section will
become aligned with the top edge of the connector.
3-20
Securely push in the connector lock.

4STEP 9
Put the top cover and secure it with eight screws.

4STEP 10
The mounting of the floppy disk drive is completed.
3-21
3.5 µVision Board
3.5.1 µVision Board Specifications
Insetting a µVision board in the robot controller makes a variety of image
processing functions available.
Similar to other commands, image processing commands are already
incorporated and no special operations or programming are required.
Table 3-7 µVision Board Specifications
Item Specifications
CPU 32-bit CPU
Image storage memory

Horizontal (H) 512 × Vertical (V) 480 pixels, 8 bits × 4 screens
(processed image)
Overlay memory
Horizontal (H) 624 × Vertical (V) 480 pixels, 2 bits × 2 screens
(drawn image)
Search model
1 MB (H255 × V255 × 8 models), up to 100 models registrable Note (1)
registration memory
Image input,
EIA/CCIR monochrome, 256 gradations, 2 channels
number of channels
Image output EIA/CCIR monochrome, 256 gradations, 1 channel
Binary feature extract

(area, center of gravity, main axis angle, luminance integration), histogram,
Image processing
edge detection, image-to-image operation, filtering, labeling,
light/dark image search, code recognition (QR code)
Processing range Up to 512 windows registrable

specification (window) (shape: straight line, rectangle, circle, ellipse, sector)
Memory check, incorrect input, incorrect processing range,

Self-diagnosis function
improper camera connection, etc.
Error display Errors will be displayed on the teach pendant (option).
Power source 5 VDC, 12 V (supplied from controller ISA) Note (2)
Environmental conditions
(during operation) Humidity: 90 %RH or less
(Dew condensation shall not be allowed.)
Outside dimensions
21.4 × 114 × 185 mm (excluding projections of connectors)
(H x W x D)
Note (1) The number of registrable models depends on the model image and/or size.
(2) Since power is supplied from the inside of the robot controller, no external power
source is required.
3-22
Operating condition setting switch (all off)

Program adjustment connector (unused)
ISA mapping switch (fixed) Camera trigger (unused) short pin
Camera 1 input
connector
Camera 2 input
connector
Monitor output
connector
Serial port (unused)

I/O port (unused)
Extension connector (unused) Interrupt setting short pin (unused)
Figure 3-9 µVision Board
Note (1) The switches and the short pins on the board are already preset at the factory. Do not
change the settings. A failure may result.
Note (2) Do not connect anything to the unused connectors on the board. A failure may result.
Note (3) The serial port and the I/O port on the board are unusable. Do not connect anything to
them. A failure may result.
3-23
[ 1 ] Location of the µVision Board and Names of Connectors
Insert a µVision board into extension slot 3 (Figure 3-10).
Inserting the board in a wrong slot may damage the internal circuits of the robot
controller. For installation procedure, refer to Subsection 3.8, "Mounting
Extension Boards."
Extension slot 1
Extension slot 2
Extension slot 3
Camera input
connector 1
µVision board
Serial port
I/O port (RS-232C not used)
(TTL I/O not used)
Camera input connector 2
Monitor output connector
Figure 3-10 Location of µVision Board and Names of Connectors
Camera input connector 1 Used for connection with camera 1 (12-pin, round connector)
Camera input connector 2 Used for connection with camera 2 (12-pin, round connector)
Monitor output connector Used for connection with the monitor (BNC).
Serial port RS-232C port (not used)
I/O port TTL level input/output: 1 point each (not used)
Table 3-8 Camera Input Connector Pin Layout (Manufacturer: Hirose Electric
HR10A-10R-12S or equivalent)
Pin No. Signal name Remarks
1 GND Camera power GND
2 +12V Camera power 12V
3 GND Camera power GND
4 VIDEO Video signal
5 HDGND HD synchronous signal GND
6 HD Horizontal synchronous signal
7 VD Vertical synchronous signal
8 NC Not connected
9 NC Not connected
10 NC Not connected
11 TRIG Trigger signal (not used)
12 VDGND VD synchronous signal GND
3-24
[ 2 ] Block Diagram and Internal Configuration of µVision Board
Camera 1 Animation Selec-

Selector (camera image) tor
A/D LT LT Overlay circuit D/A Monitor
(superpose)
Camera 2
Image storage Static image Drawn image

memory (image memory)
(4 processed
screens)
Image
processing CPU
circuit
Dedicated drawn image

memory (2 screens)
Figure 3-11 Block Diagram of µVision Board
Figure 3-11 illustrates the processing flow of the µ Vision board as reference.
The actual circuit configuration is different from this diagram.
Camera selector Selects camera image.

A/D Converts analog signals into digital signals (8-bit).
Selects whether to display the camera or the static image

Monitor selector
on the monitor.
LT Converts 8-bit data values using the appropriate table.

Overlays a drawn image, stored in the dedicated drawn
Overlay circuit image memory, on the camera or the static image (see
Figure 3-12, the overlay conceptual diagram).
D/A Converts digital data into analog signals.
Reads and stores camera images. Images are displayed on
Image storage
the monitor as static images. Up to four screens can be
memory
stored on this board.
The memory used to store drawn images of characters and
Dedicated drawn figures. Images can be displayed on the monitor using the
image memory overlay circuit. Up to two screens can be stored on this
board.
Image processing
The circuit to process images.
circuit
CPU Manages the entire system.
3-25
X = 280
Y = 245
Overlaying
(superpose)
Camera and processed screen image (256 gradations)

X = 280
Y = 245
Camera and processed screen image (256 gradations)
Figure 3-12 Overlay Concept
3-26
3.5.2 Peripheral Devices
[ 1 ] General Information about the Camera
C mount
Camera cable (option)
4-M3 depth 3.5 (tightening torque: 7 kg⋅cm)
Connected to connector for camera

input of µVision board
CS-8320B camera (back)
4-M2 depth 3 (tightening torque: 0.39 N⋅m)
Figure 3-13 Camera Dimensions and its Parts Names
Table 3-9 Camera Specifications
Item Specifications
Manufacturer Tokyo Electronic Industry Co., Ltd.
Manufacturer’s model CS8320B
Image pickup interline transfer system CCD pixels: 768 (H) × 493 (V)
Lens mount C mount
Image output NTSC signal 1.0 Vp-p/75 Ω
Power source/Ambient temperature Supplied from power adapter, 0 to +40°C
Weight 120 g
98 m/s, 10G
Vibration-proof (10 to 50 Hz, 30 minutes in each of X, Y and Z directions)
Cables (Option)
Cable length Camera cable model
3m CPC3440-03
5m CPC3440-05
15 m CPC3440-15
3-27
Caution (1) When mounting the camera to the equipment, tighten the
screws securely to the specified torque. See Figure 3-14.
(2) Do not apply a strong impact or vibration to the camera. A
failure may result.
(3) Do not touch the inside of the camera. An electric shock or
accident may result.
(4) For setting camera data, refer to the instruction manual that
comes with the camera.
3-28
[ 2 ] General Information about the Monitor
Input impedance
Image signal output
Image signal input
Adjuster cover
Power switch
Pilot lamp BNC cable

To µvision board
monitor output
connector
Figure 3-14 Monitor Dimensions and its Parts Names
Table 3-10 Monitor Specifications
Item Specifications
Manufacturer Chuo Musen Co., Ltd.
Manufacturer’s model TMP-232-03
Cathode-ray tube 9-inch, monochrome
Image input NTSC signal 0.7 Vp-p (straight polarity)
Power supply 100 VAC, 50/60 Hz
Power consumption Approx. 30 W
Ambient temperature 0 to 40°C
Humidity 90% or less (without dew condensation)
Cables (Option)
Cable length BNC coaxial cable type

1m 3CV-PP (1)
3m 3CV-PP (3)
5m 3CV-PP (5)
Caution (1): NEVER disassemble the monitor.

(2): Be sure to set a ferrite core clamp (ZCAT1518) to the BNC
cable at the monitor output connector of the µVision board.
3-29
3.6 Ethernet Board
If the robot controller has an Ethernet board integrated, it can communicate with
the PC teaching system using the TCP/IP protocol.
This board is helpful for communication between a single PC teaching system
and more than one robot controller. It also provides faster communication than
an RS-232C cable, contributing to improved response of the PC teaching
system.
3.6.1 Ethernet Board Position and Connector Names

Insert the Ethernet board in extension slot 1 (upper slot) or extension slot 2
(middle slot). See Figure 3-15.
Inserting the board into a wrong slot may damage the internal circuits of the
robot controller. For installation procedure of the Ethernet board, refer to
Subsection 3.8, "Mounting Extension Boards."
Table 3-11 Ethernet Board Specifications
Item Specifications
Standard 10Base2, 10BaseT (IEEE 802.3)
Baud rate 10 Mbits/sec.
BNC connector
RJ-45UTP connector
Link LED
Ethernet board
CRS LED
Figure 3-15 Location of Ethernet Board and its Parts Names
3-30
Table 3-12 LEDs and Connectors on the Ethernet Board
Name Function
Link LED Lights when a signal is detected at the UTP port.

Lights when a carrier signal is detected or remains ON when neither
CRS LED
the UTP connector nor the BNC connector is connected.
RJ-45 UTP
Used for 10BaseT connection.
connector
Used for 10Base2 connection.
Caution (1) When not using 10Base2, attach a BNC connector
cap (that comes with the Ethernet board) to the
BNC connector BNC connector.
(2) When using 10Base2, use insulation tape to
cover all exposed metallic parts of connectors
and the T-branch connector.
3-31
3.7 DeviceNet Board
3.7.1 Overview
The robot controller is a slave unit for serial communications which is compliant
with the open network DeviceNet. It may easily exchange I/O data with a variety
of DeviceNet-compliant control devices of many manufacturers.
[ 1 ] Features
(1) DeviceNet-compliant board
The DeviceNet is an internationally open network developed by Allen-
Bradley and is designed to allow control devices (e.g., sensors and
actuators) to communicate with each other.
(2) Can be networked with control devices of various manufacturers
The robot controller equipped with DeviceNet board can be networked with
DeviceNet-compliant control devices of various domestic and foreign
manufacturers since the communications specifications are open.
(3) Easy wiring and maintenance
The 5-core special cable and detachable connector of the DeviceNet board
make it easy to install wiring between nodes (communications units) and
disassembly/restructure the network. This will sharply reduce cost in wiring
and maintenance, as well as making replacement of units easy at the time
of failure.
(4) Sufficient number of I/Os
The controller is capable of handling a large quantity of I/O data as listed
below. Further, increase or decrease of the number of user-input I/Os is
possible in the 8 steps.
Number of I/Os
Standard Mode, specific 24 to 224
Transmission
Special Mode, specific 24 to 224
Standard Mode, specific 24 to 216
Reception
Special Mode, specific 40 to 232
[ 2 ] Typical Network
The figure below illustrates a typical network.
PLC
(Programmable controller)
Control panel Field unit This controller FA computer
3-32
3.7.2 Product Specifications

The figure below shows the location of the LEDs, DIP switches, and DeviceNet
connector on the DeviceNet board.
"A" "C"
"B"
"C"
"A"
BR
3-33
[ 1 ] Components and Functions
(1) Status indicator LEDs

The status indicators MS and NS ("A" in the figure given on the previous page)
can light or flash in green or red. Each of the ON, flashing, and OFF states of
those indicators shows the module or network status as listed below.
The flashing interval is once per second (0.5 second of ON and 0.5 second of
OFF).
LED name Color State Definition Explanation
Normal state • The unit works normally.

Green
Setup not completed • Reading the DIS switch settings.
MS Fatal error • Hardware failure.

(Module
Red
Status)
Recoverable error • Wrong DIP switch settings, etc.
• No power is supplied to the DeviceNet module.

− No power supplied • Resetting data.
• Waiting for initialization.
Communications link The network is working normally. (The line is
established connected.)
Green
Communications link The network is working normally, but the line is not
not established connected yet.
The unit detects any error disabling communication
NS on the network.
Fatal communications
(Network error • Node address double-assigned.
Status) Red
• "Bus off" detected.
Recoverable
Communications error in some slaves.
communications error
Network power supply • Not connected to the master unit.
−
failure • Communications line broken.
: ON : Flashing : OFF
3-34
(2) DIP switch

Use the DIP switch for setting the node address and bit rate as shown below.
Node address setting Bit rate setting

DIP Switch Setting
NOTE: Always turn off the controller power (including the network power) before
setting the DIP switch.
Setting the node address

Set the node address of the robot controller using selectors 1 through 6 of the
DIP switch, referring to the table below. You may freely set any of 0 through 63
to a node address unless the address is double-assigned on the same network
including the master and slaves. Double assignment will cause an address
double-assignment error, disabling the network.
Node Address Setting by the DIP Switch

DIP switch DIP switch
Node Node
1 2 3 4 5 6 address 1 2 3 4 5 6 address
(32) (16) (8) (4) (2) (1) (32) (16) (8) (4) (2) (1)
0 0 0 0 0 0 0 0 0 0 0 0 0 32
0 0 0 0 0 1 1 0 0 0 0 0 1 33
0 0 0 0 1 0 2 0 0 0 0 1 0 34
0 0 0 0 1 1 3 0 0 0 0 1 1 35
0 0 0 1 0 0 4 0 0 0 1 0 0 36
0 0 0 1 0 1 5 0 0 0 1 0 1 37
0 0 0 1 1 0 6 0 0 0 1 1 0 38
0 0 0 1 1 1 7 0 0 0 1 1 1 39
0 0 1 0 0 0 8 0 0 1 0 0 0 40
0 0 1 0 0 1 9 0 0 1 0 0 1 41
0 0 1 0 1 0 10 0 0 1 0 1 0 42
0 0 1 0 1 1 11 0 0 1 0 1 1 43
0 0 1 1 0 0 12 0 0 1 1 0 0 44
0 0 1 1 0 1 13 0 0 1 1 0 1 45
0 0 1 1 1 0 14 0 0 1 1 1 0 46
0 0 1 1 1 1 15 0 0 1 1 1 1 47
0 1 0 0 0 0 16 0 1 0 0 0 0 48
0 1 0 0 0 1 17 0 1 0 0 0 1 49
0 1 0 0 1 0 18 0 1 0 0 1 0 50
0 1 0 0 1 1 19 0 1 0 0 1 1 51
0 1 0 1 0 0 20 0 1 0 1 0 0 52
0 1 0 1 0 1 21 0 1 0 1 0 1 53
0 1 0 1 1 0 22 0 1 0 1 1 0 54
0 1 0 1 1 1 23 0 1 0 1 1 1 55
0 1 1 0 0 0 24 0 1 1 0 0 0 56
0 1 1 0 0 1 25 0 1 1 0 0 1 57
0 1 1 0 1 0 26 0 1 1 0 1 0 58
0 1 1 0 1 1 27 0 1 1 0 1 1 59
0 1 1 1 0 0 28 0 1 1 1 0 0 60
0 1 1 1 0 1 29 0 1 1 1 0 1 61
0 1 1 1 1 0 30 0 1 1 1 1 0 62
0 1 1 1 1 1 31 0 1 1 1 1 1 63
Note 1 : Selector OFF and ON are expressed by 0 and 1, respectively. (Before shipment from the factory, all switches are set
to 0 by default.)
3-35
Setting the bit rate
To match the bit rate of the robot controller with that of the network, use selectors
7 and 8 of the DIP switch, referring to the table below:
Bit Rate Setting By DIP Switch
Selectors on the DIP switch

Bit rate
Selector 7 Selector 8
0 0 125 kbps
0 1 250 kbps
1 0 500 kbps
1 1 500 kbps
Note 1: Selector OFF and ON are expressed by 0 and 1, respectively. (Before shipment from the factory, both of
these selectors are set to 0 (=500 kbps) by default.
Note 2: On the same network, set the same bit rate to all nodes (master and slaves). Otherwise, slaves whose
bit rate is different from that of the master cannot communicate only, but also they may cause a
communications error between correctly set nodes.
(3) DeviceNet connector

The new robot controller uses an open type screw connector whose pin
arrangement is shown below.
NOTE: When the controller power (including the network power) is on, do not
disconnect/connect the communication connector or touch its pins. Doing so will
result in a failure.
1: V (Black)
2: CAN _ L (Blue)
3: Drain (Shield)
4: CAN _H (White)
5: V+ (Red)
1 2 3 4 5
It is recommended that either of the following crimp terminals be used for the
communication cable.
No. Crimp terminal Tools required

(1) AI series (Phoenix Contact) ZA3 (Phoenix Contact)
(2) TC series (Nichifu) NH-32
For thin cables: TME TC-0.5
For thick cables: TME TC-2-11 (for power
supply)
TME TC-1.25-11 (for
communication)
3-36
[ 2 ] General Specifications
The following tables list the controller environmental and communication
specifications.
(1) Environmental requirements

Item Specifications
Power
5 VDC (supplied via the controller ISA bus)
requirements
Operating
0 to 40°C
temperature
Operating
90% RH or less (without condensation)
relative humidity
(2) DeviceNet communications specifications

Item Specifications
Communications
DeviceNet-compliant
protocol
Connection Master/slave connection : Polling I/O function
supported Compliant with DeviceNet communications rules
Connection type Multi-drop type with possible combination of T-branch
(Note1) (to trunk and branch lines)
Bit rate 500, 250, 125 kbps (selection by switch)
Communications Special cable with 5 wires
media (2 for signals, 2 for power supply and 1 as a shield wire)
Max. network Branch
Bit rate Total branch length
length length
100 m or less
500 kbps 6 m or less 39 m or less
Communications (Note 2)
cable length 250 m or less
(Note 2)
500 m or less
(Note 2)
Communication
External supply of 24 VDC ±10%
power supply
Max. number of
connectable 64 nodes (including configurator (converter) if connected)
nodes
Standard assignment
40 points for system input
32 points for system output
24 points to 216 for user input
24 to 224 points for user output
No. of I/Os can be set in unit of 8 points.
Number of I/Os
Special assignment
24 points for system input
32 points for system output
40 to 232 points for user input
24 to 224 points for user output
No. of I/Os can be set in unit of 8 points.
Error check CRC
Note 1: Terminator resistors are needed at both ends of the trunk line.
Note 2: These values may apply when a special thick cable is used as a trunk line.
If a special fine cable is used, the max. network length is 100 m or less.
3-37
3.7.3 Assignment of Serial I/O Data
[ 1 ] Standard Assignment Mode
In the standard assignment mode, serial input/output data are assigned as
shown in the table below:
The controller with a DeviceNet board transfers the system input/output data
only through the DeviceNet, disabling the parallel port. The controller, however,
can handle the user input/output data using both parallel ports and DeviceNet.
The following signals are transferred only through the parallel ports; robot stop,
enable auto, and CPU normal.
(1) Input Data
No. Content No. Content No. Content No. Content
512 Step stop (all tasks) 520 Bit 0 in data area 1 528 Bit 0 in data area 2 536 Bit 8 in data area 2
513 – 521 Bit 1 in data area 1 529 Bit 1 in data area 2 537 Bit 9 in data area 2
514 Halt (all tasks) 522 Bit 2 in data area 1 530 Bit 2 in data area 2 538 Bit 10 in data area 2
515 Strobe signal 523 Bit 3 in data area 1 531 Bit 3 in data area 2 539 Bit 11 in data area 2
516 Skip interrupt 524 Bit 4 in data area 1 532 Bit 4 in data area 2 540 Bit 12 in data area 2
519 Command data odd parity 527 Bit 7 in data area 1 535 Bit 7 in data area 2 543 Bit 15 in data area 2
No. Content No. Content No. Content

544 Bit 0 in command area 552 INPUT 552 760 INPUT 760
548 – 556 INPUT 556 764 INPUT 764
549 – 557 INPUT 557 765 INPUT 765
550 – 558 INPUT 558 766 INPUT 766
551 – 559 INPUT 559 767 INPUT 767
Note 1: The numerals at No. are the I/O port numbers of the controller.
Note 2: The input data is handled in bytes (8 points). Default is 64 points. Up to 256 points can be
used.
(2) Output Data
768 776 Robot warning 784 Bit 0 in status area 792 Bit 8 in status area
769 Robot running 777 Continue start permitted 785 Bit 1 in data area 793 Bit 9 in status area
770 Robot alarm 778 Reserved 786 Bit 2 in status area 794 Bit 10 in status area
771 Servo ON 779 Reserved 787 Bit 3 in status area 795 Bit 11 in status area
772 Robot initialization finished 780 Reserved 788 Bit 4 in status area 796 Bit 12 in status area
773 Auto mode 781 Reserved 789 Bit 5 in status area 797 Bit 13 in status area
774 External mode 782 Command process finished 790 Bit 6 in status area 798 Bit 14 in status area
775 Battery warning 783 Status area odd parity 791 Bit 7 in status area 799 Bit 15 in status area

800 OUTPUT 800 808 OUTPUT 808 1016 OUTPUT 1016
Note 2: The input data is handled in bytes (8 points). Default is 56 points. Up to 256 points can be
used.
3-38
[ 2 ] Special Assignment Mode

In the special assignment mode, the serial input/output data are assigned as
shown in the table below:
The controller with a DeviceNet board transfers the system input/output data
only through the DeviceNet, disabling the parallel ports. The controller, however,
can handle the user input/output data using both parallel ports and DeviceNet.
The following signals are transferred only through the parallel ports: robot stop,
enable auto, and CPU normal.
(1) Input Data
512 Step stop (all tasks) 520 Program selection bit 528 Motor power ON 536 INPUT 536
513 Continue start 521 Bit 1 for program selection 529 CAL execution 537 INPUT 537
514 Halt (all tasks) 522 Bit 2 for program selection 530 – 538 INPUT 538
515 Operation ready start 523 Bit 3 for program selection 531 SP100 539 INPUT 539
516 Skip interrupt 524 Bit 4 for program selection 532 Switching to external mode 540 INPUT 540
517 Program start 525 Bit 5 for program selection 533 Program reset 541 INPUT 541
518 – 526 Bit 6 for program selection 534 Robot alarm 542 INPUT 542
519 – 527 Program selection parity 535 – 543 INPUT 543

544 INPUT 544 552 INPUT 552 760 INPUT 760
Note 2: The input data is handled in bytes (8 points). Default value is 64 points. Up to 256 points can
be used.
(2) Output Data
768 – 776 Robot power ON finished 784 Error code, unit, 20 792 Error code, hundreds, 20
769 Robot running 777 Servo ON 785 Error code, unit, 21 793 Error code, hundreds, 21
770 Robot alarm 778 CAL finished 786 Error code, unit, 22 794 Error code, hundreds, 22
771 Auto mode 779 Teaching 787 Error code, unit, 23 795 Error code, hundreds, 23
772 External mode 780 Single cycle end 788 Error code, tens, 21 796 –
773 Program start reset 781 Battery warning 789 Error code, tens, 22 797 –
774 – 782 Robot warning 790 Error code, tens, 23 798 –
775 – 783 Continue start permitted 791 Error code, tens, 24 799 –

Note 2: The input data is handled in bytes (8 points). Default value is 64 points. Up to 256 points can
be used.
3-39
3.7.4 Parameter Entry Procedure
[ 1 ] Entering the Number of Input/Output Slots
This controller allows you to increase or decrease the number of input/output
slots in bytes. The number of input slots can be set in the range from 8 (default)
to 32 (max.), and the number of output slots in the range from 7 (default) to 32
(max.). The setting procedure is given below:
Press [F4 I/O] on the following screen.

4STEP 1 YR-UPJ3-B00
F4
Press [F6 Aux.] on the following screen.

4STEP 2 YR-UPJ3-B00
F6
3-40
Press [F1 Set H/W] on the following screen.

4STEP 3 YR-UPJ3-B00
F1
Select the box for changing the number of DeviceNet input/output

4STEP 4 slots and then press [F5 Change].
YR-UPJ3-B00
F5
Enter a required number of slots on the following screen and press

4STEP 5 OK. The quick reference table given in the next subsection [ 2 ] will be
helpful for you to determine the number of input/output slots.
YR-UPJ3-B00
3-41
Check that the number has been correctly changed (from 8 to 10 in this
4STEP 6 example) and press OK.
YR-UPJ3-B00
Turn the controller power OFF and then turn it back ON according to
4STEP 7 the message on the following screen.
NOTE: The internal data that you have changed will not go into effect
until you turn the controller power off and on.
YR-UPJ3-B00
3-42
[ 2 ] Quick Reference Table for the Number of Input/Output Slots

The table below lists the correspondence between the number of input/output
slots and the number of user input/output points.
Number of Max user input Max user input Number of Max user output Max user output
DeviceNet input points in standard points in special DeviceNet output points in standard points in special
slots assignment assignment slots assignment assignment
8 24 40 7 24 24
9 32 48 8 32 32
10 40 56 9 40 40
11 48 64 10 48 48
12 56 72 11 56 56
13 64 80 12 64 64
14 72 88 13 72 72
15 80 96 14 80 80
16 88 104 15 88 88
17 96 112 16 96 96
18 104 120 17 104 104
19 112 128 18 112 112
20 120 136 19 120 120
21 128 144 20 128 128
22 136 152 21 136 136
23 144 160 22 144 144
24 152 168 23 152 152
25 160 176 24 160 160
26 168 184 25 168 168
27 176 192 26 176 176
28 184 200 27 184 184
29 192 208 28 192 192
30 200 216 29 200 200
31 208 224 30 208 208
32 216 232 31 216 216
32 224 224
3-43
3.7.5 Error Code Table
Here, only the error codes relative to DeviceNet communication errors are
described in the table below. For other error codes, refer to the ERROR CODE
TABLES, "2 Controller Error Code Table."
DeviceNet Error Code Table

LEDs
Error code What has happened: What to do:
MS NS
1201 Preparing for communications (link not Establish the link from the master
established) device.
• The DeviceNet module is working normally, G G
but has not established link with the master
device.
1202 Preparing for communications (link not Establish the I/O link from the master
established) device.
• The DeviceNet module is working normally G G
and has established explicit link with the
master device, but not established an I/O link.
1203 Preparing for communications Check the contents of I/O data that the
(communications idling) master device sends.
• The DeviceNet module is working normally, G G
but cannot receive data except empty data
from the master device.
1204 Preparing for communications (I/O timeout) Check that the DeviceNet cable is not
broken or its connector is firmly
• The DeviceNet module is working normally, plugged in.
but cannot receive data from the master
device within the specified time. Check the DeviceNet cable length
and that a terminator resistor is G R
attached to each end of the trunk line.
1205 Initial setting error in the communications Turn the controller power off and then
processor on, and do the same operation again.
− −
• Failed to establish the initial link with the
DeviceNet communication processor.
1210 A DeviceNet internal communications error has Turn the controller power off and then
− −
occurred. on, and do the same operation again.
1213 The network is broken or "bus off." Check whether the DeviceNet cable is
connected with the robot controller. If
• The DeviceNet cable is broken or not this error occurs after you change the
connected. DIP switch setting, check whether the
bit rate setting made with the DIP G R
switch matches the network's bit rate.
1215 Preparing for communications (Initial setting Check whether the bit rate setting
error) made with the DIP switch matches the
network's bit rate.. G
• No initial settings have been received from
the robot.
1216 Data length setting error Turn the controller power off and then
on. Then, set correct DeviceNet
• DeviceNet INSLOT or OUTSLOT is not 32 or INSLOT and OUTSLOT values. R
less.
1217 Node address double-assign error Assign an exclusive node address to
each node (including the robot
• The same node address is double assigned controller) on the same DeviceNet. G R
to the robot controller and any other online
node.
: ON : Flashing : OFF – : Indefinite
3-44
LEDs
Error code What has happened: What to do:
MS NS
1230 Retry error in the DPRAM built in the robot Turn the controller power off and then
− −
controller on, and do the same operation again.
1232 Reset command received Turn the controller power off and then
on, and do the same operation again.
• The robot controller has received a reset G G
command from the master device.
1234 DeviceNet internal RAM error Turn the controller power off and then
R
1235 Reserved for System
−
R
1236 DeviceNet internal DPRAM error Turn the controller power off and then
R
1237 DeviceNet EEPROM error Turn the controller power off and then
R
1238 Retry error in the DeviceNet DPRAM Turn the controller power off and then
R
: ON : Flashing : OFF – : Indefinite
3-45
RC5 EDS File ($ DeviceNet Manager Generated Electronic Data Sheet)
[File]
DescText= "RC5 EDS File";
CreateDate= 11-14-1997;
CreateTime= 15:00:00;
ModDate= 06-26-1999;
ModTime= 10:57:07;
Revision= 1.1;
[Device]
VendCode = 171; $ Vendor Code
ProdType = 12; $ Product Type
ProdCode = 1; $ Product Code
MajRev = 1; $ Major Rev
MinRev = 1; $ Minor Rev
VendName =
ProdTypeStr = "Communication Adapter";
ProdName = "RC5";
Catalog = "";
[IO_Info]
Default = 0X0001; $ Poll Only
PollInfo = 0X0001, $ Poll Only
1, $ Default Input = Input1
1; $ Default Output = Output1
$Input Connections
Input1 =
7, $ From 7 to 32 Bytes, Variability
0, $ All bits are significant
0x0001, $ Poll Only Connection
"Data", $ Name
6, $ Path Length
"20 07 24 02 30 04", $ Register Object Instance 2 Attribute 4
"Robot Output Data"; $ Help
$Output Connections
Output1 =
8, $ From 8 to 32 Bytes,Variability
0, $ All bits are significant
0x0001, $ Poll Only Connection
"Data", $ Name
6, $ Path Length
"20 07 24 01 30 04", $ Register Object Instance 1 Attribute 4
"Robot Input Data"; $ Help
3-46
3.8 Mounting Extension Boards

This section describes how to mount the µVision board, Ethernet board, and
DeviceNet board.
When mounting only one of these boards, skip the steps for mounting other
boards.
In the illustrations below, the typical controller model is drawn.
Remove the eight screws from the controller top cover.
4STEP 1
Lift and remove the top cover from the robot controller.
4STEP 2
3-47
Remove the two screws fastening the side plate from the front panel of
4STEP 3 the robot controller as shown below.
Remove the side plate.

4STEP 4
3-48
Remove the panel fastening screw and then the panel hole blind plate.
4STEP 5 To mount the µVision board, remove the lower blind plate.
To mount the Ethernet board or DeviceNet board, remove the upper or
the middle blind plate.
To mount the µVision board to the robot controller (RC5-VM6A),

4STEP 6 remove the screws from the extension board retaining strut and take
off the strut.
If you do not mount the µVision board, skip to STEP 8.
3-49
Insert the µVision board in the lower slot connector.
4STEP 7
Insert the Ethernet board or the DeviceNet board into the upper or the
4STEP 8 middle slot connector.
3-50
Using the removed panel hole blind plate, push up the panel of each
4STEP 9 extension board. Secure the extension board with the panel fastening
screw.
Secure the board support plate to the extension board strut.

4STEP 10
3-51
Set the assembled extension board strut back into place and tighten
4STEP 11 the screws.
Tightening torque: 0.69 Nm ±20%
Adjust the position of each board support plate with the screw so that
4STEP 12 each extension board will be supported firmly.
When installing more than one extension board, be sure to tighten
screws starting from one on lower board.
Tightening torque: 0.15 Nm ±20% for the lower slot
0.10 Nm ±20% for the middle slot
0.15 Nm ±20% for the higher slot
3-52
Install the side plate and tighten the two screws.

4STEP 13
Put the top cover and secure it with the eight screws.
4STEP 14
The mounting of the extension boards is now finished.
3-53
3.9 Controller Protective Box
A controller protective box is available as an optional heat exchanger box to
protect the robot controller from an undesirable environment (dust, oil mist) in
plant.
3.9.1 Components in Package

Check that the following components are contained in the package of the
controller protective box.
Controller protective box (1 pc) Binding band (4 pcs)
3.9.2 Names of the Components
Top cover
Rear panel
Partition plate (B)
Partition plate (A)
Controller fixture
(4 locations)
Heat exchanger
DS5-1093C23-FB10
Front panel
Drain hole screw (M5 x 5L)
3-54
3.9.3 Setting up the Controller Protective Box

Placing the controller protective box
Place the controller protective box on a flat, level plane.
Preparing a power supply

Make a single-phase 200 VAC power supply ready for use.
Connect the power supply to the fan motor drive terminal.
Recommended cable: 1.25 mm2 x 3-core (outside diameter: 11 to 13 mm)
Note (1) Make the controller protective box share the same circuit breaker
of the power supply (200 VAC) with the robot controller.
Note (2) Ground the controller protective box to prevent an electric shock.
Setting the robot controller into the protective box

(1) Remove the top cover from the controller protective box.
(2) For the controller protective box, remove the wing bolt and take off the
partition plate (A).
(3) Put the robot controller into the protective box so that its rubber feet will be
fitted into the controller fixtures of the protective box.
(4) For the controller protective box , secure the partition plate (A) with the wing
bolt.
(5) Route the necessary cables through the ducts and connect them. As shown
below, tie up each duct with an attached binding band.
Note: Tying up duct(s) not in use
Binding band Binding band
Box Box
Note: Tie up the opening of each duct not in use with an attached
binding band to prevent entry of dust, water, etc. into the
controller protective box.
3-55
3.9.4 Precautions
(1) The controller protective box is a dust-proof, splash-proof structure
equivalent to JIS IP53.
The controller protective box is not explosion-proof and must not be installed
in the following environments and locations to ensure safety:
• in an environment full of combustible gas, flammable liquid, etc;
• in an environment full of acid or alkali corrosive gas;
• in a location close to electric noise sources, such as large inverters,
high-output high-frequency generators, large conductors and welders;
• in a location where the controller protective box will not be used outside
the ambient temperature range from 0°C to 40°C;
• in a location where the controller protective box will be exposed to rain or
dew;
• in an environment where the controller protective box will be exposed
directly to water, oil or chips;
• in an environment where fine chips will be produced from cutting, etc;
• in an environment using oil other than YASKAWA's recommended oil.
YASKAWA's recommended oil: YUSHIRON OIL No. 4
(2) Seal the mounting face and screws of the controller protective box when
using it in an environment full of oil mist. Otherwise oil mist may remain on
the fin, resulting in a collection of oil. Regularly clean the controller
protective box.
(3) If oil mist, etc. collects in the controller protective box, remove the drain hole
screw and drain off the oil.
(4) The controller protective box is not equipped with a power switch. Turn ON
or OFF the controller using an external means.
(5) The controller protective box must be installed horizontally. Vertical
installation will cause accidents.
3-56
Chapter 4
Specifying Your
Robot
This chapter specifies how to customize your

robot.
Contents
Chapter 4 Specifying Your Robot

4.1 Modifying Software Motion Limits to Define New Motion Space........................................... 4-1
4.1.1 What Is a Software Motion Limit?................................................................................................ 4-1
4.1.2 Changing Software Motion Limits................................................................................................ 4-2
4.1.3 Precautions When Changing the Software Motion Limits........................................................... 4-3
4.1.4 Procedure for Changing the Software Motion Limits .................................................................. 4-3
4.1.5 Changing the Software Motion Limit Temporarily ....................................................................... 4-6
4.2 CALSET ........................................................................................................................................ 4-8

4.2.1 What Is CALSET? ....................................................................................................................... 4-8
4.2.2 CALSET Procedure ..................................................................................................................... 4-8
4.2.3 Procedure for Performing CALSET ............................................................................................. 4-9
4.2.3.1 CALSET of a Single Axis .............................................................................................. 4-9
4.2.3.2 CALSET of all Axes .................................................................................................... 4-11
4.2.3.3 Input the Absolute Data .............................................................................................. 4-11
4.3 Setting Control Set of Motion Optimization ........................................................................... 4-15
4.4 Setting Robot Installation Conditions..................................................................................... 4-17
4.5 Recovery Procedure After Encoder Reference Position Error ............................................ 4-18
4.5.1 Purpose of the Encoder Reference Position Error.................................................................... 4-18
4.5.2 Operation Limitation When Encoder Reference Position Error ................................................ 4-20
4.5.3 Setting the Encoder Reference Position ................................................................................... 4-21
4.5.4 Recovery Procedure After Encoder Reference Position Error.................................................. 4-24
4.5.5 Moving the Robot to the Encoder Reference Position .............................................................. 4-26
4.5.6 Displaying the Current Status.................................................................................................... 4-26
4.1 Modifying Software Motion Limits to

Define New Motion Space
4.1.1 What Is a Software Motion Limit?
A limit to the operation range of the robot defined by the software is called a
software motion limit. Software motion limits become valid after CAL of the robot
has been completed and the robot has entered the range set by the limits.
A mechanical operation limit is called a mechanical end and set by a mechanical
stop. To prevent the robot from striking against a mechanical stop, each software
motion limit is set slightly in front of the mechanical end as shown in Figure 4-1.
Although there is no mechanical stop for the sixth axis, a software motion limit is
set.
If the robot reaches a software motion limit during manual or automatic operation,
an error message will be displayed (error code starting from 6070; the first digit
represents the axis number) and the robot will come to a stop. The power to the
motor is also turned OFF in such a case during automatic operation.
All axes are assigned a software motion limit in both the positive and negative
direction of the operation range. The software motion limit in the positive
direction is called the positive-direction software motion limit and that in the
negative direction is called the negative-direction software motion limit.
Motion
Motionrange
range Software motion limit
Mechanical end
Restricted
Restricted range
range
NLIM(Negative-direction software
motion limit)
PLIM(Positive-direction software
motion limit)
Figure 4-1 Software Motion Limits and Mechanical Ends
4-1
4.1.2 Changing Software Motion Limits
If the robot interferes with any other device, change the software motion limits to
make the motion space smaller as shown in Figures 4-2.
Motion range
(after change) Software motion limit
Mechanical end
Positive-direction Restricted range

software motion Negative-direction
limit(1st axis) software motion
limit(1st axis)
Oth
e
dev r
ice
Figure 4-2 Changing Software Motion Limits
4-2
4.1.3 Precautions When Changing the Software Motion Limits

(1) Confirm the operating space of the robot in the actual working environment.
Set the software motion limits using the correct unit of measurement.
If the operating space is too small, the robot may seem to become
inoperable.
4.1.4 Procedure for Changing the Software Motion Limits

Described below is the procedure for changing the software motion limits.
Turn the power switch of the robot controller to ON.
4STEP 1
Set the mode selector switch of the teach pendant to MANUAL.
4STEP 2
Press [F2 Arm] on the top screen of the teach pendant.
4STEP 3 YR-UPJ3-B00
F2
The Current Robot Position window appears as shown in Step 4.
4-3
Press the SHIFT key and then press [F12 Maint.].
4STEP 4 YR-UPJ3-B00
F12
The Maintenance Functions (Arm) window will appear.
Press [F1 M Space] on the Maintenance Functions (Arm) window.

4STEP 5 The Motion Space window will appear as shown below.
YR-UPJ3-B00
F5
4-4
Select the item to be modified, then press [F5 Change].

4STEP 6 The numeric keypad will appear as shown below.
YR-UPJ3-B00
Enter a desired value using the numeric keys, then press OK.
The new value will be set on the line of the item selected in the Motion Space
window.
If two or more items must be changed, repeat Steps 4 and 5.
Press OK in the Motion Space (Software motion limit) window.

4STEP 7
Turn OFF the power to the robot controller.
4STEP 8
4-5
4.1.5 Changing the Software Motion Limit Temporarily
The robot can be operated by releasing limit check temporarily even if
the robot stops by the software limit.
Following check function are released.
①Software Motion Limit Check for Each Axis
②Robot Arm Interference Check
③Motion Space Check
NOTE 1:
When the software motion limits are released, the motion and
the current position can not be set to the variable.
NOTE 2:
The software motion limit release is canceled by the following operation.
①Cancel of the software limit release is operated.
②Automatic mode or teaching mode is selected.
③Controller's power supply is turned off.
Described below is the procedure for releasing the software motion limits.
Turn the power switch of the robot controller to ON.
4STEP 1
Set the mode selector switch of the teach pendant to MANUAL.
4STEP 2
4STEP 3
Press [F6 Aux.].
4STEP 4
YR-UPJ3-B00
4-6
① When the limit release button is pressed in the normal state(limit not
4STEP 5 released), the following message is displayed.
Press OK to release the limit.
②When the limit release button is pressed in the limit released state,
the following message is displayed.
Press the OK key to release the limit.
4-7
4.2 CALSET
4.2.1 What Is CALSET?
Calibrating the relationship between position-related information recognized by
the robot controller and the actual position of the robot body is called CALSET.
CALSET must be performed when the motor is replaced or when the backup
battery for the encoder goes dead and the position-related data retained in the
encoder is lost as a result.
After CALSET is completed, the calibrated data of the robot body will be
recorded in the robot controller. This data is called calsetting data, and it is
different on each robot.
4.2.2 CALSET Procedure

Move the robot arm into contact with the CALSET position
by the axis operation in manual mode.
There are two types of CALSET as follow.
-Single axis CALSET by specifying independent axis

-All axes CALSET by specifying all axes.
If you already know the absolute data in the CALSET position, input that data.
The robot arm position for CALSET is called CALSET position.
In CALSET which performs before the robot is shipped,
the position shown in Figure 4-3, 4-4 is set at the CALSET position.
The angle of the U-axis The angle of the central line of The angle of the U-axis The angle of the central line of
against the horizon is 0 the B-axis against the central against the horizon is 0 the B-axis against the central
degrees line of the U-axis is 0 degrees. degrees line of the U-axis is 0 degrees.
The angle of the L-axis The angle of the L-axis

prependicular to the prependicular to the
ground. ground.
Figure1-a UPJ)
Figure 4-3
Figure1-b(SV3X,CR3X)
Figure 4-4
4-8
4.2.3 Procedure for Performing CALSET

4.2.3.1 CALSET of a Single Axis
CALSET only a specified axis is called single axis CALSET.
Perform single axis CALSET when the motor of an axis is replaced and the axis
must therefore be CALSET, or when some axes cannot be moved to the
CALSET positions at any given time because of interference between the
equipment installed near the robot and the robot. The procedure for CALSET a
single axis is described below:
NOTE: Steps 1 and 2 are required for CALSET of the 6th axis. To CALSET any
other axis, skip to Step 3.
Move the desired axis to the CALSET position in manual mode and
4STEP 1 turn off the power to the motor.
Press [F2 Arm] on the teach pendant.

4STEP 2 YR-UPJ3-B00
Press [F12 Maint.]

4STEP 3 YR-UPJ3-B00
4-9
Press [F6 CALSET.]
4STEP 4 YR-UPJ3-B00
Press the axis number to be CALSET to turn ON CALSET (green

4STEP 5 display).
Turn OFF CALSET (black display) for the other axes that are not
required to be CALSET.
YR-UPJ3-B00
Press OK.
4STEP 6 The system message appears asking whether you want to carry out
CALSET with a caution that
the robot reference position will change.
YR-UPJ3-B00
Press OK.
4STEP 7 The system message appears informing that CALSET is completed.
4-10
4.2.3.2 CALSET of all Axes

The CALSET of all axes is called all-axis CALSET.
The procedure is the same as that for CALSET of a single axis.
4.2.3.3 Input the Absolute Data

Value of motor encoder at robot reference position is called absolute data.
Even if the robot controller is replaced,
CALSET can be performed by inputting this absolute data of the old one.
Described below is the procedure for input the absolute data.
Press [F2 Arm] on the teach pendant.

4STEP 1 YR-UPJ3-B00
Press [F12 Maint.].

4STEP 2 YR-UPJ3-B00
4-11
Press [F6 CALSET.].
4STEP 3 YR-UPJ3-B00
Press [F1 ABS.DATA].

4STEP 4 YR-UPJ3-B00
The example of changing the absolute data of the J1 axis from 606 to
4STEP 5 706 is shown in the following.
Press [F5 Change].
YR-UPJ3-B00
4-12
Input "706".
4STEP 6 YR-UPJ3-B00
Press OK.
4STEP 7 YR-UPJ3-B00
Press OK.
4STEP 8 YR-UPJ3-B00
4-13
Press Cancel.
4STEP 9 The altering of the absolute data has been completed.
YR-UPJ3-B00
4-14
4.3 Setting Control Set of Motion

Optimization
The optimum speed or acceleration depends on the payload and center of
gravity of the end-effector or workpiece that is to be set at the end of the robot
arm. Set the payload and center of gravity position of the end-effector or
workpiece and the control set of motion optimization according to the end load
on or position of the robot.
For further information, see the PROGRAMMER'S MANUAL, Section 4.7
"Setting the Master Control Parameters in User Preferences." For the setting
procedure, refer to the SETTING-UP MANUAL, Section 2.9, "Setting the Master
Control Parameters of the Payload, Center of Gravity, and Control Set of Motion
Optimization."
The mass of payload is the total weight of the end-effector and workpiece,
expressed in grams.
The payload center of gravity is represented by the TOOL0 coordinate system
(see Figure 4-5) in the unit of mm.
The origin of the TOOL0 coordinate system is the center of the sixth axis flange.
Its Y-component is in the direction from the flange center to the φ6H7 pin hole
(orientation vector direction). The Z-component is in the vertical direction to the
flange face across the flange center (approach vector direction). The X-
component is in the X-axis direction of the right hand coordinate system (normal
vector direction) with the orientation vector as the Y-axis and the approach
vector as the Z-axis. (See Figure 4-6.)
+ Zb
Orientation vector (Y-axis)
Orientation vector φ6H7 (pin hole)
Normal vector (X-axis)
Approach vector (Z-axis)
6th axis flange
face
Center of flange
Approach vector
TOOL0 coordinate axis
+ Xb + Yb
Z
Position of payload center of gravity
(X6, Y6, Z6)
X6
Y
Z6
Y6
X
Figure 4-5 Payload Center of Gravity
4-15
Y-axis positive direction (orientation vector)
Z-axis positive direction

(approach vector)
X-axis positive direction

(normal vector)
Figure 4-6 Right Hand Coordinate System
4-16
4.4 Setting Robot Installation Conditions

The optimum operating conditions will differ depending on whether the robot is
floor-mounted or overhead-mounted.
The operating conditions set prior to delivery from the plant are for floor
installation. If the installation conditions change, the settings must be changed
accordingly.
For the setting procedure, refer to the SETTING-UP MANUAL, Section 2.10,
"Setting the Robot Installation Condition" and the PROGRAMMER'S MANUAL,
Subsection 4.7.2 "Setting Robot Installation Conditions."
4-17
4.5 Recovery Procedure After Encoder
Reference Position Error
Warning: Move the robot in low speed which can be stopped at once with
paying attention to the robot movement.
Do not approach the robot when the robot operates.
4.5.1 Purpose of the Encoder Reference Position Error

If the encoder value detected at power on does not match the data stored in the
encoder the last time the power was turned off, an error occurs when the
controller power is turned on.
However, this error does not occur when the encoder line of all axis is not
connected ("J# encoder initialization error" occurs, #: axis no.) at controller
power ON.
There are two possible causes of this error:
･ Error in the encoder system
･ The robot was moved after the power was turned OFF.
If there is an error with the encoder system, the manipulator may stall when the
program operation is started.
Therefore, if the encoder reference position error has occurred, the automatic
operation and the teaching check operation are set not to function until the
position check operation is done.
4-18
After encoder reference position

error occurs
Reset error
Turn ON servo power

Procedure After Error Occurs
①Position checking
(Move the robot to the encoder reference
position with the axis JOG operation)
NG
②Compare the encoder reference
position and the current robot
position
OK
OK：Program operation possible
NG：Error occurs again
③Recovery operation
･ Motor replacement
･ CALSET
Program operation possible
①Position Check
If the encoder reference position error occurs, move to the encoder reference
position using the axis keys and check the position. Automatic operation, teach
check operation, and other operations will not function.
②Pulse Difference Check
The pulse number at the encoder reference position is compared with that at the
current position.
If the difference is within the allowable range, the program operation is enabled.
If not, the encoder reference position error occurs again.
･The allowable range is the number of pulses per rotation of the motor.
･The initial value of the encoder reference position is the RANG value (CALSET
position). This can be changed. For details, refer to "4.5.3 Setting the Encoder
Reference Position".
③Alarm Occurence
If the encoder reference position error occurs again, there may be an error in the
encoder system.
Check the system.
After adjusting the erroneous axis, perform CALSET operation for the erroneous
axis, then check the position again.
All axes CALSET enables the program operation without having to check the
Position.
4-19
4.5.2 Operation Limitation When Encoder Reference Position
Error
The each function concerning an encoder reference position cannot be executed
as shown in the following table based on the detection result of an encoder
reference position error at the controller power ON.
State Position Check Information Move Reference Reset Reference

Change
Undetection Disable Enable Disable Disable Disable
On Error Enable Enable Disable Enable Enable
Normal Unnecessary Enable Enable Enable Enable
Undetection : When the encoder line of all axis is not connected at

controller power ON
On Error : When there is an axis which exceeds tolerance in the
detection result at controller power ON
Normal : When all axis are in tolerance in the detection result at
controller power ON
Note: Even if an encoder reference position error is occuring, the error

can be canceled by performing "Reference Change" and "Reference
Reset".
Do not perform before confirming that the encoder is normal.
4-20
4.5.3 Setting the Encoder Reference Position

The position set as a checkpoint of the encoder value is an encoder reference
position besides an absolute data which the robot has in the peculiarity.
There are two kinds of setting an encoder reference position: Reference Change,
Reference Reset.
Reference Change (Set the current position as the encoder reference position)
Move the robot to the position where the encoder reference position is
4STEP 1 set.

4STEP 2 YR-UPJ3-B00
Press [F6 Maint.] with SHIFT key simultaneously.

4STEP 3 YR-UPJ3-B00
4-21
Press [F8 ENC Ref]
4STEP 4 YR-UPJ3-B00
Press [F5 chg.Ref]

4STEP 5 YR-UPJ3-B00
The system message is displayed.

To continue this operation, press [OK].
To cancel this operation, press [Cancel].
YR-UPJ3-B00
YR-UPJ3-B00
4-22
Reference Reset (Set the RANG value (CALSET position) as the encoder reference position)
Perform the same operation as from STEP2 to STEP4 of the Reference
4STEP 1 Change.
Press [F5 Ref rst]

4STEP 2
YR-UPJ3-B00

YR-UPJ3-B00
4-23
4.5.4 Recovery Procedure After Encoder Reference Position
Error
When the encoder reference position error occurs, perform the following
operations:
･ Reset the encoder reference position error
･ Turn the motor power ON.
Then, perform the position check operation as follow.
If the encoder system is abnormal, give appropriate treatment like the exchange
etc.
4STEP 1 Change.
Press [F1 POS chk]

4STEP 2 YR-UPJ3-B00

If the encoder reference position error can not be canceled, the

abnormal axis is displayed in the error message.
Move the robot again to the encoder reference position and perform
the position check operation.
4-24
If the encoder reference position error can not be canceled because

the encoder line of all axis is not connected at controller power ON,
"Detection Error" is displayed in the error message.
Check the encoder system.
Detection Error.
Follow the steps below when you perform the position check operation with the
operating panel.
Move the robot to the encoder reference position.

4STEP 1 The encoder reference position equals to the robot home position at
the factory shipment.
Turn the motor power OFF.

4STEP 2
Press the [shift] key and then press the [cal] key.
4STEP 3 “FO:ENC.REF” is displayed in the LCD.
Press the [OK] key. The position is confirmed and the result is
4STEP 4 displayed.
When the encoder reference position error is released, “No Problem”
is displayed in the LCD.
If it is not released, ×○×○○○○○ is displayed in the LCD.
(×
×:Error, ○:Normal, 1th axis, 2nd axis, from the left)
4-25
4.5.5 Moving the Robot to the Encoder Reference Position
Turn the motor power ON.

4STEP 1
4STEP 2 Change.
Press [F4 Move]

4STEP 3 YR-UPJ3-B00
Choose the PTP motion mode or the CP motion mode.

After completing choosing the motion mode, keep pressing the OK
key of the teach pendant while squeezing the deadman switch until the
operation is completed.
4.5.6 Displaying the Current Status

4STEP 1 Change.
The content same as the result of the position check is displayed.

4STEP 2
4-26
Chapter 5
Robot Controller
Interface
This chapter describes the necessary require-

ments to connect the PLC and other external
devices to the controller.
Contents

5.1 General Information about the Interface................................................................................... 5-1
5.1.1 Standard Mode and Special Mode .............................................................................................. 5-1
5.1.1.1 Switching Modes........................................................................................................... 5-1
[ 1 ] Switching from the Teach Pendant.................................................................................. 5-2
[ 2 ] Switching from the Personal Computer........................................................................... 5-5
5.1.2 Robot Controller Appearance and Connector Names .............................................................. 5-11
5.1.3 Example of Control System Configuration ................................................................................ 5-12
5.1.4 Types and General Information about I/O Signals .................................................................... 5-13
5.1.4.1 Standard Mode ........................................................................................................... 5-13
5.1.4.2 Special Mode .............................................................................................................. 5-14
5.2 Using User I/O Signals.............................................................................................................. 5-15

5.2.1 I/O Type Variable Declaration.................................................................................................... 5-15
5.2.1.1 I/O Type Global Variables ........................................................................................... 5-15
5.2.1.2 I/O Type Local Variables............................................................................................. 5-15
5.2.2 User Input Commands............................................................................................................... 5-15
5.2.2.1 IN Command............................................................................................................... 5-15
5.2.2.2 WAIT Command ......................................................................................................... 5-15
5.2.3 User Output Commands............................................................................................................ 5-16
5.2.3.1 SET Command ........................................................................................................... 5-16
5.2.3.2 RESET Command ...................................................................................................... 5-16
5.2.3.3 OUT Command........................................................................................................... 5-16
5.3 System I/O Signals Standard Mode ........................................................................................ 5-17

5.3.1 Types and Functions of System Output Signals (Standard Mode)........................................... 5-17
5.3.2 Usage of System Output Signals (Standard Mode) .................................................................. 5-18
5.3.2.1 Robot Initialization Complete (Output) ....................................................................... 5-18
5.3.2.2 Auto Mode (Output) .................................................................................................... 5-19
5.3.2.3 External Mode (Output) .............................................................................................. 5-20
5.3.2.4 Servo ON (Output)...................................................................................................... 5-21
5.3.2.5 Robot in Operation (Output) ....................................................................................... 5-22
5.3.2.6 Normal CPU (Output) ................................................................................................. 5-23
5.3.2.7 Robot Error (Output) ................................................................................................... 5-24
5.3.2.8 Robot Warning (Output).............................................................................................. 5-25
5.3.2.9 Dead Battery Warning (Output) .................................................................................. 5-26
5.3.2.10 Continue Start Permitted (Output) .............................................................................. 5-27
5.3.3 Types and Functions of System Input Signals (Standard Mode).............................................. 5-27
5.3.4 Usage of System Input Signals (Standard Mode)..................................................................... 5-28
5.3.4.1 Enable Auto (Input)..................................................................................................... 5-28
5.3.4.2 Robot Stop (Input) ...................................................................................................... 5-29
5.3.4.3 Step Stop (All Tasks) (Input)....................................................................................... 5-30
5.3.4.4 Instantaneous Stop (All Tasks) (Input) ....................................................................... 5-31
5.3.4.5 Interrupt Skip (Input) ................................................................................................... 5-32
5.4 Command Execution I/O Signals Dedicated to Standard Mode .......................................... 5-34
5.4.1 General Information about Commands ..................................................................................... 5-34
5.4.2 Processing I/O Commands ....................................................................................................... 5-35
5.4.2.1 General Information about Processing....................................................................... 5-35
5.4.2.2 Using Each Signal Line............................................................................................... 5-37
[ 1 ] Command and Data Areas ............................................................................................ 5-37
[ 2 ] Strobe Signal (Input)...................................................................................................... 5-38
[ 3 ] Command Processing Complete (Output) .................................................................... 5-39
[ 4 ] Status Area .................................................................................................................... 5-40
5.4.3 I/O Commands Details .............................................................................................................. 5-41
5.4.3.1 List of I/O Commands ................................................................................................. 5-41
5.4.3.2 Program Operation Command (0001)........................................................................ 5-42
5.4.3.3 External Speed and Acceleration Setting (0010) ....................................................... 5-45
5.4.3.4 Error Read (0100)....................................................................................................... 5-46
5.4.3.5 Type I Variable Write (0101) ....................................................................................... 5-47
5.4.3.6 Type I Variable Read (0110) ....................................................................................... 5-48
5.4.3.7 Mode Switching (0111) ............................................................................................... 5-49
5.4.3.8 Robot Error Clear (1000) ............................................................................................ 5-50
5.4.3.9 I/O Write (1001) .......................................................................................................... 5-51
5.4.3.10 I/O Read (1010) .......................................................................................................... 5-52
5.4.4 Example of Using System I/O Signals in Standard Mode......................................................... 5-53
5.5 System I/O Signals Special Mode ........................................................................................... 5-57

5.5.1 Types and Functions of System Output Signals(Special Mode)............................................... 5-57
5.5.2 Usage of System Output Signals in the Special Mode ............................................................. 5-58
5.5.2.1 Robot Power ON Complete ........................................................................................ 5-58
5.5.2.2 Auto Mode (Output) .................................................................................................... 5-59
5.5.2.3 Servo ON (Output)...................................................................................................... 5-60
5.5.2.4 CAL Complete (Output) .............................................................................................. 5-61
5.5.2.5 External Mode (Output) .............................................................................................. 5-62
5.5.2.6 Teaching (Output) ....................................................................................................... 5-63
5.5.2.7 Program Start Reset (Output)..................................................................................... 5-64
5.5.2.8 Robot Running (Output).............................................................................................. 5-65
5.5.2.9 Single-Cycle End (Output).......................................................................................... 5-66
5.5.2.10 Normal CPU (Output) ................................................................................................. 5-67
5.5.2.11 Robot Error (Output) ................................................................................................... 5-68
5.5.2.12 Robot Warning (Output).............................................................................................. 5-69
5.5.2.13 Dead Battery Warning (Output) .................................................................................. 5-70
5.5.2.14 Error No. (Output) ....................................................................................................... 5-71
5.5.2.15 Continue Start Permitted (Output) .............................................................................. 5-72
5.5.3 Types and Functions of System Input Signals (Special Mode)................................................. 5-73
5.5.4 Usage of System Input Signals in Special Mode ...................................................................... 5-74
5.5.4.1 Enable Auto (Input)..................................................................................................... 5-74
5.5.4.2 Operation Preparation Start (Input) ............................................................................ 5-75
5.5.4.3 Program No. Select (Input)......................................................................................... 5-77
5.5.4.4 Program Start (Input) .................................................................................................. 5-79
5.5.4.5 Program Reset (Input) ................................................................................................ 5-85
5.5.4.6 Robot Stop (Input) ...................................................................................................... 5-87
5.5.4.7 Step Stop (All Tasks) (Input)....................................................................................... 5-88
5.5.4.8 Instantaneous Stop (All Tasks) (Input) ....................................................................... 5-89
5.5.4.9 Robot Error Clear (Input) ............................................................................................ 5-90
5.5.4.10 Interrupt Skip (Input) ................................................................................................... 5-91
5.5.4.11 Continue Start (Input) ................................................................................................. 5-92
5.5.5 Example of Using System I/O Signals in Special Mode ........................................................... 5-93
5.6 I/O Circuits and Connectors (PNP type) ................................................................................. 5-97

5.6.1 I/O Signal Connector Pin Layout ............................................................................................... 5-97
5.6.1.1 Connector Pin Layout Common to Both Modes......................................................... 5-97
5.6.1.2 Connector Pin Layout for Standard Mode .................................................................. 5-99
5.6.1.3 Connector Pin Layout for Special Mode................................................................... 5-101
5.6.2 Robot Controller I/O Circuits ................................................................................................... 5-103
5.6.2.1 User-Input, System-Input and Hand-Input Circuits .................................................. 5-103
5.6.2.2 Robot Stop Input and Enable Auto Input Circuits..................................................... 5-105
5.6.2.3 User-Output, System-Output, and Hand-Output Circuits......................................... 5-106
5.6.2.4 Emergency Stop Output Circuit ................................................................................ 5-109
5.6.2.5 I/O Power Connector ................................................................................................ 5-110
5.6.3 Precautions When Wiring the Robot Controller I/O Connectors............................................. 5-112
5.7 I/O Wiring.................................................................................................................................. 5-114

5.7.1 Multi-core Cables with Connectors.......................................................................................... 5-114
5.7.2 Wiring ................................................................................................................................. 5-115
5.1 General Information about the Interface

5.1.1 Standard Mode and Special Mode
The Robot Controller can be operated in two different modes – standard mode
and special mode. The default setting is standard mode. Determine and select
either mode before operating the Robot Controller.
In the standard mode, all of the advantages can be expected from the new
model Robot Controller by simultaneously running plural programs with
multitasking.
In the special mode, there are some restrictions on the use of new functions,
such as multitasking.
5.1.1.1 Switching Modes

Switch from one mode to the other using the teach pendant or the personal
computer teaching system.
Caution: The selected mode will not become valid until the power to the
Robot Controller is turned OFF and turned ON again, after the
change.
5-1
[ 1 ] Switching from the Teach Pendant
Follow the procedure below when switching from one mode to the other from the
teach pendant:
Press [F4 I/O] on the top screen.

4STEP 1
YR-UPJ3-B00
F6
The I/O Monitor window appears.
Press [F6 Aux.].

4STEP 2
YR-UPJ3-B00
F1
The Auxiliary Functions (I/O) window appears.
5-2
Press [F1 Set H/W].

4STEP 3 The I/O Hardware Settings window appears.
Using the jog dial or cursor keys, select the Allocation mode field.
4STEP 4
YR-UPJ3-B00
Special Special-DV
Special Special-DV
F5
Press [F5 Change.].

4STEP 5
YR-UPJ3-B00
Special
Special
The Change Parameter window appears.
5-3
Enter the number of the desired mode by pressing the corresponding
4STEP 6 number key, then press OK.
The modes and their numbers are shown in the table below.
Modes and Their Numbers
Allocation mode Number

Special mode 0
Standard mode 1
Press OK.
4STEP 7 YR-UPJ3-B00
The above system message appears, requesting you to restart the

controller.
Press OK.
4STEP 8 The screen returns to the Auxiliary Functions (I/O) window.
Turn the controller power OFF.

4STEP 9
Turn the controller power ON again.

4STEP 10 The I/O allocation mode is changed.
5-4
[ 2 ] Switching from the Personal Computer

Follow the procedure below when changing from one mode to the other from the
personal computer.
Start WINCAPSII on the personal computer. Log in with Programmer.

4STEP 1 Start WINCAPSII according to the procedure given in WINCAPSII GUIDE,
Chapter 3, Section 3.1.
For details on the user level of Programmer, refer to the WINCAPSII GUIDE,
Chapter 1, Section 1.3.
Click on the DIO Manager button in the System Manager.

4STEP 2
Start the DIO Manager and the DIO Manager window opens.
5-5
Select the SETTING command from the Tools menu of DIO Manager.
4STEP 3
The SETTING window appears.
Click on the Hardware tab in the Options window.

4STEP 4
Special
The hardware settings are displayed.
5-6
Double-click on the Allocation mode value setting field.

4STEP 5
Special
The Allocation mode value setting field is ready for entering.
Enter the number of the desired mode.

4STEP 6 The modes and their numbers are shown in the table below.
Modes and Their Corresponding Numbers
Allocation mode Number

Special mode 0
Standard mode 1
5-7
Click on OK in the setting window.
4STEP 7 The setting window closes.
Click on the Connect button to connect the personal computer to the

4STEP 8 Robot Controller.
The Connect button appears in a pressed state.
Click on the Transfer button.

4STEP 9 The Transfer Environment Table window appears.
5-8
Check off the check box by clicking on the Hard setting field.
4STEP 10
Click on the Transfer button.

4STEP 11
DioManager
A message window appears confirming that you are sure to update the
data.
5-9
Click on the Yes button.
4STEP 12
The Transmitting hard setting table window appears displaying a bar graph
that indicates the transfer progress.
After the Transmitting hard setting table window disappears from the
4STEP 13 screen, set the power switch of the Robot Controller to OFF.
Set the power switch of the Robot Controller to ON.

4STEP 14 The I/O allocation mode is changed.
5-10
5.1.2 Robot Controller Appearance and Connector Names

Figure 5-1 shows the appearance of the Robot Controller and Table 5-1 shows
the connector names.
<Front>
Floppy disk drive (option)
FG terminal
Robot stop button
Memory back-up battery holder
Pilot lamp
Fuse box
Transistor array box Power switch
<Left side> <Right side>
Exhaust air filters Radiating fin

Air intake filters
Figure 5-1 Robot Controller Appearance
Table 5-1 Connector Names
No. Mark Name No. Mark Name
CN1 RS232C Serial Communication Connector CN7 I/O POWER I/O Power Connector
CN2 CRT CRT Connector CN8 INPUT User-input/System-input Connector
CN3 KEYBD Keyboard Connector CN9 HAND I/O End-effector I/O Connector
CN4 MOUSE PS/2 Mouse Connector CN10 OUTPUT User-output/System-output Connector
CN5 PENDANT Teach Pendant Connector CN11 INPUT AC Power Connector
CN6 PRINTER Printer Connector CN12 MOTOR Motor Connector
CN13 ENCODER Encoder Connector
Caution: The Robot Controller connectors have a screw or ring locking

mechanism. Lock them securely. If not securely locked, an incomplete
contact may occur, resulting in an error.
Engaging or disengaging the power connector or motor connector with
the power switch of the Robot Controller ON may damage the internal
circuit of the connector. Turn OFF the power switch before engaging or
disengaging any of the connectors.
5-11
5.1.3 Example of Control System Configuration
Figure 5-2 shows an example of the control system configuration.
Robot body
Motor
Encoder (Directly controlled
from the robot)
CN12
Solenoid valve, relay
CN13
Teach
pendant CN9 I/O Connect the
following
CN5 Robot controller if necessary.
Power
Operating CN7 source
panel (24V)
CN1
Visual
device
CN10 CN8 RS232C

Printer
Personal
computer
PLC
Equipment Power
operation source
panel (24V)
Solenoid valve, relay, motor, etc.
Photoelectric switch,
proximity switch, etc.
Figure 5-2 System Configuration Example
5-12
5.1.4 Types and General Information about I/O Signals

This section describes the I/O signals for the Robot Controller.
The I/O signals are grouped into user I/O signals and system I/O signals.
Note that the connector pin meanings are different between standard mode and
compatible mode. Some of the signal lines used for user I/O in special mode are
used for system input in standard mode.
Additionally, part of the signal lines used for system I/O in special mode is used
for command execution I/O signals in standard mode.
5.1.4.1 Standard Mode

In standard mode, 30 input points for command execution are used to direct
program start and other instructions as I/O commands.
Table 5-2 shows the types of I/O signals used in standard mode.
Table 5-2 Types of System I/O Signals Used in Standard Mode
Fixed by system
No. of
Type Function
points
Robot stop, Enable Auto, interrupt skip, instantaneous stop (all tasks),
System input 5
step stop (all tasks)
Normal CPU, robot initialization complete, robot in operation, robot error,

robot warning, automatic operation mode, servo ON, dead battery
System output 12
warning, external mode, continue start permitted, emergency stop, SS
mode
Input for command Command (4 bits) data area 1 (8 bits), data area 2 (16 bits), odd parity bit,
30
execution strobe signal
Output for command

18 Command processing complete, status area (16 bits), odd parity bit
execution
Controlled by user program
No. of
Type Function
points
Inputs to read the external I/O status with an IN command or IO [ ]

variable.
User input 12
Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.
Outputs to issue a signal to the external device during program execution

User output 24
with a SET command, RESET command, etc.
Inputs to read the external I/O status with an IN command or IO [ ]
Hand input 8 variable.
Used to confirm the end-effector check status, etc.
Outputs to issue a signal to the external device with a SET command,
Hand output 8 RESET command, etc.
Used to control the opening and closing of the end-effector.
5-13
5.1.4.2 Special Mode
Table 5-3 shows the types of I/O signals used in special mode.
Table 5-3 Types of I/O Signals Used in Special Mode
Fixed by system
No. of
Type Function
points
Inputs to turn ON the power to the robot from the external device (PLC), or
System input 22 select and start a program instead of operations by the operating panel or
teach pendant.
Outputs to inform the external device (PLC) of the robot status, such as the
System output 27
robot in operation or the occurrence of an error.
Controlled by user program
No. of
Type Function
points
Inputs to read the external I/O status with an IN command or IO [ ] variable.

User input 25 Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.
Outputs to issue a signal to the external device during program execution

User output 24
with a SET command, RESET command, etc.
Inputs to read the external I/O status with an IN command or IO [ ] variable.

Hand input 8
Used to confirm the end-effector check status, etc.
Outputs to issue a signal to the external device (valve) with a SET
Hand output 8 command, RESET command, etc.
Used to control the opening and closing of the end-effector.
5-14
5.2 Using User I/O Signals

To use user I/O signals you need to first declare, in the program, the use of user
I/O as I/O type variables with a DEFIO command. Next, access the user I/O by
writing it to the I/O type variables or reading it.
5.2.1 I/O Type Variable Declaration

I/O type variables are classified into I/O type global variables that are available
without any declaration, and I/O type local variables that are not available
without a declaration.
5.2.1.1 I/O Type Global Variables

I/O type global variables are used to refer to or change user I/O signals bit by bit.
Since they are global variables, they can be used without any declaration.
I/O type global variables are expressed in either of the following two ways:
IO[nn] (nn: terminal number) Example: IO[104]
IOnn (nn: terminal number) Example: IO104
5.2.1.2 I/O Type Local Variables

I/O type local variables are used to collectively refer to or change 1-bit, 8-bit,
16-bit or 32-bit user I/O signals starting from a specified terminal number.
I/O type local variables require a declaration, which will be made with a DEFIO
command, before they are used. For further information about declarations with
a DEFIO command, refer to the PROGRAMMER'S MANUAL, Chapter 9,
Section 9.7 "DEFIO (Statement) [Conforms to SLIM]."
5.2.2 User Input Commands

There are two types of user input commands, IN and WAIT. The IN command
substitutes the input result for a variable. The WAIT command waits until the
input result meets specified conditions.
5.2.2.1 IN Command
The IN command inputs a signal from the user input specified by an IO type
variable and substitutes it for an arithmetic variable.
For further information about the IN command, refer to the PROGRAMMER'S
MANUAL, Chapter 13, Section 13.1 "IN."
5.2.2.2 WAIT Command

The WAIT command suspends the execution of the program until specified
conditions are met. If an I/O type variable is used for the conditional statement,
this command suspends the execution of the program until the status of the
signal from a specified user input is checked and meets the specified conditions.
For further information about the WAIT command, refer to the
PROGRAMMER'S MANUAL, Chapter 12, Section 12.5 "WAIT."
5-15
5.2.3 User Output Commands
There are three types of user output commands, SET, RESET and OUT. The
SET and RESET commands turn ON and OFF all user outputs specified by I/O
type variables. The OUT command outputs data to a specified user output.
5.2.3.1 SET Command

The SET command turns ON all user outputs specified by I/O type variables.
For further information about the SET command, refer to the PROGRAMMER'S
MANUAL, Chapter 13, Section 13.1 "SET."
5.2.3.2 RESET Command

The RESET command turns OFF all user outputs specified by I/O type variables.
For further information about the RESET command, refer to the
PROGRAMMER'S MANUAL, Chapter 13, Section 13.1 "RESET."
5.2.3.3 OUT Command

The OUT command outputs data to the user output specified by an I/O type
variable.
For further information about the OUT command, refer to the PROGRAMMER'S
MANUAL, Chapter 13, Section 13.1 "OUT."
5-16
5.3 System I/O Signals Standard Mode

5.3.1 Types and Functions of System Output Signals (Standard
Mode)
Table 5-4 shows the system output signals used in standard mode.
Table 5-4 Types and Functions of System Output Signals to be Used in Standard Mode
Application Signal name Function
Robot initialization Outputs when preparations for operation are ready to

complete start.
Auto mode Outputs when the robot is in Auto mode.
Start-up External mode Outputs when the robot is in external mode.
Servo ON Outputs when the power to the motor is turned ON.
Continue start
Outputs when Continue Start is enabled.
permitted
Outputs when the robot is in operation (the program is

Program execution Robot in operation
being executed).
Outputs when the CPU (hardware) of the Robot
Normal CPU
Controller is normal.
Outputs when a serious error, such as a servo error
Robot error
and a program error, occurs.
Robot warning Outputs when a slight error occurs.

Error/Warning
Dead battery Outputs when the voltage of the encoder back-up
warning battery or memory back-up battery dangerously low.
Outputs when the robot is in SS mode. Refer to the
SS mode SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6
"SS (Safe Start) Function."
5-17
5.3.2 Usage of System Output Signals (Standard Mode)
The usage of each system output signal in standard mode is described below:
5.3.2.1 Robot Initialization Complete (Output)

(1) Function
The signal outputs to the external device that a MODE SWITCHING
COMMAND is ready to execute from the device.
(2) Terminal number

No.5 of connector CN10.
(3) Usage
The "mode switching command" will be executed as soon as this signal and
the auto mode signal are turned ON, after the power is turned ON.
(4) ON conditions
c The signal will be turned ON when the system program for the Robot
Controller normally starts, after the power, is turned ON and the mode
switching command is ready to execute.
d The signal will be turned ON when a robot error is cleared by the CANCEL
key of the operating panel or teach pendant or by a ROBOT ERROR
CLEAR COMMAND, after the power is turned OFF.
(5) OFF condition
The signal will be turned OFF when a robot error or robot warning signal is
turned ON.
⋅ A robot error is cleared with the OK or CANCEL

key of the operating panel or teach pendant.
⋅ The system properly started to ⋅ A robot error is cleared with a ROBOT ERROR
operate after the power was CLEAR COMMAND from an external device.
turned ON.
ROBOT
FORMAT output
⋅ Robot error or robot warning
Figure 5-3 Robot Format Output
5-18
5.3.2.2 Auto Mode (Output)

(1) Function
The signal outputs to the external device that the robot is in auto mode.
(2) Terminal number

(3) Usage
Starting the program from the external device requires an EXTERNAL
MODE SWITCHING BY MODE SWITCHING COMMAND input and a
PROGRAM START BY PROGRAM OPERATION COMMAND input. The
signal is used to monitor the auto mode output signal and determine whether
to execute the command.
(4) ON condition
The signal will be output when the robot enters auto mode by setting the
mode selector switch of the operating panel or teach pendant to AUTO.
(5) OFF conditions

The signal will be turned OFF under the following conditions.
c The mode selector switch of the operating panel is set to MANUAL or the
teach pendant is set to MANUAL or TEACH CHECK.
d The Enable Auto OFF is input..
(Note: The signal will not be turned OFF in the pendantless state
described in Chapter 3, Subsection 3.2.3, "[ 3 ] Pendantless State.")
Caution: The signal will not be turned OFF with INSTANTANEOUS STOP,
STEP STOP or CYCLE STOP commands.
⋅ When the mode selector switch of the operating panel or teach

pendant is set to AUTO.
Auto mode
output
⋅ When the mode selector switch of the operating panel is set

to MANUAL or that of the teach pendant is set to MANUAL
or TEACH CHECK.
⋅ When Enable Auto OFF is input
Figure 5-4 Auto mode Output
5-19
5.3.2.3 External Mode (Output)
(1) Function
The signal outputs to the external device that the robot is in external mode.
(2) Terminal number

(3) Usage
Starting the program from the external device requires an EXTERNAL
MODE SWITCHING BY MODE SWITCHING COMMAND input and a
PROGRAM START BY PROGRAM OPERATION COMMAND input. The
signal is used to confirm that the robot is in external mode.
(4) ON conditions
c The signal will be turned ON under the following conditions.
The external mode is selected on the teach pendant.
d The EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL ON state.
e The EXTERNAL MODE SWITCHING BY MODE SWITCHING
COMMAND is input from the external device.
(5) OFF conditions
The signal will be turned ON under the following conditions.
c When internal mode is selected on the teach pendant.
d When the mode selector switch of the teach pendant is set to MANUAL or
TEACH CHECK in external mode.
e When EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL OFF state.
f When ROBOT STOP is input.
g When ROBOT ERROR is output.
STEP STOP or CYCLE STOP.
h When an Enable Auto input is turned OFF.
⋅ When the mode is switched to external mode on the teach pendant.

⋅ When EXTERNAL/INTERNAL is input on the operating panel.
⋅ When a MODE SWITCHING COMMAND (EXTERNAL MODE SWITCHING)
is input from an external device.
External mode
output
⋅ When internal mode is selected on the teach pendant.

⋅ When the mode selector switch of the teaching pendant is set to
MANUAL or TEACH CHECK.
⋅ When EXTERNAL/INTERNAL is input on the operating panel.
⋅ ROBOT STOP or ROBOT ERROR
⋅ When an Enable Auto input is turned OFF.
Figure 5-5 External Mode Output
5-20
5.3.2.4 Servo ON (Output)

(1) Function
The signal outputs to the external device that the power to the motor of the
robot is turned ON.
(2) Terminal number

(3) Usage
Starting the program requires the power to the motor to be turned ON. This
signal is used to light the motor power ON indicator lamp on an external
operating panel.
(4) ON conditions
The signal will be turned ON when the power to the motor is turned ON.
c When the MOTOR key of the operating panel or teach pendant is
activated; or
d When the motor runs with a MOTOR ON AND CAL EXECUTION BY
MODE SWITCHING COMMAND input from the external device.
(5) OFF conditions
The signal will be turned OFF when the power to the motor is turned OFF.
c When the MOTOR key of the operating panel or teach pendant is
deactivated and the ROBOT STOP button is operated;
d When ROBOT STOP is input from the external device; or
e When a ROBOT ERROR is output. If errors 0 × 6071 to 607B, 0 × 6671 to
667B, 0 × 607F occur, the servo will be turned OFF in automatic or
external mode but will not be turned OFF in the manual or the teach check
mode.
⋅ When the MOTOR key of the operating panel or teach pendant is activated.
⋅ When MOTOR ON AND CAL EXECUTION WITH MODE SWITCHING
COMMAND is input from an external device.
ON
Servo ON output OFF
⋅ When the MOTOR key of the operating panel or teach pendant is

deactivated and the ROBOT STOP button is operated.
⋅ When ROBOT STOP is input from an external device.
⋅ When a ROBOT ERROR occurs.
Figure 5-6 Servo ON Output
5-21
5.3.2.5 Robot in Operation (Output)
(1) Function
This signal outputs to the external device that the robot is in operation.
(2) Terminal number

(3) Usage
The signal is used to light the robot operating indicator lamp of an external
operating panel.
Since the signal is turned OFF with STOP ALL PROGRAMS, outputs to the
external device that all programs are stopped.
(4) ON conditions
The signal will be turned ON during execution of the program and also while
in the WAIT STATE with a condition branch or timer command.
(5) OFF conditions

The signal will be turned OFF with STOP ALL PROGRAMS.
Caution: STOP ALL PROGRAMS means the operation of the ROBOT

STOP or STOP button of the operating panel or teach pendant
and INSTANTANEOUS STOP (ALL TASKS), STEP STOP (ALL
TASKS) and ROBOT STOP inputs.
5-22
5.3.2.6 Normal CPU (Output)

(1) Function
The signal outputs to the external device that the Robot Controller CPU
(hardware) is normal.
(2) Terminal number

(3) Usage
c The signal is used to light the Robot Controller external operating panel
error indicator lamp.
d The signal is used when a normal CPU SIGNAL is turned OFF because
of an error and the PLC corrects it.
(4) ON conditions
The signal will be turned ON by the hardware when the Robot Controller
CPU operates normally with the power turned ON.
(5) OFF conditions

The signal will be turned OFF by the hardware when the CPU does not
operate normally.
Caution: The OFF state of this signal indicates that the Robot Controller
internal arithmetic circuit may be damaged. Therefore, ROBOT
ERROR, ERROR NUMBER, and other outputs may not be
correct.
⋅ Power ON (CPU operating properly)
Normal CPU output
Abnormal CPU (hardware error)
Figure 5-7 Normal CPU Output
5-23
5.3.2.7 Robot Error (Output)
(1) Function
The signal outputs to the external device that a problem, such as a servo
error or a program error, occurs with the robot.
(2) Terminal number

(3) Usage
c The signal is used to light the robot external operating panel error
indicator lamp of an.
d The signal is used to help the PLC clear an error in response to a
ROBOT ERROR signal.
(4) ON conditions
As shown in Figure 5-8, the signal will be turned ON under the following
conditions.
c When an error, such as a servo error, a program error or program
undefined, occurs at the start of the program and during execution of the
program.
d When an error occurs during execution of the program in internal
operation by the operating panel or the teach pendant or in external
operation by the PLC.
Caution: The signal will not be output when an error, such as a program
input error occurs in manual operation, except when a servo
error occurs in manual operation. For further information, see
the "ERROR CODE TABLES."
(5) OFF conditions

As shown in Figure 5-8, the signal will be turned OFF under the following
conditions.
c When a ROBOT ERROR CLEAR COMMAND is input and the existing
error is cleared.
d When the existing error is cleared by operating the OK or Cancel key on
the operating panel or the teach pendant.
⋅ Program number, parity error, or undefined program number, at

パリティーエラー、
external start.
⋅ Robot error during automatic operation (bot h internal operation
and external operation)
Robot error
⋅ When a ROBOT ERROR CLEAR COMMAND is input.

⋅ When the OK or Cancel key of the operating panel or teach
pendant is operated.
Figure 5-8 Robot Error Output
5-24
5.3.2.8 Robot Warning (Output)

(1) Function
The signal outputs to the external device that a minor error occurs with an
I/O command or during servo processing.
Caution: The signal will not be output if a minor error, such as a program
selection error caused by the operation of the teach pendant or
operating panel.
(2) Terminal number
(3) Usage
⋅ The signal is used to light the robot warning indicator lamp of the external
operating panel.
⋅ The signal is used to help the PLC clear an error in response to a ROBOT
WARNING signal.
(4) ON condition
As shown in Figure 5-9, the signal will be turned ON if a minor error occurs
during I/O processing, execution of the program or servo processing,
irrespective of the operation mode.
(5) OFF conditions
As shown in Figure 5-9, the robot-warning signal will be turned OFF under
the following conditions.
⋅ When a ROBOT ERROR CLEAR COMMAND is input from the external
device and the existing error is cleared.
⋅ When operating the OK or Cancel key on the operating panel or the teach
pendant clears the existing error.
⋅ When a slight error occurs during I/O processing, execution of the

program or servo processing.
Robot warning
⋅ When a ROBOT ERROR CLEAR COMMAND is input from an external

device and the existing error is cleared .
⋅ When the existing error is cleared by operating the OK or Cancel key
of the operating panel or teach pendant.
Figure 5-9 Robot Warning Output
5-25
5.3.2.9 Dead Battery Warning (Output)
(1) Function
The signal will be output when the voltage of the encoder back-up battery or
memory back-up battery becomes lower than acceptable.
(2) Terminal number

(3) Usage
The signal is used to check the timing battery replacement. For example,
the battery voltage becomes lower than acceptable.
(4) ON condition
The signal will be turned ON when the voltage of the encoder back-up
battery or memory back-up battery becomes lower than acceptable.
Caution: The operating panel shows any of ERROR64A1 to 64A6 when

the encoder back-up battery voltage is low. Meanwhile, the
teach pendant shows ERROR6103 when the memory back-up
battery voltage is low.
(Refer to Chapter 6, Section 6.4, "Biennial Inspections.")
(5) OFF condition

The signal will be turned OFF when the power is turned ON after the dead
battery was replaced.
Power ON Power OFF Power ON Power OFF Power ON

Robot power ON state
⋅ The voltage of the

encoder backup
battery or memory
back-up battery
becomes dangerously
low.
Dead battery
warning output
⋅ Battery replaced
Figure 5-10 Dead Battery Warning Output
5-26
5.3.2.10 Continue Start Permitted (Output)

(1) Function
The controller will output this signal when the continue start is permitted.
(2) Terminal number

(3) Usage
Use this signal when you want to know whether the continue start is
permitted.
(4) ON condition
This signal comes on when the continue start is permitted. For details, refer
to the SETTING-UP MANUAL.
(5) OFF condition

This signal goes off by carrying out the "Task Status Change Operation."
5.3.3 Types and Functions of System Input Signals (Standard

Mode)
Table 5-5 shows the system input signals to be used in standard mode:
Table 5-5 Types and Functions of System Input Signals to be Used in Standard Mode
Application Signal Name Function
Start-up Enable Auto Enables switching to automatic operation.
Robot stop Stops the robot with canceling signals.
Instantaneous Immediately stops all programs being executed with

Stop
stop (all tasks) canceling signals.
Step stop (all Step-stops all programs being executed with canceling
tasks) signals.
Interrupts the execution of the current step and starts

Program interrupt Interrupt skip
executing the next step.
5-27
5.3.4 Usage of System Input Signals (Standard Mode)
The usage of each system input signal in standard mode is described below.
5.3.4.1 Enable Auto (Input)

(1) Function
c The signal enables switching of the robot mode to auto mode (shorted
state).
d The signal enables switching of the robot mode to manual mode or teach
check mode (open state).
(2) Terminal number
(3) Usage
The signal is used for the AUTO/TEACHING selector switch of an external
operating panel and can be combined with a safety fence switch.
(4) Input conditions and operation

c As shown in Table 5-6, the selectable operation mode depends on
whether this input is shorted or open.
d If the input becomes open during automatic operation, the mode will be
switched to manual mode and ERROR21FC will be displayed.
e If manual operation or a teach check is conducted with this input shorted,
ERROR21F2 will be displayed.
f If the mode selector switch of the teach pendant or operating panel is set
to AUTO with this input open, ERROR21F3 will be displayed.
Since this state is shown as × in Table 5-5, this error will remain
displayed until the robot exits this state.
g Although ERROR21FD or ERROR21FC will be displayed when the state
is changed from { to ∆ or ×, they will not be displayed when the state is
changed from ∆ or × to {.
h When the input is turned OFF (open) in external mode, the external
mode output will also be turned OFF.
Table 5-6 Relationship Between Enable Auto Input and Selectable Mode
Enable Auto
Operation mode Application
ON (shorted) OFF (open)
Manual operation with the operating panel or the teach
Manual mode ∆ {
pendant.
Teach check mode Program check with the teach pendant. ∆ {
Automatic operation with the operating panel or teach
Internal auto mode { ×
pendant.
External auto mode Automatic operation with the external device. { ×
Note: { = Mode selectable × = Mode not selectable
∆ = Mode selectable but manual operation program not executable
Caution: In the pendantless state described in Chapter 2, Subsect. 3.2.3 [ 3 ], auto

mode is valid even if the Enable Auto input is open. (The external mode
cannot be switched and the program cannot begin execution.)
Perform the following when operating the robot in the pendantless state:
c Set the robot so that it will not start to operate when the Enable Auto
input is open.
d Enable Auto input open state and auto mode output (See "5.3.2.2
Auto mode" and "5.5.2.2 "Auto Mode".)
Add c and d with the external sequence circuit.
5-28
5.3.4.2 Robot Stop (Input)

(1) Function
c The signal stops the robot from the external device by opening the robot
stop input.
d The signal readies the power to the robot motor to be turned ON by
shorting the robot stop input.
(2) Terminal number


c The robot stops with this input OFF (open).
d The power to the robot motor is made ready to be turned ON with this
input ON (shorted).
e Irrespective of whether internal mode, operation by the teach pendant, or
external mode, remote operation by the external device, is selected, the
power to the robot motor cannot be turned ON with this input OFF (open)
and neither manual nor automatic operation can be performed until this
input is turned ON (shorted). (ERROR2008 will be displayed.)
f By turning OFF (open) this input the following conditions may result.
1) The power to the motor will be turned OFF irrespective of whether
manual, automatic, internal or external mode is selected.
2) During execution of the program, robot in operation output ON, the
power to the motor will be turned OFF and the mode will be switched
to internal mode after the robot decelerates to a stop;
3) When the program is not executed in manual and auto modes in
manual and auto modes, everything will be the same except the
power to the motor will be turned OFF. The power to the motor can be
turned ON and the suspended operation can, therefore, be resumed
by shorting the ROBOT STOP input. (However, the program will be
executed from the beginning.)
g Opening the ROBOT STOP input and pressing the ROBOT STOP
button of the operating panel or the teach pendant function is the same.
(4) Timing of the input

This input will be processed prior to all commands and input signals.
5-29
5.3.4.3 Step Stop (All Tasks) (Input)
(1) Function
Input this signal to step-stop the program being executed from the external
device. All tasks will be step-stopped.
(2) Terminal

c If the state of this signal is changed from ON (shorted) to OFF (open), the
robot will stop all tasks as soon as the ongoing step is completed, and
the robot in operation output will be turned OFF. However, auto mode or
external mode will remain valid, and the suspended program will be
resumed by inputting a program operation command (start). See Figure
5-11.
d For resuming the program after a step stop, see Chapter 5, "5.5.4.4
Program Start (Input)".
Robot status
1-cycle operation
Operating halfway At step-stop Performing

Remaining operation
Program start signal (input) ON (shorted)

OFF (open)
Step-stop signal (input) ON (shorted)

OFF (open)
Robot in operation (output) ON (shorted)

OFF (open)
Figure 5-11 Step Stop Signal
5-30
5.3.4.4 Instantaneous Stop (All Tasks) (Input)

(1) Function
Input this signal to instantaneously stop the running programs from an
external device. All tasks will stop.
(2) Terminal number


c If the state of this signal is turned from ON (shorted) to OFF (open), the
robot will immediately stop in the middle of the ongoing step, and the
robot in operation output will be turned OFF. However, auto mode or
external mode will remain valid, and the suspended programs will be
resumed by inputting Program start signal.
d For resuming the program after an instantaneous stop, see Chapter 5,
"5.4.3.2 Program Operation Command (0001)".
e The minimum required pulse width is 50 milliseconds (msec.) or more.
ON (shorted)
Halt OFF (open)

50 ms. or more required
Figure 5-12 Minimum Instantaneous Stop Pulse Width
5-31
5.3.4.5 Interrupt Skip (Input)
(1) Function
If this signal is turned ON (shorted) during execution of the robot operation
command, within the range between INTERRUPT ON and INTERRUPT
OFF in the program, the correct step operation will immediately stop and the
next step will start.
Caution: For further information about the INTERRUPT ON and OFF

commands, see the PROGRAMMER'S MANUAL, Chapter 12,
"12.3 INTERRUPT ON/OFF (Statement)."
For further information about the robot operation command,
see the PROGRAMMER'S MANUAL, Chapter 12, "Robot Control
Statements."
(2) Terminal number

(3) Usage
See the PROGRAMMER'S MANUAL, Chapter 12, "12.3 INTERRUPT
ON/OFF."

If this signal is turned ON (shorted), the robot will immediately stop the
current operation and start executing the next step.
INTERRUPT ON
Command Operating halfway Next operation
Robot status
Interrupt skip signal (input) ON (shorted)

OFF (open)
Figure 5-13 Input Conditions and Operation of Interrupt Skip
5-32
Caution: When turning ON (shorting) the interrupt skip signal, at a

minimum either the program reset signal or the program
start signal must be turned OFF (open). If the interrupt
skip signal is turned ON, the robot interprets the program
start signal as immediately turned OFF (open).
Consequently, the program selected with the program No.
selection signal will be executed from the beginning. (See
Figure 5-14 below.)
Robot status Executing cycle halfway Executing cycle from beginning
Interrupt skip signal (input) ON (shorted)

OFF (open)

OFF (open)
Program reset signal (input) ON (shorted)

WRONG
OFF (open)
Program No. select signal (input) ON (shorted)

OFF (open)
Figure 5-14 Example of Operation When an Interrupt Skip is Input
5-33
5.4 Command Execution I/O Signals
Dedicated to Standard Mode
In standard mode the I/O commands can be executed using command
execution I/O signals. I/O commands execute the following.
⋅ Operate (start and stop) a program for each task.
⋅ Refer to or change variables from the external device.
⋅ Refer to or change inputs and outputs from the external device.
5.4.1 General Information about Commands

Table 5-7 shows the I/O commands functions.
Table 5-7 I/O Command Functions
Command Description of function

⋅ Starts the program cycle (specified program).
⋅ Step-stops the program (specified program/all programs).
Program operation
⋅ Immediately stops the program (specified program/all programs).
⋅ Resets the program (specified program/all programs).
⋅ Sets the external speed.
Speed setting ⋅ Sets the external acceleration.
⋅ Sets the external deceleration.
Error number read ⋅ Outputs the error number to the system I/O area.
Type I variable write ⋅ Reads a value from the system I/O area and substitutes it for a
Type I variable.
Type I variable read ⋅ Outputs a Type I variable to the system I/O area.
Mode switching ⋅ Switches the robot operation mode.
Robot error clear ⋅ Clears a robot error from the external device.
Internal I/O write ⋅ Sets the state of internal inputs and outputs.
Internal I/O read ⋅ Outputs the state of internal inputs and outputs to the system I/O
area.
5-34
5.4.2 Processing I/O Commands
5.4.2.1 General Information about Processing

I/O commands to be executed are processed as shown in Figure 5-15.
⋅ Command Area (input)

c j
⋅ Data Area (input)
⋅ Command and Data Area
Odd Parity (input) e
⋅ Strobe Signal (input) d
Note c 1 ms or more k
⋅ Status Area (output)
⋅ Status Parity (output)
⋅ Command processing complete (output) h
Note f 100 ms. or less

⋅ Robot Error (output) h
Figure 5-15 Outline of I/O Command Processing
5-35
c Set a command area, a data area (if necessary) and command and data
area odd parity for the command execution I/O signal from the external
device to the Robot Controller.
d After the setting is completed, turn ON the strobe signal.
Caution: c The data to be set in c must be defined more at least 1 msec.

before the strobe signal is turned ON.
d Perform command input with a strobe signal after the
system output signal ROBOT INITIALIZATION COMPLETE is
output.
e The controller reads the command area, the data area and the command
and data area odd parity as the strobe signal is input.
f The controller starts processing based on the command it read.
g If the command is one that outputs a status, the controller sets the status
area and status parity.
h After command processing has been completed and a status area has been
set, the controller turns ON the command processing complete signal.
If an error occurs in the while processing, a robot error signal will be output
together with the command processing complete signal.
i The PLC waits until the command processing complete signal is input, and
receives the status of the status area, if necessary. In this case, confirmation
that no error exists with the robot.
j After the PLC has read the status, it turns OFF the command and data areas
and the strobe signal.
k As soon as the strobe signal is turned OFF, the controller turns OFF the
status area and the command processing complete signal.
The robot error signal, which is output due to a command processing error,
remains ON until a robot error clear command is executed.
Caution: e The maximum time taken until the status area and the
command processing complete signal are turned OFF, after
the strobe signal is turned OFF in j, is 100 msec.
f If the strobe signal is turned OFF before the command
processing complete signal is turned ON in h, the command
processing complete signal and the status area will be
output and then turned OFF within 100 msec.
5-36
5.4.2.2 Using Each Signal Line
[ 1 ] Command and Data Areas

This section describes the usage of the command area (4 bits, input), data area
1 (8 bits, input), data area 2 (16 bits, input) and command and data area odd
parity (input).
(1) Function
Specifies the commands to be executed by the Robot Controller.
Sets the command area at all times, and data areas 1 and 2, if necessary.
(2) Terminal numbers

Command area: No.35 to No.38 of connector CN8.
Data area 1: No.11 to No.18 of connector CN8.
Data area 2: No.19 to No.34 of connector CN8.
Command and data area odd parity: No.10 of connector CN8.

c Set the command area whenever I/O commands are to be executed.
Set data for data areas 1 and 2 if commands require them.
d "Shorted" represents the bit value = 1.
"Open" represents the bit value = 0.
"Parity bit " is odd parity.
e Input the command area, data areas 1 and 2, and command and data
area odd parity before the strobe signal (1 msec. or more). Retain the
status until the command processing complete signal is output.
f Input 1 or 0 as the parity bit so that the total of 1s existing in the
command area, data areas 1 and 2 and the command and data area odd
parity will be odd
The data areas count even commands, which do not require any data
area, in a check sum calculation.
g Checksum can be set valid or invalid using a parameter. When
checksum is invalid, no checksum check will be performed.
5-37
[ 2 ] Strobe Signal (Input)
(1) Function
This signal informs the Robot Controller that the command area, data areas
1 and 2, and the command and data area odd parity bit have been set.
Additionally it directs the start of command processing.
Caution: Perform command input with a strobe signal after the system
output signal ROBOT INITIALIZATION COMPLETE is output.
(2) Terminal number


c By turning ON this input in automatic or external mode, the Robot
Controller reads the command area, data areas 1 and 2, and the
command and data area odd parity bit starts processing.
d Retain the status until a command processing complete signal is output
and the necessary status data is read. If the strobe signal is turned OFF
before a command processing complete signal is output, the status area
will not be output.
e By turning OFF this input after the status is read, the command
processing complete output, the status area and the status parity will be
turned OFF.
5-38
[ 3 ] Command Processing Complete (Output)
(1) Function
The signal outputs to the external device that I/O command processing is
completed.
(2) Terminal number

(3) Usage
The signal is used to confirm that I/O command processing is complete, or
as a timing signal for obtaining the result of I/O command processing.
(4) ON conditions
c The signal will be turned ON upon completion of processing the I/O
command given and determination of outputting the status area.
d If an error occurs as a result of executing an I/O command, the result will
not be output to the status area, but the robot error signal and the
command processing complete signal will be turned simultaneously ON.
(5) OFF conditions

c The signal will be turned OFF when the strobe signal is turned OFF.
d If the strobe signal is turned OFF, before command processing is
completed, the command processing complete signal will be output and
then turned OFF within 100 msec.
5-39
[ 4 ] Status Area
This section describes the usage of the status area (16 bits, output) and of
status area odd parity (output).
(1) Function
The signal outputs the result of I/O command processing to the external
device.

No.17 to No.32 of connector CN10.
(3) Usage
The signal is used to execute an I/O command and obtain the result of the
PLC.
(4) ON conditions
c When processing of the I/O given is completed, the status corresponding
to the command will be set.
d "ON" represents the bit value = 1.
"OFF" represents the bit value = 0.
"Parity bit" is odd parity.
e Input 1 or 0 as the parity bit so that the total of 1s existing in the
command area and status area parity will be odd.
The status area counts even commands, which do not require any data
area, in a parity calculation.
f Parity can be set valid or invalid with a parameter. When parity is invalid,
no parity check will be performed.
(5) OFF conditions

c The signal will be turned OFF when the strobe signal is turned OFF.
d If the strobe signal is turned OFF, before command processing is
completed, the status signal will be output and then turned OFF within
100 msec.
5-40
5.4.3 I/O Commands Details
5.4.3.1 List of I/O Commands

Table 5-8 shows a list of I/O commands.
Table 5-8 List of I/O Commands
Command area Data area 1 Data area 2 Status area

0001 00000001 Program reset start Program number 
Program operation 00000010 Program start Program number 
00000100 Continue start
00010000 Step stop Program number 
00100000 Instantaneous stop Program number 
01000000 Reset Program number 
0010 00000001 Speed setting Set speed value 
External speed and 00000010 Acceleration setting Set acceleration 
acceleration setting 00000100 Deceleration setting value 
Set deceleration
value
0100   Error
Error read number
0101 Type I variable number Set variable value 
Type I variable write (lower 16 bits)
0110 Type I variable number  Variable
Type I variable read value (lower
16 bits)
0111 00000001 Motor ON, CAL execution  
Mode switching 00000010 External speed 100
10000000 External mode switching
10000011 Execution of all above
(Motor ON→SP100→External)
1000   
Robot error clear
1001 Set I/O value First internal I/O port 
I/O write address
1010  First internal I/O port I/O
I/O read address
NOTE: In execution of Continue Start command, program

numbers will be ignored.
5-41
5.4.3.2 Program Operation Command (0001)
(1) Function
This command controls the operating state of the program specified in data
area 2 based on the setting of data area 1.
(2) Format
Command area (4 bits, input)
0001
Data area 1 (8 bits, input)

00000001: Program reset start
00000010: Program start
00000100: Continue start
00010000: Step stop
00100000: Instantaneous stop
01000000: Reset
An error (ERROR2032) will occur if data is other than the above is set.

Program number: Program number to start
When the number given in data area 2 is nn, the operating state of PR0nn
will be controlled as given in data area 1. If the program number is negative
in the case of a step stop, instantaneous stop or reset command, all
programs will stop or be reset. If the program number is negative with a
program reset start or program start command, ERROR73E4 will result.
Status area (16 bits, output)

Nothing will be output.
(3) Description
c Program reset start
This command is executable only in external mode. If executed in other
mode an error will occur.
This command initializes and starts the program of the program number
specified in data area 2. PRO0 to PRO32767 can be started.
If the program number specified in data area 2 is negative, an error
(ERROR73E4) will occur.
Either of the following operations takes place according to the operating
status of the program:
⋅ If the specified program is terminated (stopped), step-stopped or
immediately stopped, it will start from the beginning.
⋅ If the specified program is running, an error (ERROR21F5) will be
displayed, and the program will stop.
5-42
d Program start
This command is executable only in external mode. An error
(ERROR2032) will occur in other modes.
This command starts the program of the program number specified in
data area 2. PRO0 to PRO32767 can be started.
If the program number specified in data area 2 is negative, an error
(ERROR73e4) will occur.
One of the following operations takes place according to the operating
status of the program.
⋅ If the specified program is terminated (stopped), it will start from the
beginning.
⋅ If the specified program is step-stopped, it will resume from the step
following the suspended step.
⋅ If the specified program is immediately stopped, it will resume from
the step following the suspended step. When the program is
instantaneously stopped in while in execution of an operation
command, it will resume from the operation still undone.
⋅ If the specified program is running, an error (ERROR21F5) will be
displayed, and the program will stop.
e Continue start
This command is executable only in external mode when the Continue
Start Permitted signal is on. The data area will be ignored.
f Step stop
This command step-stops the program of the program number specified
in data area 2. PRO0 to PR032767 can be step-stopped.
If the program number specified in data area 2 is negative, all programs
being executed will step-stop.
immediately stopped, nothing will happen.
⋅ If the specified program is running, it will step-stop. If started after a
step stop, the stopped program will resume from the step following
the suspended step.
g Instantaneous top
This command immediately stops the program of the program number
specified in data area 2. PRO0 to PR032767 can be stopped
immediately.
being executed will step-stop.
status of the program:
immediately stopped, nothing will happen.
⋅ If the specified program is running, it will immediately stop. If started
after an instantaneous stop, the stopped program will resume from
the suspended step. If the program is immediately stopped in the
middle of execution of an operation command, it will resume, starting
from the last uncompleted operation.
5-43
h Reset
This command immediately stops and also initializes the program of the
program number specified in data area 2. PRO0 to PR032767 can be
stopped.
This command cannot be used together with the program start
command.
To start a step-stopped or cycle-stopped program from the beginning,
use the program reset start command.
being executed will be reset.
One of the following operations takes place according to the operating
⋅ When the specified program is terminated (stopped), nothing will
happen.
⋅ When the specified program is step-stopped or immediately stopped,
it will be initialized. The initialized program will resume from the
beginning.
⋅ When the specified program is running, it will immediately stop and
also be initialized. If started after an instantaneous stop, the stopped
program will resume from the beginning.
5-44
5.4.3.3 External Speed and Acceleration Setting (0010)

(1) Function
This command sets the external speed, acceleration and deceleration
values selected in data area 1 to the values specified in data area 2.
This command is executable only in external mode. An error will occur in
other modes.
(2) Format
0010

00000001: Speed setting
00000010: Acceleration setting
00000100: Deceleration setting
An error (ERROR2032) will occur if data other than the above is set.

Set values: Speed, acceleration and deceleration to be set
Enter any of the external speed, acceleration and deceleration values
specified in data area 1.
The values must be between 1 and 100. If they are out of this range, an
error (ERROR2003) will occur.

(3) Description
c Speed setting
The external speed is set to the value specified in data area 2. The value
must be between 1 and 100. An error (ERROR2003) will occur if the
value is out of this range.
The external acceleration and deceleration will be set simultaneously as
shown below by setting the external speed:
External acceleration and external deceleration = External speed^2/100
(minimum value: 1)
d Acceleration setting
The external acceleration is set to the value specified in data area 2. The
value must be between 1 and 100. An error (ERROR2003) will occur if
the value is out of this range.
e Deceleration setting
The external deceleration is set to the value specified in data area 2.
The value must be between 1 and 100. An error (ERROR2003) will occur
if the value is out of this range.
5-45
5.4.3.4 Error Read (0100)
(1) Function
This command outputs the existing error number to the status area.
This command is output to the status area only when the strobe signal
remains ON.
Caution: This command will not be output if a minor error occurs, such
as a program selection error, caused by the operation of the
teach pendant or the operating panel.
(2) Format
0100
Nothing will be input.
The existing error code will be output.
(3) Hexadecimal codes

Refer to Fig. 5-16.
×××× →0 ×{×{ → 5 {×{× →A

×××{ →1 ×{{× → 6 {×{{ → B
××{× →2 ×{{{ → 7 {{×× →C
××{{ →3 {××× →8 {{×{ → D
×{×× →4 {××{ → 8 {{{× → E {⋅⋅⋅ON
{{{{ → F ×⋅⋅⋅⋅OFF
Figure 5-16 Hexadecimal Codes
Figure 5-17 shows an example of error number output when ERROR6174

(overload error with the fourth axis) occurs.
Thousands of error No. Hundreds of error No. Tens of error No. Units of error No.
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
× { { × × × × { × { { { × { × ×
Terminal No.
(Connector CN10)
ERROR 6 1 7 4
Figure 5-17 Example of Error Number Output
(4) Description
If a command is executed when a robot error or the robot warning signal is
output, the error number, which caused the robot error or robot warning
signal to be output, will be output to the status area.
If no error exists after an error has been cleared, 0 will be output to the
status area. Also, when there is an error that does not output any robot error
or robot warning signal, 0 will be output.
5-46
5.4.3.5 Type I Variable Write (0101)

(1) Function
This command substitutes the value specified in data area 2 for the Type I
(integer type) global variable of the number specified in data area 1.
(2) Format
0101

The number of the Type I variable for which a value will be substituted. Any
number between I [0] and I [255] can be specified. When the input data in
data area 1 is nn, the value specified in data area 2 will be substituted for
the Type I variable I [nn].

The value to be substituted for the Type I variable specified in data area 1.
Any value between -32768 and 32767 can be set.

(3) Description
The value specified in data area 2 is substituted for the Type I variable
specified in data area 1.
Although the type I variable has a storage area of 32 bits, the 16-bit data in
data area 2 will be substituted for the lower 16 bits. Zero will be substituted
for the upper 16 bits of the Type I variable.
5-47
5.4.3.6 Type I Variable Read (0110)
(1) Function
This command outputs to the status area the value of the Type Ι (integer
type) global variable of the number specified in data area 1.
(2) Format
0110

The number of the Type I variable for which a value will be substituted. Any
number between I [0] and I [255] can be specified. When the input data in
data area 1 is nn, the value specified in data area 2 will be substituted for
the Type I variable I [nn].


The lower 16 bit value of the Type I variable specified in data area 1 will be
output.
(3) Description
The value of the Type I variable specified in data area 1 is output to the
status area.
Although the Type I variable has a storage area of 32 bits, the lower 16 bits
will be output to the status area.
Therefore, any value between -32768 and 32767 can be output properly.
However, if the value is out of this range, only the lower 16 bits of the data
will be output.
5-48
5.4.3.7 Mode Switching (0111)

(1) Function
This command switches the robot mode from the external device to prepare
the robot for operation.
This command is executable only in auto mode. An error will occur in other
modes. Before executing this command, select auto mode on the operating
panel or the teach pendant.
(2) Format
0111

Bit 0 (00000001): Motor ON
Bit 1 (00000010): External speed 100
Bit 7 (10000000): External mode switching
These bits can be set together to execute commands. When two or more
bits are set, commands will be executed one after another.
For example, when bits 0, 1 and 7 are set, motor ON, external speed 100
and external mode will be executed in this order.
If bits other than the above are set, an error will result.


(3) Description
This command is used for equipment using the robot to switch the operation
mode of the robot to external mode from the external device
The processing operations to be executed are specified by the bits set in
data area 1 and will be executed from bit 0 to bit 7.
c Motor ON (bit 0)
When this bit is set, the power to the Robot Controller motor will be
turned ON.
d External speed 100 (bit 1)
When this bit is set, the external speed, external acceleration and
external deceleration of the Robot Controller will be set to 100.
e External mode switching (bit 7)

When this bit is set, the mode of the Robot Controller will be switched
from automatic to external.
5-49
5.4.3.8 Robot Error Clear (1000)
(1) Function
This command clears a robot error that has occurred.
(2) Format
1000



(3) Description
If a robot error occurs, this command clears it. When there is no error, no
processing will take place
When an error is displayed, the same processing as when the OK or
Cancel key of the operating panel or the teach pendant is operated will be
performed.
5-50
5.4.3.9 I/O Write (1001)

(1) Function
This command substitutes the status specified in data area 1 for the 8-bit
internal I/O area starting from the number specified in data area 2.
(2) Format
1001

The status to be set will be specified in the internal I/O area starting from the
number specified in data area 2.

This is first number of the internal I/O (8-bit) area for which the status will be
substituted. The number can be set between 128 and 504. If the number is
out of this range, an error (ERROR2034) will occur.

(3) Description
This command substitutes the status specified in data area 1 for the 8-bit
internal I/O area starting from the number specified in data area 2.
5-51
5.4.3.10 I/O Read (1010)
(1) Function
This command outputs to the lower 8 bits of the status area the status of the
8-bit internal I/O area starting from the number specified in data area 2.
(2) Format
1010


This is the first number of the internal I/O (8-bit) area whose status will be
output. The number can be set between 128 and 504. If the number is out of
this range, an error (ERROR2034) will occur.

The status of the 8-bit internal I/O area starting from the number specified in
data area 2 will be output to the lower 8 bits of this area.
(3) Description
This command outputs to the lower 8 bits of the status area the status of the
8-bit internal I/O area starting from the number specified in data area 2.
Zero will be output to the upper 8 bits.
5-52
5.4.4 Example of Using System I/O Signals in Standard Mode

This section illustrates an example of starting and stopping the robot using
system I/O signals.
(1) Equipment example

Equipment, which makes the robot perform operations by operating an
external equipment operating panel connected to the Robot Controller
through a PLC as shown in Figure 5-18 and equipped with a display, lamps
and switches listed in Table 5-9.
Robot
Robot
Controller
PLC
Other Equipment
(Conveyor)
Operating Panel
Figure 5-18 Example of Equipment Using a Robot
5-53
Table 5-9 Example of Equipment Operating Panel Functions
Classificati
Part Application
on
Displays messages, such as ROBOT PREPARATION

Display Display OK.
c Automatic operation ⋅ Lights during automatic operation.

⋅ Turned OFF when the robot is not in automatic
indicator lamp operation.
Lamp d Robot external mode ⋅ Lights when the robot is in external mode.
indicator lamp ⋅ Turned OFF when the robot is not in external mode.
e Operation OK indicator ⋅ Lights when the Enable Auto signal is ON.

lamp ⋅ Turned OFF when the Enable Auto signal is OFF.
c Robot preparation button Starts the preparation of the robot.
d Automatic start button Starts the operation of the equipment.
Switch
e Cycle stop button Stops the equipment after a cycle of operations is
completed.
Automatic operation of the robot possible when
f Operation/Adjustment OPERATION is selected.
selector switch Manual operation or teach check of the robot possible
when ADJUSTMENT is selected.
Caution: Actual equipment requires emergency stop, interlock and other functions; however,
described here are the necessary functions.
(2) Outline of procedure

Described below is the outline of the procedure when using the equipment
taken as an example shown in Figure 5-18.
Follow steps c to e.
c Operation preparation start
After setting the MOTOR ON, CAL EXECUTION, EXTERNAL SPEED
100 and EXTERNAL MODE SWITCHING bits, execute the mode
switching command to bring the robot into external automatic operation
mode. This operation will be completed when the EXTERNAL MODE
output signal is turned ON.
d Automatic operation
Start the program by which the robot starts from the operation origin,
performs operations, and returns to the operation origin.
e Operation end
Terminate the day’s operations with a cycle stop, and turn OFF the
power.
(3) Start and stop procedure, and system I/O signals

Figures 5-19 and 5-20 show the relationship between the system I/O
signals and*
c The operations by the operator.
d The display on the equipment operating panel, processing by the PLC.
e The operation of the robot when starting and stopping the robot.
5-54
Operation by operator and display

Step on equipment operating panel
PLC processing Robot operation
Equipment power ON
Setting
operation/adjustment
Enable Auto ON (Internal processing)
selector switch to
operation
Operation OK indicator
lamp ON
Setting Mode selector

switch of the operating
panel or the teach

pendant to AUTO
(Note c)
Robot preparation Data area 1 input ON
button ON
Executing mode
Motor power ON
switching command
Executing CAL
Setting SP 100
Switching mode to
external mode
Robot external mode External mode ON

indicator lamp ON (Internal processing)
Moving robot arm close

d Operation start area check
to operation origin,
when external mode
indicator lamp is ON
and operation position
1 indicator lamp is OFF.
Robot operation origin Operation position 1 ON

indicator lamp ON (Internal processing)
Robot preparation OK When both are ON

display (Internal processing)
Figure 5-19 Start and Stop Procedure and System I/O Signals-1
(Continued on following page)
5-55
(Continued from preceding page)
Equipment’s Automatic Program No. Select ON
Regular operation
program is selected
and output to data
area 2.
e Automatic operation
Automatic Operation Executing Program Program start

indicator lamp ON Operation Command
(Program start)
END
Program No. select ON Robot running OFF
Regular operation
program is selected
and output to data
area 2.
Repeated
Program start ON
Equipment’s Cycle Cycle Stop ON Executing 1-cycle

Stop button ON
END
f Operation end
Automatic operation (Internal processing)

indicator lamp OFF Robot running OFF
Equipment power OFF
Note e: In data area 1, the bit to each of "motor ON, CAL execution," "external speed 100" and
"External Mode switching" will be turned ON. Refer to Chapter 5 "5.4.3.7 Mode
Switching (0111)".
f: in the figure indicates a system I/O signal, and ←represents the flow of the signal.
5-56
5.5 System I/O Signals Special Mode

5.5.1 Types and Functions of System Output Signals
(Special Mode)
Table 5-10 shows the system output signals used in the special mode.
Table 5-10 Types and Functions of System Output Signals to be Used in Special Mode
Robot power ON Outputs when preparations for operation are ready to

complete start.
Auto mode Outputs when the robot is in auto mode.
Start-up Servo ON Outputs when the power to the motor is turned ON.
CAL complete Outputs when calibration is completed.
External mode Outputs when the robot is in external mode.
Program
Outputs when the robot is in manual or teach check
pre-execution Teaching
mode.
check
Outputs when execution of the program starts in
Program start reset
response to the program start signal received.
Program execution Outputs when the robot is in operation (the program is

Robot running
being executed).
Continue start permitted Outputs when the continue start is permitted.
Program end Single cycle end Outputs when the program completes a cycle.
Outputs when the CPU (hardware) of the Robot

Normal CPU
Controller is normal.
Outputs when an error, such as a servo error and a
Robot error
program error, occurs in the robot.
Robot warning Outputs when a slight error occurs.

Error/warning
Outputs when the voltage of the encoder back-up
Dead battery warning
battery or memory back-up battery lowers.
An error number will be output in BCD code if an error
Error No.
occurs.
SS mode Outputs when the robot is in Safe Start (SS) mode.
5-57
5.5.2 Usage of System Output Signals in the Special Mode
The usage of each system output signal in the special mode is described below.
5.5.2.1 Robot Power ON Complete

(1) Function
The signal outputs to the external device that OPERATION PREPARATION
START is possible.
(2) Terminal number
(3) Usage
OPERATION PREPARATION START will be executed after this signal and
the auto mode signal are turned ON after the power was turned ON.
(4) ON conditions
c The signal will be turned ON when the Robot Controller system program
properly starts. Preparations for operation can be started after the power
was turned ON.
d The signal will be turned ON when the robot error is cleared by the OK or
Cancel key of the operating panel or the teach pendant or by ROBOT
ERROR CLEAR and OPERATION PREPARATION START signals, after
the power was turned OFF.
(5) OFF conditions
The signal will be turned OFF when a robot error or robot warning signal is
turned ON.
⋅ A robot error is cleared by the OK or Cancel

key of the operating panel or teach pendant.
⋅ When a robot error was cleared with ROBOT
⋅ The system properly ERROR CLEAR and OPERATION PRE-
starts to operate after PARATION START signals from the external
the power is turned device.
ON.
ROBOT POWER ON
COMPLETE output
⋅ Robot error
Figure 5-21 Robot Power ON Complete Output
5-58
5.5.2.2 Auto Mode (Output)

(1) Function
The signal outputs to the external device that the robot is in the auto mode.
(2) Terminal number
(3) Usage
Starting the program from the external device requires an SWITCH EXT
MODE input, a PROGRAM NO. SELECT input and a PROGRAM START
input. The signal is used to confirm that the robot is in the auto mode.
(4) ON conditions
The signal will be output when the robot enters the auto mode under the
following conditions.
c The mode selector switch of the operating panel or the teach pendant is
set to AUTO.
(5) OFF conditions
c When the mode selector switch of the operating panel is set to MANUAL
or the teach pendant is set to MANUAL or TEACH CHECK.
d When Enable Auto OFF is input.
(Caution: The signal will not be turned OFF in the pendantless state
described in Chapter 3, Subsection 3.2.3, "[ 3 ] Pendantless State."
STEP STOP or CYCLE STOP.
⋅ The Mode selector switch of the operating panel or the teach pendant is
set to AUTO.
⋅ SWITCH AUTO MODE and OPERATION PREPARATION START are
input from the external device.
Auto mode output
⋅ The mode selector switch of the operating panel is set to

MANUAL or that of the teach pendant is set to MANUAL or
TEACH CHECK.
⋅ Enable Auto OFF is input.
Figure 5-22 Auto Mode Output
5-59
5.5.2.3 Servo ON (Output)
(1) Function
The signal outputs to the external device that the power to the robot motor is
turned ON.
(2) Terminal number
(3) Usage
Executing CAL from the external device or starting the program requires the
power to the motor to be turned ON. This signal is used to confirm that the
power to the motor is turned ON and to light the motor power ON indicator
lamp on an external operating panel.
(4) ON conditions
The signal will be turned ON when the power to the motor is turned ON
under the following conditions.
c The MOTOR switch on the operating panel or the teach pendant is
activated.
d MOTOR POWER ON + OPERATION PREPARATION START signals
are input from the external device.
(5) OFF conditions
The signal will be turned OFF when the power to the motor is turned OFF
under the following conditions.
c The MOTOR switch of the operating panel or the teach pendant is
deactivated and the ROBOT STOP button is operated.
d ROBOT STOP is input from the external device.
e ROBOT ERROR is output. If any of errors 0 × 6071 to 607B, 0 × 6671 to
667B, 0 × 607F occurs, the servo ON signal will be turned OFF in
External Auto mode but will not be turned OFF in manual or teach check
mode.
⋅ When the MOTOR button of the operating panel or the teach pendant is
turned ON. 操作
「MOTOR」ON
⋅ When MOTOR POWER ON and OPERATION PREPARATION START
signals are input from the external device.
Servo ON output
⋅ When the MOTOR button of the operating panel or the teach pendant is
turned OFF and the ROBOT STOP button is operated.
⋅ When「MOTOR」OFF
a ROBOT STOP signal is input from an external device.
⋅ When a ROBOT ERROR occurs.
Figure 5-23 Servo ON Output
5-60
5.5.2.4 CAL Complete (Output)

(1) Function
The signal outputs to the external device that CAL is completed.
(2) Terminal number

(3) Usage
This signal is used to determine whether to execute CAL.
Once CAL is completed, it does not need to be executed again.
(4) ON conditions
The signal will be turned ON upon proper completion of CAL under the
following conditions.
c When CAL is performed by the operating panel or teach pendant.
d When CAL EXECUTION and OPERATION PREPARATION START
(5) OFF conditions
The signal will be turned OFF when CAL is not properly completed as
shown in Figure 5-24.
It will remain OFF until CAL is performed again and properly completed.
⋅ CAL is performed by the teach pendant.

⋅ CAL EXECUTION and OPERATION
PREPARATION START commands are
input from the external device.
(Prerequisite: MOTOR POWER ON) ⋅ CAL is executed again.
When CAL has properly ended
CAL complete
⋅ Normal CAL end When a CAL error occurs.
Figure 5-24 CAL Complete Output
5-61
5.5.2.5 External Mode (Output)
(1) Function
The signal outputs to the external device that the robot is in the external
mode.
(2) Terminal number

(3) Usage
Starting the program from the external device requires an SWITCH EXT
MODE input, PROGRAM NO. SELECT input and a PROGRAM START
input. The signal is used to confirm to the external device that the robot is in
external mode.
(4) ON conditions
The signal will be turned ON under the following conditions.
c When INTERNAL/EXTERNAL is input on the teach pendant and the
external mode is selected.
d When EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL ON state.
e When SWITCH EXT MODE and OPERATION PREPARATION START
(5) OFF conditions
c When the mode selector switch of the teach pendant is set to MANUAL
or TEACH CHECK in external mode.
d When EXTERNAL/INTERNAL is input on the teach pendant and
e When EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL OFF state.
f When ROBOT STOP is input.
g When ROBOT ERROR is output.
Caution: The signal will not be turned OFF with STEP STOP.
h When an Enable Auto input is turned OFF.
⋅ When INTERNAL/EXTERNAL is input on the teach pendant and external mode is selected.
⋅ When INTERNAL/EXTERNAL is input on the operating panel in AUTO MODE and in the
INTERNAL CONTROL ON state.
⋅ When EXTERNAL MODE SWITCHING and OPERATION PREPARATION START signals are input
from the external device.
ON
External mode output OFF
⋅ When internal mode is selected on the teach pendant.

⋅ When INTERNAL/EXTERNAL is input on the teach pendant and
⋅ When INTERNAL/EXTERNAL is input on the operating panel in
AUTO MODE and in the INTERNAL CONTROL ON state.
⋅ When ROBOT STOP is input.
⋅ When ROBOT ERROR is output.
⋅ When an Enable Auto input is turned OFF.
Figure 5-25 External Mode Output
5-62
5.5.2.6 Teaching (Output)

(1) Function
The signal outputs to the external device that the robot is in the manual
mode or teaches check mode.
(2) Terminal number

(3) Usage
This signal is used to inform an external operating panel that the robot is
teaching when they are installed separately from each other.
(4) ON conditions
The signal will be turned ON when the mode selector switch of the operating
panel or the teach pendant is set to MANUAL or TEACH CHECK, as shown
in Figure 5-26.
(5) OFF conditions
The signal will be turned OFF when the mode selector switch of the
operating panel or teach pendant is set to AUTO and the Enable Auto input
is turned ON.
・オペレーティングパネルで「Manual」操作
⋅・When
ティthe
ーチ mode
ング selector
ペンダ switch
ントofでthe「 operating
MANUAL 」・panel is set to
「 Teach
MANUAL.
Check」操作
⋅ When the mode selector switch of the teach pendant is set to
MANUAL or TEACH CHECK.
Teaching
⋅ When・オペレーティングパネルまたはティーチング
the mode selector switch of the operating panel or the
teach pendant is set to AUTO and the Enable Auto input is
ペンダントで「Auto」操作、かつ外部より自
turned ON from the external device.
動運転イネーブル入力が ON
Figure 5-26 Teaching Output
5-63
5.5.2.7 Program Start Reset (Output)
(1) Function
This signal is output to the external device when the robot receives a start
signal from the external device and starts to operate.
(2) Terminal number

(3) Usage
c The signal is used to prompt the external device to receive information
that the robot program has started to run, and to process subsequent
sequence programs.
d The signal is used as a condition to turn OFF the PROGRAM START
signal sent from the external device to the robot.
(4) ON conditions
The signal will be turned ON immediately after the robot program starts to run,
as shown in Figure 5-27.
(5) OFF conditions

The signal will be turned OFF automatically when the PROGRAM START
signal sent to the robot is turned OFF.
Robot status
Single-cycle operation Single-cycle operation

OFF (open)
Program start
Reset (output)
Figure 5-27 Program Start Reset Output ON Condition
5-64
5.5.2.8 Robot Running (Output)

(1) Function
The signal outputs to the external device that the robot is in operation
(executing more than one task ).
(2) Terminal number

(3) Usage
The signal is used to light the robot operating indicator lamp of the external
operating panel.
Since the signal is turned OFF with STOP ALL PROGRAMS, it outputs to
the external device that all programs are stopped.
(4) ON conditions
The signal will be turned ON while executing the program and also in the
Wait State with a condition branch or timer command.
(5) OFF conditions

The program will be turned OFF with STOP ALL PROGRAMS.
Caution: STOP ALL PROGRAMS means the operation of the ROBOT

STOP or STOP button of the operating panel or the teach
pendant and INSTANTANEOUS TOP (ALL TASKS), STEP STOP
(ALL TASKS) and ROBOT STOP inputs.
5-65
5.5.2.9 Single-Cycle End (Output)
(1) Function
The signal outputs to the external device that a single-cycle of the program
is completed.
Caution c: The single-cycle end signal will be output upon reading END
of the program. However, it will be output earlier than the
end of the actual robot operation because the Robot
Controller pre-reads the program.
d: The single-cycle end signal will be output on the premise
that only one program is executed at a time. If two or more
programs are executed simultaneously (multi-tasks), the
single-cycle end signal will be turned ON immediately after
any of the programs reads an END command.
(2) Terminal number

(3) Usage
The signal is used to operate another equipment in synchronization with a
single-cycle end of the program.
(4) ON conditions
The signal will be turned ON when the program is read to the end.
(5) OFF conditions

The signal will be turned OFF immediately after the program starts to run.
Robot status Single-cycle Single-cycle

operation Wait for start operation
PROGRAM START input
1-CYCLE END
Figure 5-28 Single-Cycle End Output
5-66
5.5.2.10 Normal CPU (Output)

(1) Function
The signal outputs to the external device that the CPU (hardware) of the
Robot Controller is normal.
(2) Terminal number

(3) Usage
c The signal is used to light the Robot Controller error indicator lamp of an
external operating panel.
d The signal is used when the NORMAL CPU signal is turned OFF
because of an error and the PLC corrects it.
(4) ON conditions
The signal will be turned ON by the hardware when the CPU of the Robot
Controller operates normally with the power turned ON.
(5) OFF conditions

The signal will be turned OFF by the hardware when the CPU does not
operate normally.
Caution: The OFF state of this signal indicates that the internal
arithmetic circuit of the Robot Controller may be damaged and
ROBOT ERROR, ERROR NUMBER and other outputs may not
be correct.
⋅ Power ON (CPU operates properly)
Normal CPU output
⋅ CPU error (hardware error)
Figure 5-29 Normal CPU Output
5-67
5.5.2.11 Robot Error (Output)
(1) Function
The signal outputs to the external device that a problem, such as a servo
error and a program error, occurs with the robot.
(2) Terminal number

(3) Usage
c The signal is used to light the robot error indicator lamp of an external
operating panel.
ROBOT ERROR signal.
(4) ON conditions
As shown in Figure 5-30, the signal will be turned ON under the following
conditions.
c When an error, such as a servo error, a program error and undefined
program, occurs at the start of the program and during execution of the
program.
d When an error occurs during execution of the program in internal
operation by the operating panel or the teach pendant or in external
operation by the PLC.
e When an error, such as undefined program, occurs at the start of the
program only in external operation.
Caution: The signal will not be output when an error, such as a program
input error occurs in manual operation, except when a servo
error occurs in manual operation. For further information, see
"ERROR CODE TABLES."
(5) OFF conditions

As shown in Figure 5-30, the signal will be turned OFF under the following
conditions.
c When a ROBOT ERROR CLEAR COMMAND is input from the external
device and the existing error is cleared.
d When the existing error is cleared by operating the Cancel key of the
operating panel or the teach pendant.
⋅ Program number, parity error, or an undefined program number at

external start. バリティーエラー、
⋅ The robot errors during automatic operation (both internal operation and
external operation).
Robot error
⋅ When ROBOT ERROR CLEAR and OPERATION PREPARATION

START signals are input.
⋅ When the Cancel key of the operating panel or the teach pendant is
「Cancel」キー操作
operated.
Figure 5-30 Robot Error Output
5-68
5.5.2.12 Robot Warning (Output)

(1) Function
The signal outputs to the external device that a minor error has occurred
with an I/O command or during servo processing.
Caution: The signal will not be output in case of a minor error, such as a
program selection error, caused by the operation of the teach
pendant or operating panel.
(2) Terminal number

(3) Usage
c The signal is used to light the robot warning indicator lamp of an external
operating panel.
ROBOT WARNING signal.
(4) ON conditions
As shown in Figure 5-31, the signal will be turned ON when a minor error
occurs during I/O processing, execution of the program or servo processing,
irrespective of the operation mode.
(5) OFF conditions

As shown in Figure 5-31, the robot-warning signal will be turned OFF under
the following conditions.
c When ROBOT ERROR CLEAR and OPERATION PREPARATION
START signals are input from the external device and the existing error is
cleared.
d When the existing error is cleared by operating the OK or Cancel key of
the operating panel or the teach pendant.
⋅ When a slight error occurs during I/O processing, execution of the

program or servo processing.
Robot warning
⋅ When a ROBOT ERROR CLEAR COMMAND is input from the

external device and the existing error is cleared.
⋅ When the existing error is cleared by operating the OK or Cancel key
of the operating panel or teach pendant.
Figure 5-31 Robot Warning Output
5-69
5.5.2.13 Dead Battery Warning (Output)
(1) Function
The signal will be output when the voltage of the encoder back-up battery or
memory back-up battery becomes dangerously low.
(2) Terminal number

(3) Usage
The signal is used to check the timing of battery replacement (lowering of
the battery voltage).
(4) ON conditions
The signal will be turned ON when the voltage of the encoder back-up
battery or memory back-up battery becomes dangerously low.
Caution: Any error of ERROR64A1 to 64A6 indicating the dead encoder

back-up battery or ERROR6103 informing the dead memory
back-up battery will be displayed on the operating panel and
the teach pendant respectively.
(For details, refer to Chapter 6, Section 6.4, "Biennial
Inspections.")
(5) OFF conditions

The signal will be turned OFF when the power is turned ON after the dead
battery was replaced.
Power ON Power OFF Power ON Power OFF Power ON

Robot power ON state
⋅ The voltage of the encoder backup

battery or memory back-up battery
becomes dangerously low.
Dead battery
warning output
⋅ Battery replaced
Figure 5-32 Dead Battery Warning Output
5-70
5.5.2.14 Error No. (Output)

(1) Function
When an error occurs, the signal outputs the error number in a 3-digit (12-
bit) hexadecimal code.

(3) Usage
The signal is used to display an error number on the external device.
(4) Output conditions

The signal will be output when an error occurs.
(5) Clear conditions
The signal will be cleared when ROBOT ERROR CLEAR and OPERATION
PREPARATION START signals are input or by operating the Cancel key of
the operating panel or the teach pendant. When this signal is cleared, all
states will become OFF (0).
(6) Hexadecimal codes

See Figure 5-33.
×××× →0 ×{×{ →5 {×{× → A

×××{ →1 ×{{× →6 {×{{ → B
××{× →2 ×{{{ →7 {{×× → C
××{{ →3 {××× →8 {{×{ → D
×{×× →4 {××{ →9 {{{× → E {⋅⋅⋅ON
{{{{ → F ×⋅⋅⋅⋅OFF
Figure 5-33 Hexadecimal Codes
Figure 5-34 shows an example of error number output, when ERROR174

(overload error with the fourth axis) occurs.
Hundreds of error No. Tens of error No. Units of error No.

Terminal No. 28 27 26 25 24 23 22 21 20 19 18 17
(connector CN10）
Figure 5-34 Example of Error Number Output
5-71
5.5.2.15 Continue Start Permitted (Output)
(1) Function
The controller will output this signal when the continue start is permitted.
(2) Terminal number

(3) Usage
Use this signal when you want to know whether the continue start is
permitted.
(4) ON condition
This signal comes on when the continue start is permitted. For details, refer
to the SETTING-UP MANUAL.
(5) OFF condition

This signal goes off by carrying out the "Task Status Change Operation."
5-72
5.5.3 Types and Functions of System Input Signals (Special

Mode)
Table 5-11 shows the system input signals to be used in special mode.
Table 5-11 Types and Functions of System Input Signals to be Used in Special Mode
Enable Auto Enables switching to Auto mode.
Motor power ON
Turns ON the power to the motor.
+ operation preparation start
CAL execution
Executes calibration.
SP100
Start-up Sets the speed to 100%.
Switch Ext Mode

Switches the mode to external mode.
Initializes all programs on halt. Starting a

Program reset
program after initialization will execute the
program from the beginning.
Program No. select

Executes a specified program.
+ program start
Program reset Cancels the current program and starts

+ program No. select executing a specified program from the
+ program start beginning.
Program execution
Continue start
Executes a continue start.
+ program start
Robot stop Stops the robot by opening signals.

Robot stop Stops the robot by canceling signals.
Step stop Step-stops all programs by opening signals.
Stop
Immediately stops all programs by opening
Instantaneous stop
signals.
Robot error clear

Error clear Clears an error.
Interrupts the execution of the current step

Program interrupt Interrupt skip
and starts the next step.
Caution: Two or more signal names shown in the signal name field
indicate that they should be used in combination.
5-73
5.5.4 Usage of System Input Signals in Special Mode
The usage of each system input signal in Special mode is described below:
5.5.4.1 Enable Auto (Input)

(1) Function
c The signal enables switching of the robot mode to the Auto mode
(shorted state).
d The signal enables switching of the robot mode to the manual mode or
the teach check mode (open state).
(2) Terminal number
(3) Usage
The signal is used for the AUTO/TEACHING selector switch of the external
operating panel and can be combined with the safety fence switch.
c As shown in Table 5-12, the selectable operation mode depends on
whether this input is shorted or open.
d If the input becomes open during automatic operation, the mode will be
switched to manual mode and ERROR21FC will be displayed.
e If manual operation or a teach check is conducted with this input shorted,
ERROR21F2 will be displayed.
f If the mode selector switch of the teach pendant or the operating panel is
set to AUTO with this input open, ERROR21F3 will be displayed.
Since this state is × in Table 5-12, this error will remain displayed until the
robot leaves this state.
g Although ERROR21FD or ERROR21FC will be displayed when the state
is changed from { to ∆ or × shown in Table 5-12, they will not be
displayed when the state is changed from ∆ or × to {.
h When the input is turned OFF (open) in external mode, the external
mode output will also be turned OFF.
Table 5-12 Relationship Between Enable Auto Input and Selectable Mode
Enable Auto
Operation Mode Application ON OFF
(shorted) (open)
Manual operation with the operating panel or teach
Manual mode ∆ {
pendant
Teach check mode Program check with the teach pendant ∆ {
Automatic operation with the operating panel or teach {
Internal Auto mode ×
pendant
External Auto mode Automatic operation with the external device { ×
Note:{ = Mode selectable × = Mode not selectable
∆ = Mode selectable but manual operation and program not executable
Caution: In the pendantless state described in Chapter 3, subsection 3.2.3 [ 3 ], auto

mode is valid even if the Enable Auto input is open (external mode cannot
be switched and the program cannot start to run).
Perform the following when operating the robot in the pendantless state:
c Set the robot not to start to operate when the Enable Auto input is
open.
d Enable Auto input open state and auto mode output (See 5.3.2.2 and
5.5.2.2 "Auto Mode ".)
Add c and d with the external sequence circuit.
5-74
5.5.4.2 Operation Preparation Start (Input)

(1) Function
⋅ By turning ON (short) this signal, input signals c to f described in (3),
input conditions and operation will be detected and the robot will
automatically start to operate. Input these signals with the system output
ROBOT POWER ON COMPLETE turned ON.
⋅ By turning ON (short) ROBOT ERROR CLEAR, an error that has occurred
will be cleared.
(2) Terminal number
Before inputting an operation preparation start signal, turn ON (short) inputs
c to f below:
c Motor power ON (input)

⋅ Terminal number: No.19 of connector CN8
⋅ By turning ON (short) the operation preparation start signal with this
signal turned ON (shorted), the power to the motor will be turned ON.
However, this signal can be used only in the Auto mode.
d CAL execution (input)
signal turned ON (shorted), calibration takes place. However, this
signal cannot be used when the power to the motor is turned OFF (c
not executed).
e SP100 (input)
signal turned ON (shorted), SP100% will be set.
f Switch Ext Mode (input)
signal turned ON (shorted), the mode will be set to the external mode.
However, this signal cannot be used when the power to the motor is
turned OFF and CAL is not completed.
g Program reset (input)
signal turned ON (shorted), all programs will be initialized.
Caution: By turning ON (short) the operation preparation start signal

with all inputs c to g turned ON (shorted), c to g will be
executed one by one. Input d cannot be executed until input c
is completed. Inputs c to g will also become valid when part
of them are executed by the operating panel or teach pendant.
5-75
For the input timing of the operation preparation start signal and c to f, see
Figure 5-35.
Caution: The operation preparation start signal and each input signal,
except the Enable Auto signal, will be turned OFF (falling) upon
turning ON of the external mode output is turned ON.
Although the robot is made to execute all items at start-up,
execute only necessary items at the time of recovery from
suspension during operation to reduce recovery time.
The required time to execute all items may be about 5 seconds
depending on CAL time. The time is about 1.3 seconds without
CAL. (Once CAL is completed, it does not need to be executed
again as long as the power to the Robot Controller is turned
ON.) Determine whether to execute CAL according to the CAL
complete output.
Automatic ON (shorted)
operation enable OFF (open)
1 ms. or more
Operation ON (shorted)
preparation start OFF (open)
The power to the motor is turned ON.

c Motor power ON ON (shorted)
OFF (open)
Input
CAL starts CAL ends

d CAL execution ON (shorted)
OFF (open)
SP is set to 100.
e SP100 ON (shorted)
OFF (open)
The mode is switched
to external mode.
f External ON (shorted)
mode switching OFF (open)
Automatic ON (shorted)
mode output OFF (open)
Servo ON ON (shorted) Approx.2.0s

OFF (open)
Output
Approx. 2.5s CAL time

CAL complete ON (shorted)
OFF (open)
Approx. 0.5s
External ON (shorted)
mode output OFF (open)
Caution：
： indicates the input or output of the signal, and indicates robot operation.
Figure 5-35 Example of Operation Preparation Start Signal Timing Chart
5-76
5.5.4.3 Program No. Select (Input)

(1) Function
The program number to be executed can be specified from the external
device by inputting this signal.


c This signal is executable only in the external mode. In other modes, an
error (ERROR21E2, 21E4, 21E6) will be displayed, and the terminal
motor power will be turned OFF.
d As shown in Table 5-13, the program No. select signal is made up of
eight bits of 20 to 26 and the parity bit.
e Input a decimal program number by converting it into binary 20 to 26 and
parity bit.
f "Short" represents the bit value = 1, "open" represents the bit value = 0,
and the parity bit is odd parity.
g As shown in Figure 5-36, input the program No. select signal before the
program start signal (1 msec. or more), and hold the state until the robot
starts to operate. If this condition is not met, ERROR2031 or
ERROR2033 will be displayed, the power to the motor will be turned
OFF, and the mode will be switched to the Auto mode.
Wait for start

Robot status or preceding cycle Single-cycle operation
Program ON (shorted)
start (input) OFF (open)
Program No. select signal

20 to 26 ON (shorted)
Parity OFF (open)
Figure 5-36 Program No. Select Signal
h Input 1 or 0 as the parity bit so that the total of 1’s existing in the eight bits
of 20 to 26 and the parity bit will be odd.
Example: When the program number is 15, the bit status of 20 to 26 is
(001111), and the total number of 1s is four, an even number.
Set 1 as the parity bit to make the total number of 1s five, an
odd number.
Caution c: The bit value =1 represents short, and the bit value =0
represents open.
d: The program numbers executable from the external device
are limited to Pro0 to Pro127.
5-77
Table 5-13 Example of Program No. Select Signals
Program No. (decimal)

Input signal
1 15 26 65
20 = 1 1 1 0 1
21 = 2 0 1 1 0
22 = 4 0 1 0 0
23 = 8 0 1 1 0
24 = 16 0 0 1 0
25 = 32 0 0 0 0
26 = 64 0 0 0 1
Parity 0 1 0 1
Figure 5-37 shows an example of a program No. select signal sequence circuit
considering parity.
Lower 4-bit, odd
Upper 3-bit, odd
Program No. select
Figure 5-37 Example of Program No. Select Signal Sequence Circuit
5-78
5.5.4.4 Program Start (Input)

(1) Function
This signal starts the program specified with the program No. select signal
from the external device.
(2) Terminal number


By switching the status of this signal from ON (open) to ON (shorted) in
external mode, operations c, d and e described below will take place.
(The status of the signal must be switched from OFF to ON.)
c If the program start signal is input (switched from OFF to ON) when the
robot has not yet completed the program or is at rest after it has
completed a cycle of the program, the program No. select signal will be
read, the program will execute a cycle, and the robot will come to a stop.
Single-cycle Single-cycle
1-cycle Operation Wait for start operation Wait for start operation
Robot status
Program ON (shorted)
start signal OFF (open)
Figure 5-38 Program Start Operation-1
Caution: The program start signal requires program start preparation

time (50 msec. or more) before input from OFF (open) to ON
(shorted).
The program start signal must remain OFF (open) during the
program start preparation time. If it is turned ON (shorted)
during that time, the next cycle will not start to run.
To start a new cycle, the status of the external start signal must
be switched from OFF to ON before each cycle.
5-79
d When the status of the program start signal is switched from OFF to ON
with the program step-stopped, the program will resume from the step
following the suspended step and stop at the cycle end.
Single-cycle operation
Robot status
Performing
remaining
Operating halfway At step-stop operation
Program start ON (shorted)

signal (input) OFF (open)
Step-stop ON (shorted)
Caution: To cancel the execution of the remaining steps of a step-

stopped program and start it from the beginning, input a
program reset signal, a program No. select signal and a
program start signal at the same time. For further
information, refer to Chapter 5 "5.5.4.5 Program Reset
(Input)".
5-80
e When the status of the program start signal is switched from OFF to ON
with the program immediately stopped, the program will resume from the
suspended step and stop at the cycle end.
Robot status Single-cycle operation

Performing
Operating On halt remaining
halfway operation

Instantaneous stop ON (shorted)

Caution: To cancel the execution of the remaining steps of an

instantaneously stopped program and start it from the
beginning, input a program reset signal, a program No. select
signal and a program start signal at the same time. For further
information, refer to Chapter 5 "5.5.4.5 Program Reset (Input)".
5-81
(4) Example of program start signal (rise) ON and (fall) OFF timing
c Example of program start signal rise (ON) timing
Figure 5-41 shows how to make the program start signal rise with robot
system outputs (external mode output and single-cycle end output).
Wait for start Single-cycle Next cycle

Robot status operation operation
External mode ON
(output) OFF
1-cycle end ON
(output) OFF
200 ms. or
more required
Figure 5-41 Example of Program Start Signal Rise Timing
Caution: The program start signal for the first cycle rises as soon as the
external mode becomes valid and the conditions of the
peripheral devices are met. The program start signal for
subsequent cycles rises after output of a single-cycle end
signal.
5-82
d Example of program start signal fall (OFF) timing

a) Figure 5-42 shows how to make the program start signal fall with a
robot system output (program start reset output).
When the robot program starts to run, a program start reset signal is
output. The external device receives it and makes the program start
signal fall (OFF).
Robot status Wait for start

or preceding cycle Single-cycle operation
Program start ON
reset (output) OFF
Figure 5-42 Example of Program Start Signal Fall Timing-1
b) Figure 5-43 shows how to make the program start signal fall with the
simplified method (1 shot method using a timer).
Robot status Wait for start Single-cycle operation

Figure 5-43 Example of Program Start Signal Fall Timing-2
Caution c: Although the 1 shot method is easy, the timer setting for
falling to raise the program start signal in the middle of the
preceding cycle is difficult.
Use this method only to raise the program start signal after
the robot stops at the end of each cycle.
d: The status of the robot running, program start reset and
single cycle end output signals changes in sequence after
the program start signal is input (T1→T2→T3 in Figure 5-44).
The change of the status of these signals takes place within
100 msec. after the program start signal rises (ON). See
Figure 5-44.
5-83
T1, T2, T3: within 100 ms.

Robot in operation
(output)
Program start reset

(output)
Single-cycle end
(output)
Figure 5-44 Program Start Signal Rise Output Signal Timing
5-84
5.5.4.5 Program Reset (Input)

(1) Function
By turning ON (short) this signal, any program can be forcibly executed
from the beginning in a step-stopped state and a suspended state.
Caution: Generally, a step-stopped or suspended program resumes

from where it stopped.
(2) Terminal number


When issued with the Program Start
c Figure 5-45 shows the input conditions and an operation timing chart.
d Use the program reset signal together with a program No. select signal,
and input it before the program start signal (1 msec. or more).
e Turn OFF the program reset signal after the robot starts to operate (after
a program start reset signal is output).
f A program No. select signal is required to execute the same program
number as the suspended one from the beginning.
Executing cycle
Robot status Executing cycle Stop from beginning
(input) OFF (open)

(input) OFF (open)
Program No. ON (shorted)

select signal (input) OFF (open)
Program reset ON (shorted)

(input) OFF (open)
Figure 5-45 Input Conditions and Operation of Program Reset Signal
5-85
When issued with the Operation Preparation Start
c Figure 5-46 shows the input conditions and an operation timing chart.
d Input Program Reset before Operation Preparation Start (1 msec. or
more).
e After turned ON, this signal may take a maximum of one second for
initializing all programs. During the period, do not input signals to the
robot.
Initializing all
Executing cycle Stop programs
Max. 1 sec.
Instantaneous stop signal (input)
Operation preparation start signal

(input)
Program reset (input) 1 ms. or more
Continue start permitted (output)
Figure 5-46 Input Conditions and Operation of Program Reset Signal
5-86
5.5.4.6 Robot Stop (Input)

(1) Function
c The signal stops the robot with the external device by opening the robot
stop input
d The signal readies the power to the robot motor to be turned ON by
shorting the robot stop input.
(2) Terminal number


c The robot stops with this signal OFF (open).
d The power to the robot motor is ready to be turned ON with this signal ON
(shorted).
e Irrespective of whether internal mode (operation with the teach pendant)
or external mode (remote operation by the external device) is selected,
the power to the robot motor cannot be turned ON with this signal OFF
(open). Neither manual nor automatic operation can be performed until
this signal is turned ON (shorted). (ERROR2008 will be displayed.)
f By turning OFF (open) this signal under the following conditions.
1) The power to the motor will be turned OFF, irrespective of whether
Manual, Internal Auto, or External Auto mode is selected.
2) During execution of the program (robot running output ON), the power
to the motor will be turned OFF and the mode will be switched to
internal mode after the robot decelerates to a stop.
3) When the program is at a stop in the Manual and the Auto mode the
power to the motor will be turned OFF. The suspended operation can
be resumed by turning ON the power to the motor and shorting the
ROBOT STOP signal.
g Opening the ROBOT STOP signal and pressing the ROBOT STOP
button of the operating panel or the teach pendant function the same.
(4) Input timing

This signal will be processed prior to all commands and input signals.
5-87
5.5.4.7 Step Stop (All Tasks) (Input)
(1) Function
Input this signal to step-stop the program being executed from the external
device. All tasks will be step-stopped.
(2) Terminal number


c If the status of this signal is changed from ON (shorted) to OFF (open),
the robot will stop all tasks immediately after the ongoing step is
completed, and the robot running output will be turned OFF. However,
External Auto mode will remain valid, and the suspended program will be
resumed by inputting a program start signal. See Figure 5-47.
d Turning OFF (open) this signal when inputting a program start signal
makes the robot stop step by step.
e Internal operation with the teach pendant is valid only when the status of
this signal is changed from ON (shorted) to OFF (open).
f For resuming the program after a step stop, refer to Chapter 5 "5.5.4.4
Program Start (Input)".
Robot status Single-cycle operation

Performing
remaining
Operating halfway Step-stop operation

Robot in operation ON
(output) OFF
Figure 5-47 Step Stop Signal
5-88
5.5.4.8 Instantaneous Stop (All Tasks) (Input)

(1) Function
Input this signal to instantaneously stop the program being executed from
the external device. All tasks will instantaneously stop.
(2) Terminal number


c If the status of this signal is changed from ON (shorted) to OFF (open),
the robot will instantaneously stop in the middle of the ongoing step, and
the robot running output will be turned OFF. However, Auto mode or
external mode will remain valid, and the suspended program will be
resumed by inputting a program start signal.
d Internal operation by the teach pendant is valid only when the status of
this signal is changed from ON (shorted) to OFF (open).
e For resuming the program after an instantaneous stop, refer to Chapter 5
"5.5.4.4 Program Start (Input)".
f The minimum required pulse width is 50 msec. or more.
ON (shorted)
Instantaneous
stop OFF (open)
Figure 5-48 Minimum Instantaneous Stop Pulse Width
5-89
5.5.4.9 Robot Error Clear (Input)
(1) Function
The robot can recover from a stopped state, resulting from a robot error by
turning ON (shorted) the operation preparation start signal with this signal
ON (shorted).
(2) Terminal number
Caution: The number of the terminal of connector CN8 for the operation
preparation start signal is No. 8.
(3) Usage
The signal is used to clear an error that brought the robot to a stop.

c When a robot error occurs, clear the error display on the teach pendant
and the external output ERROR NUMBER to ready the robot to operate.
d When the robot error clear signal is turned ON (shorted), other input
signals (MOTOR POWER ON, CAL EXECUTION, SP100 and SWITCH
EXT MODE), which are to be used in combination with the operation
preparation start signal, will be ignored.
To turn ON the power to the motor after a robot error is cleared, turn OFF
(open) the robot error clear signal after turning OFF the robot error signal
(output) as shown in Figure 5-49.
e Input the robot error clear signal before (1 msec. or more) the operation
preparation start signal.
Stop due
Robot status to robot error Robot error clear Motor power ON
Operation preparation ON
start (input) OFF
1 ms.
Robot error ON or more
required
clear (input) OFF
Motor power ON
ON (input) OFF
Robot error ON
(output) OFF
Servo ON ON
(output) OFF
Figure 5-49 Input Conditions and Operation of Robot Error Clear Signal
5-90
5.5.4.10 Interrupt Skip (Input)

(1) Function
If this signal is turned ON (shorted) during execution of the robot operation
command within the range between INTERRUPT ON and INTERRUPT
OFF in the program, the operation of the ongoing step will stop and the next
step will start.
Caution: For further information about the INTERRUPT ON and OFF

commands, refer to Chapter 12 "12.3 INTERRUPT ON/OFF
(Statement)" in PROGRAMMER'S MANUAL.
For further information about the robot operation command,
refer to Chapter 12 "Robot Control Statements" in
PROGRAMMER'S MANUAL.
(2) Terminal number

(3) Usage
Refer to Chapter 12 "12.3 INTERRUPT ON/OFF" in PROGRAMMER'S
MANUAL."

If this signal is turned ON (shorted), the robot will immediately stop the
ongoing operation and start executing the next step.
INTERRUPT ON
command Operating halfway Next operation
Robot status
50 ms. or
more required
Interrupt skip ON (shorted)

Figure 5-50 Input Conditions and Operation of Interrupt Skip
5-91
Caution:
: When turning ON (shorted) the interrupt skip signal, at least
either the program reset signal or the program start signal
must be turned OFF (open).
If the interrupt skip signal is turned ON, the robot interprets
the program start signal as instantaneously turned OFF
(open). Consequently, the program selected with the
program No. select signal will be executed from the
beginning. (See Figure 5-51.)
Executing cycle
Robot status Executing cycle halfway from beginning
Interrupt skip ON (shorted)


Program reset ON (shorted)

WRONG
Program No. select ON (shorted)

Figure 5-51 Example of Operation When an Interrupt Skip Signal is Input
5.5.4.11 Continue Start (Input)

(1) Function
Turning the program start signal ON when this continue start signal is ON
will resume the current program being on halt.
(2) Terminal number


This signal is executable only in external mode. If this signal is on, program
numbers will be ignored at execution of Program start and the current
program being on halt will be resumed. If Continue Start Permitted signal is
not ON, the controller will issue ERROR27A8.
5-92
5.5.5 Example of Using System I/O Signals in Special Mode

This section describes an example of starting and stopping the robot using
system I/O signals.
(1) Equipment example

In this example there is equipment which makes the robot perform
operations by operating an external equipment operating panel connected
to the Robot Controller through a PLC as shown in Figure 5-52 and
equipped with a display, lamps and switches listed in Table 5-14.
Figure 5-52 Example of Equipment Using a Robot
5-93
Table 5-14 Example of Equipment Operating Panel Functions
Classification Part Application
Displays messages, such as ROBOT PREPARATION

Display Display OK.
⋅ Lights during automatic operation.
c Automatic operation ⋅ Not illuminated when the robot is not in automatic
indicator lamp operation.
Lamp d Robot external mode ⋅ Lights when the robot is in external mode.
indicator lamp ⋅ Turned OFF when the robot is not in external mode.
e Operation OK indicator ⋅ Lights when the Enable Auto signal is ON.

lamp ⋅ Turned OFF when the Enable Auto signal is OFF.
c Robot operation button Starts the robot preparation.
d Automatic start button Starts the operation of the equipment.
Switch
e Cycle stop button Stops the equipment after a cycle of operations is
completed.
Automatic operation of the robot possible when
f Operation/Adjustment OPERATION is selected.
selector switch Manual operation or teach check of the robot possible
when ADJUSTMENT is selected.
Caution: Actual equipment requires emergency stop, interlock and other functions. However,
described here are only necessary functions and others are omitted.
(2) Outline of procedure

Described below is the outline of the procedure when using the equipment,
as shown in Figure 5-52.
Follow steps c to e.
Setting the MOTOR POWER ON, CAL EXECUTION, SP100 and
SWITCH EXT MODE bits, brings the robot into the External Auto mode.
This operation will be completed when the EXTERNAL MODE output
signal is turned ON.
d Automatic operation
Start the program by which the robot starts from the operation origin,
performs operations, and returns to the operation origin.
e Operation end
Terminate the day’s operations with a cycle stop, and turn OFF the power.
(3) Start and stop procedure and system I/O signals

Figures 5-53 and 5-54 show the relationship between the system I/O signals
and the operations by the operator display on the equipment operating panel,
processing by the PLC and the operation of the robot when starting and
stopping the robot.
5-94

Equipment power ON
Setting
operation/adjustment
Enable Auto ON (Internal processing)
selector switch to
operation
Operation OK indicator
lamp ON
(Note c)
Robot preparation System input for start-
button ON
up ON
Operation Motor power ON

Preparation Start ON
Executing CAL
Setting SP 100
Switching mode to
external mode
Robot external mode (Internal processing) Motor power ON

indicator lamp ON
Moving robot arm close

d Operation start area check
to operation origin,
when external mode
indicator lamp is ON
and operation position
1 indicator lamp is OFF.
Robot operation origin (Internal processing) Operation position 1 ON

indicator lamp ON
Robot preparation OK When both are ON

display (Internal processing)
(Continued on following page)
5-95
(Continued from preceding page)
Equipment’s Program No. Select ON

Automatic Start
Regular Operation
Program is
selected.
e Automatic operation
Automatic Operation Program start ON Program start

indicator lamp ON
END
Program No. select ON Single-cycle End ON
Regular Operation
Program is
selected.
Repeated
Program start ON
Equipment’s Cycle Cycle Stop ON Executing single-cycle

Stop button ON
END
f Operation end
Automatic operation (Internal processing) Single-cycle End ON

indicator lamp OFF
Equipment power OFF
Note c: The system inputs for startup here are four types of system inputs – "motor power ON,"
"CAL execution," "SP100" and "External Mode switching." Refer to Chapter 5 "5.5.4.2
Operation Preparation Start (Input)".
d: in the figure indicates a system I/O signal, and ←represents the flow of the signal.
5-96
5.6 I/O Circuits and Connectors (PNP type)

This section explains the I/O circuit of PNP type (sink input and source output).
For the circuit of NPN type (source input and sink output), refer to Appendix 1.
5.6.1 I/O Signal Connector Pin Layout

This section describes the Robot Controller connector pin layouts for I/O signals.
The definitions of the signals and pins of the output connector CN10 and input
connector CN8 are different between the standard mode and the compatible
mode.
As for the other connectors, the definitions of the pins are common to the
standard mode and the compatible mode.
5.6.1.1 Connector Pin Layout Common to Both Modes

(1) HAND I/O CN9: Connector for end-effector I/O (common to both
modes)
Table 5-15 CN9 Pin Layout (Common to both modes)
View from cable side engaging face
Wire color Wire color

Terminal Port Terminal Port
Name Name
No. number High No. number High
Standard Standard
strength strength
1 Hand output 64 Black Blue 11 Hand Input 50 Pink White
2 Hand output 65 Brown Yellow 12 Hand Input 51 Pink White
3 Hand output 66 Black Green 13 Hand Input 52 White White
4 Hand output 67 Brown Red 14 Hand Input 53 White White
5 Hand output 68 Red Violet 15 Hand Input 54 White White
Hand Input
6 Hand output 69 Orange Blue 16 55 White Brown
(interrupt input)
7 Hand output 70 Yellow Yellow 17 Power E0V for Hand  White Brown
8 Hand output 71 Green Green 18 Power E24V for Hand  White Brown
9 Hand input 48 Blue Red 19 Not connected  White Brown
10 Hand input 49 Violet Violet 20 Not connected  White Brown
5-97
(2) I/O POWER CN7: Power connector for I/O (common to both modes)
Terminal No. Name
1 Internal power source output +24V
3 Internal power source output 0V
5 FG
6 Power input E0V
7 Power input E0V
8 Power input E24V
9 Power input E24V
Caution: When using the internal power source, keep the total current
capacity below 1.3 A. To use the internal power source of the
Robot Controller, connect the wiring so that the internal
power source will be separate from the external power
source. Improper wiring may damage the internal circuit.
5-98
5.6.1.2 Connector Pin Layout for Standard Mode

(1) OUTPUT CN10: User-/System-output connector (standard mode)
Table 5-17 CN10 Pin Layout (Standard mode)
Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color
1 Normal CPU 72 Black 35 User output 106 Pink
2 Robot in operation 73 Brown 36 User output 107 Pink
3 Robot Error 74 Red 37 User output 108 Pink
4 Servo ON 75 Orange 38 User output 109 Pink
5 Robot initialization complete 76 Yellow 39 User output 110 Pink
6 Auto mode 77 Black 40 User output 111 White
7 External mode 78 Brown 41 User output 112 White
8 Dead battery warning 79 Red 42 User output 113 White
9 Robot warning 80 Orange 43 User output 114 White
10 Continue start permitted 81 Yellow 44 User output 115 White
11 SS mode 82 Green 45 User output 116 White
12 Reserved 83 Blue 46 User output 117 White
13 Reserved 84 Violet 47 User output 118 White
14 Reserved 85 Gray 48 User output 119 White
15 Command processing complete 86 Pink 49 User output 120 White
16 Status area odd parity 87 Black 50 User output 121 Gray
17 Status area bit 0 88 Black 51 User output 122 Violet
18 Status area bit 1 89 Brown 52 User output 123 Violet
19 Status area bit 2 90 Red 53 User output 124 Violet
20 Status area bit 3 91 Orange 54 User output 125 Violet
21 Status area bit 4 92 Yellow 55 User output 126 Violet
22 Status area bit 5 93 Green 56 User output 127 Violet
23 Status area bit 6 94 Blue 57 Unused  Violet
24 Status area bit 7 95 Gray 58 Unused  Violet
25 Status area bit 8 96 Pink 59 Unused  Violet
26 Status area bit 9 97 Brown 60 Unused  Gray
27 Status area bit 10 98 Red 61 Unused  Gray
28 Status area bit 11 99 Orange 62 Unused  Gray
29 Status area bit 12 100 Yellow 63 Unused  Gray
30 Status area bit 13 101 Green 64 Unused  Gray
31 Status area bit 14 102 Blue 65 Emergency stop +  Gray
32 Status area bit 15 103 Pink 66 Emergency stop −  Gray
33 User output 104 Black 67 Unused  Blue
34 User output 105 Brown 68 Unused  Blue
5-99
(2) INPUT CN8: User-/System-input connector (standard mode)

Name Name
Power for robot stop

1  Black 26 Data area 2 bit 7 21 Pink
(internal +24V)
2 Robot stop  Brown 27 Data area 2 bit 8 22 Pink
Power for Enable Auto

3  Red 28 Data area 2 bit 9 23 Pink
(internal +24V)
4 Enable Auto  Black 29 Data area 2 bit 10 24 White
5 Step-stop (all tasks) 0 Brown 30 Data area 2 bit 11 25 White
6 Unused 1 Red 31 Data area 2 bit 12 26 White
Instantaneous stop
7 2 Orange 32 Data area 2 bit 13 27 White
(all tasks)
8 Strobe signal 3 Yellow 33 Data area 2 bit 14 28 White
9 Interrupt skip 4 Green 34 Data area 2 bit 15 29 White
Command and data odd

10 5 Blue 35 Command area 0 bit 0 30 White
parity
11 Data area 1 bit 0 6 Violet 36 Command area 0 bit 1 31 White
12 Data area 1 bit 1 7 Black 37 Command area 0 bit 2 32 Gray
13 Data area 1 bit 2 8 Brown 38 Command area 0 bit 3 33 Gray
14 Data area 1 bit 3 9 Red 39 User input 34 Gray
15 Data area 1 bit 4 10 Orange 40 User input 35 Gray
16 Data area 1 bit 5 11 Yellow 41 User input 36 Gray
17 Data area 1 bit 6 12 Green 42 User input 37 Gray
18 Data area 1 bit 7 13 Blue 43 User input 38 Gray
19 Data area 2 bit 0 14 Violet 44 User input 39 Gray
20 Data area 2 bit 1 15 White 45 User input 40 Gray
21 Data area 2 bit 2 16 Pink 46 User input 41 Gray
22 Data area 2 bit 3 17 Black 47 User input 42 Violet
23 Data area 2 bit 4 18 Brown 48 User input 43 Violet
24 Data area 2 bit 5 19 Red 49 User input 44 Violet
25 Data area 2 bit 6 20 Orange 50 User input 45 Violet
5-100
5.6.1.3 Connector Pin Layout for Special Mode

(1) OUTPUT CN10: User-/System-output connector (Special mode)
Table 5-19 CN10 Pin Layout (Special mode)

Name Name
2 Robot running 73 Brown 36 User output 107 Pink
3 Robot error 74 Red 37 User output 108 Pink
4 Auto mode 75 Orange 38 User output 109 Pink
5 External mode 76 Yellow 39 User output 110 Pink
6 Program start reset 77 Black 40 User output 111 White
7 Unused 78 Brown 41 User output 112 White
8 Unused 79 Red 42 User output 113 White
9 Robot power ON complete 80 Orange 43 User output 114 White
10 Servo ON 81 Yellow 44 User output 115 White
11 CAL complete 82 Green 45 User output 116 White
12 Teaching 83 Blue 46 User output 117 White
13 Single-cycle complete 84 Violet 47 User output 118 White
14 Dead battery warning 85 Gray 48 User output 119 White
15 Robot warning 86 Pink 49 User output 120 White
16 Continue start permitted 87 Black 50 User output 121 Gray
17 Error units bit 0 88 Black 51 User output 122 Violet
18 Error units bit 1 89 Brown 52 User output 123 Violet
19 Error units bit 2 90 Red 53 User output 124 Violet
20 Error units bit 3 91 Orange 54 User output 125 Violet
21 Error tens bit 0 92 Yellow 55 User output 126 Violet
22 Error tens bit 1 93 Green 56 User output 127 Violet
23 Error tens bit 2 94 Blue 57 Not connected  Violet
24 Error tens bit 3 95 Gray 58 Not connected  Violet
25 Error hundreds bit 0 96 Pink 59 Not connected  Violet
26 Error hundreds bit 1 97 Brown 60 Not connected  Gray
27 Error hundreds bit 2 98 Red 61 Not connected  Gray
28 Error hundreds bit 3 99 Orange 62 Not connected  Gray
29 SS mode 100 Yellow 63 Not connected  Gray
30 Unused 101 Green 64 Not connected  Gray
31 Unused 102 Blue 65 Emergency stop +  Gray
32 Unused 103 Pink 66 Emergency stop −  Gray
33 User output 104 Black 67 Not connected  Blue
34 User output 105 Brown 68 Not connected  Blue
5-101
(2) INPUT CN8: User-/System-input connector (Special mode)
Table 5-20 CN8 Pin Layout (Special mode)

Name Name
1 Power for robot stop (internal +24V) - Black 26 User input 21 Pink
2 Robot stop - Brown 27 User input 22 Pink
3 Power for Enable Auto (internal +24V) - Red 28 User input 23 Pink
4 Enable Auto - Black 29 User input 24 White
5 Step-stop (all tasks) 0 Brown 30 User input 25 White
6 Continue start 1 Red 31 User input 26 White
7 Instantaneous stop (all tasks) 2 Orange 32 User input 27 White
8 Operation preparation start 3 Yellow 33 User input 28 White
9 Interrupt skip 4 Green 34 User input 29 White
10 Program start 5 Blue 35 User input 30 White
11 Program No. select bit 0 6 Violet 36 User input 31 White
12 Program No. select bit 1 7 Black 37 User input 32 Gray
13 Program No. select bit 2 8 Brown 38 User input 33 Gray
14 Program No. select bit 3 9 Red 39 User input 34 Gray
15 Program No. select bit 4 10 Orange 40 User input 35 Gray
16 Program No. select bit 5 11 Yellow 41 User input 36 Gray
17 Program No. select bit 6 12 Green 42 User input 37 Gray
18 Program No. select odd parity bit 13 Blue 43 User input 38 Gray
19 Motor power ON 14 Violet 44 User input 39 Gray
20 CAL execution 15 White 45 User input 40 Gray
21 Reserved 16 Pink 46 User input 41 Gray
22 SP100 17 Black 47 User input 42 Violet
23 Switch Ext Mode 18 Brown 48 User input 43 Violet
24 Program reset 19 Red 49 User input 44 Violet
25 Robot error clear 20 Orange 50 User input 45 Violet
5-102
5.6.2 Robot Controller I/O Circuits
5.6.2.1 User-Input, System-Input and Hand-Input Circuits

Figures 5-55 and 5-56 show examples of the user-input, system-input and
hand-input circuit configurations and connections of the robot controller.
The maximum allowable current capacity of the robot controller's internal power
source is 1.3 A.
Use the internal power source within this allowable range.
Caution c: Either an external power supply type or built-in power type

Output card is available for the PLC. However, an external
power supply type requires an additional power source (24V)
to be installed. The power capacity is 15W or more.
d: When controlling two or more robots with a single PLC using
the internal power source of the Robot Controller, set a PLC
Output card for each robot.
e: Other than a PLC, a proximity switch, or a relay contact may
be connected directly to the input terminal of the Robot
Controller. In such a case, use the power input to pins 6 to 9
of the I/O power connector. A two-wire photoelectric switch
or proximity switch can be connected if its leakage current is
1 mA or less.
f: Use a multi-core shielding cable for the purpose of protecting
the Robot Controller from noise. Ground it to the Robot
Controller.
5-103
F1
F2
Interval
Power source
Internal circuit
Photo-coupler
PLC Robot controller
Figure 5-55 User-Inpput, System-Input and Hand-Input Circuits

(When the internal power source is used)
I/O POWER
Power
connector
source
Internal circuit
Photo-coupler
Figure 5-56 User-Input, System-Input and Hand-Input Circuits

(When an external power source is used)
5-104
5.6.2.2 Robot Stop Input and Enable Auto Input Circuits

The robot stop signal and the Enable Auto signal are important for safety. The
input circuit for these signals must have contacts as shown in Figure 5-57.
Use the INPUT CN8 (pins 1 and 3) of the robot controller for the power source,
irrespective of whether the power source to be used for other I/O signals is the
internal power source or an external power source.
Internal power source +24V
F8
1.3A
Robot Stop
Enable Auto
Internal power source 0V
Robot controller
Figure 5-57 Robot Stop Input and Enable Auto Input Circuit
5-105
5.6.2.3 User-Output, System-Output, and Hand-Output Circuits
Figures 5-58 and 5-59 show an example of the configuration and connection of
the Robot Controller's user-input output, system-output and hand-output circuit.
Since the initial resistance of a lamp is small, the output circuit may be damaged
by rush current that flows when the lamp lights.
When directly turning a lamp ON or OFF, use a lamp whose rating is 0.5W or
less.
To reduce rush current, connect a resistor R that allows dark current 1/3 or less
of the rated current to flow when the lamp goes OFF.
Figure 5-60 shows an example of connecting a lamp.
(1) The User-Output, System-Output and Hand-Output Circuit are open
collector output circuits.
(2) The maximum allowable intake current is 70mA.
Keep the current consumption of a device to be connected to the
Robot Controller, such as a PLC and a relay coil, below the allowable
current.
(3) Select an induction load, such as a relay coil, which has a built-in
diode (for absorbing inverse electromotive force).
To use an induction load without a built-in diode, add a diode
equivalent to the 1S1888 (Toshiba) in close vicinity to the coil.
Caution: When externally attaching a diode, connect it with

correct polarity. Incorrect polarity may damage the
Output circuit.
(4) Connecting a lamp requires a circuit through which dark current

flows.
Caution: Since the initial resistance of a lamp is small, the output

circuit may be damaged by rush current that flows when
the lamp lights.
Refer to Figure 5-60.
(5) When using the internal power source, prepare a PLC input circuit unit
that does not contain a power source.
Caution: Keep the total current capacity of the internal power

source below 1.3A.
(6) Use a multi-core shielding cable for the purpose of protecting the
devices from external noise. Ground it to the Robot Controller.
(7) 24V internal power source of the robot controller must not be
grounded.
Caution: If the output terminal +24V of internal power source is

grounded, there may be a case where the controller is
damaged.
5-106
F1
F2
Figure 5-58 User-Output, System-Output and Hand-Output Circuit


5-107
Supplied from the II/O power connector
when the internal power source is used
Lamp
Transistor array
Controller
Figure 5-60 Example of Circuit with Lamp
5-108
5.6.2.4 Emergency Stop Output Circuit

Figures 5-61 and 5-62 show the examples of configuration and connection of
emergency stop circuit for the robot controller.
The red mushroom-shaped switch provided on the robot controller front panel,
on the teach pendant, or on the operating panel can be used as a switch for
stopping the equipment in case of emergency.
F1
F2
F9 Emergency
Stop +
Emergency
Stop −
F8
Figure 5-61 Emergency Stop Output Circuit (Activated by Internal Power Source)
F9 Emergency
Stop +
Emergency
Stop −
F8
Figure 5-62 Emergency Stop Output Circuit (Activated by External Power Source)
5-109
5.6.2.5 I/O Power Connector
For the power source to communicate signals between the robot controller and
the external device, the internal power source of the robot controller or an
external power source is used.
Figure 5-63 shows an example of connecting I/O power connectors when the
internal power source is used, and Figure 5-64 shows an example of connecting
I/O power connectors when an external power source is used.
0.5 mm2 or F1
more
AWG20 or more 0.5 mm2 or F2

more
Internal
power source
AWG20 or more
PLC
I/O circuit
Robot controller
Figure 5-63 Example of Connecting I/O Power Connectors (When the internal power source is used)
Caution: To use the internal power source of the robot controller,

connect the wiring so that the internal power source will be
separate from the external power source. Improper wiring
may damage the internal circuit.
+24V internal power source of the robot controller must not
be grounded.
5-110
F1
F2
Internal
power source
0.5 mm2 or more
0.5 mm2 or more
External power source I/O circuit
Robot controller
Figure 5-64 Example of Connecting I/O Power Connectors (When an external power source is used)
Caution: Use a cable of 0.5 mm2 or more in size for the wiring between the
external power source and the I/O power input connectors of the
robot controller.
5-111
5.6.3 Precautions When Wiring the Robot Controller I/O
Connectors
After the wiring of the I/O connectors of the Robot Controller is completed, check
the following before turning ON the power:
(1) Using a tester, check across the "+24V terminal" and "0V terminal" of each
connector and across the "E24V terminal" and the "E0V terminal" to see
that there is no continuity. See Figure 5-65.
Caution: If the connector wiring between the Robot Controller's "+24V

terminal" and "0V terminal" and between the "E24V terminal"
and the "E0V terminal" is shorted, damage to the power
circuit of the Robot Controller will result.
(2) Using a tester, check across "each signal Output terminal" and "+24V
terminal" or "E24V terminal" of each connector to see that there is no
continuity. See Figure 5-65.
Caution: If the wiring between "each signal Output terminal" and

"+24V terminal" or "E24V terminal" of each connector is
shorted, damage to the Output circuit and power circuit of
the Robot Controller will result.
Caution: Wind adhesive vinyl tape around all ends of the unconnected
wiring of each connector to prevent them from contacting
other wiring and parts, which results in shorting.
Tester
Robot
controller External
Robot controller's “+24V
terminal” and “E24V device
terminal”
Robot controller's “0V

terminal” and “E0V
terminal”
Figure 5-65 Checking Example
5-112
Table 5-21 Connector Terminals Requiring Checking

Connector for hand I/O Connector for user/system input

Terminal Check Terminal Check
Number Name Meaning point Number Name Meaning point
+24V internal +24V internal
Hand output
1 to 8 24V at output (2) 1, 3 power source power source (1)
terminal
terminal output
Power
Power (GND)
17 terminal for (1)
output
hand (E0V)
Power
24V power
18 terminal for (1)
output
hand (E24V)
Connector for user/system output Connector for I/O power source


Name Meaning Name Meaning
number point number point
Signal output 24V at
1 to 56 (2) 1, 2 power source power source (1)
terminal output
terminal output
0V internal 0V internal
3, 4 power source power source (1)
terminal output
E0V (GND) Power (GND)

6, 7 (1)
input terminal input
E24V input 24V power

8, 9 (1)
terminal input
5-113
5.7 I/O Wiring
5.7.1 Multi-core Cables with Connectors
Use the recommended connectors and cables listed in Table 5-22.
Table 5-22 Standard of Recommended Connectors and Cables for I/O Cables
Connector Connector
Standard Cable Remarks
name model/manufacturer
PCR-E68FS connector UL2789 - With shield Caution: Set the shielding wire at
the end of the prepared
PCS-E68LA cover Equivalent to AWG28-68P cable, as shown in
OUTPUT
Honda Communications Figure 5-63. Without
Industry Co., Ltd. this preparation, a noise
malfunction may result.
PCR-E20FS connector UL2789 - With shield
PCS-E20LA cover Equivalent to AWG28-20P
HAND I/O
Honda Communications
Industry Co., Ltd.
PCR-E50FS connector UL2789 - With shield
PCS-E50LA cover Equivalent to AWG28-50P
INPUT
Honda Communications
Industry Co., Ltd.
DE-9P connector UL2405 - With shield
I/O DE-C4-J6 cover Equivalent to AWG20-2P
POWER Japan Aviation
Electronics Industry, Ltd.
Crimping terminal
Vinyl tube
The connector
shell must be a
Shielding conductive metal
braided wire Shielding wire body.
I/O cable
Fasten to the connector
I/O power
connector Vinyl tube
Figure 5-63 Example of Preparing Shielding Wire
5-114
5.7.2 Wiring
Observe the following precautions when wiring the I/Os of the robot controller:
(1) Connect the robot power cable to a power source separate from the welder
power source.
(2) Ground the grounding wire (green) of the robot power cable.
(3) Ground the grounding terminal of the robot controller using a wire of 1.25
mm2 or more in size.
(4) For the robot power supply, use a grounding wire with grounding resistance
of 100 Ω or less.
(5) If the supply power source for the robot controller requires a leakage breaker,
use a high frequency-proof leakage breaker for inverters.
(6) Prepare wires of an appropriate capacity for the 200 VAC main line and other
cables according to Tables 5-23.
Table 5-23 Robot Controller Specifications
Power voltage: 3-phase, 200 VAC -15% to Pin assignment on connector (CN11), 3-phase
230 VAC + 10%, 50/60 Hz
A: 200 VAC, phase R
B: 200 VAC, phase S
C: 200 VAC, phase T
D: Ground
(View from pin face)
Power voltage: Singe-phase, 200 VAC -10% Pin assignment on connector (CN11), single-
to 230 VAC + 10%, 50/60 H phase
(Available only for A: 200 VAC, phase R

MOTOMAN-UPJ3) B: 200 VAC, phase S
C: Not used.
D: Ground
(View from pin face)

Max. rush current when
the power is turned ON: 50 A (for 1/50 or 1/60 second)
Caution: If ERROR6102 (power voltage drop) occurs when the robot is in

operation, it may be attributable to an insufficient capacity of
the primary side power source.
(7) Do not bundle the teach pendant cables, I/O cables or motor cables together
with high power lines such as 200 VAC lines and peripheral device cables, or
route the motor cables near high power devices (motor, welder, parts feeder,
etc.).
(8) Do not route any additional cables or air tubes of end-effectors through the
robot unit. Doing so will result in broken cables or tubes.
5-115
Chapter 6
Maintenance and
Inspection
This chapter describes the regular maintenance

and inspections necessary for maintaining the
performance and functions of the robot.
Contents
Chapter 6 Maintenance and Inspection

6.1 Maintenance & Inspection Intervals and Purposes................................................................. 6-1
6.2 Daily Inspections ......................................................................................................................... 6-2

6.2.1 Check Items................................................................................................................................. 6-2
6.3 Quarterly Inspections ................................................................................................................. 6-4

6.3.1 Check Items................................................................................................................................. 6-4
6.3.2 Cleaning the Cooling Fan Filters in the Robot Controller ........................................................... 6-5
6.4 Biennial Inspections.................................................................................................................... 6-9

6.4.1 Battery Replacement and Check Items....................................................................................... 6-9
6.4.2 Replacing the Memory Backup Battery..................................................................................... 6-10
6.4.3 Setting the Next Battery Replacement Date ............................................................................. 6-14
6.5 Supplies...................................................................................................................................... 6-15

6.5.1 Supplies ..................................................................................................................................... 6-15
6.6 Replacing Fuses ........................................................................................................................ 6-16

6.6.1 Replacing Fuses........................................................................................................................ 6-18
6.7 Replacing the Output ICs ......................................................................................................... 6-22

6.7.1 Replacing an Output IC ............................................................................................................. 6-24
6.8 Checking the Odometer and Trip Meter .................................................................................. 6-27

6.8.1 Displaying the Odometer, Trip Meter, and Oil Change Intervals............................................... 6-27
6.8.2 Resetting the Trip Meter to Zero ............................................................................................... 6-29
6.9 Checking the Controller ON-Time and the Robot Running Time and Resetting
Their User Counters .................................................................................................................. 6-31
6.9.1 Displaying the Controller ON-time and the Robot Running Time ............................................. 6-31
6.9.2 Resetting the User Counters of the Controller ON-Time and the Robot Running Time ........... 6-33
6.1 Maintenance & Inspection Intervals and

Purposes
Table 6-1 lists the intervals and purposes of maintenance & inspection required
for your robot.
Caution: Before performing maintenance and inspection jobs, read the

SAFETY PRECAUTIONS, "3 Precautions while robot is
running" and "4 Daily and periodical inspections."
Table 6-1 Maintenance & Inspection Intervals and Purposes
No. Intervals Purposes
1 Daily Perform inspection jobs specified in To use your robot safely.

Section 6.2 every day before starting
operations.
2 Quarterly Perform inspection jobs specified in To maintain the precision of the robot and
Section 6.3 every three months. to prevent failures caused by overheat of
3 Biennial Replace backup batteries as To retain the robot-specific data
specified in Section 6.5 every two (programs, parameters, etc.) stored in the
years. internal memory of the robot controller
and the position data stored in the
electronic absolute encoder build in the
robot unit.
6-1
6.2 Daily Inspections
6.2.1 Check Items
Before starting operations, check the items listed in Table 6-2 every day.
Table 6-2 Daily Inspections Table
Controller What to do:

No. Check: How to check: Criterion
Power (Note 1)
Connectors (CN1 to Engage the

CN12 on the robot No looseness, parts properly
1 OFF Visually
controller) and their disengagement or dirt. and clean
mating parts them.
Cables (connected to
CN1 to CN12 on the
Free of damage or Repair or
2 robot controller) and OFF Visually
gouges. replace.
robot’s external
cables
LCD on the teach Repair or
3 ON Visually Properly displayed
pendant replace.
Pilot lamps on the Repair or

4 ON Visually Should light.
robot controller replace.
Cooling fan in the Visually Repair or

5 ON Should work properly.
robot controller (Note 2) replace.
No error or unusual Repair or

6 Calibration ON Visually
noise. replace.
ROBOT STOP button The robot should
Press the ROBOT Repair or
7 on the operating panel ON come to an
STOP button. replace.
or the teach pendant emergency stop.
Operate the safety The robot should
Repair or
8 Safety door ON door switch and open come to an
replace.
the switch-wiring door. emergency stop.
Note 1 Some repair and replacement operations, shown in "What to do:"

column, may involve special work. Contact the YASKAWA Service
Section.
Note 2 The normal operation of the cooling fan is as shown in Figure 6-1.
6-2
(Left panel)
Air Intake
(Right panel)
Exhaust
Figure 6-1 Normal Operation of Cooling Fan
6-3
6.3 Quarterly Inspections
6.3.1 Check Items
Check the items listed in Table 6-3 every three months.
Table 6-3 Quarterly Inspections Table
Controller
No. Check: How to check: Criterion What to do:
Power
Cooling fan filters OFF Visually No dust or dirt. Clean the cooling
1 in the robot fan filters. (Refer to
controller Subsect. 6.3.2.)
6-4
6.3.2 Cleaning the Cooling Fan Filters in the Robot Controller

The robot controller has two cooling fan filters—inlet port filter and exhaust port
filter.
If either of the filters is clogged, the robot controller becomes badly ventilated to
overheat so that the internal electronic devices may fail due to heat.
If a power module error appears, it may be caused by clogged filters, so clean
those filters.
Turn the POWER switch of the Robot Controller OFF.

4STEP 1
Remove the screws with your fingers to release the inlet port filter.
4STEP 2
6-5
Remove the support frame of the inlet port filter.
4STEP 3
Remove the filter element from the support frame.

4STEP 4
6-6
Remove the screws with your fingers to release the exhaust port filter.
4STEP 5
Remove the support frame of the exhaust port filter.

4STEP 6
Remove the filter element from the support frame.

4STEP 7
6-7
Blow compressed air to the filter elements in the direction opposite to
4STEP 8 the regular air flow.
NOTE: Use dehumidified, oil-free, pure compressed air for cleaning.
If the filters are excessively dirty, wash them with water or warm water
(40°C or lower). A neutral detergent is most effective.
Notes (1) Dry the washed filters completely before replacing them.
(2) If the filters are still dirty after air blowing or washing, replace
them with new ones.
Reinstall the filters in the reverse order of removal.

4STEP 9
6-8
6.4 Biennial Inspections

6.4.1 Battery Replacement and Check Items
Replace the two types of backup batteries listed in Table 6-4 during biennial
inspections and maintenance.
Table 6-4 Backup Battery Types
Battery type Used to: Located: Refer to:
Back up programs, In the robot

1 Memory backup battery Subsect. 6.4.2
parameters, and CAL data. controller
Programs, parameters, CAL data, etc. are stored in the internal memory of the
robot controller.
The backup battery for each memory retains the above data while the power to
the robot controller is turned OFF. However, these batteries have a limited
lifetime and must, therefore, be replaced regularly.
NOTE: If two years elapse from replacement of either backup battery, the "Time
to change controller backup battery" message will appear on the teach pendant.
Caution: Without replacing the backup batteries, important robot-

specific data stored in each memory will be lost.
6-9
6.4.2 Replacing the Memory Backup Battery
This section gives an example of replacing the memory backup battery using a
floppy disk.
Caution: Before replacing the memory backup battery, save (write) the
Robot Controller memory data onto a floppy disk. The built-in
floppy disk drive is an option.
Save (write) the controller memory data onto a floppy disk.

4STEP 1 Floppy disk drive
For the procedure on saving the memory data, see the SETTING-UP
MANUAL, Section 5.7 "Displaying the FDD Access Menu, [F6 Set]-[F3
FD.]-[F2 Write].
Prepare a new memory backup battery.

4STEP 2
Turn the controller power ON, wait at least one minute, and turn it to
4STEP 3 OFF again.
6-10
Remove the screw to release the backup battery support.

4STEP 4
Pull out the backup battery support.

4STEP 5
6-11
Disconnect the backup battery connector.
4STEP 6
Caution: Complete the operations in Steps 6 and 7 within three

minutes. If the battery is disconnected for over three
minutes, the memory data will be lost.
Connect the new memory backup battery prepared in Step 2, to the

4STEP 7 robot controller.
6-12
Push the backup battery support into the robot controller.

4STEP 8
Caution: Take care not to pinch the battery lead wires between
covers or internal parts. Shorting many occur, resulting
in an unexpected failure.
Secure the backup battery support with a screwdriver.

4STEP 9
6-13
6.4.3 Setting the Next Battery Replacement Date
After replacing the memory backup battery, set the next battery replacement
date from the teach pendant, according to the following procedure.
NOTE: This procedure cannot be performed with the operating panel.
NOTE: Check that the system clock of the robot controller shows the correct
date beforehand. If it is incorrect, the next replacement date will also become
incorrect.
4STEP 1
On the top screen of the teach pendant, press [F6 Set].
The Settings (Main) window appears.
Press [F6 Maint.] in the Settings (Main) window.

4STEP 2 The Maintenance menu appears.
Press [F4 Battery] in the Maintenance menu.

4STEP 3 The Next Battery Replacement Date window appears.
In the top of the window, the current setting is displayed.
The date entry areas show the default replacement date that is two years
later the current data at which you open this window, assuming that the
battery service life is two years.
Press OK.
4STEP 4 NOTE: If you do not want to change the replacement date, press Cancel.
The message "Are you sure you want to set the next battery replacement
date?" appears.
Press OK.
4STEP 5 The screen returns to the Settings (Main) window.
6-14
6.5 Supplies
Tables 6-5 lists the supplies to be replaced regularly and required tools, out of
components used in robots.
6.5.1 Supplies
Table 6-5 List of Supplies
No Name Part No. Remarks
1 Filter (left) Cooling fan filter (inlet port filter) in the robot
410041-0760
controller
2 Filter (right) Cooling fan filter (exhaust port filter) in the robot
410041-1220
controller
3 Memory backup unit 410076-0090 Memory backup battery for controller
(with metal plate)
4 Fuse (1.3A) 410054-0230 Fuse LM13 (1.3A) for controller I/O
5 Fuse (0.3A) 410054-0240 Fuse LM03 (0.3A) for controller I/O
6 IC for output (NPN) 410077-0010 IC (M54522P) for controller output
7 IC for output (PNP) 410077-0020 IC (M54564P) for controller output
6-15
6.6 Replacing Fuses
The robot controller is equipped with fuses to protect it from external wiring
shorted.
If any fuse is blown, replace it according to the following procedure
The fuse box containing fuses is mounted on the panel of the robot controller.
See Figure 6-2.
F9 F10
(Reserved)
Figure 6-2 Locations and Names of Fuses
6-16
Table 6-6 lists connectors corresponding to the fuses. If an output signal error
occurs, check the corresponding fuse.
Table 6-6 Output Connectors and Fuses

Connector No. Connector pin No. Output IC No. Fuse No.
1 
F1 (1.3A)
2 
I/O POWER CN7
3 
F2 (1.3A)
4 
17  F3 (1.3A)
1
2
3
HAND I/O CN9 4
IC 1
5
6
7
8
F4 (1.3A)
1
2
3
4
IC 2
5
6
7
8
9
10
11
12
IC 3
13
14
15
16
F5 (1.3A)
17
18
19
20
IC 4
21
22
23
24
25
26
27
28
IC 5
OUTPUT CN10 29
30
31
32
F6 (1.3A)
33
34
35
36
IC 6
37
38
39
40
41
42
43
44
IC 7
45
46
47
48
F7 (1.3A)
49
50
51
52
IC 8
53
54
55
56
65  F9 (0.3A)
1 
INPUT CN8 F8 (1.3A)
3 
Note: For the connector pin layout, refer to Chapter 5, Subsection 5.6.1
"I/O Signal Connector Pin Layout”.
6-17
6.6.1 Replacing Fuses
Replace fuses according to the following procedure:

4STEP 1
Remove the fuse cover mounting screw with a screwdriver.

4STEP 2
6-18
Remove the fuse cover.

4STEP 3
Pull out the fuse to be checked.

4STEP 4
6-19
Using a circuit tester, check the removed fuse for continuity.
4STEP 5
If no continuity is observed with the fuse in Step 5:

4STEP 6 (1) Check the wiring of the corresponding output connector and
remove the cause of the blown fuse.
(2) Insert a new fuse into place in the fuse box.
If continuity is observed with the fuse in Step 5, set the removed fuse
back into place in the fuse box.
6-20
Set the fuse cover to the robot controller.

4STEP 7
Replace the fuse cover mounting screw with a screwdriver.

4STEP 8 Tightening torque: 0.6 ±0.2 Nm.
6-21
6.7 Replacing the Output ICs
If an output signal error persists even after replacement of the output fuse, the
related output IC needs to be replaced.
Output ICs are located in the panel of the robot controller as shown below.
Figure 6-3 Location and Names of Output ICs
Table 6-7 lists output signals and related IC numbers and fuses.
6-22
Table 6-7 Output ICs and Fuses
Connector No. Connector terminal No. I/O Port No. Output IC No. Fuse No.
1 64
2 65
3 66
4 67
HAND I/O CN9 IC 1
5 68
6 69
7 70
8 71
F4 (1.3A)
1 72
2 73
3 74
4 75
IC 2
5 76
6 77
7 78
8 79
9 80
10 81
11 82
12 83
IC 3
13 84
14 85
15 86
16 87
F5 (1.3A)
17 88
18 89
19 90
20 91
IC 4
21 92
22 93
23 94
24 95
25 96
26 97
27 98
28 99
OUTPUT CN10 IC 5
29 100
30 101
31 102
32 103
F6 (1.3A)
33 104
34 105
35 106
36 107
IC 6
37 108
38 109
39 110
40 111
41 112
42 113
43 114
44 115
IC 7
45 116
46 117
47 118
48 119
F7 (1.3A)
49 120
50 121
51 122
52 123
IC 8
53 124
54 125
55 126
56 127
6-23
6.7.1 Replacing an Output IC
Replace an output IC according to the procedure given below:

4STEP 1
Remove the two screws to release the output IC cover with a

4STEP 2 screwdriver.
6-24
Remove the output IC cover.

4STEP 3
Check the ICs marked with "IC1" to "IC8" on the PC board, and remove
4STEP 4 the defective output IC with an IC pull-out jig and replace the IC.
Caution (1) If any output IC is damaged, remove the cause of

damage, and replace it with a new output IC.
(2) Do not directly touch the elements and their
terminals on each PC board.
6-25
Install the output IC cover to the robot controller.
4STEP 5
Secure the output IC cover with two mounting screws.

4STEP 6 Tightening torque: 0.6 ±0.2 Nm.
6-26
6.8 Checking the Odometer and Trip Meter

You may check the odometer and trip meter which count traversed distance of
each axis in the Odometer window of the teach pendant. With the trip meter, you
may learn when oil change should be made.
The access to the Odometer window is [F6 Set]—[F6 Maint.]—[F5 Odometer].
The Odometer window shows the following items:
[Odometer] Shows the total distance of each axis traversed after the robot
leaves the factory. You cannot reset the odometer.
[Trip meter] Shows the distance of each axis traversed after you reset the trip
meter to zero.
[Interval] Shows the oil change intervals specified for each axis, as a guide.
6.8.1 Displaying the Odometer, Trip Meter, and Oil Change

Intervals
4STEP 1
Turn the controller power ON.
4STEP 2
On the teach pendant, set the mode switch to the MANUAL position.
4STEP 3
On the top screen, press [F6 Set].
The Settings (Main) window appears as shown below.
YR-UPJ3-B00
F6
Press [F6 Maint.].
6-27
4STEP 4
The Maintenance menu appears as shown below.
YR-UPJ3-B00
F5
Press [F5 Odometer].
4STEP 5
The Odometer window appears as shown below.
YR-UPJ3-B00
F6
In the above Odometer window, the J1 through J6 are expressed in rpm.

If the Trip meter count exceeds the Interval value, the oil change prompt
message will appear.
6-28
6.8.2 Resetting the Trip Meter to Zero
4STEP 1
YR-UPJ3-B00
F6
Press [F6 Maint.].
4STEP 2
YR-UPJ3-B00
F5
Press [F5 Odometer].
6-29
4STEP 3
The Odometer window appears as shown below.
YR-UPJ3-B00
F6
Press [F6 Reset].
4STEP 4
The following message appears.
YR-UPJ3-B00
Press the OK button.

The trip meter has been reset to zero.
6-30
6.9 Checking the Controller ON-Time and the

Robot Running Time and Resetting Their
User Counters
You may check the robot controller ON-time and the robot running time in the
Total hours window of the teach pendant.
The Total hours window shows the following items:
[Total operation] Shows the grand total of the robot controller ON-time
counted after the controller leaves the factory.
[Total running] Shows the grand total of the robot running time counted
after the robot leaves the factory.
[Cumu. operation] Shows the total of the robot controller ON-time counted after
you reset the user counter to zero.
[Cumu. running] Shows the total of the robot running time counted after you
reset the user counter to zero.
[Operation] Shows the ON-time of the robot controller counted after it is
turned ON this time.
[Running] Shows the running time of the robot counted after the robot
controller is turned ON this time.
6.9.1 Displaying the Controller ON-time and the Robot Running

Time
4STEP 1
Turn the robot controller power ON.
4STEP 2
On the teach pendant, set the mode switch to the MANUAL position.
4STEP 3
YR-UPJ3-B00
F6
Press [F6 Maint.].
6-31
4STEP 4
YR-UPJ3-B00
F1
Press [F1 Total h].
4STEP 5
The Total hours window appears as shown below.
YR-UPJ3-B00
6-32
6.9.2 Resetting the User Counters of the Controller ON-Time and

the Robot Running Time
4STEP 1
On the teach pendant, press [F6 Set].
YR-UPJ3-B00
F6
Press [F6 Maint.].
4STEP 2
YR-UPJ3-B00
F1
Press [F1 Total h].
6-33
4STEP 3
The Total hours window appears as shown below.
YR-UPJ3-B00
F4
To reset the user counter of the controller ON-time to zero, press [F4
Cumu. o].
4STEP 4
The following system message appears.
YR-UPJ3-B00
Press the OK button.
6-34
The user counter of the controller ON-time has been reset to zero.
YR-UPJ3-B00
6-35
Appendix
Contents
Appendix
Appendix 1 I/O Circuits and Connectors (NPN type) .........................................................Appendix-1
1.1 I/O Signal Connector Pin Layout..........................................................................................Appendix-1
1.1.1 Connector Pin Layout Common to Both Modes....................................................Appendix-1
1.1.2 Connector Pin Layout for Standard Mode.............................................................Appendix-3
1.1.3 Connector Pin Layout for Compatible Mode .........................................................Appendix-5
1.2 Robot Controller I/O Circuits ................................................................................................Appendix-7
1.2.1 User-Input, System-Input and Hand-Input Circuits ...............................................Appendix-7
1.2.2 Robot Stop Input and Enable Auto Input Circuits .................................................Appendix-9
1.2.3 User-Output, System-Output, and Hand-Output Circuits....................................Appendix-10
1.2.4 Emergency Stop Output Circuit...........................................................................Appendix-13
1.2.5 I/O Power Connector...........................................................................................Appendix-14
1.3 Precautions When Wiring the Robot Controller I/O Connectors .......................................Appendix-16
Appendix
Appendix 1 I/O Circuits and Connectors (NPN

type)
This section explains the I/O circuit of NPN type (source input and sink output).
For the circuit of PNP type (sink input and source output), refer to Chapter 5,
Section 5.6, "I/O Circuits and Connectors (PNP type)."
1.1 I/O Signal Conne ctor Pin Layout

This section describes the Robot Controller connector pin layouts for I/O signals.
The definitions of the signals and pins of the output connector CN10 and input
connector CN8 are different between the standard mode and the compatible
mode.
As for the other connectors, the definitions of the pins are common to the
standard mode and the compatible mode.
1.1.1 Connector Pin Layout Common to Both Modes

(1) HAND I/O CN9: Connector for end-effector I/O (common to both modes)
View from the cable side
Wire color Wire color

Terminal Port Terminal Port
Name Name
No. number High No. number High
Standard Standard
strength strength
1 Hand output 64 Black Blue 11 Hand Input 50 Pink White
2 Hand output 65 Brown Yellow 12 Hand Input 51 Pink White
3 Hand output 66 Black Green 13 Hand Input 52 White White
4 Hand output 67 Brown Red 14 Hand Input 53 White White
5 Hand output 68 Red Violet 15 Hand Input 54 White White
Hand Input
6 Hand output 69 Orange Blue 16 55 White Brown
(interrupt input)
7 Hand output 70 Yellow Yellow 17 Power E24V for Hand  White Brown
8 Hand output 71 Green Green 18 Power E0V for Hand  White Brown
9 Hand input 48 Blue Red 19 Not connected  White Brown
10 Hand input 49 Violet Violet 20 Not connected  White Brown
Appendix-1
(2) I/O POWER CN7: Power connector for I/O (common to both modes)
Terminal No. Name
5 FG
6 Power input E24V
7 Power input E24V
8 Power input E0V
9 Power input E0V
Caution: When using the internal power source, keep the total
current capacity below 1.3 A. To use the internal power
source of the robot controller, connect the wiring so that
the internal power source will be separated from the
external power source. Improper wiring may damage the
internal circuit.
Appendix-2
Appendix
1.1.2 Connector Pin Layout for Standard Mode

(1) OUTPUT CN10: User-/System-output connector (standard mode)

Name Name
2 Robot in operation 73 Brown 36 User output 107 Pink
3 Robot Error 74 Red 37 User output 108 Pink
4 Servo ON 75 Orange 38 User output 109 Pink
5 Robot initialization complete 76 Yellow 39 User output 110 Pink
6 Automatic mode 77 Black 40 User output 111 White
7 External mode 78 Brown 41 User output 112 White
8 Dead battery warning 79 Red 42 User output 113 White
9 Robot warning 80 Orange 43 User output 114 White
10 Continue start permitted 81 Yellow 44 User output 115 White
11 SS mode 82 Green 45 User output 116 White
12 Reserved 83 Blue 46 User output 117 White
13 Reserved 84 Violet 47 User output 118 White
14 Reserved 85 Gray 48 User output 119 White
15 Command processing complete 86 Pink 49 User output 120 White
16 Status area odd parity 87 Black 50 User output 121 Gray
17 Status area bit 0 88 Black 51 User output 122 Violet
18 Status area bit 1 89 Brown 52 User output 123 Violet
19 Status area bit 2 90 Red 53 User output 124 Violet
20 Status area bit 3 91 Orange 54 User output 125 Violet
21 Status area bit 4 92 Yellow 55 User output 126 Violet
22 Status area bit 5 93 Green 56 User output 127 Violet
23 Status area bit 6 94 Blue 57 Not used.  Violet
24 Status area bit 7 95 Gray 58 Not used.  Violet
25 Status area bit 8 96 Pink 59 Not used.  Violet
26 Status area bit 9 97 Brown 60 Not used.  Gray
27 Status area bit 10 98 Red 61 Not used.  Gray
28 Status area bit 11 99 Orange 62 Not used.  Gray
29 Status area bit 12 100 Yellow 63 Not used.  Gray
30 Status area bit 13 101 Green 64 Not used.  Gray
31 Status area bit 14 102 Blue 65 Emergency stop +  Gray
32 Status area bit 15 103 Pink 66 Emergency stop −  Gray
33 User output 104 Black 67 Not used.  Blue
34 User output 105 Brown 68 Not used.  Blue
Appendix-3
(2) INPUT CN8: User-/System-input connector (standard mode)

number Name number color number
Name
number color
Power for robot stop (internal

1  Black 26 Data area 2 bit 7 21 Pink
+24V)
2 Robot stop  Brown 27 Data area 2 bit 8 22 Pink
Power for Enable Auto

3  Red 28 Data area 2 bit 9 23 Pink
(internal +24V)
4 Enable Auto  Black 29 Data area 2 bit 10 24 White
5 Step-stop (all tasks) 0 Brown 30 Data area 2 bit 11 25 White
6 Unused 1 Red 31 Data area 2 bit 12 26 White
Instantaneous stop
7 2 Orange 32 Data area 2 bit 13 27 White
(all tasks)
8 Strobe signal 3 Yellow 33 Data area 2 bit 14 28 White
9 Interrupt skip 4 Green 34 Data area 2 bit 15 29 White
Command and data odd

10 5 Blue 35 Command area 0 bit 0 30 White
parity
11 Data area 1 bit 0 6 Violet 36 Command area 0 bit 1 31 White
12 Data area 1 bit 1 7 Black 37 Command area 0 bit 2 32 Gray
13 Data area 1 bit 2 8 Brown 38 Command area 0 bit 3 33 Gray
14 Data area 1 bit 3 9 Red 39 User input 34 Gray
15 Data area 1 bit 4 10 Orange 40 User input 35 Gray
16 Data area 1 bit 5 11 Yellow 41 User input 36 Gray
17 Data area 1 bit 6 12 Green 42 User input 37 Gray
18 Data area 1 bit 7 13 Blue 43 User input 38 Gray
19 Data area 2 bit 0 14 Violet 44 User input 39 Gray
20 Data area 2 bit 1 15 White 45 User input 40 Gray
21 Data area 2 bit 2 16 Pink 46 User input 41 Gray
22 Data area 2 bit 3 17 Black 47 User input 42 Violet
23 Data area 2 bit 4 18 Brown 48 User input 43 Violet
24 Data area 2 bit 5 19 Red 49 User input 44 Violet
25 Data area 2 bit 6 20 Orange 50 User input 45 Violet
Appendix-4
Appendix
1.1.3 Connector Pin Layout for Compatible Mode

(1) OUTPUT CN10: User-/System-output connector (compatible mode)
Table 1-5 CN10 Pin Layout (Compatible mode)

Name Name
2 Robot running 73 Brown 36 User output 107 Pink
3 Robot error 74 Red 37 User output 108 Pink
4 Auto mode 75 Orange 38 User output 109 Pink
5 External mode 76 Yellow 39 User output 110 Pink
6 Program start reset 77 Black 40 User output 111 White
7 Unused 78 Brown 41 User output 112 White
8 Unused 79 Red 42 User output 113 White
9 Robot power ON complete 80 Orange 43 User output 114 White
10 Servo ON 81 Yellow 44 User output 115 White
11 CAL complete 82 Green 45 User output 116 White
12 Teaching 83 Blue 46 User output 117 White
13 Single-cycle complete 84 Violet 47 User output 118 White
14 Dead battery warning 85 Gray 48 User output 119 White
15 Robot warning 86 Pink 49 User output 120 White
16 Continue start permit 87 Black 50 User output 121 Gray
17 Error units bit 0 88 Black 51 User output 122 Violet
18 Error units bit 1 89 Brown 52 User output 123 Violet
19 Error units bit 2 90 Red 53 User output 124 Violet
20 Error units bit 3 91 Orange 54 User output 125 Violet
21 Error tens bit 0 92 Yellow 55 User output 126 Violet
22 Error tens bit 1 93 Green 56 User output 127 Violet
23 Error tens bit 2 94 Blue 57 Not connected  Violet
24 Error tens bit 3 95 Gray 58 Not connected  Violet
25 Error hundreds bit 0 96 Pink 59 Not connected  Violet
26 Error hundreds bit 1 97 Brown 60 Not connected  Gray
27 Error hundreds bit 2 98 Red 61 Not connected  Gray
28 Error hundreds bit 3 99 Orange 62 Not connected  Gray
29 SS mode 100 Yellow 63 Not connected  Gray
30 Unused 101 Green 64 Not connected  Gray
31 Unused 102 Blue 65 Emergency stop +  Gray
32 Unused 103 Pink 66 Emergency stop −  Gray
33 User output 104 Black 67 Not connected  Blue
34 User output 105 Brown 68 Not connected  Blue
Appendix-5
(2) INPUT CN8: User-/System-input connector (Compatible mode)
Table 1-6 CN8 Pin Layout (Compatible mode)

Name Name
1 Power for robot stop (internal +24V) - Black 26 User input 21 Pink
2 Robot stop - Brown 27 User input 22 Pink
3 Power for Enable Auto (internal +24V) - Red 28 User input 23 Pink
4 Enable Auto - Black 29 User input 24 White
5 Step-stop (all tasks) 0 Brown 30 User input 25 White
6 Continue start 1 Red 31 User input 26 White
7 Instantaneous stop (all tasks) 2 Orange 32 User input 27 White
8 Operation preparation start 3 Yellow 33 User input 28 White
9 Interrupt skip 4 Green 34 User input 29 White
10 Program start 5 Blue 35 User input 30 White
11 Program No. select bit 0 6 Violet 36 User input 31 White
12 Program No. select bit 1 7 Black 37 User input 32 Gray
13 Program No. select bit 2 8 Brown 38 User input 33 Gray
14 Program No. select bit 3 9 Red 39 User input 34 Gray
15 Program No. select bit 4 10 Orange 40 User input 35 Gray
16 Program No. select bit 5 11 Yellow 41 User input 36 Gray
17 Program No. select bit 6 12 Green 42 User input 37 Gray
18 Program No. select odd parity bit 13 Blue 43 User input 38 Gray
19 Motor power ON 14 Violet 44 User input 39 Gray
20 CAL execution 15 White 45 User input 40 Gray
21 Reserved 16 Pink 46 User input 41 Gray
22 SP100 17 Black 47 User input 42 Violet
23 Switch Ext Mode 18 Brown 48 User input 43 Violet
24 Program reset 19 Red 49 User input 44 Violet
25 Robot error clear 20 Orange 50 User input 45 Violet
Appendix-6
Appendix
1.2 Robot Controller I/O Circuits
1.2.1 User-Input, System-Input and Hand-Input Circuits

Figures 1-1 and 1-2 show examples of the user-input, system-input and hand-
input circuit configurations and connections of the robot controller.
The maximum allowable current capacity of the robot controller's internal power
source is 1.3 A.
Use the internal power source within this allowable range.
Caution c Either an external power supply type or built-in power type

Output card is available for the PLC. However, an external
power supply type requires an additional power source (24V)
to be installed. The power capacity is 15W or more.
d When controlling two or more robots with a single PLC using
the internal power source of the Robot Controller, set a PLC
Output card for each robot.
e Other than a PLC, a proximity switch, or a relay contact may
be connected directly to the input terminal of the Robot
Controller. In such a case, use the power input to pins 6 to 9
of the I/O power connector. A two-wire photoelectric switch
or proximity switch can be connected if its leakage current is
1 mA or less.
f Use a multi-core shielding cable for the purpose of
protecting the Robot Controller from noise. Ground it to the
Robot Controller.
Appendix-7
I/O POWER connector
F1
F2
Internal
power source
Internal circuit
Photo-coupler

Power I/O POWER

source connector
Internal circuit
Photo-coupler

Appendix-8
Appendix
1.2.2 Robot Stop Input and Enable Auto Input Circuits

The robot stop signal and the Enable Auto signal are important for safety. The
input circuit for these signals must have contacts as shown in Figure 1-3.
Use the INPUT CN8 (pins 1 and 3) of the robot controller for the power source,
irrespective of whether the power source to be used for other I/O signals is the
internal power source or an external power source.
Internal power source +24V
F8
1.3A
Robot Stop
Enable Auto
Internal power source 0V
Robot controller
Figure 1-3 Robot Stop Input and Enable Auto Input Circuit
Appendix-9
1.2.3 User-Output, System-Output, and Hand-Output Circuits
Figures 1-4 and 1-5 show an example of the configuration and connection of the
Robot Controller's user-input output, system-output and hand-output circuit.
Since the initial resistance of a lamp is small, the output circuit may be damaged
by rush current that flows when the lamp lights.
When directly turning ON and OFF a lamp, use a lamp whose rating is 0.5W or
less.
To reduce rush current, select and connect a resistor R that allows dark current
1/3 or less of the rated current to flow when the lamp goes OFF.
Figure 1-6 shows an example of connecting a lamp.
(1) The User-Output, System-Output and Hand-Output Circuit are open

collector output circuits.
(2) The maximum allowable intake current is 70mA.

Keep the current consumption of a device to be connected to the
Robot Controller, such as a PLC and a relay coil, below the allowable
current.
(3) Select an induction load, such as a relay coil, which has a built-in
diode (for absorbing inverse electromotive force).
To use an induction load without a built-in diode, add a diode
equivalent to the 1S1888 (Toshiba) in close vicinity to the coil.
Caution: When externally attaching a diode, connect it with correct

polarity. Incorrect polarity may damage the Output circuit.
(4) Connecting a lamp requires a circuit through which dark current

flows.
Caution: Since the initial resistance of a lamp is small, the output

circuit may be damaged by rush current that flows when
the lamp lights.
Refer to Figure 1-6.
(5) When using the internal power source, prepare a PLC input circuit unit
that does not contain a power source.
Caution: Keep the total current capacity of the internal power

source below 1.3A.
(6) Use a multi-core shielding cable for the purpose of protecting the
devices from external noise. Ground it to the Robot Controller.
(7) +24V internal power source of the robot controller must not be
grounded.
Caution: If the output terminal +24V of internal power source is

grounded, there may be a case where the controller is
damaged.
Appendix-10
Appendix
I/O POWER connector
Internal power source
F4 to 7
PLC Externally attached fuse Robot controller
1.3A

Power
source
I/O POWER connector
F4 to 7
PLC Externally attached fuse Robot controller
1.3A

Appendix-11
Supplied from the I/O power connector
when the internal power source is used
Lamp
Transistor array
Controller
Figure 1-6 Example of Circuit with Lamp
Appendix-12
Appendix
1.2.4 Emergency Stop Output Circuit

Figures 1-7 and 1-8 show the examples of configuration and connection of
emergency stop circuit for the robot controller.
The red mushroom-shaped switch provided on the robot controller front panel,
on the teach pendant, or on the operating panel can be used as a switch for
stopping the equipment in case of emergency.
Robot controller
F1 CN7
Internal 24V Fuse (1.3A)
Fuse (1.3A) Emergency stop circuit

Internal 0V F2 (prepared by customers)
F9 Emergency CN10
Fuse (0.3A) Stop +
Emergency
Stop + Output
Internal
24V F8 CN8
Fuse (1.3A) Robot stop switch circuit
(prepared by customers)
Emergency stop switch
on the front panel of the Input
controller
CN5 Teach pendant

on teach pendant
Internal 0V
Figure 1-7 Emergency Stop Output Circuit (Activated by Internal Power Source)
Robot controller
Emergency stop circuit
F9 Emergency CN10
Stop + External 24V
Fuse (0.3A)
Emergency
Stop - Output
External 0V
Internal
24V F8 CN8
Fuse (1.3A)
Robot stop switch circuit
on the front panel of the Input
controller
Teach pendant
CN5
on teach pendant
Internal 0V
Figure 1-8 Emergency Stop Output Circuit (Activated by External Power Source)
Appendix-13
1.2.5 I/O Power Connector
For the power source to communicate signals between the robot controller and
the external device, the internal power source of the robot controller or an
external power source is used.
Figure 1-9 shows an example of connecting I/O power connectors when the
internal power source is used, and Figure 1-10 shows an example of connecting
I/O power connectors when an external power source is used.
0.5 mm2 or
more
F1
AWG20 or more 0.5 mm2 or

more
F2
Internal
AWG20 or more power source
PLC
I/O circuit
Robot controller
Figure 1-9 Example of Connecting I/O Power Connectors (When the internal power source is used)
Caution: To use the internal power source of the robot controller,

connect the wiring so that the internal power source will be
separate from the external power source. Improper wiring
may damage the internal circuit.
Appendix-14
Appendix
F1
F2
Internal
power source
0.5 mm2 or
more
0.5 mm2 or more
External power source I/O circuit
Robot controller
Figure 1-10 Example of Connecting I/O Power Connectors (When an external power source is used)
Caution: Use a cable of 0.5 mm2 or more in size for the wiring
between the external power source and the I/O power input
connectors of the robot controller.
Appendix-15
1.3 Precautions Whe n Wiring the Robot Controller I/O
Connectors
After the wiring of the I/O connectors of the Robot Controller is completed, check
the following before turning ON the power:
(1) Using a tester, check across the “+24V terminal” and “0V terminal” of each
connector and across the “E24V terminal" and the “E0V terminal” to see
that there is no continuity. See Figure 1-11.
Caution: If the connector wiring between the Robot Controller's

“+24V terminal” and “0V terminal” and between the “E24V
terminal” and the “E0V terminal” is shorted, damage to the
power circuit of the Robot Controller will result.
(2) Using a tester, check across “each signal Output terminal” and “+24V
terminal” or “E24V terminal” of each connector to see that there is no
continuity. See Figure 1-11.
Caution: If the wiring between “each signal Output terminal” and

“+24V terminal” or “E24V terminal” of each connector is
shorted, damage to the Output circuit and power circuit of
the Robot Controller will result.
Caution: Wind adhesive vinyl tape around all ends of the

unconnected wiring of each connector to prevent them
from contacting other wiring and parts, which results in
shorting.
Tester
Robot
controller External
Robot controller's “+24V
terminal” and “E24V device
terminal”
Robot controller's “0V

terminal” and “E0V
terminal”
Figure 1-11 Checking Example
Appendix-16
Appendix
Table 1-7 Connector Terminals Requiring Checking

Connector for hand I/O Connector for user/system input

Number point Number point
Hand output 0V (GND) at
terminal output
terminal output
Power
24V power
17 terminal for (1)
output
hand (E24V)
Power
Power (GND)
18 terminal for (1)
output
hand (E0V)
Connector for user/system output Connector for I/O power source


number point number point
Signal output 0V (GND)
terminal at output
terminal output
0V internal 0V internal
3, 4 power source power source (1)
terminal output
E24V input 24V power

6, 7 (1)
terminal input
E0V (GND) Power (GND)

8, 9 (1)
input terminal input
Appendix-17
JRC INSTALLATION & MAINTENANCE GUIDE
2nd Edition
April 2001
YASKAWA ELECTRIC CORPORATION
Robotics Division
The purpose of this manual is to provide accurate information in the handling and operating of the
robot. Please feed free to send your comments regarding any errors or omissions you may have
found, or any suggestions you may have for generally improving the manual.
In no event will YASKAWA be liable for any direct or indirect damages resulting from the
application of the information in this manual.
JRC
INSTALLATION & MAINTENANCE
TOKYO OFFICE
New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo 105-6891, Japan
Phone 81-3-5402-4511 Fax 81-3-5402-4580
MOTOMAN INC. HEADQUARTERS

805 Liberty Lane West Carrollton, OH 45449, U.S.A
Phone 1-937-847-6200 Fax 1-937-847-6277
MOTOMAN INC. TROY FACILITY

1050 S. Dorset, Troy, OH 45373, U.S.A
Phone 1-937-440-2600 Fax 1-937-440-2626
YASKAWA MOTOMAN CANADA LTD.

2280 Argentia Road, Mississauga, Ontario, L5N 6H8, Canada
Phone 49-6196-569-300 Fax 1-905-813-5911
YASKAWA ELECTRIC EUROPE GmbH

Am Kronberger Hang 2, 65824 Schwalbach,Germany
Phone 81-3-5402-4511 Fax 81-3-5402-4580
Motoman Robotics Europe AB

Box 504 S38525 Torsås, Sweden
Phone 46-486-48800 Fax 46-486-41410
Motoman Robotec GmbH

Kammerfeldstraβe1,85391 Allershausen, Germany
Phone 49-8166-900 Fax 49-8166-9039
YASKAWA ELECTRIC KOREA CORPORATION

Kfpa Bldg #1201, 35-4 Youido-dong, Yeongdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
安川エンジニアリング株式会社
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park Singapore 556741, Singapore
Phone 65-282-3003 Fax 65-289-3003
習志野駐在 TEL習志野 (0474)54-4138 FAX(0474)54-4142
YATEC
北関東営業 ENGINEERING
所 CORPORATION
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan
Phone
西関東営業 886-2-2563-0010
所 Fax 886-2-2567-4677
浜松営業OFFICE
BEIJING 所
Room No. 301 Office Building of Beijing Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
豊田営
Phone 業所
86-10-6532-1850 Fax 86-10-6532-1851
鈴鹿駐在所
SHANGHAI OFFICE
関 Hui
27 西 He支Road
店 Shanghai 200437 China
Phone 86-21-6553-6600 Fax 86-21-6531-1851
岡山営業所
YASKAWA
広島営業所 JASON (HK) COMPANY
TEL広　島 LIMITED
(082)284-7223 FAX(082)284-7229
Rm. 2909-10, Hong Kong Plaza, 186-191 Connaught Road West, Hong Kon
Phone
九州 852-2803-2385
支店 TEL北九州 Fax(093)645-8874
852-2547-5773 FAX(093)622-5855
在所 TEL熊　本
熊本駐 OFFICE
TAIPEI (096)349-6755 FAX(096)349-6766
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD.

30 Xue Yuan Road, Haidian, Beijing 100083, China
Phone 86-10-6233-2782 Fax 86-10-6232-1536
SHOUGANG MOTOMAN ROBOT CO., LTD.

7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area,
Beijing 100076, P.R. China
Phone 86-10-6788-0551 Fax 86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
Specifications are subject to change without notice MANUAL NO. RE-CTO-A206

for on going product modifications and improvements. c Printed in Japan April 2001 01-04

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YASKAWA

Do not submit this electronic data to the customer.

THIS MATERIAL IS FOR STUDY PURPOSE ONLY.

MANUAL NO. RE-CTO-A206

INSTALLATION & MAINTENANCE GUIDE - this book -

WINCAPSII GUIDE (that comes with WINCAPSII)

ERROR CODE TABLES

Chapter 1 General Information about Robot

Chapter 2 Installing Robot Components

Chapter 3 Optional Devices

Chapter 4 Customizing Your Robot

Chapter 5 Robot Controller Interface

Chapter 6 Maintenance and Inspections

WARNING Alerts you to those conditions, which could result

CAUTION Alerts you to those conditions, which could result

Terminology and Definitions

(*RIA: Robotic Industries Association)

When using the robot controller in an environment exposed to

2.5 Protection of electrical If there is any possibility of the electrical wiring or

2.6 Positioning of Emergency stop switches should be provided in a position where

2.7 Positioning of Operating status indicators should be positioned in such a way

2.13 Lighting Sufficient illumination should be assured for safe robot

3.7 Precautions for (1) At start-up

Chapter1 General Information about Robot

Chapter2 Installing Robot Components

Chapter3 Optional Devices

Chapter4 Specifying Your Robot

Chapter5 Robot Controller Interface

Chapter6 Maintenance and Inspection

This chapter touches on general information

Chapter 1 General Information about Robot

1.2 Robot Configuration.................................................................................................................... 1-2

1.3 Robot Controller Specifications ................................................................................................ 1-5

1.1 Items Contained in the Package

Table 1-1 Standard Items

No. Item Qty.

(1) Robot controller 1

(4) Pendantless connector (Dummy connector) 1

(5) Spare output IC for robot controller 1

(6) Connector for primary power supply 1

Controller Sequencer (prepared

I/O cable Monitor

Printer cable Power cable (200 Ethernet board

Power connector for I/O Teach pendant µVision board

Personal computer system

Figure 1-1 Robot Components

1.2.2 Names of the Robot Controller Components

Transistor array box Power switch

<Left side> <Right side>

Figure 1-2 Names of Robot Controller Components

Connector Marking Name Connector Marking Name

CN7 I/O Power connector for

Caution: The robot controller connectors are of a screw-lock type or

1.3 Robot Controller Specifications