rc7m 1

ROBOT
RC7M
CONTROLLER MANUAL
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Copyright © DENSO WAVE INCORPORATED, 2005-2008
All rights reserved. No part of this publication may be reproduced in any form or by any means without
permission in writing from the publisher.
Specifications are subject to change without prior notice.
All products and company names mentioned are trademarks or registered trademarks of their respective
holders.

Preface
Thank you for purchasing this high-speed, high-accuracy assembly robot.
This manual describes the RC7M controller configured in the **-G robot system. It also covers interfacing
required when you integrate your robot system into your facilities, as well as providing the maintenance &
inspection procedures.
Before use, read this manual carefully together with related manuals to safely get the maximum benefit
from your robot in your assembling operations.
Note: The name of this manual has changed from the "RC7M Controller INTERFACE MANUAL" to the
"RC7M CONTROLLER MANUAL."
Robot controller covered by this manual
RC7M controller
Caution in connecting/disconnecting the motor & encoder cable

The CN7 (MOTOR) connector for the motor & encoder cable on the RC7M controller uses a rigid
structure.
Connection: Lock the connector properly.
Disconnection: Release the lock carefully and safely. It cannot be easily released.
Connection Disconnection
Release the lock carefully

and safely.
Important
To ensure operator safety, be sure to read the precautions and instructions in "SAFETY PRECAUTIONS."

How the documentation set is organized
The documentation set consists of the following books. If you are unfamiliar with this robot and option(s),
please read all books and understand them fully before operating your robot and option(s).
GENERAL INFORMATION ABOUT ROBOT

Provides the packing list of the robot and outlines of the robot system, robot unit, and robot
controller.
INSTALLATION & MAINTENANCE GUIDE

Provides instructions for installing the robot components and customizing your robot, and
maintenance & inspection procedures.
STARTUP HANDBOOK
Introduces you to the DENSO robot system and guides you through connecting the robot unit
and controller with each other, running the robot with the teach pendant, and making and
verifying a program. This manual is a comprehensive guide to starting up your robot system.
SETTING-UP MANUAL
Describes how to set up or teach your robot with the teach pendant or mini-pendant.
For the panel designer functions, refer to the Panel Designer User's Manual (SUPPLEMENT).
WINCAPSII GUIDE
Provides instructions on how to use the teaching system WINCAPSII which runs on the PC
connected to the robot controller for developing and managing programs.
PROGRAMMER'S MANUAL I, Program Design and Commands

Describes the PAC programming language, program development, and command
specifications in PAC. This manual consists of two parts; Part 1 provides the basic programming
knowledge, and Part 2, details of individual commands.
PROGRAMMER'S MANUAL II, PAC Library

Describes the program libraries that come with WINCAPSII as standard.
RC7M CONTROLLER MANUAL - this book -

Provides the specifications, installation and maintenance of the RC7M controller. It also
describes interfacing with external devices, system- and user-input/output signals, and I/O
circuits.
ERROR CODE TABLES

List error codes that will appear on the teach pendant, mini-pendant, or PC screen if an error
occurs in the robot series or WINCAPSII. These tables provide detailed description and
recovery ways.
OPTIONS MANUAL
Describes the specifications, installation, and use of optional devices.
For the extension board "conveyer tracking board," refer to the OPTIONS MANUAL
(SUPPLEMENT).
ii

How this book is organized
This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS
and chapters one through eight.
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 Outline of the RC7M Controller

Provides an outline of the RC7M controller. The robot controller is available in several models that will
differ in detailed specifications to match robot models to be connected.
Chapter 2 General Information about the Interface

Introduces you to the interface required for connecting the robot controller with a PLC or other external
equipment.
Chapter 3 System I/O Signals

Describes system I/O signals, and describes I/O signals that execute I/O commands.
Chapter 4 I/O Circuits and Connectors (NPN type)

Describes the I/O circuits and connector pin layout of an NPN I/O board (source input and sink output).
The NPN I/O board is designed for the use in Japan.
Chapter 5 I/O Circuits and Connectors (PNP type)

Describes the I/O circuits and connector pin layout of a PNP I/O board (sink input and source output).
Chapter 6 Installation & Maintenance for the RC7M controller

Provides instructions for installing the robot controller, and maintenance & inspection procedures.
Chapter 7 I/O Allocation for I/O Extension Board(s)

Lists the I/O allocation tables to apply when I/O extension boards are mounted.
Chapter 8 I/O Allocation for I/O Conversion Box (only for standard type of controller)
Lists the I/O allocation tables to apply when the I/O conversion box is mounted.
Using the I/O conversion box on the RC7M controller with an optional parallel I/O board mounted allows
the "INPUT (CN8)," "OUTPUT (CN10)," and "I/O POWER (CN7)" used on the RC5 controller to be used
on the RC7M controller as is.
Note: The I/O conversion box cannot be used for the global type of the controller.
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 space which can be swept by the moving parts of the robot as defined by
the manufacturer, plus the space which can be swept by the end-effector and the workpiece. (Quoted
from the ISO 10218-1:2006.)
Restricted space: Refers to the portion of the maximum space restricted by limiting devices (i.e.,
mechanical stops) that establish limits which will not be exceeded. (Quoted from the ISO 10218-1:2006.)
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. (The "motion
space" is DENSO WAVE-proprietary terminology.)
Operating space: Refers to the portion of the restricted space that is actually used while performing all
motions commanded by the task program. (Quoted from the ISO 10218-1:2006.)
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 ISO 10218-1:2006.)

1. Introduction This section provides safety precautions to be observed for the
robot system.
The installation shall be made by qualified personal and should
confirm to all national and local codes.
2. Warning Labels The robot unit and controller have warning labels. These labels
alert the user to the danger of the areas on which they are
pasted. Be sure to observe the instructions printed on those
labels.
Warning label Instructions printed on the label

Risk of injury.
Never enter the restricted space.
Label (1)
<Except HM> For UL-Listed robot units only

Risk of injury.
This label alerts the user that pressing
the brake release switch could drop the
arm.
(Example: Location of labels)
<HM>
Label (2)
Risk of electrical shock.

Never open the controller cover when
the power is on.
Never touch the inside of the controller
Label (3)
for at least 3 minutes even after turning
the power off and disconnecting the
power cable.
Risk of injury.
Be sure to perform lockout/tagout
before starting servicing.
Label (4)
Turning the power ON when a person is
inside the safety fence may move the
arm, causing injuries.

SAFETY PRECAUTIONS
3. Installation Precautions
3.1 Insuring the proper

installation environment
For standard type and The standard and cleanroom type have not been designed to
cleanroom type withstand explosions, dust-proof, nor is it splash-proof.
Therefore, 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 material,
(4) there is a mist,
(5) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other
sources of electrical noise.
For dust- & splash-proof The dust- & splash-proof type has an IP54-equivalent structure,
type but it has not been designed to withstand explosions. (The
HM/HS-G-W and the wrist of the VM/VS-G-W are an
IP65-equivalent dust- and splash-proof structure.)
Note that the robot controller is not a dust- or splash-proof
structure. Therefore, when using the robot controller in an
environment exposed to mist, put it in an optional protective box.
The dust- & splash-proof type should not be installed in any
environment where:
(1) there are any flammable gases or liquids,
(2) there are any acidic, alkaline or other corrosive material,
(3) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other
sources of electrical noise,
(4) it may likely be submerged in fluid,
(5) there are any grinding or machining chips or shavings,
(6) any machining oil not specified in this manual is in use, or
Note: Yushiron Oil No. 4C (non-soluble) is specified.
(7) there is sulfuric cutting or grinding oil mist.
3.2 Service space The robot and peripheral equipment should be installed so that
sufficient service space is maintained for safe teaching,
maintenance, and inspection.

3.3 Control devices The robot controller, teach pendant and mini-pendant should be
outside the robot's installed outside the robot's restricted space and in a place where
you can observe all of the robot’s movements and operate the
restricted space
robot easily.
3.4 Positioning of gauges Pressure gauges, oil pressure gauges and other gauges should
be installed in an easy-to-check location.
3.5 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
3.6 Grounding resistance The grounding resistance of the robot power supply should not
be more than 100Ω.
3.7 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.
3.8 Positioning of Operating status indicators should be positioned in such a way

operating status where workers can easily see whether the robot is on a
temporary halt or on an emergency or abnormal stop.
indicators
Note: The UL-Listed robot units have motor ON lamps on their
robot arms.

SAFETY PRECAUTIONS
3.9 Setting-up a safety A safety fence should be set up so that no one can easily enter
fence the robot's restricted space.
(1) The fence should be constructed so that it cannot be easily
moved or removed.
(2) The fence should be constructed so that it cannot be easily
damaged or deformed through external force.
(3) Establish the exit/entrance to the fence. Construct the fence
so that no one can easily get past it by climbing over the
fence.
(4) The fence 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:
1) Place a door, rope or chain across the entrance/exit of
the fence, 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
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,
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.
3.10 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
2.

3.11 No robot modification Never modify the robot unit, robot controller, teach pendant or
allowed other devices.
3.12 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.
3.13 Lighting Sufficient illumination should be assured for safe robot operation.
3.14 Protection from objects If there is any risk of workers being injured in the event that the
thrown by the object being held by the end-effector is dropped or thrown by the
end-effector, consider the size, weight, temperature and
end-effector
chemical nature of the object and take appropriate safeguards to
ensure safety.
3.15 Affixing the warning Place the warning label packaged

label with the robot on the exit/entrance
of the safety fence or in a position
where it is easy to see.

SAFETY PRECAUTIONS
4. Precautions Touching the robot while it is in

while Robot is Warning operation can lead to serious
Running injury. Please ensure the fol-
lowing conditions are
maintained and that the
cautions listed from Section
4.1 and 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 4.3
"Ensuring safety of workers performing jobs within the
robot's restricted space" are taken.
4.1 Creation of working When entering the robot’s restricted space to perform teaching or
regulations and 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 4.2 on the next
page.)
2) Assuring the safety of workers performing jobs within the
robot's restricted space (See Section 4.3 on the next
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.

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".
4.2 Display of operation To prevent anyone other than the worker from accessing the start
panel switch or the changeover switch by accident during operation,
display something to indicate it is in operation on the operation
panel or teach pendant. Take any other steps as appropriate,
such as locking the cover.
4.3 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.
An emergency stop device should be activated
immediately upon a malfunction.
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 emergency button on the teach pendant) immediately if
it should be necessary to do so.
4.4 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.

SAFETY PRECAUTIONS
4.5 Release of residual air Before disassembling or replacing pneumatic parts, first release
pressure any residual air pressure in the drive cylinder.
4.6 Precautions for test Whenever possible, have the worker stay outside of the robot's
runs restricted space when performing test runs.
4.7 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.
4.8 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 specified in this manual.

5. 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.
6. Management of (1) Carefully handle and store the "Initial settings" floppy disks
packaged with the robot, which store special data exclusively
Floppy Disks prepared for your robot.
(2) After finishing teaching or making any changes, always save
the programs and data onto 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.
(3) Write the names of each of the floppy disks used for storing
task programs to prevent incorrect disks from loading into
the robot controller.
(4) 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.
7. Safety Codes The safety standards relating to robot systems are listed below.
As well as observing the safety precautions given in this manual,
ensure compliance with all local and national safety and
electrical codes for the installation and operation of the robot
system.
Standards Title
ANSI/RIA R15.06-1999 Industrial Robots and Robot Systems--Safety Requirements
ANSI/UL1740: 1998 Safety for Robots and Robotic Equipment
CAN/CSA Z434-03 Industrial Robots and Robot Systems--General Safety Requirements
ISO10218-1: 2006 Robots for industrial environments--Safety requirements--Part 1: Robot
NFPA 79: 2002 Electrical Standard for Industrial Machinery
8. Battery Recycling DENSO Robot uses lithium batteries.

Discard batteries according to your local and national recycling
law.

Contents
Preface ................................................................................................................................................................................ i
How the documentation set is organized ........................................................................................................................ii
SAFETY PRECAUTIONS
Chapter 1 General Information about RC7M Controller............................................................................................. 1

1.1 Controller Model Name on Nameplate.................................................................................................................... 1
1.2 Names of the Controller Components ..................................................................................................................... 4
1.2.1 Controller Components .............................................................................................................................. 4
1.2.2 Warning and Caution Labels...................................................................................................................... 5
1.3 Controller Specifications ......................................................................................................................................... 7
1.4 Controller System Configuration........................................................................................................................... 10
1.4.1 Internal Circuits of the Controller (Typical configuration) ...................................................................... 10
1.4.2 Typical Robot System Configuration....................................................................................................... 11
Chapter 2 General Information about the Interface ................................................................................................... 12

2.1 Types and General Information about I/O Signals ................................................................................................ 12
2.1.1 Types of System I/O Signals (Standard type of controller)...................................................................... 12
2.1.2 Types of System I/O Signals (Global type of controller) ......................................................................... 13
2.2 Usage of User I/O Signals ..................................................................................................................................... 14
2.2.1 I/O Type Variable Declaration.................................................................................................................. 14
2.2.2 I/O Type Global Variables........................................................................................................................ 14
2.2.3 I/O Type Local Variables ......................................................................................................................... 14
2.2.4 User Input Commands ............................................................................................................................. 14
2.2.5 User Output Commands........................................................................................................................... 15
Chapter 3 System I/O Signals ........................................................................................................................................ 16

3.1 Types and Functions of System Output Signals .................................................................................................... 16
3.2 Usage of System Output Signals ........................................................................................................................... 17
3.2.1 Robot Initialized (output) ......................................................................................................................... 17
3.2.2 Auto Mode (output) .................................................................................................................................. 18
3.2.3 Operation Preparation Completed (output)............................................................................................. 19
3.2.4 Robot Running (output)............................................................................................................................ 20
3.2.5 CPU Normal (output) .............................................................................................................................. 21
3.2.6 Robot Error (output) ................................................................................................................................ 22
3.2.7 Battery Warning (output) ......................................................................................................................... 23
3.2.8 Continue Start Permission (output): Selectable by I/O hardware setting...................................... 24
3.2.9 Emergency Stop Circuit Contact Outputs (Standard type of controller) .................................................. 25
3.2.10 Safety Circuit Contact Outputs (Global type of controller) ..................................................................... 28
3.3 Types and Functions of System Input Signals ....................................................................................................... 31
3.4 Usage of System Input Signals.............................................................................................................................. 32
3.4.1 Step Stop (All tasks) (input)...................................................................................................................... 32
3.4.2 External Emergency Stop (input) ............................................................................................................. 33
3.4.3 Enable Auto (input) (Standard type of controller).................................................................................... 34
3.4.4 Enable Auto (input) (Global type of controller)....................................................................................... 35
3.4.5 Protective Stop (input): Global type of controller ............................................................................ 36

3.5 Command Execution I/O Signals .......................................................................................................................... 37
3.5.1 General Information about Commands .................................................................................................... 37
3.5.2 Processing I/O Commands....................................................................................................................... 38
3.5.3 I/O Commands Details............................................................................................................................. 41
3.6 Example of Using System I/O Signals .................................................................................................................. 44
Chapter 4 Connector Pin Assignment and I/O Circuits (NPN type) .......................................................................... 48
4.1 Connector Pin Assignment (NPN type) ................................................................................................................. 48
4.1.1 RS-232C (CN1): RS-232C connector...................................................................................................... 48
4.1.2 HAND I/O (CN9) .................................................................................................................................... 49
4.1.3 Mini I/O (CN5): User- or System-I/O connector ..................................................................................... 50
4.1.4 Safety I/O (CN10)：System-I/O connecter (Global type of controller) .................................................. 52
4.2 Robot Controller I/O Circuits (NPN type)............................................................................................................. 53
4.2.1 Setting up Mini I/O Power Supply........................................................................................................... 53
4.2.2 User-Input, System-Input and Hand-Input Circuits (NPN type).............................................................. 54
4.2.3 User-Output, System-Output, and Hand-Output Circuits (NPN type) ..................................................... 56
4.2.4 Configuration of Emergency Stop Circuitry (Standard type of controller) ............................................. 59
4.2.5 Configuration of Safety Circuit (Global type of controller)..................................................................... 61
4.3 Wiring Notes for Controller I/O Connectors (NPN type)...................................................................................... 63
Chapter 5 Connector Pin Assignment and I/O Circuits (PNP type)........................................................................... 65

5.1 Connector Pin Assignment (PNP type).................................................................................................................. 65
5.1.1 RS-232C (CN1): RS-232C connector...................................................................................................... 65
5.1.2 HAND I/O (CN9) .................................................................................................................................... 66
5.1.3 Mini I/O (CN5): User- or System-I/O connector ..................................................................................... 67
5.1.4 Safety I/O (CN10)：System-I/O connecter (Global type of controller) .................................................. 69
5.2 Robot Controller I/O Circuits (PNP type) ............................................................................................................. 70
5.2.1 Setting up Mini I/O Power Supply........................................................................................................... 70
5.2.2 User-Input, System-Input and Hand-Input Circuits (PNP type)............................................................... 71
5.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP type)...................................................... 73
5.2.4 Configuration of Emergency Stop Circuitry (Standard type of controller) ............................................. 76
5.2.5 Configuration of Safety Circuit (Global type of controller)..................................................................... 78
5.3 Wiring Notes for Controller I/O Connectors (PNP type)....................................................................................... 80
Chapter 6 Installation and Maintenance of the RC7M Controller ............................................................................ 82

6.1 Supplies for the Controller .................................................................................................................................... 82
6.2 Mounting the Controller ........................................................................................................................................ 82
6.2.1 Installation Requirements for the Controller............................................................................................ 82
6.2.2 Mounting the Robot Controller................................................................................................................ 83
6.3 I/O and AC Input Wiring ....................................................................................................................................... 85
6.3.1 Multi-core Cables with Connectors ......................................................................................................... 85
6.3.2 Wiring of Primary Power Source ............................................................................................................. 86
6.3.3 Disconnecting the Robot from the Power Source .................................................................................... 88
6.4 Cleaning the Air Intake Filters............................................................................................................................... 89
6.5 Replacing the Memory Backup Battery ................................................................................................................ 91
6.5.1 Replacing procedures............................................................................................................................... 91
6.5.2 Setting the Next Battery Replacement Date............................................................................................. 94

6.6 Replacing Fuses and Output ICs ........................................................................................................................... 95
6.6.1 Positions of Fuses and Output ICs ........................................................................................................... 95
6.6.2 Replacing procedures............................................................................................................................... 97
6.7 Replacing IPM Boards ........................................................................................................................................ 100
6.7.1 Location of IPM Boards......................................................................................................................... 100
6.7.2 Replacing the IPM board ....................................................................................................................... 101
Chapter 7 I/O Allocation for I/O Extension Board(s) ................................................................................................ 103

7.1 Combination of I/O Extension Boards and Allocation Modes ............................................................................ 103
7.2 I/O Allocation in Individual Allocation Modes ................................................................................................... 104
7.3 Notes on Using I/O Extension Boards................................................................................................................. 104
7.4 Hand I/O (CN9): Common to All Allocation Modes........................................................................................... 105
7.5 I/O Allocation Tables for Individual Allocation Modes....................................................................................... 106
7.5.1 Mini I/O Board (CN5 on standard type of controller) in Mini I/O Dedicated Mode ............................. 106
7.5.2 Mini I/O Board (CN5 on global type of controller) in Mini I/O Dedicated Mode................................. 107
7.5.3 Mini I/O Board (CN5 on standard type of controller) in Compatible,
Standard and All User I/O Modes .......................................................................................................... 108
7.5.4 Mini I/O Board (CN5 on global type of controller) in Compatible, Standard,
and All User I/O Modes ......................................................................................................................... 109
7.5.5 Parallel I/O Board in Compatible Mode ................................................................................................ 110
7.5.6 Parallel I/O Board in Standard Mode..................................................................................................... 111
7.5.7 Parallel I/O Board (1st) in All User I/O Mode ....................................................................................... 112
7.5.8 Parallel I/O Board (2nd) in All User I/O Mode...................................................................................... 113
7.5.9 DeviceNet Slave Board in Compatible Mode ........................................................................................ 114
7.5.10 DeviceNet Slave Board in Standard Mode ............................................................................................ 115
7.5.11 DeviceNet Slave Board in All User I/O Mode....................................................................................... 116
7.5.12 CC-Link Board (2 stations occupied) in Compatible Mode................................................................... 117
7.5.15 CC-Link Board (2 stations occupied) in Standard Mode ....................................................................... 120
7.5.18 CC-Link Board (2 stations occupied) in All User I/O Mode ................................................................. 123
7.5.21 PROFIBUS-DP Slave Board in Compatible Mode................................................................................ 126
7.5.22 PROFIBUS-DP Slave Board in Standard Mode .................................................................................... 127
7.5.23 PROFIBUS-DP Slave Board in All User I/O Mode............................................................................... 128
7.5.24 DeviceNet Master Board in All User I/O Mode..................................................................................... 129
7.5.25 S-Link V Master Board in All User I/O Mode....................................................................................... 130
Chapter 8 I/O Allocation for I/O Conversion Box (only for standard type of controller) ...................................... 131
8.1 I/O Allocation Modes with I/O Conversion Box Mounted.................................................................................. 131
8.2 I/O Allocation in Individual Allocation Modes ................................................................................................... 132
8.3 Notes on Using the I/O Conversion Box ............................................................................................................. 132
8.4 Allocation Common to All Allocation Modes ..................................................................................................... 133
8.4.1 I/O POWER (CN9): Common to All Modes ......................................................................................... 133
8.4.2 HAND I/O (CN9): Common to All Modes............................................................................................ 133

8.5 I/O Allocation Tables for Individual Allocation Modes....................................................................................... 134
8.5.1 OUTPUT (CN10) in I/O-Box Compatible Mode................................................................................... 134
8.5.2 INPUT (CN8) in I/O-Box Compatible Mode ........................................................................................ 135
8.5.3 OUTPUT (CN10) in I/O-Box Standard Mode ....................................................................................... 136
8.5.4 INPUT (CN8) in I/O-Box Standard Mode............................................................................................. 137
8.5.5 OUTPUT (CN10) in I/O-Box All User I/O Mode ................................................................................. 138
8.5.6 INPUT (CN8) in I/O-Box All User I/O Mode ....................................................................................... 139
8.5.7 DeviceNet Slave Board in I/O-Box Compatible Mode.......................................................................... 140
8.5.8 DeviceNet Slave Board in I/O-Box Standard Mode .............................................................................. 141
8.5.9 CC-Link Board (2 stations occupied) in I/O-Box Compatible Mode .................................................... 142
8.5.12 CC-Link Board (2 stations occupied) in I/O-Box Standard Mode......................................................... 145
8.5.15 PROFIBUS-DP Slave Board in I/O-Box Compatible Mode.................................................................. 148
8.5.16 PROFIBUS-DP Slave Board in I/O-Box Standard Mode ...................................................................... 149
8.5.17 Parallel I/O Board in I/O-Box Al User I/O Mode .................................................................................. 150
8.5.18 DeviceNet Master Board in I/O-Box All User I/O Mode ...................................................................... 151
8.5.19 S-Link V Master Board in I/O-Box All User I/O Mode......................................................................... 152

Chapter 1
General Information about RC7M Controller
The RC7M controller is available in several models which differ in detailed
specifications to match robot models.
1.1 Controller Model Name on Nameplate

The model name of the controller is printed on the nameplate attached to the rear side
of the controller as shown below. The model name is coded as listed below.
Coding of Controller Model Name
RC7M - VSG 6 B A - B P
(a) (b) (c) (d) (e) (f) (g)
Code
Position Denotes: Coding
sample
(a) VSG Robot model name VMG: VM-G series, VSG: VS-G series,
VPG: VP-G series, HMG: HM-G series,
HSG: HS-G series, XRG: XR-G series
(b) 6 No. of controllable axes 4: 4 axes, 5/6: 5 or 6 axes, 6: 6 axes
(c) B Engineering symbol 1 B: Encoder B
C: Encoder C
(d) A Engineering symbol 2 A: 24V brake
(e) Engineering symbol 3 Blank: 200 VAC power
A: 100 VAC power
(f) B Controller type (Note) Blank: Standard type
B: Global type (with safety board)
C: Global type (with safety box)
D: UL-Listed（with safety board）
E: UL-Listed(with safety box)
(g) P I/O type Blank or N: NPN I/O
P: PNP I/O
(Note) For the differences between the global and standard types, see the next page.

Differences between Global and Standard Types of Robot Controllers
The global type of the robot controller has either a safety board or safety box which the
standard type has not. Described below are the functional differences between the
global and standard types.
[ 1 ] Deadman switch function (Enable switch function)

The global type controls the deadman switch provided on the teach pendant or
mini-pendant in a partially different way than the standard type does. When reading the
instruction manuals that are prepared for the standard type, be careful with the
following differences.
(1) Location of deadman switches (enable switches) on the teach pendant and mini-pendant
Deadman switch
(Enable switch) Deadman
switch
(Enable
switch)
Teach pendant
Mini-pendant
(2) Difference in deadman switch operation

The table below lists the functional differences of the teach pendant and mini-pendant
between the global and standard types in Manual mode and Teach check mode.
Standard type
Global type
(described in the instruction manuals)
(1) Unless the deadman switch is held down, you (1) Unless the deadman switch is held down, you
can neither operate the robot nor turn the motor cannot operate the robot, but you can turn the
power ON. motor power ON.
(2) When the robot is in operation, releasing the (2) When the robot is in operation, releasing the
deadman switch will stop not only the robot but deadman switch will stop the robot but not turn
also turn the motor power OFF. the motor power OFF (servo lock).
2

[ 2 ] "Single point of control" function
The global type of the robot controller supports the "single point of control" function,
while other types do not.
(1) Single point of control
The "single point of control" function, which is one of the robot safety functions, limits
the robot control sources (command sources) to only one. This function is specified by
the parameter "Single point of control" that limits the control to either "Internal Auto" or
"External Auto" limited mode.
Internal Auto limited mode

The "Auto mode" is limited to the "Internal Auto" limited mode in which a program start
can be triggered from the teach pendant, but cannot from external equipment.
External Auto limited mode

The "Auto mode" is limited to the "External Auto" limited mode in which a program start
can be triggered from external equipment, but cannot from the teach pendant.
Note: In this mode, the teach pendant operation panel editor "Panel Designer" cannot
be used in External Auto.
(2) Setting the Internal/External Auto Limited Mode Parameters

Using the teach pendant, set the parameters with the following access.
Note 1: The "Internal Auto Limited Mode" is the factory default.
Note 2: The global type displays letter "A" following the robot type on the teach pendant
screen.
Access: [Top screen]—[F4 I/O]—[F6 Aux.]—[F1 Set H/W]—[F3 Jump To]—"31"
In Ver. 2.3 or later:
Access: [Top screen]—[F4 I/O]—[F6 Aux.]—[F4 Int/Ext]
"A" displayed "A" displayed
Setting on the "I/O Hardware Settings" window Setting on the "Single point of control" window
(Ver. 2.3 or later)

1.2 Names of the Controller Components
1.2.1 Controller Components
The following figures show the names of the robot controller components.
Front Panel
Connector No. Marking Name

CN1 RS-232C Serial interface connector
CN2 USB USB connector (2 lines)
CN3 PENDANT Teach pendant connector
CN4 LAN Ethernet connector
CN5 Mini I/O User/system I/O connector
CN6 INPUT AC Power supply connector
CN7 MOTOR Motor/encoder connector
CN9 HAND I/O Hand I/O connector
CN10 SAFETY I/O Safety I/O connector
(only on the global type)
Names of RC7M Robot Controller

1.2.2 Warning and Caution Labels
The robot unit has warning and caution labels pasted as shown below. They alert
the user to the dangers of the areas on which they are pasted. Be sure to observe
the instructions printed on those labels.
Location of Labels on the Controller

Warning and Caution Labels on the Robot Controller
Warning and caution labels on the controller Contents
Warning label 1 (For maintenance of the controller)

Risk of electrical shock.
Never open the controller cover when the power is ON.
Never touch the inside of the controller for at least 3
minutes even after turning the power OFF and
disconnecting the power cable.
Warning label 2 (For controller power switch)

Risk of injury.
Be sure to perform lockout/tagout before starting
servicing.
Turning the power ON may move the arm, causing injuries
if a person is inside the safety fence.
Caution label (For cooling fans)
Risk of injury.
Do not insert fingers, sticks or other foreign objects
through the openings.
Caution label The controller is not designed to be dust-, splash-, or

explosion-proof. Before installation, be sure to read the
user's manual.
Do not put anything on the controller or apply any impact
or shock to it.
Caution label When using an external power source, never apply the
voltage not specified. Doing so can result in a controller
failure.
Caution label After turning the power switch OFF, do not turn it ON for at
least six seconds.

1.3 Controller Specifications
[ 1 ] Specifications
The table below lists the robot controller specifications.
RC7M Robot Controller Specifications
Item Specifications
XYC-4G XR-G
Robot series VM-G series VS-G series VP-G series HM-G series HS-G series
series series
VMG- VSG- VPG- HMG- HSG- XYCG- XR-
Model (RC7M-)
6∗∗∗-∗∗ 6∗∗∗-∗∗ 5/6∗∗∗-∗∗ 4∗∗∗-∗∗ 4∗∗∗-∗∗ 4∗∗∗-∗∗ 43***G*
Controllable axes 6 axes 5 or 6 axes 4 axes
Control system PTP, CP 3-dimensional linear, 3-dimensional circular
Drive system All axes: Full-digital AC servo
Language used DENSO robot language (conforming to SLIM)
Memory capacity 3.25 MB (equivalent to 10,000 steps, 30,000 points)
1) Direct teaching 1) Remote teaching
1) Remote teaching
Teaching system 2) Remote teaching 2) Numerical input
2) Numerical input (MDI)
3) Numerical input (MDI) (MDI)
Input: 8 user open points + 11 fixed system points
Mini I/O Output: 8 user open points + 14 fixed system points
Standard (Note: The global type of the controller cannot use system-fixed emergency stop I/Os.)
I/O
Input: 8 user open points
HAND I/O
Output: 8 fixed system points
SAFETY I/O Input: 6 fixed system points
(only on global type) Output: 5 fixed system points
2 boards Input: 80 user open points
Parallel I/O
mounted Output: 96 user open points (addition possible)
extension
External boards Single
Input: 40 user open points
signals (option) board
Output: 48 user open points (addition possible)
(I/O) mounted
Master/ Input: 1024 points (master) + 256 points (slave)
Slave Output: 1024 points (master) + 256 points (slave)
DeviceNet
Input: 1024 points
board Master
Output: 1024 points
(option)
Input: 256 points
Slave
Output: 256 points
CC-Link
Input: 128 points
board Slave
Output: 128 points
(option)
RS-232C: 1 line
External communication Ethernet: 1 line
USB: 2 lines (Supporting flash memory)
Extension slots 3 (For optional boards)
Self-diagnosis function Overrun, servo error, memory error, input error, etc.
Timer function 0.02 to 10 sec. (in units of 1/60 sec.)
Error codes will be outputted on the external I/O.
Error display Error messages will be displayed in English on the teach pendant (option).
Error codes will be displayed on the mini-pendant (option).
Standard: 4 m, 6 m, Standard: Standard: 4 m, 6 m, Standard:
Robot control Standard:
12 m (Standard 4 m, 6 m, 12 m (Standard 4 m, 6 m,
cable (option) 4 m, 6 m
type/splash-proof type) 12 m type/splash-proof type) 12m
Cables
I/O cable (option) 8 m, 15 m (for Mini I/O, HAND I/O, parallel I/O extension boards, safety I/O board)
Power cable 5m

Item Specifications
Environmental conditions Temperature: 0 to 40°C
(in operation) Humidity: 90% RH or less (no condensation allowed) Altitude: 1,000m or less
VM-G series Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 3.3 kVA
Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1.85 kVA
VS-G series
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1.85 kVA
Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1 kVA
VP-G 200 VAC type
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1 kVA
series
100 VAC type Single-phase, 100 VAC -10% to 110 VAC +10%, 50/60 Hz, 1 kVA
Power Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 2.45 kVA
source HM-G series
HS-G series
XYC-4G series
XR-G series
External power
A 24 VDC ±10% should be supplied from external equipment. Note: Refer to Sections
I/O power source 4.2.1 and 5.2.1 "Setting
source Internal power A 24 VDC ±10% should be supplied internally in the robot up Mini I/O Power
source controller. Supply."
VM-G series: Approx. 20 A , VS-G series: Approx. 11 A , VP-G series: Approx. 5 A ,
Rated output current
HM-G series: Approx. 19 A , HS-G series: Approx. 14 A, XR-G series:Approx. 10A
With safety board: Compliant with safety category 3
Safety category With safety box: Compliant with safety category 4
(Only the controller with safety box is available to the XYC-4G series of robots.)
Degree of protection IP20
4-axis standard type: Approx. 17 kg
6-axis standard type: Approx. 18 kg
4-axis global type, UL-Listed (w/ safety board): Approx. 18 kg
Weight (Mass)
6-axis global type, UL-Listed (w/ safety board): Approx. 19 kg
4-axis global type, UL-Listed (w/ safety box): Approx. 21 kg
6-axis global type, UL-Listed (w/ safety box): Approx. 22 kg
Note: When handling the controller, be sure to observe the following.
Controller Handling Notes
WARNING
- DO NOT touch fins. Their hot surfaces may cause severe burns.
- DO NOT insert fingers or foreign objects into openings. Doing so may cause
bodily injury.
- Before opening the controller cover and accessing the inside of the controller
for maintenance, be sure to turn off the power switch, disconnect the power
cable, and wait 3 minutes or more. This is for protecting you from electric shock.
- DO NOT connect or disconnect connectors to/from the controller when the AC
power or the 24 VDC power for I/O is being supplied. Doing so may cause
electric shock or controller failure.
CAUTION IN INSTALLATION
- This controller is not designed to be dust-, splash-, or explosion-proof.
- Read operation manuals before installation.
- Do not place anything on the controller or apply an impact or shock to the
controller.
- Avoid mounting the controller in an environment where excessive vibration is
applied to the controller.
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.

[ 2 ] Outer Dimensions
The outer dimensions of the robot controller are shown below.
Outer Dimensions of RC7M Robot Controller

1.4 Controller System Configuration
1.4.1 Internal Circuits of the Controller (Typical configuration)
The block diagram below shows the internal circuits of the RC7M controller designed
for a 6-joint robot.
Block Diagram of the RC7M Controller
10

1.4.2 Typical Robot System Configuration
The block diagram below shows a typical robot system configuration.
Robot System Configuration
11

Chapter 2
General Information about the Interface
2.1 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: For the interface to apply when an I/O extension board or I/O conversion box is
mounted, refer to Chapter 7 or 8 in this manual, respectively, and the OPTIONS
MANUAL.
2.1.1 Types of System I/O Signals (Standard type of controller)

Seven input points for command execution are used to direct program start and other
instructions as I/O commands.
The table below lists the types of system I/O signals.
Types of System I/O Signals (Standard type of controller)
Fixed by system
No. of
Type points Function
External Emergency Stop 1, External Emergency Stop 2,

System input 4
Enable Auto, Step Stop (All tasks)
Auto Mode, Robot Initialized, Robot Running, CPU Normal,
Robot Error, Operation Preparation Completed, Battery Warning,
Emergency Stop 1, Emergency Stop 2,
13
System output Deadman SW 1 [Enable SW 1], Deadman SW 2 [Enable SW 2],
(Note)
Pendant Emergency Stop 1, Pendant Emergency Stop 2,
Continue Start Permission (selectable by I/O hardware setting)
(See Note below.)
Input for command
7 Command (3 bits), data area (3 bits), and Strobe Signal
execution
Output for command
1 Command Processing Completed
execution
Controlled by user program
No. of
Type points Function
Inputs to read the external I/O status with an IN command or IO [ ] variable.

User input 8 Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.
8 Outputs to issue a signal to the external device during program execution
User output
(Note) with SET and RESET commands, etc.

HAND input 8
Used for checking the hand status.
Outputs to issue signals to the external devices with SET and RESET
HAND output 8 commands, etc.
Used for controlling the hand to open or close.
Note: Terminal #53 on CN5 (port 24) is assigned a user output by factory default. It can be assigned the
Continue Start Permission output signal with the I/O hardware setting.
12

2.1.2 Types of System I/O Signals (Global type of controller)
The global type of the controller concentrates emergency stop related system I/Os on
the safety I/O (CN10), so it does not use the Mini I/O (CN5). (Refer to Sections 4.1.3,
4.1.4, 5.1.3, and 5.1.4.)
It issues PROGRAM START commands as I/O commands by using seven command
execution inputs.
The table below lists the types of system I/O signals.
Types of System I/O Signals (Global type of controller)
Fixed by system
No. of
Type Function
points
External Emergency Stop 1, External Emergency Stop 2, Enable Auto 1,
System input 7
Enable Auto 2, Step Stop (All tasks), Protective Stop 1, Protective Stop 2
Auto Mode, Robot Initialized, Robot Running, CPU Normal,
Robot Error, Operation Preparation Completed, Battery Warning,
12 Pendant Emergency Stop 1, Pendant Emergency Stop 2,
System output
(Note) Deadman SW 1 [Enable SW 1], Deadman SW 2 [Enable SW 2],
Contactor Contact Monitor, Continue Start Permission (selectable by I/O
hardware setting) (Note)
Input for command
7 Command (3 bits), data area (3 bits), and Strobe Signal
execution
Output for command

1 Command Processing Completed
execution
Controlled by user program
No. of
Type Function
points
User input 8 Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.
7 Outputs to issue a signal to the external device during program execution
User output
(Note) with SET and RESET commands, etc.

HAND input 8
Used for checking the hand status.
Outputs to issue signals to the external devices with SET and RESET
HAND output 8 commands, etc.
Used for controlling the hand to open or close.
Note: Terminal #53 on CN5 (port 24) is assigned a user output by factory default. It can be assigned the
Continue Start Permission output signal with the I/O hardware setting.
13

2.2 Usage of User I/O Signals
User I/O signals are used as I/O type variables. Access the user I/O by writing it to the
I/O type variables or reading it.
2.2.1 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.
2.2.2 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 denotes I/O port number) Example: IO [104]
IOnn (nn denotes I/O port number) Example: IO104
2.2.3 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 (I), Chapter 9, Section 9.7
"DEFIO (Statement) [Conforms to SLIM]."
2.2.4 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.
• 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
(I), Chapter 13, Section 13.1 "IN."
• 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 (I), Chapter 12, Section
12.5 "WAIT."
14

2.2.5 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.
• 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 (I), Chapter 13, Section 13.1 "SET."
• 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 (I), Chapter 13, Section 13.1 "RESET."
• 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 (I), Chapter 13, Section 13.1 "OUT."
15

Chapter 3 System I/O Signals
3.1 Types and Functions of System Output Signals
The table below lists the system output signals.
Types and Functions of System Output Signals
Application Output signal name Function
Outputs to the external device that the

Robot Initialized OPERATION PREPARATION command is
executable.
Start-up
Auto Mode Outputs when the robot is in Auto mode.
Operation Preparation Outputs when the motor power is turned on and the
Completed robot is in External auto mode.
Outputs when the robot is in operation (one or

Program execution Robot Running
more tasks are being executed).
Outputs when the CPU of the robot controller is
CPU Normal
normal.
Outputs when a servo error, program error, or any
Robot Error
Error/Warning other serious error occurs.
Outputs when the voltage of the encoder or
Battery Warning memory backup battery drops below the specified
level.
Continue Start Permission
Continue Note: It is necessary to specify Outputs when Continue Start is permitted.

this output signal by I/O
hardware setting beforehand.
Emergency Stop
Outputs when the robot is emergency-stopped.
(dual line)
Emergency stop circuit
Pendant Emergency Stop Outputs the status of the emergency stop button
(Standard type of (dual line) on the teach pendant or mini-pendant.
controller)
Deadman SW [Enable SW] Outputs the status of the deadman switch (enable
(dual line) switch) on the teach pendant or mini-pendant.
Pendant Emergency Stop Outputs the status of the emergency stop button
(dual line) on the teach pendant or mini-pendant.
Safety circuit Deadman SW [Enable SW] Outputs the status of the deadman switch (enable
(dual line) switch) on the teach pendant or mini-pendant.
(Global type of
controller) Outputs the status of the auxiliary contact of the
motor contactor in the robot controller.
Contactor Contact Monitor
This signal comes on when the motor is turned on;
it comes off when the motor is turned off.
16

3.2 Usage of System Output Signals
The usage of each system output signal is described below:
3.2.1 Robot Initialized (output)

(1) Function
This signal tells the external device that the OPERATION PREPARATION
command is ready to execute.
(2) Terminal number

#48 on connector CN5
(3) Usage
With this signal and Auto Mode output signal being ON, the OPERATION
PREPARATION command must be executed.
(4) ON conditions
This signal will be turned ON when:
(a) Turning the controller power on normally starts the system program in it
and the OPERATION PREPARATION command becomes ready to
execute.
(b) A robot error is cleared by the OK or Cancel key on the teach pendant or
mini-pendant or by Clear Robot Error (001) after this signal has been
turned OFF.
(5) OFF condition

This signal will be turned OFF when a robot error occurs.
- Pressing the OK or Cancel key on the teach

pendant of mini-pendant has cleared a robot error.
After the power was turned ON,
the system has started normally. - Entry of Clear Robot Error (001) from an external
device has cleared a robot error.
Robot error
Robot Initialized Output
17

3.2.2 Auto Mode (output)
(1) Function
This signal tells the external device that the robot is in Auto mode.
(2) Terminal number

(3) Usage
With this signal being ON, the OPERATION PREPARATION or PROGRAM
START command must be executed.
(4) ON condition
This signal will be turned ON when the robot controller enters Auto mode by
turning the mode selector switch on the teach pendant or mini-pendant to
AUTO with the Enable Auto input signal being ON.
(5) OFF conditions

This signal will be turned OFF under the following conditions.
(a) The operation mode is switched to the Manual or Teach check mode by
using the teach pendant or mini-pendant.
(b) The Enable Auto input signal is OFF.
Note: The Enable Auto input signal will not be turned OFF in the
pendantless state described in the OPTIONS MANUAL, Chapter 1,
Section 1.3.3.
Caution: The Auto Mode output signal will not be turned OFF with
INSTANTANEOUS STOP, STEP STOP or CYCLE STOP
commands.
- The mode selector switch on the teach pendant or

mini-pendant is set to MANUAL or TEACH CHECK.
- Enable Auto OFF
Auto Mode Output
18

3.2.3 Operation Preparation Completed (output)
(1) Function
This signal tells that the motor power is ON and the robot is in External auto
mode.
(2) Terminal number

(3) Usage
With this signal being ON, the robot must be in External auto mode and the
motor power must be ON to run the robot from the external device.
(4) ON conditions
The signal will be turned ON under the External auto mode and motor ON.
Operation to switch to External auto mode
(a) When the External mode is selected on the teach pendant or
mini-pendant.
(b) When the External mode is turned ON by the OPERATION
PREPARATION command from the external device.
Operation to switch the motor ON

(a) When the motor key is pushed on the teach pendant or mini-pendant.
(b) When the motor is turned ON by the OPERATION PREPARATION
command from the external device.
(5) OFF conditions

The signal will be turned OFF under the following conditions;
- Out of the External auto mode
- Under the motor OFF.
Operation to exit External auto mode

(a) When internal mode is selected on the teach pendant or mini-pendant.
(b) When the mode selector switch of the teach pendant or mini-pendant is
set to MANUAL or TEACH CHECK in External mode.
(c) When an Emergency Stop input signal is turned ON.
(d) When a Robot Error output signal is turned ON. (Except level 2 error)
(e) When an Enable Auto input signal is turned OFF.
(f) When a Protective Stop input signal is turned OFF. (Only for the global
type of controller)
Operation to switch the motor OFF

(a) When the motor power is turned off with the MOTOR key or the
emergency stop button is pressed on the teach pendant or mini-pendant.
(b) When a Robot Error output signal is turned ON.
Note: If any of ERROR 6071 to 607B, 6671 to 667B and 607F occurs in
the Manual mode or Teach check mode, the motor power will not be
turned OFF.
(6) Note for software version 2.00 or later

To get the Operation Preparation Completed signal status using an
SYSSTATE command, AND Bit 2 "Servo ON" and Bit 5 "External Mode" to use
the result of the logical operation.
19

Operation Preparation Completed Output
3.2.4 Robot Running (output)

(1) Function
This signal tells the external device that the robot is in operation (that is, one
or more tasks are being executed).
(2) Terminal number

(3) Usage
This signal is used to light the robot operating indicator lamp of an external
operating panel.
Performing the "Stop all programs" operation* turns this signal OFF, allowing
you to check that all programs are stopped.
(4) ON conditions
This signal will be turned ON during execution of the program and also in the
WAIT STATE with a conditional branch or timer command.
(5) OFF conditions

This signal will be turned OFF with the "Stop all programs" operation*.
* "Stop all programs" operation
This operation includes the following: Depression of the emergency stop
button and STOP key and input of Step Stop (All task) and External
Emergency Stop signals.
Robot Running ON
(output) OFF
Robot Running Output
20

3.2.5 CPU Normal (output)
(1) Function
This signal tells the external device that the CPU of the robot controller is
normal.
(2) Terminal number

(3) Usage
(a) This signal is used to light the robot controller error indicator lamp on the
external operating panel.
(b) If this signal is turned OFF, perform the error recovery with the PLC.
(4) ON conditions
This signal will be turned ON by the hardware when the CPU of the robot
controller operates normally.
(5) OFF conditions

This 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.
CPU Normal Output
21

3.2.6 Robot Error (output)
(1) Function
This signal tells the external device that a servo error, program error, or any
other serious error has occurred in the robot.
(2) Terminal number

(3) Usage
(a) This signal is used to light the robot error indicator lamp on the external
operating panel.
(b) If this signal is turned ON, perform the error recovery with the PLC.
(4) ON conditions
When a level 2 error or higher one occurs.
Note: Except the error caused by the wrong operation of the teach pendant
or mini-pendant.
(5) OFF conditions

As shown below, the signal will be turned OFF under the following
conditions.
(a) When a Clear Robot Error (001) signal is inputted and the existing error
is cleared.
(b) When the existing error is cleared by operating the OK or Cancel key on
the teach pendant or the mini-pendant.
Robot Error ON
(output) OFF
- Input of Clear Robot Error (001)

- OK or CANCEL key operation on the
teach pendant or mini-pendant
Robot Error Output
22

3.2.7 Battery Warning (output)
(1) Function
This signal tells the external device that the voltage of the encoder or
memory backup battery has dropped below the specified level.
(2) Terminal number

(3) Usage
This signal is used to check the timing for battery replacement (to check
when the battery voltage drops below the specified lower level).
(4) Output condition

This signal will be issued when the voltage of the encoder or memory
backup battery has dropped below the specified level.
Note: The teach pendant or mini-pendant shows any of ERROR64A1 to

64A6 when the encoder backup battery voltage is low. Meanwhile, the
teach pendant shows ERROR6103 when the memory backup battery
voltage is low.
(5) OFF condition

The signal will be turned OFF when the power is turned ON after the dead
battery was replaced.
Battery Warning Output
23

3.2.8 Continue Start Permission (output): Selectable by I/O hardware setting
Terminal #53 on CN5 (port 24) is assigned a user output by factory default. It
can be assigned the Continue Start Permission output signal with the I/O
hardware setting.
When the "Continue Start Permission" is set:
(1) Function
The controller will output this signal when Continue Start is permitted.
(2) Terminal number

(3) Usage
Use this signal when you want to know whether Continue Start is permitted.
(4) ON condition
This signal comes on when Continue Start is permitted. For details, refer to
the SETTING-UP MANUAL, Chapter 3, Section 3.4.5 "Continue Function."
(5) OFF condition

This signal goes off by carrying out the "Task Status Change Operation."
24

3.2.9 Emergency Stop Circuit Contact Outputs (Standard type of
controller)
3.2.9.1 Emergency Stop (output) (Standard type of controller)
(1) Function
This signal outputs the emergency stop status (dual line).
(2) Terminal number

Signal name Terminal number
Emergency Stop 1 #6 and #40 on CN5
Emergency Stop 2 #7 and #41 on CN5
(3) Usage
This signal is used to confirm that an Emergency Stop input has been
entered. For details about the emergency stop circuits, refer to Sections
4.2.4 and 5.2.4.
This signal can emergency-stop the external device when the emergency
stop button on the teach pendant or mini-pendant is pressed. Turning the
controller power OFF is functionally equivalent to the Emergency Stop
output.
Note: Do not enter this signal into the controller's External Emergency Stop
input circuit. Doing so makes it impossible to reset the emergency stop
state.
(4) Output conditions
Turning an External Emergency Stop input signal OFF or pressing the
emergency stop button on the teach pendant or mini-pendant turns OFF the
Emergency Stop output signal (mini relay contact in the controller).
Emergency Stop Output (Standard type of controller)

25

3.2.9.2 Pendant Emergency Stop Output (Standard type of controller)
(1) Function
This signal outputs the status of the emergency stop button on the teach
pendant or mini-pendant (dual line).
(2) Terminal number

Pendant Emergency Stop 1 #28 and #62 on CN5
(3) Usage
This signal is used to emergency-stop the external device when the
emergency stop button on the teach pendant or mini-pendant is pressed.
This signal is issued independently of the controller ON/OFF state.
For details about the emergency stop circuits, refer to Sections 4.2.4 and
5.2.4.
(4) Output conditions (Normal close type, b contact)
Two contacts of the emergency stop button (4b) on each of the teach
pendant or mini-pendant are connected each other. Pressing the
emergency stop button turns the Pendant Emergency Stop output signal
(contacts) OFF.
Pendant Emergency Stop Output (Standard type of controller)
26

3.2.9.3 Deadman SW [Enable SW] (output) (Standard type of controller)
(1) Function
This signal outputs the status of the deadman switch (enable switch) on the
teach pendant or mini-pendant (dual line).
(2) Terminal number

Deadman SW 1 [Enable SW 1] #8 and #42 on CN5
(3) Usage
This signal is used to display the operation status of the deadman switch or
interlock the deadman switch with other device (e.g., stopping or running the
conveyor).
For details about the emergency stop circuits, refer to Sections 4.2.4 and
5.2.4.
Holding down the deadman switch closes the mini relay contact in the
controller, turning ON the Deadman SW output signal (Contact output:
close).
Deadman SW Output (Enable SW Output) (Standard type of controller)
27

3.2.10 Safety Circuit Contact Outputs (Global type of controller)
3.2.10.1 Pendant Emergency Stop (output) (Global type of controller)
(1) Function
This signal outputs the status of the emergency stop button on the teach
pendant or mini-pendant (dual line).
(2) Terminal number

(3) Usage
This signal is used to emergency-stop the external device when the
emergency stop button on the teach pendant or mini-pendant is pressed.
This signal is issued independently of the controller ON/OFF state.
For details about the safety circuits, refer to Sections 4.2.5 and 5.2.5.
(4) Output conditions (Normal close type, b contact)
Two contacts of the emergency stop button (4b) on each of the teach
pendant or mini-pendant are connected each other. Pressing the
emergency stop button turns the Pendant Emergency Stop output signal
(contacts) OFF.
Pendant Emergency Stop Output (Global type of controller)
28

3.2.10.2 Deadman SW [Enable SW] (output) (Global type of controller)
(1) Function
This signal outputs the status of the deadman switch (enable switch) on the
teach pendant or mini-pendant (dual line).
(2) Terminal number

(3) Usage
This signal is used to display the operation status of the deadman switch or
interlock the deadman switch with other device (e.g., stopping or running the
conveyor).
Holding down the deadman switch closes the safety relay contact in the
controller, turning ON the Deadman SW output signal (Contact output:
close).
Deadman SW Output (Enable SW Output) (Global type of controller)
29

3.2.10.3 Contactor Contact Monitor (output) (Global type of controller)
(1) Function
This signal outputs the status of the auxiliary contact of the motor contactor
in the robot controller. The contact output signal comes on when the motor is
turned on; it comes off when the motor is turned off.
(2) Terminal number

#17 and #35 on CN10
(3) Usage
This signal is used to confirm the ON/OFF state of the motor on the monitor.
Contactor Contact Monitor Output (Global type of controller)
30

3.3 Types and Functions of System Input Signals
The table below lists the system input signals.
Types and Functions of System Input Signals
Applicable
Use to: Signal name Function
controller type
Stop Any type Releasing the signal step-stops all programs
Step Stop (All tasks)
being executed.
(Note 1)
Instantaneous Stop Releasing this signal instantaneously stops all
(All tasks) programs being executed.
(Note 2)
Standard type External Emergency Releasing this signal stops the robot in an
Stop (dual line) emergency.
Global type External Emergency Releasing this signal stops the robot in an
Stop (dual line) emergency.
Select mode Standard type Enable Auto Short-circuiting this signal enables switching to
Auto mode.
Global type Enable Auto Short-circuiting this signal enables switching to
(dual line) Auto mode.
Protective Stop The Enable Auto and Protective Stop input
(dual line) signal circuits are connected in series in the
controller, so two types of inputs are available
as an automatic operation permission signal.
Prepare for Any type Strobe Signal This signal initiates the processing of the I/O
operation commands set in the data and command areas.
Start program Data areas These areas are used to specify I/O commands
(3 bits) that enable the following:
Clear error
Command areas - Start/stop each task program.
(3 bits) - Prepare for operation
- Clear robot errors.
Note: For details, refer to Section 3.5.3 "I/O

Commands Details
(Note 1) In External automatic operation, be careful with the following:

- The moment each of these signals is released, the corresponding stop processing starts.
- As long as it is not necessary to stop the robot, these stop signals should be short-circuited.
(Note 2)
The Instantaneous Stop signal becomes available only when an I/O extension board is used and the
allocation mode is changed to Standard or Compatible mode. Like other stop signals, this signal should be
short-circuited as long as it is not necessary to stop the robot.
31

3.4 Usage of System Input Signals
The usage of each system input signal is described below.
3.4.1 Step Stop (All tasks) (input)

(1) Function
This signal allows the external device to step-stop all tasks being executed,
except supervisory tasks.
(2) Terminal
(3) Input conditions and operation

(a) Turning (opening) this signal OFF stops all tasks upon completion of the
on-going step and turns OFF the Robot Running output signal.
(b) For resuming the program after a step stop, see Chapter 3, Section
3.5.3.2 "OPERATION PREPARATION (000)."
Step Stop (All tasks) Input
32

3.4.2 External Emergency Stop (input)
(1) Function
This signal allows the external device to emergency-stop the robot.
(2) Terminal number

Controller type Signal name Terminal number
External Emergency Stop 1 #2 and #36 on CN5
Standard type
Global type*
* The global type of controller must use two separate contacts to control two
External Emergency Stop input signals. Two circuits connected in parallel using a
single contact or an always-shorted circuit will be interpreted as an external circuit
failure so that the circuitry will not operate.

(a) Turning (opening) this signal OFF emergency-stops the robot.
1) The OFF signal turns the motor power OFF irrespective of whether the
robot is in Manual, Internal auto, or External auto mode.
2) During execution of programs (Robot Running signal ON), the OFF
signal turns the motor power OFF and places the robot in internal
mode after decelerating the robot to a stop. It also resets programs so
as not to execute the subsequent and the following steps.
3) When the program is stopped in Manual or Auto mode, the OFF signal
produces nothing except it turns the power to the motor OFF.
(b) This signal must be turned ON (shorted) in order to turn the motor power
ON and run the robot in Manual or Auto mode.
(c) Opening the External Emergency Stop input is functionally equivalent to
pressing the emergency stop button on the teach pendant or
mini-pendant.
(4) Input timing

This input signal will be processed prior to all commands and input signals.
Notes
(1) The different status between two emergency stop circuits, if kept for
at least approx. one second, will be interpreted as an occurrence of
trouble, triggering an error "279E: Inconsistent robot stop input" and
shutting down the motor power.
(2) The global type of controller should control two external emergency
stop inputs with separate contacts. Two circuits connected in parallel
with a single contact or either one circuit always short-circuited will
be interpreted as an external circuit error, producing no circuit
operation.
33

3.4.3 Enable Auto (input) (Standard type of controller)
(1) Function
(a) Turning this signal ON (shorting) enables switching to Auto mode.
(b) Turning this signal OFF (opening) enables switching to Manual or Teach
check mode.
(2) Terminal number

#1 and #35 on connector CN5
(3) Usage
This signal is used to connect the Auto/Teaching selector switch of an

(a) As shown below, the selectable operation mode depends on whether this
input is shorted or open.
(b) If the input becomes open during automatic operation, the mode will be
switched to Manual mode and ERROR21FC will be displayed.
(c) If manual operation or a teach check is conducted with this input shorted,
ERROR21F2 will be displayed.
(d) With this signal being opened, turning the mode selector switch on the
teach pendant or mini-pendant from the MANUAL or TEACH CHECK to
AUTO position triggers ERROR21F3.
Since this state is shown as × in the table below, this error will remain
displayed until the robot exits this state.
(e) Although ERROR21FD or ERROR21FC will be displayed when the state
is changed from to Δ or ×, they will not be displayed when the state is
changed from Δ or × to .
(f) Turning this signal OFF (open) in External mode switches to the internal
mode and turns the Operation Preparation Completed output signal OFF.
Relationship Between Enable Auto Input and Selectable Mode
Enable Auto
Operation mode Application
ON (shorted) OFF (open)
Manual operation with the teach pendant or
Manual mode Δ
mini-pendant.
Teach check mode Program check with the teach pendant or mini-pendant. Δ
Automatic operation with the teach pendant or
Internal auto mode ×
mini-pendant.
External auto mode Automatic operation with the external device. ×
Note: = Mode selectable × = Mode not selectable

Δ = Mode selectable but manual operation program not executable
Caution: In the pendantless state, 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:
(a) Set the robot so that it will not start to operate when the Enable Auto input is open.
(b) Enable Auto input open state and Auto Mode output (See Section 3.2.2 "Auto Mode
(output).")
Set the equipment to make an emergency stop in an AND state.
34

3.4.4 Enable Auto (input) (Global type of controller)
(1) Function
(a) Turning this signal ON (shorting) enables switching to Auto mode. (Dual
line)
Note: The Enable Auto and Protective Stop input signal circuits are
connected in series in the controller and those signals are used as an
automatic operation permission signal when turned ON (closed).
(b) Turning this signal OFF (opening) enables switching to Manual or Teach
check mode.
(2) Terminal number

Enable Auto input 1 #7 and #25 on CN10
Enable Auto input 2 #8 and #26 on CN10
Note: For the circuit configuration, refer to Sections 4.2.5 and 5.2.5. Two
Enable Auto input signal circuits must be controlled with two separate
contacts each. Two circuits connected in parallel using a single contact or
an always-shorted circuit will be interpreted as an external circuit error so
that the circuitry will not operate.
(3) Usage
This signal is used to connect the AUTO/TEACHING selector switch of an
(4) Input conditions and operation (with Protective Stop input signal ON)
(a) As shown below, the selectable operation mode depends on whether this
input is shorted or open.
(b) Turning this signal OFF (open) during automatic operation turns the motor
power OFF (Continue stop) and displays ERROR21FC.
(c) If manual operation or a teach check is conducted with this input shorted,
ERROR21F2 will be displayed.
(d) With this signal being opened, turning the mode selector switch on the
teach pendant or mini-pendant from the MANUAL or TEACH CHECK to
AUTO position triggers ERROR21F3.
Since this state is shown as × in the table below, this error will remain
displayed until the robot exits this state.
(e) Although ERROR21FD or ERROR21FC will be displayed when the state
is changed from to Δ or ×, they will not be displayed when the state is
changed from Δ or × to .
(f) Turning this signal OFF (open) in External mode turns the motor and the
Operation Preparation Completed output signal OFF.
Relationship Between Enable Auto Input and Selectable Mode

(With Protective Stop input signal ON)
Enable Auto
Operation mode Application
ON (shorted) OFF (open)
Manual mode Manual operation with the teach pendant or mini-pendant. Δ
Teach check mode Program check with the teach pendant or mini-pendant. Δ
Automatic operation with the teach pendant or
Internal auto mode ×
mini-pendant.
External auto mode Automatic operation with the external device. ×
Note: = Mode selectable × = Mode not selectable
Δ = Mode selectable but manual operation program not executable
35

Caution: In the pendantless state, 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:
(a) Set the robot so that it will not start to operate when the Enable Auto input is open.
(b) Enable Auto input open state and Auto Mode output (See Section 3.2.2 "Auto Mode
(output).")
Set the equipment to make an emergency stop in an AND state.
3.4.5 Protective Stop (input): Global type of controller

(1) Function
Opening this input signal circuit in Auto mode allows the external device to
continue-stop the robot. (dual line)
connected in series in the controller and those signals are used as an
automatic operation permission signal when turned ON (closed).
(2) Terminal number

Protective Stop input 1 #5 and #23 on CN10
Protective Stop input 2 #6 and #24 on CN10
(3) Usage
This signal is used for a safety door switch and other safety devices.
(4) Input conditions and operation (with Enable Auto input signal ON)
connected in series in the controller and have the same function. (See
Section 3.4.4.)
(a) Turning this signal OFF (open) in Auto mode turns the motor power OFF
and continue-stops the robot.
(b) Turning this signal OFF (open) in Manual mode turns the motor power
OFF.
Note: For the circuit configuration, refer to Sections 4.2.5 and 5.2.5. Two
Protective Stop input signal circuits must be controlled with two separate
contacts each. Two circuits connected in parallel using a single contact or
an always-shorted circuit will be interpreted as an external circuit error so
that the circuitry will not operate.
(5) Input timing

In Auto mode, this signal will be processed prior to other input signals and all
commands.
Note: Switching the Protective Stop and Enable Auto input signals from
open to close does not require temporal conditions, but requires any
action to switch.
36

3.5 Command Execution I/O Signals
The I/O commands can be executed using command execution I/O signals.
I/O commands execute the following.
⋅ Start/stop each task program.
⋅ Enable running the robot from the external device.
⋅ Clear robot errors.
3.5.1 General Information about Commands

The table below shows the I/O commands functions.
I/O Command Functions
Command Description of function

⋅ Starts the program cycle (specified program).
Program Operation ⋅ Step-stops the program (specified program/all programs).
⋅ Resets the program (specified program/all programs).
Operation Preparation ⋅ Enables running the robot from the external device.
Clear Robot Error ⋅ Clears a robot error from the external device.
37

3.5.2 Processing I/O Commands
3.5.2.1 General Information about Processing

I/O commands to be executed are processed as shown below.
Outline of I/O Command Processing
(1) Set a command area and a data area (if necessary) for the command
execution I/O signal from the external device to the robot controller.
Note: The data to be set must be defined at least 1 ms before the Strobe
Signal is turned ON
(2) After completion of setting, turn the Strobe Signal ON.
Note: The command input with a Strobe Signal should be preceded by the
output of the Robot Initialized. If a Robot Error signal has been issued,
however, execute a Clear Robot Error (001) since no Robot Initialized will
be issued.
38

(3) The controller reads the command area and the data area according to the
input of Strobe Signal.
(4) The controller starts processing based on the command read.
(5) After completion of command processing, the controller turns ON the
Command Processing Completed signal.
If an error has occurred during processing, a Robot Error signal will be
outputted together with the Command Processing Completed signal.
Note: If the Strobe Signal is turned OFF before the Command Processing
Completed signal is turned ON, the Command Processing Completed
signal will be output and then turned OFF within 100 ms
(6) The PLC waits until the Command Processing Completed signal is input.
In this case, confirm that no error exists with the robot.
(7) The PLC turns OFF the command and data areas and the Strobe Signal.
(8) As soon as the Strobe Signal is turned OFF, the controller turns OFF the
Command Processing Completed signal.
The Robot Error signal, which is outputted due to a command processing
error, remains ON until Clear Robot Error (001) is executed.
Note: The maximum allowable time from when the Strobe Signal is turned
OFF until the Command Processing Completed signal is turned OFF, is 100
ms.
3.5.2.2 Using Each Signal Line
[ 1 ] Command and Data Areas

This section describes the usage of the command area (3 bits, input) and data
area (3 bits, input).
(1) Function
Specifies the commands to be executed by the Robot Controller.
Sets the command area at all times, and data area if necessary.
(2) Terminal numbers

Command area: #16 to #18 on connector CN5.
Data area: #13 to #15 on connector CN5.

(a) Set the command area whenever I/O commands are to be executed. Set
data for data area if commands require them.
(b) "Shorted" represents the bit value = 1.
"Open" represents the bit value = 0.
(c) Input the command area and data area before the Strobe Signal (1 ms or
more). Retain the status until the Command Processing Completed signal
is output.
39

[ 2 ] Strobe Signal (input)
(1) Function
This signal informs the Robot Controller that the command area and data
area have been set. Additionally it directs the start of command processing.
Caution: Perform command (Except Clear Robot Error (001)) input with a
Strobe Signal after the system output signal "Robot Initialized"
is output.
(2) Terminal number

#12 on connector CN5.

By turning ON this input in Auto or External mode, the robot controller reads
the command area and data area, and starts processing.
[ 3 ] Command Processing Completed (output)

(1) Function
This signal outputs to the external device that I/O command processing is
completed.
(2) Terminal number

#52 on connector CN5.
(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
(a) The signal will be turned ON upon completion of processing the I/O
command given.
(b) If an error occurs as a result of executing an I/O command, the Robot
Error signal and the Command Processing Completed signal will be
turned simultaneously ON.
(5) OFF conditions

(a) The signal will be turned OFF when the Strobe Signal is turned OFF.
(b) If the Strobe Signal is turned OFF before command processing is
completed, the Command Processing Completed signal will be output
and then turned OFF within 100 ms.
40

3.5.3 I/O Commands Details
3.5.3.1 List of I/O Commands

The table below lists I/O commands.
List of I/O Commands
Command area Data area

001 Motor Power ON, CAL Execution
000 010 External speed 100
Operation Preparation 100 External Mode switching
111Execution of all above
(Motor Power
ON→CAL→SP100→External)
001
Clear Robot Error ⎯
010
Program Start Program number
011
Continue Start ⎯
100
Specified Program Reset Program number
101
All Programs Reset ⎯
3.5.3.2 OPERATION PREPARATION (000)

(1) Function
Prepares to operate the robot by switching the operation mode from the
external devices.
(2) Format
Command area (3 bits, input)
000
Data area (3 bits, input)

0 bit: Motor Power ON, CAL Execution
1 bit: External speed 100
2 bit: External mode switching
These bits can be set at the same time and can be executed. If plural bits are
set, the commands are executed in order.
For example: If the 0 bit, 1 bit and 2 bit are set, commands are executed as
follows;
Motor Power ON, CAL Execution, External speed 100 and External mode
switching
(3) Description
This command can be executed in Auto mode. In other modes, an error
occurs at execution. When executing this command, select the Internal auto
mode on the teach pendant or mini-pendant beforehand.
41

3.5.3.3 CLEAR ROBOT ERROR (001)
(1) Function
This command clears a robot error that has been caused.
(2) Format
001
Data area (3 bits, input):
Nothing will be input.
(3) Description
If a robot error occurs, this command clears it. When there is no failure, no
processing will take place
When an error is displayed, the same processing as when the OK or Cancel
key of the teach pendant or the mini-pendant is operated will be performed.
3.5.3.4 PROGRAM START (010)

(1) Function
This command starts the specified program in the data area.
(2) Format
010
Data area (3 bits, input)
Program number: Program number to be started.
If the specified number is "n", PRO n starts.
(3) Description
This command is executable only in External mode. An error will occur in other
modes. This command starts the program of the program number specified in
data area. PRO 0 to PRO 7 can be started.
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 instantaneously stopped (Halt), 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.
42

3.5.3.5 CONTINUE START (011)
(1) Function
This command starts Continue Start.
(2) Format
011
(3) Description
This command is executable only in External mode. An error will occur in
other modes.
An attempt to execute this command when the Continue Start Permission
signal is off, will cause an error (ERROR 27A8).
3.5.3.6 SPECIFIED PROGRAM RESET (100)

(1) Function
This command immediately stops and also initializes the program of the
program number specified in data area.
(2) Format
100

Program number: The program number to be reset.
If the number "n" is specified in data area, resets PRO n.
(3) Description
This command can reset the programs for PRO 0 to PRO 7.
One of the following operations takes place according to the operating
status of the program.
⋅ When the specified program is terminated (stopped), nothing will
happen.
⋅ When the specified program is step-stopped or immediately stopped
(halt), it will be initialized. The initialized program will resume from the
beginning.
⋅ When the specified program is running, it will immediately stop (halt)
and also be initialized. If started after the stop, the stopped program
will resume from the beginning.
43

3.5.3.7 ALL PROGRAMS RESET (101)
(1) Function
This command immediately stops all programs and also initializes them.
(2) Format
101

(3) Description
This command can reset all programs.
One of the following operations takes place according to the operating
status of the program.
⋅ When the specified program is terminated (stopped), nothing will
happen.
⋅ When the specified program is step-stopped or immediately stopped
(halt), it will be initialized. The initialized program will resume from the
beginning.
⋅ When the specified program is running, it will immediately stop (halt)
and also be initialized. If started after the stop, the stopped program
will resume from the beginning.
3.6 Example of Using System I/O Signals

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

This example shown below assumes an equipment setup which allows you to
run the robot by operating an external equipment’s operation panel connected
via the PLC to the robot controller. It is assumed that the operating panel has a
display, lamps and switches listed on the next page.
Example of Equipment Setup Using a Robot
44

Function Example of External Equipment Operating Panel
Classification Part Application
Display Display Displays messages, such as ROBOT PREPARATION OK.
(1) Automatic operation - Lights during automatic operation.

indicator - Turned OFF when the robot is not in automatic operation.
- Lights when the Operation Preparation Completed signal
(2) Robot external is ON.
running OK indicator - Turned OFF when the Operation Preparation Completed
signal is OFF.
Lamp
(3) Operation OK - Lights when the Enable Auto input signal is ON.
indicator - Turned OFF when the Enable Auto input signal is OFF.
- Lights when the robot is in the home position for working.
(4) Robot home - Turned OFF when the robot is out of the home position
position indicator for working.
(By programming with an user-output)
(1) Robot preparation Starts the preparation of the robot.
button
(2) Automatic start Starts the operation of the equipment.

button
Switch Stops the equipment after a cycle of operations is
(3) Cycle stop button
completed.
(4) Operation/ Automatic operation of the robot possible when

OPERATION is selected.
Adjustment 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 for using the equipment
taken as an example shown on the previous page.
Follow steps (a) to (d).
(a) Operation preparation
The OPERATION PREPARATION command brings to be able to operate
the robot into external automatic operation mode. This operation will be
completed when the Operation Preparation Completed signal is turned
ON.
(b) Operation start area check
When the robot arm is in the home position for working, the robot home
position indicator lights and "ROBOT PREPARATION OK" displays.
(c) Automatic operation
Start the program by which the robot starts from the home position for
working, performs operations, and returns to the home position.
(d) 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

The following pages show the relationship between the system I/O signals
for start and stop, worker’s operation, display on the equipment operation
panel, PLC proceeding, and robot motion.
45

Start and Stop Procedure and System I/O Signals-1
Worker’s operation and display on
Step equipment’s operation panel
PLC processing Robot operation
Equipment power ON
Setting
operation/adjustment
Enable Auto ON (Internal processing)
selector switch to
operation
Operation OK indicator
ON
Setting Mode selector

(a) Operation preparation
switch of the teach

pendant or the
mini-pendant to AUTO
(Note 1)
Robot preparation Command area input ON
button ON
Executing Operation
Preparation command Motor power ON
Setting SP100
Switching mode to
external mode
Robot external running Operation Preparation

OK indicator ON (Internal processing)
Completed signal ON
Robot external running OK

(b) Operation start area check
indicator
Run the user program for moving
robot arm close to the home
position, when the robot home
position indicator is OFF.
Robot home position User output signal ON

indicator ON (Internal processing)
(for robot home position)
Robot preparation OK When both are ON

display (Internal processing)
(Continued on following page)
46

(Continued from preceding page)
Start and Stop Procedure and System I/O Signals-2
Worker’s operation and display on
Step equipment’s operation panel
PLC processing Robot operation
Equipment’s Automatic Data area input ON

Start Button ON
Program Number
selection
(c) Automatic operation
Automatic Operation Executing Program Program start

indicator ON Operation Command
(Program start)
(Note 2)
END
Program Number Robot Running signal

selection OFF
Program start
command ON
Repeated
Equipment’s Cycle Cycle Stop ON Executing 1-cycle

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

indicator OFF Robot Running signal
OFF
Equipment power OFF
Note 1: Refer to Section 3.5.3.2, "OPERATION PREPARATION (000)."

Note 2: Refer to Section 3.5.3.4, "PROGRAM START (010)."
Note 3: Symbol signification
: System I/O signal : Flow of signal
47

Chapter 4
Connector Pin Assignment and I/O Circuits
(NPN type)
This chapter explains the connector pin assignment and circuits of NPN type (source
input and sink output) on an I/O board. I/O boards designed for the use in Japan are of
an NPN type.
For a PNP type (sink input and source output), refer to Chapter 5, "Connector Pin
Assignment and I/O Circuits (PNP type)."
4.1 Connector Pin Assignment (NPN type)

This section describes the pin assignment of I/O connectors on the robot controller.
4.1.1 RS-232C (CN1): RS-232C connector

RS-232C (CN1) Pin Assignment
Terminal No. Name Terminal No. Name

1 ⎯ 6 DSR
2 RXD 7 RTS
3 TXD 8 CTS
4 DTR 9 ⎯
5 SG
48

4.1.2 HAND I/O (CN9)
HAND I/O (CN9) Pin Assignment (NPN type)
View from the cable side
Port Wire color Port Wire color

Terminal Name Terminal Name
No. No. No. No.
Standard Reinforced Standard Reinforced
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
6 Hand output 69 Orange Blue 16 Hand input 55 White Brown
7 Hand output 70 Yellow Yellow 17 Internal power ⎯ White Brown

source output
+24V
8 Hand output 71 Green Green 18 Internal power ⎯ White Brown

source output
0V
9 Hand input 48 Blue Red 19 NC ⎯ White Brown
10 Hand input 49 Violet Violet 20 NC ⎯ White Brown

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #11, #2 and #12, #10 and #20.
Note 2: The unused pins should be prevented from direct contact with other pins or conductive part. Direct contact could result in a
controller failure or damage.
49

4.1.3 Mini I/O (CN5): User- or System-I/O connector
[ 1 ] Standard type of controller
Mini I/O (CN5) Pin Assignment (For standard type of controller)

Terminal Port Wire Terminal Port Wire
Signal name Signal name
No. No. color No. No. color
1 Enable Auto (Internal +24V) (input) ⎯ Black 35 Enable Auto (input) ⎯ Pink
External Emergency Stop 1, b-1 (input)

2 ⎯ Brown 36 External Emergency Stop 1, b-2 (input) ⎯ Pink
(Internal +24V)
3 ⎯ Red 37 External Emergency Stop 2, b-2 (input) ⎯ Pink
(Internal +24V)
4 Reserved. ⎯ Orange 38 Reserved. ⎯ Pink
5 Reserved. ⎯ Yellow 39 Reserved. ⎯ Pink
Emergency Stop 1, -1 (output) Emergency Stop 1, -2 (output)
6 ⎯ Black 40 ⎯ White
(Mini relay) (Mini relay)
7 ⎯ Brown 41 ⎯ White
Deadman SW 1, -1 (output) Deadman SW 1, -2 (output)
8 ⎯ Red 42 ⎯ White
[Enable SW 1, -1] (Mini relay) [Enable SW 1, -2] (Mini relay)
9 ⎯ Orange 43 ⎯ White
10 ⎯ ⎯ Yellow 44 ⎯ ⎯ White
11 Step Stop (All tasks) (input) 0 Green 45 CPU Normal (No monitor allowed) (output) 16 White
12 Strobe Signal (input) 1 Blue 46 Robot Running (output) 17 White
13 Data area bit 0 (input) 2 Violet 47 Robot Error (output) 18 White
14 Data area bit 1 (input) 3 Gray 48 Robot Initialized (output) 19 White
15 Data area bit 2 (input) 4 Pink 49 Auto Mode (output) 20 White
16 Command area bit 0 (input) 5 Black 50 Operation Preparation Completed (output) 21 Gray
17 Command area bit 1 (input) 6 Black 51 Battery Warning (output) 22 Violet
18 Command area bit 2 (input) 7 Brown 52 Command Processing Completed (output) 23 Violet
User output/
19 User input 8 Red 53 24 Violet
Continue Start Permission (output)
20 User input 9 Orange 54 User output 25 Violet
21 User input 10 Yellow 55 User output 26 Violet
22 User input 11 Green 56 User output 27 Violet
23 User input 12 Blue 57 User output 28 Violet
24 User input 13 Gray 58 User output 29 Violet
25 User input 14 Pink 59 User output 30 Violet
26 User input 15 Brown 60 User output 31 Gray
27 ⎯ ⎯ Red 61 ⎯ ⎯ Gray
Pendant Emergency Stop 1, b-1 (output) Pendant Emergency Stop 1, b-2 (output)
28 ⎯ Orange 62 ⎯ Gray
(Dry output) (Dry output)
29 ⎯ Yellow 63 ⎯ Gray
Dedicated to conveyor tracking board Dedicated to conveyor tracking board
30 (when JP12 on mini I/O board is shorted. ⎯ Green 64 (when JP13 on mini I/O board is shorted. ⎯ Gray
Internal power source +24V) Internal power source 0V)
31 ⎯ ⎯ Blue 65 ⎯ ⎯ Gray
32 DC power input +24V (when external ⎯ Pink 66 DC power input 0V (when external power ⎯ Gray
power source is used) source is used)
33 ⎯ Black 67 ⎯ Blue
DC power output +24V (when internal DC power output 0V (when internal power
34 power source is used) ⎯ Brown 68 source is used) ⎯ Blue
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could
result in a controller failure or damage.
Note 3: To use Pendant Emergency Stop output signals, be sure to supply 24 V to terminals #28 and #29.
50

[ 2 ] Global type of controller (with safety board or safety box)
The global type of the controller handles stop-related I/Os by using the safety I/O
(CN10) given on the next page.
Mini I/O (CN5) Pin Assignment (For global type of controller)

1 Reserved. ⎯ Black 35 Reserved. ⎯ Pink
2 Reserved. ⎯ Brown 36 Reserved. ⎯ Pink
3 Reserved. ⎯ Red 37 Reserved. ⎯ Pink
6 Reserved. ⎯ Black 40 Reserved. ⎯ White
7 Reserved. ⎯ Brown 41 Reserved. ⎯ White
8 Reserved. ⎯ Red 42 Reserved. ⎯ White
9 Reserved. ⎯ Orange 43 Reserved. ⎯ White
CPU Normal (No monitor allowed)
11 Step Stop (All tasks) (input) 0 Green 45 16 White
(output)
Operation Preparation Completed
16 Command area bit 0 (input) 5 Black 50 21 Gray
(output)
Command Processing Completed
18 Command area bit 2 (input) 7 Brown 52 23 Violet
(output)
User output /
26 User input 15 Brown 60 Reserved. 31 Gray
27 ⎯ ⎯ Red 61 ⎯ ⎯ Gray
28 Reserved. ⎯ Orange 62 Reserved. ⎯ Gray
29 Reserved. ⎯ Yellow 63 Reserved. ⎯ Gray
Internal power source +24V) Internal power source 0V)
31 ⎯ ⎯ Blue 65 ⎯ ⎯ Gray
51

4.1.4 Safety I/O (CN10)：System-I/O connecter (Global type of controller)
Safety I/O (CN10) Pin Assignment

1 External Emergency Stop 1, b-1 (input) Black 19 External Emergency Stop 1, b-2 (input) Pink
2 External Emergency Stop 2, b-1 (input) Brown 20 External Emergency Stop 2, b-2 (input) Pink
3 Reserved. Red 21 Reserved. Pink
4 Reserved. Orange 22 Reserved. Pink
5 Protective Stop 1, -1 (input) Yellow 23 Protective Stop 1, -2 (input) Pink
6 Protective Stop 2, -1 (input) Green 24 Protective Stop 2, -2 (input) Pink
7 Enable Auto 1, -1 (input) Blue 25 Enable Auto 1, -2 (input) Pink
8 Enable Auto 2, -1 (input) Black 26 Enable Auto 2, -2 (input) Gray
9 ⎯ Brown 27 ⎯ Gray
10 Reserved. Red 28 Reserved. Gray
11 Reserved. Orange 29 Reserved. Gray
12 Reserved. Yellow 30 Reserved. Gray
13 Pendant Emergency Stop 1, b-1 Green 31 Pendant Emergency Stop 1, b-2 Gray
(output) (output)
14 Pendant Emergency Stop 2, b-1 Blue 32 Pendant Emergency Stop 2, b-2 Gray
(output) (output)
15 Deadman SW 1, -1 (output) Violet 33 Deadman SW 1, -2 (output) Gray

[Enable SW 1, -1] [Enable SW 1, -2]
(Safety relay) (Safety relay)
16 Deadman SW 2, -1 (output) Black 34 Deadman SW 2, -2 (output) White

[Enable SW 2, -1] [Enable SW 2, -2]
17 Contactor Contact Monitor 1, -1 Brown 35 Contactor Contact Monitor 1, -2 White

(output) (output)
18 Reserved. Red 36 Reserved. White
52

4.2 Robot Controller I/O Circuits (NPN type)
4.2.1 Setting up Mini I/O Power Supply

The power supply (+24 VDC) for the Mini I/O can be switched between internal and
external power sources by changing the jumper switch setting as listed below. The
factory default is external power source setting.
Power supply Jumper switches JP1 and JP3 on the

Description
for I/O controller printed circuit board
External Short-circuit Do not change the
source pins 2 and 3 factory default setting.
(factory
default)
Internal Short-circuit Remove the controller

source pins 1 and 2, top cover and change
and pins 3 the JP1 and JP3
and 4 settings with short
sockets that come with
the robot.
Note: Switching the power supply setting for I/O from external to internal changes the
assignment to terminals #32 to #34 and #66 to #68 on CN5 from external DC power input to
internal DC power output. For details, refer to the circuit configuration examples in Sections
4.2.2 and 4.2.3.
53

4.2.2 User-Input, System-Input and Hand-Input Circuits (NPN type)
The figure below shows examples of the user-input, system-input and hand-input circuit
configurations and connections of the robot controller.
Notes
(1) In addition to PLCs, proximity switches and relay contacts can be directly
connected to the input terminals of the robot controller. Note that the leakage
current from the proximity switches should be 1 mA or below.
(2) Use multi-core shielding cables for protecting the controller from external noise and
ground them at the controller side.
(When the external power source is used)
User-Input, System-Input and Hand-Input Circuits (NPN type)
54

(When the internal power source is used)
User-Input, System-Input and Hand-Input Circuits (NPN type)
55

4.2.3 User-Output, System-Output, and Hand-Output Circuits (NPN
type)
The following pages show examples of the configuration and connection of the robot
controller's user-output, system-output and hand-output circuits.
(1) The User-Output, System-Output and Hand-Output Circuits are open

collector output circuits.
(2) The maximum allowable source current is 70 mA.
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 and
use a lamp whose rating is 0.5W or less.
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. 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.
Refer to next page.
(5) Use a multi-core shielding cable for the purpose of protecting the devices
from external noise. Ground it to the robot controller.
(6) +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.
(7) For three seconds after the controller power is turned on, the I/O board will
be in a transient state, so do not use its output as valid signals.
56

User-Output, System-Output and Hand-Output Circuits (NPN type)
57

User-Output, System-Output and Hand-Output Circuits (NPN type)
Example of Circuit with Lamp (NPN type)
58

4.2.4 Configuration of Emergency Stop Circuitry
(Standard type of controller)
4.2.4.1 External Emergency Stop and Enable Auto Input Circuits
The External Emergency Stop and Enable Auto input signals are important for safety.
Be sure to configure their circuits with contacts as shown below.
Note: For the overall configuration sample of an emergency stop circuit, refer to
Section 4.2.4.2 "Emergency Stop Circuit."
External Emergency Stop and Enable Auto Input Circuits (Standard type of controller)
59

4.2.4.2 Emergency Stop Circuit (Standard type of controller)
The following figure shows the example of configuration and connection of emergency
stop circuit on the standard type of the controller. In the RC7M controller, the
emergency stop circuit consists of dual safety circuits.
The emergency stop button on the teach pendant can be used also as an emergency
stop switch of the equipment.
Emergency Stop and Pendant Emergency Stop output signals

(1) Emergency Stop output signal
The internal relay receives the External Emergency Stop input signal and the
emergency stop input from the teach pendant to output this signal. When the power
is turned OFF, the controller is in the emergency stop state.
(2) Pendant Emergency Stop output signal (Dry output)
The two contacts on the emergency stop button (4b) on the teach pendant are
connected. This signal will be issued independent of the ON/OFF state of the
controller power.
Emergency Stop Circuit in the RC7M Controller (Standard type of controller)
60

4.2.5 Configuration of Safety Circuit (Global type of controller)
4.2.5.1 Input Circuit to the Safety Circuit
Input signals to the safety circuit are important for safety. Be sure to configure their
circuits with contacts as shown below, observing the notes given below.
Note: For the overall configuration sample of a safety circuitry, refer to Section 4.2.5.2
"Safety Circuit."
Precautions on Connecting the Safety I/O (CN10)
(1) Two External Emergency Stop input signals must be controlled with separate contacts. Two circuits
connected in parallel using a single contact or an always-shorted circuit will be interpreted as an
external circuit failure so that the emergency stop state cannot be reset.
(2) Two Protective Stop input signals and two Enable Auto input signals each must be controlled with
separate contacts. Two circuits connected in parallel using a single contact or an always-shorted
circuit will be interpreted as an external circuit failure so that the circuitry will not operate.
(3) The Enable Auto and Protective Stop input signals are connected in series in the controller, so two
types of inputs are available as an automatic operation permission signal.
(4) Switching the External Emergency Stop, Protective Stop, and Enable Auto input signals from open
to close does not require temporal conditions, but requires any action to switch.
Input Circuits to the Safety Circuits (Global type of controller)
61

4.2.5.2 Safety Circuit (Global type of controller)
The figure below shows an internal connection equivalent circuit for the safety circuit in
the global type of the controller. The actual safety circuit is configured with safety relays
and others.
Safety Circuit in the RC7M Controller (Global type of controller)
Note: Different stop states resulting from emergency stop input, Protective Stop, and Enable Auto (OFF)
(1) The emergency stop input (External Emergency Stop or teach pendant/mini-pendant input) shuts down
the power to the motor and resets the program, provided that the Continue parameter is set to the default
(0: Disable) in Continue setting.
(2) The Protective Stop or Enable Auto (OFF) input signal shuts down the power to the motor and places the
robot in the Continue Stop state.
62

4.3 Wiring Notes for Controller I/O Connectors (NPN type)
After the wiring of the controller's I/O connectors is completed, check the following
before turning ON the power:
Check point (1)
Using a circuit 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.
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.
Check point (2)

Using a circuit tester, check across "each signal output terminal" and "+24V
terminal" or "E24V terminal" of each connector to see that there is no continuity.
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.
Circuit tester
Robot
controller
External
"+24V terminal" and device
"E24V terminal" of
the controller
"0V terminal" and "E0V terminal"

of the controller
Checking Example
63

Mini I/O connector (CN5)

Terminal Number Name Meaning Check point
1 to 3 +24V internal power source terminal +24V internal power output (1)
45 to 60 Signal output terminal 0V (GND) at output (2)
32 to 34 External power
+24 VDC power source input 24 VDC power input (1)
source
Internal power
+24 VDC power source output 24 VDC power output (1)
source
0 VDC power source input DC power input (GND) (1)
source
Internal power
0 VDC power source output DC power output (GND) (1)
source
HAND I/O connector (CN9)

1 to 8 Hand output terminal 0V (GND) at output (2)
17 Internal power source output (+24V) 24 VDC power output (1)
18 Internal power source output (0V) DC power output (GND) (1)
64

Chapter 5
Connector Pin Assignment and I/O Circuits
(PNP type)
This chapter explains the connector pin assignment and circuits of PNP type (sink input
and source output) on an I/O board.
For an NPN type (source input and sink output), refer to Chapter 4, "Connector Pin
Assignment and I/O Circuits (NPN type)."
5.1 Connector Pin Assignment (PNP type)

This section describes the pin assignment of I/O connectors on the robot controller.
5.1.1 RS-232C (CN1): RS-232C connector

RS-232C (CN1) Pin Assignment
Terminal No. Name Terminal No. Name

1 ⎯ 6 DSR
2 RXD 7 RTS
3 TXD 8 CTS
4 DTR 9 ⎯
5 SG
65

5.1.2 HAND I/O (CN9)
HAND I/O (CN9) Pin Assignment (PNP type)
Wire color Wire color

Terminal Port Terminal Port
Name Name
No. No. No. No.
Standard Reinforced Standard Reinforced
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
6 Hand output 69 Orange Blue 16 Hand input 55 White Brown
7 Hand output 70 Yellow Yellow 17 Internal power ⎯ White Brown

source output
(0V)
8 Hand output 71 Green Green 18 Internal power ⎯ White Brown

source output
(+24V)
9 Hand input 48 Blue Red 19 NC ⎯ White Brown
10 Hand input 49 Violet Violet 20 NC ⎯ White Brown
Note 2: The unused pins should be prevented from direct contact with other pins or conductive part. Direct contact could result in a
controller failure or damage.
66

5.1.3 Mini I/O (CN5): User- or System-I/O connector
[ 1 ] Standard type of controller
Mini I/O (CN5) Pin Assignment (For standard type of controller)

1 Enable Auto (Internal +24V) (input) ⎯ Black 35 Enable Auto (input) ⎯ Pink

2 ⎯ Brown 36 External Emergency Stop 1, b-2 (input) ⎯ Pink
(Internal +24V)
3 ⎯ Red 37 External Emergency Stop 2, b-2 (input) ⎯ Pink
(Internal +24V)
6 ⎯ Black 40 ⎯ White
7 ⎯ Brown 41 ⎯ White
8 ⎯ Red 42 ⎯ White
9 ⎯ Orange 43 ⎯ White
11 Step Stop (All tasks) (input) 0 Green 45 CPU Normal (No monitor allowed) (output) 16 White
16 Command area bit 0 (input) 5 Black 50 Operation Preparation Completed (output) 21 Gray
18 Command area bit 2 (input) 7 Brown 52 Command Processing Completed (output) 23 Violet
User output/
26 User input 15 Brown 60 User output 31 Gray
27 ⎯ ⎯ Red 61 ⎯ ⎯ Gray
28 ⎯ Orange 62 ⎯ Gray
29 ⎯ Yellow 63 ⎯ Gray
Internal power source output +24V) Internal power source output 0V)
31 ⎯ ⎯ Blue 65 ⎯ ⎯ Gray
67

[ 2 ] Global type of controller (with safety board or safety box)
The global type of the controller handles stop-related I/Os by using the safety I/O
(CN10) given on the next page.
Mini I/O (CN5) Pin Assignment (For global type of controller)

1 Reserved. ⎯ Black 35 Reserved. ⎯ Pink
2 Reserved. ⎯ Brown 36 Reserved. ⎯ Pink
3 Reserved. ⎯ Red 37 Reserved. ⎯ Pink
6 Reserved. ⎯ Black 40 Reserved. ⎯ White
7 Reserved. ⎯ Brown 41 Reserved. ⎯ White
8 Reserved. ⎯ Red 42 Reserved. ⎯ White
9 Reserved. ⎯ Orange 43 Reserved. ⎯ White
CPU Normal (No monitor allowed)
11 Step Stop (All tasks) (input) 0 Green 45 16 White
(output)
16 Command area bit 0 (input) 5 Black 50 21 Gray
(output)
18 Command area bit 2 (input) 7 Brown 52 23 Violet
(output)
User output /
26 User input 15 Brown 60 Reserved. 31 Gray
27 ⎯ ⎯ Red 61 ⎯ ⎯ Gray
28 Reserved. ⎯ Orange 62 Reserved. ⎯ Gray
29 Reserved. ⎯ Yellow 63 Reserved. ⎯ Gray
Internal power source output +24V) Internal power source output 0V)
31 ⎯ ⎯ Blue 65 ⎯ ⎯ Gray
DC power output +24V (when internal DC power output 0V (when internal
34 power source is used) ⎯ Brown 68 power source is used) ⎯ Blue
68

5.1.4 Safety I/O (CN10)：System-I/O connecter (Global type of controller)
Safety I/O (CN10) Pin Assignment

1 External Emergency Stop 1, b-1 (input) Black 19 External Emergency Stop 1, b-2 (input) Pink
2 External Emergency Stop 2, b-1 (input) Brown 20 External Emergency Stop 2, b-2 (input) Pink
3 Reserved. Red 21 Reserved. Pink
4 Reserved. Orange 22 Reserved. Pink
5 Protective Stop 1, -1 (input) Yellow 23 Protective Stop 1, -2 (input) Pink
6 Protective Stop 2, -1 (input) Green 24 Protective Stop 2, -2 (input) Pink
7 Enable Auto 1, -1 (input) Blue 25 Enable Auto 1, -2 (input) Pink
8 Enable Auto 2, -1 (input) Black 26 Enable Auto 2, -2 (input) Gray
9 ⎯ Brown 27 ― Gray
10 Reserved. Red 28 Reserved. Gray
11 Reserved. Orange 29 Reserved. Gray
12 Reserved. Yellow 30 Reserved. Gray
Pendant Emergency Stop 1, b-1 Pendant Emergency Stop 1, b-2

13 Green 31 Gray
(output) (output)

14 Blue 32 Gray
(output) (output)

15 [Enable SW 1, -1] Violet 33 [Enable SW 1, -2] Gray

16 [Enable SW 2, -1] Black 34 [Enable SW 2, -2] White
Contactor Contact Monitor 1, -1 Contactor Contact Monitor 1, -2

17 Brown 35 White
(output) (output)
18 Reserved. Red 36 Reserved. White
69

5.2 Robot Controller I/O Circuits (PNP type)
5.2.1 Setting up Mini I/O Power Supply

The power supply (+24 VDC) for the Mini I/O can be switched between internal and
external power sources by changing the jumper switch setting as listed below. The
factory default is external power source setting.
Power supply Jumper switches JP1 and JP3 on the

Description
for I/O controller printed circuit board
External Short-circuit Do not change the
source pins 2 and 3 factory default setting.
(factory default)
Internal Short-circuit Remove the controller

source pins 1 and 2, top cover and change
and pins 3 and the JP1 and JP3
4 settings with short
sockets that come with
the robot.
Note: Switching the power supply setting for I/O from external to internal changes the
assignment to terminals #32 to #34 and #66 to #68 on CN5 from external DC power input to
internal DC power output. For details, refer to the circuit configuration examples in Sections 5.2.2
and 5.2.3.
70

5.2.2 User-Input, System-Input and Hand-Input Circuits (PNP type)
The figure below shows examples of the user-input, system-input and hand-input circuit
configurations and connections of the robot controller.
Notes
(1) In addition to PLCs, proximity switches and relay contacts can be directly
connected to the input terminals of the robot controller. Note that the leakage
current from the proximity switches should be 1 mA or below.
(2) Use multi-core shielding cables for protecting the controller from external noise and
ground them at the controller side.
User-Input, System-Input and Hand-Input Circuits (PNP type)
71

User-Input, System-Input and Hand-Input Circuits (PNP type)
72

5.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP
type)
The following pages show examples of the configuration and connection of the robot
controller's user-output, system-output and hand-output circuit.
(1) The User-Output, System-Output and Hand-Output Circuits are open

collector output circuits.
(2) The maximum allowable source current is 70 mA.
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 and
use a lamp whose rating is 0.5W or less.
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. 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.
Refer to next page.
(5) Use a multi-core shielding cable for the purpose of protecting the devices
from external noise. Ground it to the robot controller.
(6) +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.
(7) For three seconds after the controller power is turned on, the I/O board will
be in a transient state, so do not use its output as valid signals.
73

User-Output, System-Output and Hand-Output Circuits (PNP type)
74

User-Output, System-Output and Hand-Output Circuits (PNP type)
Example of Circuit with Lamp (PNP type)
75

5.2.4 Configuration of Emergency Stop Circuitry
5.2.4.1 External Emergency Stop and Enable Auto Input Circuits
The External Emergency Stop and Enable Auto input signals are important for safety.
Be sure to configure their circuits with contacts as shown below.
TIP: For the overall configuration sample of an emergency stop circuitry, refer to
Section 5.2.4.2 "Emergency Stop Circuit."
External Emergency Stop and Enable Auto Input Circuits (Standard type of controller)
76

5.2.4.2 Emergency Stop Circuit (Standard type of controller)
The following figure shows the example of configuration and connection of emergency
stop circuit on the standard type of the controller. In the RC7M controller, the
emergency stop circuit consists of dual safety circuits.
The emergency stop button on the teach pendant can be used also as an emergency
stop switch of the equipment.
Emergency Stop and Pendant Emergency Stop output signals

(1) Emergency Stop output signal
The internal relay receives the External Emergency Stop input signal and the
emergency stop input from the teach pendant to output this signal. When the power
is turned OFF, the controller is in the emergency stop state.
(2) Pendant Emergency Stop output signal (Dry output)
The two contacts on the emergency stop button (4b) on the teach pendant are
connected. This signal will be issued independent of the ON/OFF state of the
controller power.
Emergency Stop Circuit in the RC7M Controller (Standard type of controller)
77

5.2.5 Configuration of Safety Circuit (Global type of controller)
5.2.5.1 Input Circuit to the Safety Circuit
Input signals to the safety circuit are important for safety. Be sure to configure their
circuits with contacts as shown below, observing the notes given below.
Note: For the overall configuration sample of a safety circuitry, refer to Section 5.2.5.2
"Safety Circuit."
Precautions on Connecting the Safety I/O (CN10)
(1) Two External Emergency Stop input signals must be controlled with separate contacts. Two circuits
connected in parallel using a single contact or an always-shorted circuit will be interpreted as an
external circuit failure so that the emergency stop state cannot be reset.
(2) Two Protective Stop input signals and two Enable Auto input signals each must be controlled with
separate contacts. Two circuits connected in parallel using a single contact or an always-shorted
circuit will be interpreted as an external circuit failure so that the circuitry will not operate.
(3) The Enable Auto and Protective Stop input signals are connected in series in the controller, so two
types of inputs are available as an automatic operation permission signal.
(4) Switching the External Emergency Stop, Protective Stop, and Enable Auto input signals from open
to close does not require temporal conditions, but requires any action to switch.
Input Circuits to the Safety Circuits (Global type of controller)
78

5.2.5.2 Safety Circuit (Global type of controller)
The figure below shows an internal connection equivalent circuit for the safety circuit in
the global type of the controller. The actual safety circuit is configured with safety relays
and others.
Safety Circuit in the RC7M Controller (Global type of controller)

Note: Different stop states resulting from emergency stop input, Protective Stop, and Enable Auto (OFF)
(1) The emergency stop input (External Emergency Stop or teach pendant/mini-pendant input) shuts down
the power to the motor and resets the program, provided that the Continue parameter is set to the default
(0: Disable) in Continue setting.
(2) The Protective Stop or Enable Auto (OFF) input signal shuts down the power to the motor and places the
robot in the Continue Stop state.
79

5.3 Wiring Notes for Controller I/O Connectors (PNP type)
After the wiring of the controller's I/O connectors is completed, check the following
before turning ON the power:
Check point (1)
Using a circuit 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.
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.
Check point (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.
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.
Circuit tester
Robot
controller
External
"+24V terminal" and device
"E24V terminal" of
the controller
"0V terminal" and "E0V terminal"

of the controller
Checking Example
80

Mini I/O connector (CN5)

1 to 3 +24V internal power source terminal +24V internal power output (1)
45 to 60 Signal output terminal 24 V at output (2)
+24 VDC power source input 24 VDC power input (1)
source
Internal power
+24 VDC power source output 24 VDC power output (1)
source
0 VDC power source input DC power input (GND) (1)
source
Internal power
0 VDC power source output DC power output (GND) (1)
source
HAND I/O connector (CN9)

1 to 8 Hand output terminal 24 V at output (2)
17 Internal power source output (+24V) 24 VDC power output (1)
18 Internal power source output (0V) DC power output (GND) (1)
81

Chapter 6 Installation and Maintenance of
the RC7M Controller
6.1 Supplies for the Controller
The table below lists the supplies for the RC7M controller.
List of Supplies for the RC7M Controller

No. Name Part Number Remarks
Air inlet filter set 410053-0100 For standard type (FS-1705W)
1
410053-0110 For global type (FS-1705)
2 Memory backup battery 410076-0260 For backup of the controller memory
3 Fuse (1.3A) 410054-0230 Fuse (LM13) for controller I/O
4 IC for output (NPN) 410077-0010 IC (M54522P) for controller output
5 IC for output (PNP) 410077-0020 IC (M54564P) for controller output
6.2 Mounting the Controller

6.2.1 Installation Requirements for the Controller
The table below lists the installation requirements for the RC7M controller.
Installation Requirements for the RC7M Controller

Item Environmental Requirements
Installation type Stand-alone and Wall-mount
Ambient temperature In operation: 0 to 40°C
In storage or during transportation: -10 to 60°C
Humidity In operation: 90% or less (No dew condensation is allowed.)
In storage or during transportation: 75% or less (No dew condensation is
allowed.)
Safe installation The robot should not be installed in an environment where:
environment • there are flammable gases or liquids,
• there are any acidic, alkaline or other corrosive material,
• there is a mist, or
• there are any large-sized inverters, high output/high frequency
transmitters, large contactors, welders, or other sources of electrical
noise.
Working space Sufficient service space must be available for inspection and
disassembly.
Installation condition Grounding resistance: 100Ω or less
82

6.2.2 Mounting the Robot Controller
Before mounting the robot controller to the target position, you need to secure the robot
controller to the controller mounting panel.
The robot controller supported by the mounting panel may be either stand-alone or
wall-mounted.
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.
[ 1 ] Securing the Robot Controller to the Controller Mounting Panel

(1) The figure below shows the bottom view of the robot controller. Five M4-nut
welded holes may be used for securing the robot controller to the mounting panel.
(2) Prepare a mounting panel large enough for mounting the robot controller and
secure the robot controller onto the mounting panel using five screws.
Caution (1) The controller mounting screws must not be more than
the thickness of the mounting panel plus 4 mm in length. If
their length is out of the specified range, the nut welded
holes may be damaged.
(2) Fix the robot controller at all of the five nut-welded holes.
Location of Mounting Screw Holes (on the bottom of the robot controller)
83

[ 2 ] Installing the Robot Controller
The robot controller can be installed stand-alone or on the wall.
Set up the robot controller as shown in the figure below.
Caution Do not place anything within 200 mm from the air inlet and outlet of
the robot controller.
Caution The robot controller has no air filter on the air outlet side. In
wall-mounted installation, therefore, to prevent free-fall dust or dirt
from getting into the controller, set up the controller with the air
outlet side not facing upward as shown below.
Stand-alone installation Wall-mounted installation
Setting up the Robot Controller
84

6.3 I/O and AC Input Wiring
6.3.1 Multi-core Cables with Connectors
Multi-core cables with connectors to be used for the I/O wiring of the Robot Controller
are options. Select an appropriate cable from the table given below if necessary.
I/O Cables (Options)

No. Name Part Number Remarks
1 Standard I/O cable set (8m) 410149-0940 Including Nos. 1-1 and 1-2
1-1 Mini I/O cable set (8m) 410141-2700 Connector set: 410159-0190
1-2 Hand I/O cable set (8m) 410141-1740
2 Standard I/O cable set (15m) 410149-0950 Including Nos. 2-1 and 2-2
2-1 Mini I/O cable set (15m) 410141-2710 Connector set: 410159-0190
2-2 Hand I/O cable set (15m) 410141-1750
If you do not use optional cables listed above, use the recommended connectors and
cables listed below.
Recommended Connectors for I/O Cables and Cable Standards
Connector Connector
Cable Standards Remarks
name model/manufacturer
PCR-E68FS connector UL2789 - With shield Caution: Be sure to modify the
PCS-E68LPA-1E cover shielding wire at the end of the
Mini I/O Equivalent to AWG28x34P
cable to be used, as shown
(HONDA TSUSHIN
below. Without this modification,
KOGYO Co., LTD)
the robot may malfunction due to
PCR-E20FS connector UL2789 - With shield noise.
PCS-E20LA cover Equivalent to AWG28x20P
HAND I/O
(HONDA TSUSHIN
KOGYO Co., LTD)
Crimp terminal
Vinyl tube
The connector shell
Braided should be made of
shielding wire Shielding wire conductive metal.
I/O cable
Fasten to the connector
I/O power
connector Vinyl tube
Modifying the Shielding Wire (Example)
85

6.3.2 Wiring of Primary Power Source
Observe the following precautions when wiring the primary power source 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 100Ω
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) When inserting a circuit breaker between the robot and the AC input power supply,
select the circuit breaker with breaking capacity higher than the following
specification.
Recommended circuit breaker example: CP33V/20 (Fuji Electric FA Components
& Systems Co., Ltd.)
Caution: Using a circuit breaker with breaking capacity lower than the following
specification may cause the circuit breaker to be shut down due to robot operation.
Breaking characteristics curve

Breaking time (s)
Breaking current (Arms)
Circuit Breaker Characteristics
86

(7) Prepare wires of an appropriate capacity for the 200/100 VAC main line and other
cables according to the tables given below.
Robot Controller Power Supply Specifications

Pin assignment on power connector (CN6)
Item Specifications
(View from the pin face of cable)
Three-phase, Three-phase, 200 VAC -15% to 230 VAC A: 200 VAC,
200 VAC +10%, 50/60 Hz phase R
VMG6BA: 3.3 kVA VSG6BA: 1.85 kVA B: 200 VAC,
phase S
Power supply VPG5/6CA: 1 kVA HMG4BA: 2.45 kVA
C: 200 VAC,
capacity
phase T
HSG4BA: 1.8 kVA XYCG4AA: 1.15 kVA
D: Ground
Single-phase, Single-phase, 230 VAC -10% to 230
200 VAC VAC +10%, 50/60 Hz A: 200 VAC,
VSG6BA: 1.85 kVA VPG5/6CA: 1 kVA phase R
Power
B: 200 VAC,
supply Power supply HMG4BA: 2.45 kVA HSG4BA: 1.8 kVA
phase S
capacity
XYCG4AA: 1.15 kVA D: Ground
Single-phase, Single-phase, 100 VAC -10% to 110 VAC

100 VAC +10%, 50/60 Hz A: 100 VAC,
phase R
B: 100 VAC,
Power supply phase S
VPG5/6CAA: 1 kVA
capacity
D: Ground
Max. rush current

when the power is 40 A (for 1/50 or 1/60 second)
turned ON
Caution: If ERROR6102 (power voltage drop) occurs when the robot is in

operation, then it may be due to an insufficient capacity of the primary power
source.
(8) Do not bundle the teach pendant cables, I/O cables or motor cables together with
high power lines such as 200/100 VAC lines and peripheral device cables, or route
the motor cables near high power devices (motor, welder, parts feeder, etc.).
(9) 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.
(10) Use the correct power source (200 VAC or 100 VAC) for the controller specification.
87

6.3.3 Disconnecting the Robot from the Power Source
If you need to cut off the power supply from the robot unit for maintenance or
transportation purpose, follow the steps below for safety.
Step 1 Turn OFF the power switch of the robot controller.
Step 2 Check that the motor ON lamp is OFF.
Step 3 Disconnect the power cable from connector CN6 on the robot controller.
88

6.4 Cleaning the Air Intake Filters
The robot controller has three air intake filters.
If those filters are clogged, the robot controller becomes insufficiently ventilated so that
the internal electronic devices may be damaged due to heat.
If a power module error appears, it may be caused by clogged filter, so clean the filter.
<Cleaning Procedures>
Step 1 Turn the controller power OFF.
Step 2 Remove the four filter covers from the front panel by loosening the screw each.
89

Step 3 Blow compressed air to the filter in the direction opposite to the regular air- flow.
Note: Use dehumidified, oil-free, pure compressed air for cleaning.
If the filter is excessively dirty, wash it with water or warm water (40°C or lower). A
neutral detergent is most effective.
Notes (1) Dry the washed filter completely before mounting it.
(2) If the filter is still dirty after air blowing or washing, replace it
with new one.
Step 4 Set the filters back into place in the reverse order of removal.
90

6.5 Replacing the Memory Backup Battery
Programs, parameters, CAL data, etc. are stored in the internal memory of the robot
controller.
The memory backup battery retains the above data while the power to the robot
controller is turned OFF. However, the battery has a limited lifetime and must, therefore,
be replaced regularly.
Note: If two years elapse from replacement of backup battery, the "Time to change
controller backup battery" message will appear on the teach pendant.
Caution: Without replacing the memory backup battery, important

robot-specific data held in the memory will be lost.
This caution applies ONLY in CALIFORNIA, USA.

Perchlorate Material – special handling may apply,
See www.dtsc.ca.gov/hazardouswaste/perchlorate
6.5.1 Replacing procedures

This section gives an example of replacing the memory backup battery.
Caution: Before replacing the memory backup battery, be sure to save the
memory data in the robot controller to the PC using WINCAPSII.
Step 1 Save the memory data held in the controller to the PC.
Step 2 Make a new memory backup battery ready for use.
Step 3 Turn the controller power ON, wait at least one minute, and then turn it OFF again.
91

Step 4 Remove two screws from the battery cover and pull them out together with the
backup battery.
Step 5 Disconnect the backup battery harness.
Caution Complete Steps 5 through 7 within three minutes. Taking more time
will lose the memory data.
92

Step 6 Set the new memory backup battery ready for use in Step 2 on the battery cover.
Step 7 Connect the backup battery harness to the controller.
Step 8 Mount the battery cover with the new backup battery into the controller and secure
the cover with the screw.
Caution Take care not to pinch the battery lead wires between covers or
internal parts. Shorting may occur, resulting in an unexpected
failure.
93

6.5.2 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: 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.
Step 1 On the top screen of the teach pendant, press [F6 Set].
The Settings (Main) window appears.
Step 2 Press [F6 Maint.] in the Settings (Main) window.

The Maintenance menu appears.
Step 3 Press [F4 Battery] in the Maintenance menu.

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.
Step 4 Press OK.

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.
Step 5 Press OK.

The screen returns to the Settings (Main) window.
94

6.6 Replacing Fuses and Output ICs
6.6.1 Positions of Fuses and Output ICs
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.
If an output signal error persists even after replacement of the output fuse, the related
output IC needs to be replaced.
Fuses and output ICs are located in the robot controller as shown in the figure below.
Mini I/O board
(Front panel side)
IPM board
Positions of Fuses (with the controller top cover removed)

Corresponding output I/O port
Fuse Capacity Signal name
connector and terminal No. No.
F2 3.2 A Mini I/O, terminals 66 to 68 DC power input 0V （E0V） ---
F3 1.3 A Mini I/O, terminals 32 to 34 DC power input +24V（E24V） ---
F4 1.3 A Mini I/O, terminals 66 to 68 DC power input 0V （E0V） ---
Power supply for Enable auto
Mini I/O, terminal 1 ---
(Internal +24V)
External emergency stop 1b-1
F5 1.3 A Mini I/O, terminal 2 ---
(Internal +24V)
External emergency stop 2b-1
Mini I/O, terminal 3 ---
(Internal +24V)
F6 1.3 A Mini I/O, terminals 45 to 60 System output/User output 16 to 31
F7 1.3 A Hand I/O, terminals 1 to 8 Hand output 64 to 70
F8 1.3 A Hand I/O, terminal 17 Power supply for hand E24V ---
Caution F2 fuse is provided for protecting the circuitry from getting damaged if a voltage
of 30V or above is applied to the 24V external power source terminals. F2 fuse is
not mounted on a Mini I/O board in controllers whose product number is 02H018
or later (short-circuited instead).
95

The table below lists the output ICs and fuses for the Mini I/O (CN5) and HAND I/O
(CN9). If an output signal error occurs, check the corresponding fuse.
Note: The Emergency Stop and Deadman output circuits use PolySwitches (resettable
fuses) that trip in an overcurrent condition to open the circuits. If a PolySwitch trips, turn
the power off and check the related circuit. (As long as the power is on, a PolySwitch
keeps tripping. After checking, therefore, turn the controller power off and on, then
check the circuit again.
Output ICs and Fuses

Connector
Application Pin No. I/O Port No. Output IC Fuse
Name
1 64
2 65
3 66
4 67
HAND I/O For output IC10 F7 (1.3A)
CN9 5 68
6 69
7 70
8 71
For power output 17, 18 – – F8 (1.3A)
45 16
46 17
47 18
48 19
IC6
49 20
50 21
51 22
52 23
For output F6 (1.3A)
53 24
54 25
55 26
56 27
IC8
57 28
Mini I/O 58 29
CN5 59 30
60 31
External Internal
power power
supply supply
32 –
F3
33 – – –
(1.3A)
34 –
For 24 VDC 66 –
F4
67 – – –
(1.3A)
68 –
1, 35 – –
F5
2, 36 – – (1.3A)
3, 37 – –
Reference: 6, 40 – – PS5 (0.15A)
PolySwitch Emergency stop 7, 41 – – PS6 (0.15A)
on Mini I/O and Deadman 8, 42 – – PS3 (0.15A)
(CN5) output
9, 43 – – PS4 (0.15A)
96

6.6.2 Replacing procedures
Replace fuses and output ICs according to the following procedure:
Warning Do not touch the inside of controller before turning off the
power switch and waiting 3 minutes or more, or you can easily
receive an electric shock.
Caution (1) Wear a wristband and connect its terminal to a grounded

portion before starting work.
(2) Do not touch elements or their terminals on any printed circuit
board with bare hand (elements could be destroyed by static
electricity).
<Replacing fuses>
Step 2 Remove the controller upper cover by unscrewing eight screws.
power switch and waiting 3 minutes or more, or you can
easily receive an electric shock.
97

Step 3 Pull out the fuse to check.
Step 4 Using a circuit tester, check the removed fuse for continuity.
Step 5 If no continuity is observed with the fuse in Step 4:

(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 controller.
If continuity is observed with the fuse in Step 4, set the removed fuse back into place
in the controller.
Step 6 Set the controller upper cover back into place and restart the controller in the reverse
order of Steps 1 through 3.
98

Proceed to the following steps when replacing output ICs
Step 7 If an output signal error persists even after replacement of the output fuse, the related
output IC needs to be replaced.
Caution (1) When replacing a damaged output IC, fix the cause that
damages the IC before replacement.
(2) Do not directly touch the electronic devices and their
terminals on printed circuit boards by hand.
Remove the three screws and take the Mini I/O board out of the controller.
Step 8 Check the IC No. on the printed circuit board and pull out the target output IC with an
IC pull-out jig. Mount a new output IC.
99

6.7 Replacing IPM Boards
6.7.1 Location of IPM Boards
The IPM boards are located in the robot controller as shown below.
Robot SLOT
SLOT 6 SLOT 5 SLOT 4 SLOT 3 SLOT 2 SLOT 1
series
VM-G Joint # 6 5 4 3 1 2
IPM model SS SS SS S L M
Motor capacity (W) 100 200 200 400 1500 750
VS-G Joint # 6 5 4 3 2 1
IPM model SS SS SS S S M
Motor capacity (W) 50 80 100 200 400 750
VP-G Joint # 6 5 4 3 2 1
IPM model SS SS SS SS SS SS
Motor capacity (W) 30 30 30 50 80 80
HM-G Joint # -- -- 4 3 2 1
IPM model -- -- M M L LL
Motor capacity (W) -- -- 300 300 600 1000
HS-G Joint # -- -- 4 3 2 1
IPM model -- -- S S M L
Motor capacity (W) -- -- 150 200 400 750
XYC-G Joint # -- -- 4 3 2 1
IPM model -- -- SS S S S
Motor capacity (W) -- -- 100 200 200 400
XR-G Joint # -- -- 4 3 2 1
IPM model -- -- SS S S M (S) *
Motor capacity (W) -- -- 50 400 400 750 (400) *
Note: The "--" in the above table denotes no board installed.
* Differs depending on the controller model.
100

6.7.2 Replacing the IPM board
Replace the IPM board with the procedure below.
Step 2 Remove the eight screws and take off the top cover of the controller.
power switch and waiting 3 minutes or more, or you can easily
receive an electric shock.
101

Step 3 Remove the two screws from the IPM board to be replaced. Disconnect the board
from its two connectors and connect a new one.
Step 4 Secure the top cover of the controller with eight screws.
Tightening torque: 1.35 to 1.45 Nm
102

Chapter 7 I/O Allocation for I/O Extension
Board(s)
This chapter lists the I/O allocation tables to apply when I/O extension boards are
mounted on the controller. For details about I/O extension boards, refer to the RC7M
CONTROLLER OPTIONS MANUAL.
7.1 Combination of I/O Extension Boards and Allocation Modes

The table below lists the permitted combination of I/O extension boards and
selectable allocation modes.
Combination of I/O Extension Boards

I/O extension boards (Max. 2 boards) Allocation modes
Combination
Allocated to Extension 1 All

Mini I/O user
#
Extension 1 Extension 2 Extension 3

dedicated Compatible Standard I/O
0 – – – √
1 – S-LINK V board – √ √
2 – DeviceNet master board – √
3 – DeviceNet master board Parallel I/O board √
4 – DeviceNet master board S-LINK V board √
5 Parallel I/O board – – √ √ √
6 Parallel I/O board Parallel I/O board – √ √ √
7 Parallel I/O board S-LINK V board – √ √ √ √
8 DeviceNet slave board – – √ √
9 DeviceNet slave board Parallel I/O board – √ √
10 DeviceNet slave board S-LINK V board – √ √ √
11 DeviceNet master/slave board – – √ √ √
12 DeviceNet master/slave board Parallel I/O board – √ √ √
13 DeviceNet master/slave board S-LINK V board – √ √ √
14 CC-Link board – – √ √
15 CC-Link board Parallel I/O board – √ √
16 CC-Link board DeviceNet master board – √ √ √
17 CC-Link board S-LINK V board – √ √ √
18 PROFIBUS-DP slave board – – √ √
19 PROFIBUS-DP slave board Parallel I/O board – √ √
20 PROFIBUS-DP slave board DeviceNet master board – √ √ √
21 PROFIBUS-DP slave board S-LINK V board – √ √ √
Note 1: Out of check-marked modes in the "Allocation modes" column, only one mode can be selected.
Note 2: Up to two I/O extension boards can be mounted on the controller. There are no restrictions on the choice of
extension slots or the mounting order.
Note 3: When two I/O extension boards are mounted, the controller recognizes the one inserted in the left-hand
extension slot as Extension 1. The allocation I/O port numbers on Extension 1 and 2 boards differ with each other.
103

7.2 I/O Allocation in Individual Allocation Modes
The table below lists the I/O allocation for extension boards in individual
allocation modes. For details, refer to Section 7.5 "I/O Allocation Tables for
Individual Allocation Modes."
Note: For the I/O allocation for the DeviceNet master/slave board, see the
allocation tables for the DeviceNet master and slave boards.
I/O Allocation of Extension Boards in Individual Allocation Modes
Allocation for CN5 and extension boards

Allocation modes
I/O Allocation tables to apply
CN5 Tables for mini I/O board in mini I/O dedicated mode
Mini I/O dedicated mode
Extensions 1, 2, 3 Tables for extension boards in all user I/O mode
CN5 Tables for mini I/O board in compatible, standard and all user
I/O modes
Compatible mode
Extension 1 Tables for extension boards in compatible mode
Extensions 2, 3 Tables for extension boards in all user I/O mode
CN5 Tables for mini I/O boards in compatible, standard and all
user I/O modes
Standard mode
Extension 1 Tables for extension boards in standard mode
Extensions 2, 3 Tables for extension boards in all user I/O mode
CN5 Tables for mini I/O board in compatible, standard and all user
All user I/O mode I/O modes
Extensions 1, 2, 3 Tables for extension boards in all user I/O mode
Note: Extensions 1, 2, and 3 correspond to the ones listed in the "Combination of I/O Extension Boards" table on
the previous page.
7.3 Notes on Using I/O Extension Boards

(1) Parameter change for switching between allocation modes
To switch between the compatible, standard, and all user I/O modes, you need to
change parameters using the teach pendant or WINCAPSII. For the changing
procedure, refer to the RC7M Controller OPTIONS MANUAL, Section 4.6.
(2) Power supply setting for mini I/O board (CN5) or parallel I/O board
When using the mini I/O board (CN5) or parallel I/O board, you need to set up the
24 V power supply (internal or external). The factory default is external power
supply.
For details about the mini I/O board, see Section 4.2.1 or 5.2.1.
For details about the parallel I/O board, refer to the RC7M Controller OPTIONS
MANUAL, Section 5.2.2.
104

7.4 Hand I/O (CN9): Common to All Allocation Modes
The RC7M controller supports hand I/O signals (CN9) as standard. This hand
I/O is common to all allocation modes.
HAND I/O (CN9): NPN type

Terminal Terminal
Signal name Port No. Signal name Port No.
No. No.
1 Hand output 64 11 Hand input 50
Internal power output
7 Hand output 70 17 ⎯
for hand (E24V)

for hand (E0V)
9 Hand input 48 19 No connection ⎯
HAND I/O (CN9): PNP type

Terminal Terminal
No. No.
for hand (E0V)

for hand (E24V)
105

7.5 I/O Allocation Tables for Individual Allocation Modes
7.5.1 Mini I/O Board (CN5 on standard type of controller) in Mini I/O
Dedicated Mode
Terminal Terminal
Signal Name Port No. Signal Name Port No.
No. No.
1 Enable Auto (Internal +24V) (input) ⎯ 35 Enable Auto (input) ⎯
External Emergency Stop 1, b-1 External Emergency Stop 1, b-2
2 ⎯ 36 ⎯
(Internal +24V) (input) (input)
3 ⎯ 37 ⎯
(Internal +24V) (input) (input)
4 Reserved. ⎯ 38 Reserved. ⎯
6 ⎯ 40 ⎯
7 ⎯ 41 ⎯
8 ⎯ 42 ⎯
9 ⎯ 43 ⎯
10 ⎯ ⎯ 44 ⎯ ⎯
11 Step Stop (All tasks) (input) 0 45 CPU Normal (No monitor allowed) (output) 16
12 Strobe Signal (input) 1 46 Robot Running (output) 17
13 Data area bit 0 (input) 2 47 Robot Error (output) 18
14 Data area bit 1 (input) 3 48 Robot Initialized (output) 19
15 Data area bit 2 (input) 4 49 Auto Mode (output) 20
Command area bit 0 (input) 5 Operation Preparation Completed 21
16 50 (output)
17 Command area bit 1 (input) 6 51 Battery Warning (output) 22
Command area bit 2 (input) 7 Command Processing Completed 23
18 52 (output)
User input 8 User output/ 24
19 53 Continue Start Permission (output)
20 User input 9 54 User output 25
27 ⎯ ⎯ 61 ⎯ ⎯
28 ⎯ 62 ⎯
(Dry output) (output) (Dry output) (output)
29 ⎯ 63 ⎯
(Dry output) (output) (Dry output) (output)
30 (when JP12 on mini I/O board is ⎯ 64 (when JP13 on mini I/O board is ⎯
shorted. Internal power source +24V) shorted. Internal power source 0V)
31 ⎯ ⎯ 65 ⎯ ⎯
32 DC power input +24V (when external ⎯ 66 DC power input 0V (when external ⎯
33 power source is used) ⎯ 67 power source is used) ⎯
106

7.5.2 Mini I/O Board (CN5 on global type of controller) in Mini I/O
Dedicated Mode
Terminal Terminal
No. No.
10 ⎯ ⎯ 44 ⎯ ⎯
11 Step Stop (All tasks) (input) 0 45 CPU Normal (No monitor allowed) (output) 16
12 Strobe Signal (input) 1 46 Robot Running (output) 17
13 Data area bit 0 (input) 2 47 Robot Error (output) 18
14 Data area bit 1 (input) 3 48 Robot Initialized (output) 19
15 Data area bit 2 (input) 4 49 Auto Mode (output) 20
16 Command area bit 0 (input) 5 50 (output) 21
17 Command area bit 1 (input) 6 51 Battery Warning (output) 22

18 Command area bit 2 (input) 7 52 (output) 23
User output/
19 User input 8 53 Continue Start Permission (output) 24

26 User input 15 60 Reserved. 31
27 ⎯ ⎯ 61 ⎯ ⎯
31 ⎯ ⎯ 65 ⎯ ⎯
107

7.5.3 Mini I/O Board (CN5 on standard type of controller) in Compatible,
Standard and All User I/O Modes
Terminal Terminal
No. No.
1 Enable Auto (Internal +24V) (input) ⎯ 35 Enable Auto (input) ⎯
2
(Internal +24V) (input) ⎯ 36
(input) ⎯

3
(Internal +24V) (input) ⎯ 37
(input) ⎯
6
(Mini relay) ⎯ 40
(Mini relay) ⎯

7
(Mini relay) ⎯ 41
(Mini relay) ⎯

8
[Enable SW 1, -1] (Mini relay) ⎯ 42
[Enable SW 1, -2] (Mini relay) ⎯

9
[Enable SW 2, -1] (Mini relay) ⎯ 43
[Enable SW 2, -2] (Mini relay) ⎯
10 ⎯ ⎯ 44 ⎯ ⎯
11 User input 0 45 CPU Normal (No monitor allowed) (output) 16
27 ⎯ ⎯ 61 ⎯ ⎯
28
(Dry output) (output) ⎯ 62
(Dry output) (output) ⎯

29
(Dry output) (output) ⎯ 63
(Dry output) (output) ⎯

31 ⎯ ⎯ 65 ⎯ ⎯
108

7.5.4 Mini I/O Board (CN5 on global type of controller) in Compatible,
Standard, and All User I/O Modes
Terminal Terminal
No. No.
10 ⎯ ⎯ 44 ⎯ ⎯
11 User input 0 45 CPU Normal (No monitor allowed) (output) 16
26 User input 15 60 Reserved. 31
27 ⎯ ⎯ 61 ⎯ ⎯
31 ⎯ ⎯ 65 ⎯ ⎯
34
power source is used) ⎯ 68 ⎯
power source is used)
109

7.5.5 Parallel I/O Board in Compatible Mode
Signal Name Direction Signal Name Direction
No. No. No. No.
Error in the hundreds place,
1 Reserved. 3840 OUT 49 3864 OUT
bit 0
2 Robot Running 3841 OUT 50 3865 OUT
bit 1
3 Robot Error 3842 OUT 51 3866 OUT
bit 2
4 Auto Mode 3843 OUT 52 3867 OUT
bit 3
5 External Mode 3844 OUT 53 SS Mode 3868 OUT
6 Program Start Reset 3845 OUT 54 Reserved. 3869 OUT
7 Reserved. 3846 OUT 55 Reserved. 3870 OUT
8 Reserved. 3847 OUT 56 Reserved. 3871 OUT
9 Robot Power ON Completed 3848 OUT 57 3872 OUT
10 Servo ON 3849 OUT 58 3873 OUT
11 CAL Completed 3850 OUT 59 3874 OUT
12 Teaching ON 3851 OUT 60 3875 OUT
13 1 Cycle End 3852 OUT 61 3876 OUT
14 Battery Warning 3853 OUT 62 3877 OUT
15 Robot Warning 3854 OUT 63 3878 OUT
16 Continue Start Permission 3855 OUT 64 3879 OUT
User output
17 Error in the units place, bit 0 3856 OUT 65 3880 OUT
21 Error in the tens place, bit 0 3860 OUT 69 3884 OUT
25 Step Stop (All tasks) 3584 IN 73 Clear Robot Error 3604 IN
26 Continue Start 3585 IN 74 3605 IN
Instantaneous Stop (All tasks)
27 3586 IN 75 3606 IN
[Halt]
28 Operation Preparation Start 3587 IN 76 3607 IN
29 Interruption Skip 3588 IN 77 3608 IN
30 Program Start 3589 IN 78 3609 IN
31 Program No. selection bit 0 3590 IN 79 3610 IN
User input
38 Program No. selection parity bit 3597 IN 86 3617 IN
39 Motor Power ON 3598 IN 87 3618 IN
40 CAL Execution 3599 IN 88 3619 IN
41 Reserved. 3600 IN 89 3620 IN
42 SP100 3601 IN 90 3621 IN
43 External Mode Change 3602 IN 91 3622 IN
44 Program Reset 3603 IN 92 3623 IN
45 Power +24V ⎯ IN 93 Power 0V ⎯ IN
110

7.5.6 Parallel I/O Board in Standard Mode
Signal Name Direction Signal Name Direction
No. No. No. No.
1 Reserved. 3840 OUT 49 Status area bit 8 3864 OUT
2 Robot Running 3841 OUT 50 Status area bit 9 3865 OUT
3 Robot Error 3842 OUT 51 Status area bit 10 3866 OUT
4 Servo ON 3843 OUT 52 Status area bit 11 3867 OUT
5 Robot Initialized 3844 OUT 53 Status area bit 12 3868 OUT
6 Auto Mode 3845 OUT 54 Status area bit 13 3869 OUT
7 External Mode 3846 OUT 55 Status area bit 14 3870 OUT
8 Battery Warning 3847 OUT 56 Status area bit 15 3871 OUT
9 Robot Warning 3848 OUT 57 3872 OUT
10 Continue Start Permission 3849 OUT 58 3873 OUT
11 SS Mode 3850 OUT 59 3874 OUT
Command Processing
15 3854 OUT 63 3878 OUT
Completed
16 Status area odd parity 3855 OUT 64 User output 3879 OUT
17 Status area bit 0 3856 OUT 65 3880 OUT
25 Step Stop (All tasks) 3584 IN 73 Data area 2 bit 6 3604 IN
26 Reserved. 3585 IN 74 Data area 2 bit 7 3605 IN
27 3586 IN 75 Data area 2 bit 8 3606 IN
[Halt]
28 Strobe Signal 3587 IN 76 Data area 2 bit 9 3607 IN
29 Interruption Skip 3588 IN 77 Data area 2 bit 10 3608 IN
Command data area odd
30 3589 IN 78 Data area 2 bit 11 3609 IN
parity
31 Data area 1 bit 0 3590 IN 79 Data area 2 bit 12 3610 IN
35 Data area 1 bit 4 3594 IN 83 Command area bit 0 3614 IN
39 Data area 2 bit 0 3598 IN 87 3618 IN
User input
111

7.5.7 Parallel I/O Board (1st) in All User I/O Mode
Signal Name Direction Signal Name
No. No. No. No. Direction
1 3840 OUT 49 3864 OUT
2 3841 OUT 50 3865 OUT
3 3842 OUT 51 3866 OUT
4 3843 OUT 52 3867 OUT
5 3844 OUT 53 3868 OUT
6 3845 OUT 54 3869 OUT
7 3846 OUT 55 3870 OUT
8 3847 OUT 56 3871 OUT
9 3848 OUT 57 3872 OUT
10 3849 OUT 58 3873 OUT
11 3850 OUT 59 3874 OUT
12 3851 OUT 60 3875 OUT
User output User output
13 3852 OUT 61 3876 OUT
14 3853 OUT 62 3877 OUT
15 3854 OUT 63 3878 OUT
16 3855 OUT 64 3879 OUT
17 3856 OUT 65 3880 OUT
18 3857 OUT 66 3881 OUT
19 3858 OUT 67 3882 OUT
20 3859 OUT 68 3883 OUT
21 3860 OUT 69 3884 OUT
22 3861 OUT 70 3885 OUT
23 3862 OUT 71 3886 OUT
24 3863 OUT 72 3887 OUT
25 3584 IN 73 3604 IN
26 3585 IN 74 3605 IN
27 3586 IN 75 3606 IN
28 3587 IN 76 3607 IN
29 3588 IN 77 3608 IN
30 3589 IN 78 3609 IN
31 3590 IN 79 3610 IN
32 3591 IN 80 3611 IN
33 3592 IN 81 3612 IN
34 3593 IN 82 3613 IN
User input User input
35 3594 IN 83 3614 IN
36 3595 IN 84 3615 IN
37 3596 IN 85 3616 IN
38 3597 IN 86 3617 IN
39 3598 IN 87 3618 IN
40 3599 IN 88 3619 IN
41 3600 IN 89 3620 IN
42 3601 IN 90 3621 IN
43 3602 IN 91 3622 IN
44 3603 IN 92 3623 IN
112

7.5.8 Parallel I/O Board (2nd) in All User I/O Mode
Signal Name Direction Signal Name
No. No. No. No Direction
1 3888 OUT 49 3912 OUT
2 3889 OUT 50 3913 OUT
3 3890 OUT 51 3914 OUT
4 3891 OUT 52 3915 OUT
5 3892 OUT 53 3916 OUT
6 3893 OUT 54 3917 OUT
7 3894 OUT 55 3918 OUT
8 3895 OUT 56 3919 OUT
9 3896 OUT 57 3920 OUT
10 3897 OUT 58 3921 OUT
11 3898 OUT 59 3922 OUT
12 3899 OUT 60 3923 OUT
13 3900 OUT 61 3924 OUT
14 3901 OUT 62 3925 OUT
15 3902 OUT 63 3926 OUT
16 3903 OUT 64 3927 OUT
17 3904 OUT 65 3928 OUT
18 3905 OUT 66 3929 OUT
19 3906 OUT 67 3930 OUT
20 3907 OUT 68 3931 OUT
21 3908 OUT 69 3932 OUT
22 3909 OUT 70 3933 OUT
23 3910 OUT 71 3934 OUT
24 3911 OUT 72 3935 OUT
25 3624 IN 73 3644 IN
26 3625 IN 74 3645 IN
27 3626 IN 75 3646 IN
28 3627 IN 76 3647 IN
29 3628 IN 77 3648 IN
30 3629 IN 78 3649 IN
31 3630 IN 79 3650 IN
32 3631 IN 80 3651 IN
33 3632 IN 81 3652 IN
34 3633 IN 82 3653 IN
35 3634 IN 83 3654 IN
36 3635 IN 84 3655 IN
37 3636 IN 85 3656 IN
38 3637 IN 86 3657 IN
39 3638 IN 87 3658 IN
40 3639 IN 88 3659 IN
41 3640 IN 89 3660 IN
42 3641 IN 90 3661 IN
43 3642 IN 91 3662 IN
44 3643 IN 92 3663 IN
113

7.5.9 DeviceNet Slave Board in Compatible Mode
Note: The table below applies also to the allocation of the slave area on the
DeviceNet master/slave board.
Input data Output data

Port No. Signal name Port No. Signal name
512 Step Stop (All tasks) 768 Reserved.
513 Continue Start 769 Robot Running
514 Instantaneous Stop (All tasks) [Halt] 770 Robot Error
515 Operation Preparation Start 771 Auto Mode
516 Interruption Skip 772 External Mode
517 Program Start 773 Program Start Reset
518 ⎯ 774 Reserved.
520 Program No. selection bit 0 776 Robot Power ON Completed
521 Program No. selection bit 1 777 Servo ON
522 Program No. selection bit 2 778 CAL Completed
523 Program No. selection bit 3 779 Teaching ON
524 Program No. selection bit 4 780 1 Cycle End
525 Program No. selection bit 5 781 Battery Warning
526 Program No. selection bit 6 782 Robot Warning
527 Program selection parity 783 Continue Start Permission
528 Motor Power ON 784 Error in the units place, bit 0
529 CAL Execution 785 Error in the units place, bit 1
530 Reserved. 786 Error in the units place, bit 2
531 SP100 787 Error in the units place, bit 3
532 External Mode Change 788 Error in the tens place, bit 0
533 Program Reset 789 Error in the tens place, bit 1
534 Clear Robot Error 790 Error in the tens place, bit 2
535 ⎯ 791 Error in the tens place, bit 3
536 INPUT 536 792 Error in the hundreds place, bit 0
540 INPUT 540 796 SS Mode
541 INPUT 541 797 Reserved.
544 INPUT 544 800 OUTPUT 800
545 INPUT 545 801 OUTPUT 801
546 INPUT 546 802 OUTPUT 802
547 INPUT 547 803 OUTPUT 803
548 INPUT 548 804 OUTPUT 804
549 INPUT 549 805
: (INPUT 550 to INPUT 764) : (OUTPUT 806 to OUTPUT 1020)
765 INPUT 765 1021 OUTPUT 1021
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
114

7.5.10 DeviceNet Slave Board in Standard Mode

513 Reserved. 769 Robot Running
515 Strobe Signal 771 Servo ON
516 Interruption Skip 772 Robot Initialized
517 ⎯ 773 Auto Mode
518 ⎯ 774 External Mode
519 Command data odd parity 775 Battery Warning
520 Data area 1 bit 0 776 Robot Warning
521 Data area 1 bit 1 777 Continue Start Permission
522 Data area 1 bit 2 778 SS Mode
523 Data area 1 bit 3 779 Reserved.
526 Data area 1 bit 6 782 Command Processing Completed
527 Data area 1 bit 7 783 Status area odd parity
528 Data area 2 bit 0 784 Status area bit 0
544 Command area bit 0 800 OUTPUT 800
548 to 551 ⎯ 804 OUTPUT 804
552 INPUT 552 805 OUTPUT 805
553 INPUT 553 806 OUTPUT 806
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
115

7.5.11 DeviceNet Slave Board in All User I/O Mode
512 INPUT 512 768 OUTPUT 768
513 INPUT 513 769 OUTPUT 769
514 INPUT 514 770 OUTPUT 770
515 INPUT 515 771 OUTPUT 771
516 INPUT 516 772 OUTPUT 772
517 INPUT 517 773 OUTPUT 773
518 INPUT 518 774 OUTPUT 774
519 INPUT 519 775 OUTPUT 775
520 INPUT 520 776 OUTPUT 776
521 INPUT 521 777 OUTPUT 777
522 INPUT 522 778 OUTPUT 778
523 INPUT 523 779 OUTPUT 779
524 INPUT 524 780 OUTPUT 780
525 INPUT 525 781 OUTPUT 781
526 INPUT 526 782 OUTPUT 782
527 INPUT 527 783 OUTPUT 783
528 INPUT 528 784 OUTPUT 784
529 INPUT 529 785 OUTPUT 785
530 INPUT 530 786 OUTPUT 786
531 INPUT 531 787 OUTPUT 787
532 INPUT 532 788 OUTPUT 788
533 INPUT 533 789 OUTPUT 789
534 INPUT 534 790 OUTPUT 790
535 INPUT 535 791 OUTPUT 791
536 INPUT 536 792 OUTPUT 792
537 INPUT 537 793 OUTPUT 793
538 INPUT 538 794 OUTPUT 794
539 INPUT 539 795 OUTPUT 795
540 INPUT 540 796 OUTPUT 796
541 INPUT 541 797 OUTPUT 797
542 INPUT 542 798 OUTPUT 798
543 INPUT 543 799 OUTPUT 799
544 INPUT 544 800 OUTPUT 800
545 INPUT 545 801 OUTPUT 801
546 INPUT 546 802 OUTPUT 802
547 INPUT 547 803 OUTPUT 803
548 INPUT 548 804 OUTPUT 804
549 INPUT 549 805 OUTPUT 805
765 INPUT 765 1021 OUTPUT 1021
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
116

7.5.12 CC-Link Board (2 stations occupied) in Compatible Mode
Remote Remote
Port output Port input
No. (Note 1) No. (Note 1)
512 Step Stop (All tasks) RYn0 768 Reserved. RXn0
513 Continue Start RYn1 769 Robot Running RXn1
514 RYn2 770 Robot Error RXn2
[Halt]
515 Operation Preparation Start RYn3 771 Auto Mode RXn3
516 Interruption Skip RYn4 772 External Mode RXn4
517 Program Start RYn5 773 Program Start Reset RXn5
518 ⎯ RYn6 774 Reserved. RXn6
520 Program No. selection bit 0 RYn8 776 Robot Power ON Completed RXn8
521 Program No. selection bit 1 RYn9 777 Servo ON RXn9
522 Program No. selection bit 2 RYnA 778 CAL Completed RXnA
523 Program No. selection bit 3 RYnB 779 Teaching ON RXnB
524 Program No. selection bit 4 RYnC 780 1 Cycle End RXnC
525 Program No. selection bit 5 RYnD 781 Battery Warning RXnD
526 Program No. selection bit 6 RYnE 782 Robot Warning RXnE
527 Program No. selection parity bit RYnF 783 Continue Start Permission RXnF
528 Motor Power ON RY(n+1)0 784 Error in the units place, bit 0 RX(n+1)0
529 CAL Execution RY(n+1)1 785 Error in the units place, bit 1 RX(n+1)1
530 Reserved. RY(n+1)2 786 Error in the units place, bit 2 RX(n+1)2
531 SP100 RY(n+1)3 787 Error in the units place, bit 3 RX(n+1)3
532 External Mode Change RY(n+1)4 788 Error in the tens place, bit 0 RX(n+1)4
533 Program Reset RY(n+1)5 789 Error in the tens place, bit 1 RX(n+1)5
534 Clear Robot Error RY(n+1)6 790 Error in the tens place, bit 2 RX(n+1)6
535 Reserved. RY(n+1)7 791 Error in the tens place, bit 3 RX(n+1)7
536 RY(n+1)8 792 Error in the hundreds place, bit 0 RX(n+1)8
User input (INPUT m)
: : 793 Error in the hundreds place, bit 1 RX(n+1)9
(Note 2)
559 RY(n+2)F 794 Error in the hundreds place, bit 2 RX(n+1)A
560 RY(n+3)0 795 Error in the hundreds place, bit 3 RX(n+1)B
: Not used. : 796 SS Mode RX(n+1)C
575 RY(n+3)F 797 Reserved. RX(n+1)D
798 Reserved. RX(n+1)E
799 Reserved. RX(n+1)F
800 RX(n+2)0
User output (OUTPUT m)
: :
(Note 2)
815 RX(n+2)F
816 RX(n+3)0
: Not used. :
825 RX(n+3)9
826 Error status flag (Note 3) RX(n+3)A
827 Remote station ready (Note 4) RX(n+3)B
828 RX(n+3)C
: Not used. :
831 RX(n+3)F
Note 1: n denotes (station number − 1) × 2 (hexadecimal notation).

Note 2: m denotes I/O port number.
Note 3: The output timing is the same as that of Robot Error (I/O port #770) and Robot Warning (I/O port #782).
Note 4: The output timing is the same as that of Robot Power ON Completed (I/O port #776).
Note 5: indicates the system area that cannot be used for user I/O.
117

Remote Remote
[Halt]
522 Program No. selection bit 2 RYnA 778 CAL Completed RxnA
526 Program No. selection bit 6 RYnE 782 Robot Warning RxnE
(Note 2)
800 RX(n+2)0
: :
(Note 2)
847 RX(n+4)F
848 RX(n+5)0
: Not used. :
857 RX(n+5)9
860 RX(n+5)C
: Not used. :
863 RX(n+5)F

118

Remote Remote
[Halt]
(Note 2)
800 RX(n+2)0
: :
(Note 2)
879 RX(n+6)F
880 RX(n+7)0
: Not used. :
889 RX(n+7)9
892 RX(n+7)C
: Not used. :
895 RX(n+7)F

119

7.5.15 CC-Link Board (2 stations occupied) in Standard Mode
Remote Remote
513 Reserved. RYn1 769 Robot Running RXn1
[Halt]
515 Strobe Signal RYn3 771 Servo ON RXn3
516 Interruption Skip RYn4 772 Robot Initialized RXn4
517 ⎯ RYn5 773 Auto Mode RXn5
518 ⎯ RYn6 774 External Mode RXn6
519 Command data area odd parity RYn7 775 Battery Warning RXn7
520 Data area 1 bit 0 RYn8 776 Robot Warning RXn8
521 Data area 1 bit 1 RYn9 777 Continue Start Permission RXn9
522 Data area 1 bit 2 RYnA 778 SS Mode RXnA
523 Data area 1 bit 3 RYnB 779 Reserved. RXnB
524 Data area 1 bit 4 RYnC 780 Reserved. RXnC
525 Data area 1 bit 5 RYnD 781 Reserved. RXnD
526 Data area 1 bit 6 RYnE 782 Command Processing Completed RXnE
527 Data area 1 bit 7 RYnF 783 Status area odd parity RXnF
528 Data area 2 bit 0 RY(n+1)0 784 Status area bit 0 RX(n+1)0
538 Data area 2 bit 10 RY(n+1)A 794 Status area bit 10 RX(n+1)A
539 Data area 2 bit 11 RY(n+1)B 795 Status area bit 11 RX(n+1)B
540 Data area 2 bit 12 RY(n+1)C 796 Status area bit 12 RX(n+1)C
541 Data area 2 bit 13 RY(n+1)D 797 Status area bit 13 RX(n+1)D
542 Data area 2 bit 14 RY(n+1)E 798 Status area bit 14 RX(n+1)E
543 Data area 2 bit 15 RY(n+1)F 799 Status area bit 15 RX(n+1)F
544 Command area bit 0 RY(n+2)0 800 RX(n+2)0
545 Command area bit 1 RY(n+2)1 : :
(Note 2)
546 Command area bit 2 RY(n+2)2 815 RX(n+2)F
548 Reserved. RY(n+2)4 : Not used. :
549 Reserved. RY(n+2)5 825 RX(n+3)9
550 Reserved. RY(n+2)6 826 Error status flag (Note 3) RX(n+3)A
Remote station ready
551 Reserved. RY(n+2)7 827 RX(n+3)B
(Note 4)
552 RY(n+2)8 828 RX(n+3)C
: : : Not used. :
(Note 2)
559 RY(n+2)F 829 RX(n+3)F
560 RY(n+3)0
: Not used. :
575 RY(n+3)F

Note 4: The output timing is the same as that of Robot Initialized (I/O port #772).
120

Remote Remote
Port output. Port input
[Halt]
522 Data area 1 bit 2 RYnA 778 SS Mode RxnA
526 Data area 1 bit 6 RYnE 782 Command Processing Completed RxnE
(Note 2)
(Note 4)
552 RY(n+2)8 860 RX(n+5)C
: : : Not used. :
(Note 2)
591 RY(n+4)F 863 RX(n+5)F
592 RY(n+5)0
: Not used. :
607 RY(n+5)F

121

Remote Remote
[Halt]
526 Data area 1 bit 6 RYnE 782 Command Processing Completed RxnE
(Note 2)
(Note 4)
552 RY(n+2)8 892 RX(n+7)C
: : : Not used. :
(Note 2)
623 RY(n+6)F 895 RX(n+7)F
624 RY(n+7)0
: Not used. :
639 RY(n+7)F

122

7.5.18 CC-Link Board (2 stations occupied) in All User I/O Mode
Remote Remote
512 INPUT 512 RYn0 768 OUTPUT 768 RXn0
522 INPUT 522 RYnA 778 OUTPUT 778 RXnA
523 INPUT 523 RYnB 779 OUTPUT 779 RXnB
524 INPUT 524 RYnC 780 OUTPUT 780 RXnC
525 INPUT 525 RYnD 781 OUTPUT 781 RXnD
526 INPUT 526 RYnE 782 OUTPUT 782 RXnE
527 INPUT 527 RYnF 783 OUTPUT 783 RXnF
528 INPUT 528 RY(n+1)0 784 OUTPUT 784 RX(n+1)0
536 RY(n+1)8 792 OUTPUT 792 RX(n+1)8
: : 793 OUTPUT 793 RX(n+1)9
(Note 2)
559 RY(n+2)F 794 OUTPUT 794 RX(n+1)A
560 RY(n+3)0 795 OUTPUT 795 RX(n+1)B
: Not used. : 796 OUTPUT 796 RX(n+1)C
575 RY(n+3)F 797 OUTPUT 797 RX(n+1)D
798 OUTPUT 798 RX(n+1)E
799 OUTPUT 799 RX(n+1)F
800 RX(n+2)0
: :
(Note 2)
815 RX(n+2)F
816 RX(n+3)0
: Not used. :
825 RX(n+3)9
826 Error status flag RX(n+3)A
827 Remote station ready RX(n+3)B
828 RX(n+3)C
: Not used. :
831 RX(n+3)F

123

Remote Remote
536 RY(n+1)8 792 OUTPUT 792 RX(n+1)8
: : 793 OUTPUT 793 RX(n+1)9
(Note 2)
591 RY(n+4)F 794 OUTPUT 794 RX(n+1)A
592 RY(n+5)0 795 OUTPUT 795 RX(n+1)B
607 RY(n+5)F 797 OUTPUT 797 RX(n+1)D
800 RX(n+2)0
: :
(Note 2)
847 RX(n+4)F
848 RX(n+5)0
: Not used. :
857 RX(n+5)9
860 RX(n+5)C
: Not used. :
863 RX(n+5)F

124

Remote Remote
536 RY(n+1)8 792 OUTPUT 792 RX(n+1)8
: : 793 OUTPUT 793 RX(n+1)9
(Note 2)
623 RY(n+6)F 794 OUTPUT 794 RX(n+1)A
624 RY(n+7)0 795 OUTPUT 795 RX(n+1)B
639 RY(n+7)F 797 OUTPUT 797 RX(n+1)D
800 RX(n+2)0
: :
(Note 2)
879 RX(n+6)F
880 RX(n+7)0
: Not used. :
889 RX(n+7)9
892 RX(n+7)C
: Not used. :
895 RX(n+7)F

125

7.5.21 PROFIBUS-DP Slave Board in Compatible Mode
527 Program No. selection parity bit 783 Continue Start Permission
528 Motor power ON 784 Error in the units place, bit 0
535 Reserved. 791 Error in the tens place, bit 3
544 INPUT 544 800 OUTPUT 800
545 INPUT 545 801 OUTPUT 801
546 INPUT 546 802 OUTPUT 802
547 INPUT 547 803 OUTPUT 803
548 INPUT 548 804 OUTPUT 804
549 INPUT 549 805 OUTPUT 805
: :
(INPUT 550 to INPUT 764) (OUTPUT 806 to OUTPUT 1020)
: :
765 INPUT 765 1021 OUTPUT 1021
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023

126

7.5.22 PROFIBUS-DP Slave Board in Standard Mode
519 Command data area odd parity 775 Battery Warning
548 to 551 ⎯ 804 OUTPUT 804
552 INPUT 552 805 OUTPUT 805
553 INPUT 553 806 OUTPUT 806
: :
: :
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
127

7.5.23 PROFIBUS-DP Slave Board in All User I/O Mode
512 INPUT 512 768 OUTPUT 768
513 INPUT 513 769 OUTPUT 769
514 INPUT 514 770 OUTPUT 770
515 INPUT 515 771 OUTPUT 771
516 INPUT 516 772 OUTPUT 772
517 INPUT 517 773 OUTPUT 773
518 INPUT 518 774 OUTPUT 774
519 INPUT 519 775 OUTPUT 775
520 INPUT 520 776 OUTPUT 776
521 INPUT 521 777 OUTPUT 777
522 INPUT 522 778 OUTPUT 778
523 INPUT 523 779 OUTPUT 779
524 INPUT 524 780 OUTPUT 780
525 INPUT 525 781 OUTPUT 781
526 INPUT 526 782 OUTPUT 782
527 INPUT 527 783 OUTPUT 783
528 INPUT 528 784 OUTPUT 784
529 INPUT 529 785 OUTPUT 785
530 INPUT 530 786 OUTPUT 786
531 INPUT 531 787 OUTPUT 787
532 INPUT 532 788 OUTPUT 788
533 INPUT 533 789 OUTPUT 789
534 INPUT 534 790 OUTPUT 790
535 INPUT 535 791 OUTPUT 791
536 INPUT 536 792 OUTPUT 792
537 INPUT 537 793 OUTPUT 793
538 INPUT 538 794 OUTPUT 794
539 INPUT 539 795 OUTPUT 795
540 INPUT 540 796 OUTPUT 796
541 INPUT 541 797 OUTPUT 797
542 INPUT 542 798 OUTPUT 798
543 INPUT 543 799 OUTPUT 799
544 INPUT 544 800 OUTPUT 800
545 INPUT 545 801 OUTPUT 801
546 INPUT 546 802 OUTPUT 802
547 INPUT 547 803 OUTPUT 803
548 INPUT 548 804 OUTPUT 804
549 INPUT 549 805 OUTPUT 805
765 INPUT 765 1021 OUTPUT 1021

766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
128

7.5.24 DeviceNet Master Board in All User I/O Mode
Note: The table below applies also to the allocation of the master area on the

1024 INPUT 1024 2048 OUTPUT 2048
1025 INPUT 1025 2049 OUTPUT 2049
1026 INPUT 1026 2050 OUTPUT 2050
1027 INPUT 1027 2051 OUTPUT 2051
1028 INPUT 1028 2052 OUTPUT 2052
1029 INPUT 1029 2053 OUTPUT 2053
1030 INPUT 1030 2054 OUTPUT 2054
1031 INPUT 1031 2055 OUTPUT 2055
1032 INPUT 1032 2056 OUTPUT 2056
1033 INPUT 1033 2057 OUTPUT 2057
1034 INPUT 1034 2058 OUTPUT 2058
1035 INPUT 1035 2059 OUTPUT 2059
1036 INPUT 1036 2060 OUTPUT 2060
1037 INPUT 1037 2061 OUTPUT 2061
1038 INPUT 1038 2062 OUTPUT 2062
1039 INPUT 1039 2063 OUTPUT 2063
1040 INPUT 1040 2064 OUTPUT 2064
1041 INPUT 1041 2065 OUTPUT 2065
1042 INPUT 1042 2066 OUTPUT 2066
1043 INPUT 1043 2067 OUTPUT 2067
1044 INPUT 1044 2068 OUTPUT 2068
1045 INPUT 1045 2069 OUTPUT 2069
1046 INPUT 1046 2070 OUTPUT 2070
1047 INPUT 1047 2071 OUTPUT 2071
1048 INPUT 1048 2072 OUTPUT 2072
1049 INPUT 1049 2073 OUTPUT 2073
1050 INPUT 1050 2074 OUTPUT 2074
1051 INPUT 1051 2075 OUTPUT 2075
1052 INPUT 1052 2076 OUTPUT 2076
1053 INPUT 1053 2077 OUTPUT 2077
1054 INPUT 1054 2078 OUTPUT 2078
1055 INPUT 1055 2079 OUTPUT 2079
1056 INPUT 1056 2080 OUTPUT 2080
1057 INPUT 1057 2081 OUTPUT 2081
1058 INPUT 1058 2082 OUTPUT 2082
1059 INPUT 1059 2083 OUTPUT 2083
1060 INPUT 1060 2084 OUTPUT 2084
1061 INPUT 1061 2085 OUTPUT 2085
2045 INPUT 2045 3069 OUTPUT 3069
2046 INPUT 2046 3070 OUTPUT 3070
2047 INPUT 2047 3071 OUTPUT 3071
129

7.5.25 S-Link V Master Board in All User I/O Mode
3072 INPUT 3072 3328 OUTPUT 3328
3073 INPUT 3073 3329 OUTPUT 3329
3074 INPUT 3074 3330 OUTPUT 3330
3075 INPUT 3075 3331 OUTPUT 3331
3076 INPUT 3076 3332 OUTPUT 3332
3077 INPUT 3077 3333 OUTPUT 3333
3078 INPUT 3078 3334 OUTPUT 3334
3079 INPUT 3079 3335 OUTPUT 3335
3080 INPUT 3080 3336 OUTPUT 3336
3081 INPUT 3081 3337 OUTPUT 3337
3082 INPUT 3082 3338 OUTPUT 3338
3083 INPUT 3083 3339 OUTPUT 3339
3084 INPUT 3084 3340 OUTPUT 3340
3085 INPUT 3085 3341 OUTPUT 3341
3086 INPUT 3086 3342 OUTPUT 3342
3087 INPUT 3087 3343 OUTPUT 3343
3088 INPUT 3088 3344 OUTPUT 3344
3089 INPUT 3089 3345 OUTPUT 3345
3090 INPUT 3090 3346 OUTPUT 3346
3091 INPUT 3091 3347 OUTPUT 3347
3092 INPUT 3092 3348 OUTPUT 3348
3093 INPUT 3093 3349 OUTPUT 3349
3094 INPUT 3094 3350 OUTPUT 3350
3095 INPUT 3095 3351 OUTPUT 3351
3096 INPUT 3096 3352 OUTPUT 3352
3097 INPUT 3097 3353 OUTPUT 3353
3098 INPUT 3098 3354 OUTPUT 3354
3099 INPUT 3099 3355 OUTPUT 3355
3100 INPUT 3100 3356 OUTPUT 3356
3101 INPUT 3101 3357 OUTPUT 3357
3102 INPUT 3102 3358 OUTPUT 3358
3103 INPUT 3103 3359 OUTPUT 3359
3104 INPUT 3104 3360 OUTPUT 3360
3105 INPUT 3105 3361 OUTPUT 3361
3106 INPUT 3106 3362 OUTPUT 3362
3107 INPUT 3107 3363 OUTPUT 3363
3108 INPUT 3108 3364 OUTPUT 3364
3109 INPUT 3109 3365 OUTPUT 3365
3325 INPUT 3325 3581 OUTPUT 3581
3326 INPUT 3326 3582 OUTPUT 3582
3327 INPUT 3327 3583 OUTPUT 3583
130

Chapter 8 I/O Allocation for I/O Conversion
Box (only for standard type of
controller)
This chapter lists the I/O allocation tables to apply when the I/O conversion box is
mounted on the controller.
The I/O conversion box should be used with an optional parallel I/O board mounted so
that the "INPUT (CN8)," "OUTPUT (CN10)," and "I/O POWER (CN7)" used on the RC5
controller can be used as is.
Note: The I/O conversion box cannot be used for the global type of the controller.
For details about the I/O conversion box, refer to the RC7M Controller OPTIONS
MANUAL, Chapter 4, Section 4.7 "I/O Conversion Box."
8.1 I/O Allocation Modes with I/O Conversion Box Mounted

Using the I/O conversion box requires an optional parallel I/O board to be
mounted, for compatibility with the RC5 controller. The ports on the parallel I/O
board offset the shortage of standard mini I/O ports.
The table below lists the selectable allocation modes when the I/O conversion
box is used.
Allocation Mode Available with the I/O Conversion Box

I/O extension boards Allocation modes
No. I/O conversion box
Extension 1 Extension 2
Compatible Standard All user I/O
1 Parallel I/O board – √ √
2 Parallel I/O board Parallel I/O board √ √
3 Parallel I/O board DeviceNet slave board √ √
4 Parallel I/O board DeviceNet master board √
5 Parallel I/O board DeviceNet master/slave board √ √ √
6 Parallel I/O board CC-Link board √ √
7 Parallel I/O board PROFIBUS-DP slave board √ √
8 Parallel I/O board S-LINK V board √ √ √
131

8.2 I/O Allocation in Individual Allocation Modes
The table below lists the I/O allocation for extension boards in individual
allocation modes. For details, refer to Section 8.5 "I/O Allocation Tables for
Individual Allocation Modes."
Note: For the I/O allocation for the DeviceNet master/slave board, see the
allocation tables for the DeviceNet master and slave boards.
I/O Allocation of Extension Boards in Individual Allocation Modes

I/O extension boards Allocation for CN8, CN10, and extension boards
Allocation modes
Extension 1 Extension 2 I/O Allocation tables to apply
I/O-box compatible CN8 INPUT (CN8) in I/O-box compatible mode
mode CN10 OUTPUT (CN10) in I/O-box compatible mode
–
I/O-box standard CN8 INPUT (CN8) in I/O-box standard mode
mode CN10 OUTPUT (CN10) in I/O-box standard mode
CN8 INPUT (CN8) in I/O-box all user I/O mode
DeviceNet slave I/O-box compatible
board CN10 OUTPUT (CN10) in I/O-box all user I/O mode
mode
Extension 2 Extension boards in I/O-box compatible mode
CC-Link board
Parallel CN8 INPUT (CN8) in I/O-box all user I/O mode
PROFIBUS-DP I/O-box standard
I/O board CN10 OUTPUT (CN10) in I/O-box all user I/O mode
slave board mode
Extension 2 Extension boards in I/O-box standard mode
CN8 INPUT (CN8) in I/O-box compatible mode
Parallel I/O board I/O-box compatible CN10 OUTPUT (CN10) in I/O-box compatible mode
mode
DeviceNet master Extension 2 Extension boards in I/O-box all user I/O mode
board CN8 INPUT (CN8) in I/O-box standard mode
S-LINK V board I/O-box standard CN10 OUTPUT (CN10) in I/O-box standard mode
mode
Extension 2 Extension boards in I/O-box all user I/O mode
Note: Extensions 1 and 2 correspond to the ones listed in the "Allocation Mode Available with the I/O Conversion Box"
table on the previous page.
8.3 Notes on Using the I/O Conversion Box

(1) Parameter change for switching between allocation modes
To switch to the I/O-box compatible or standard mode, you need to change
parameters using the teach pendant or WINCAPSII. For the changing procedure,
refer to the RC7M Controller OPTIONS MANUAL, Section 4.6.
(2) Power supply setting for mini I/O board (CN5) or parallel I/O board
To use the I/O conversion box, select 24 V power supply (internal or external) on
I/O POWER (CN7). You also need to set up the power supply for the mini I/O board
and parallel I/O board to match the power supply setting on I/O POWER (CN7).
The factory default is external power supply.
For details about the mini I/O board, see Section 4.2.1 or 5.2.1.
For details about the parallel I/O board, refer to the RC7M Controller OPTIONS
MANUAL, Section 5.2.2.
132

8.4 Allocation Common to All Allocation Modes
The RC7M controller supports hand I/O signals (CN9) as standard. This hand
I/O and I/O POWER (CN7) are common to all allocation modes.
8.4.1 I/O POWER (CN9): Common to All Modes

NPN type I/O PNP type I/O
Terminal Terminal
No. No.
1 Internal power source output (+24V) 1 Internal power source output (+24V)
2 Internal power source output (+24V) 2 Internal power source output (+24V)
3 Internal power source output (0V) 3 Internal power source output (0V)
4 Internal power source output (0V) 4 Internal power source output (0V)
5 FG 5 FG
6 Power input +24V 6 Power input 0V
7 Power input +24V 7 Power input 0V
8 Power input 0V 8 Power input +24V
9 Power input 0V 9 Power input +24V
8.4.2 HAND I/O (CN9): Common to All Modes

NPN type
Terminal Terminal
No. No.
for hand (+24V)
for hand (0V)
PNP type
Terminal Terminal
No. No.
for hand (0V)
for hand (+24V)
133

8.5 I/O Allocation Tables for Individual Allocation Modes
8.5.1 OUTPUT (CN10) in I/O-Box Compatible Mode
Signal Name Signal Name
No. No. No. No.
1 CPU Normal (No monitor allowed) 72 35 User output 106
2 Robot Running 73 36 User output 107
3 Robot Error 74 37 User output 108
4 Auto Mode 75 38 User output 109
5 External Mode 76 39 User output 110
6 Program Start Reset 77 40 User output 111
7 Reserved. 78 41 User output 112
9 Robot Power ON Completed 80 43 User output 114
10 Servo ON 81 44 User output 115
11 CAL Completed 82 45 User output 116
12 Teaching ON 83 46 User output 117
13 1 Cycle End 84 47 User output 118
14 Battery Warning 85 48 User output 119
15 Robot Warning 86 49 User output 120
16 Continue Start Permission 87 50 User output 121
17 Error in the units place, bit 0 88 51 User output 122
21 Error in the tens place, bit 0 92 55 User output 126
22 Error in the tens place, bit 1 93 56 User output 127
23 Error in the tens place, bit 2 94 57 Not used. ⎯
24 Error in the tens place, bit 3 95 58 Not used. ⎯
(Power supply for Robot Stop 1
25 Error in the hundreds place, bit 0 96 59* ⎯
(Internal power source +24V))
26 Error in the hundreds place, bit 1 97 60* (Robot Stop 1) ⎯
27 Error in the hundreds place, bit 2 98 61*
(Internal power source +24V)) ⎯
28 Error in the hundreds place, bit 3 99 62* (Robot Stop 2) ⎯
29 SS Mode 100 63* (Emergency Stop 1 (+)) ⎯
30 Reserved. 101 64* (Emergency Stop 1 (-)) ⎯
31 Reserved. 102 65 Emergency Stop 2 (+) ⎯
32 Reserved. 103 66 Emergency Stop 2 (-) ⎯
33 User output 104 67* (Deadman SW (+)) ⎯
34 User output 105 68* (Deadman SW (-)) ⎯
Note: Terminal numbers with asterisks (*) are used only in the dual-safety emergency stop circuit version.
134

8.5.2 INPUT (CN8) in I/O-Box Compatible Mode
No. No. No. No.
Power supply for Robot Stop
1* ⎯ 26 User input 21
(Internal +24V)
2* Robot Stop ⎯ 27 User input 22
Power supply for Enable Auto
3
(Internal +24V) ⎯ 28 User input 23
4 Enable Auto ⎯ 29 User input 24

5 Step Stop (All tasks) 0 30 User input 25
6 Continue Start 1 31 User input 26
7 Instantaneous Stop (All tasks) [Halt] 2 32 User input 27
8 Operation Preparation Start 3 33 User input 28
9 Interruption Skip 4 34 User input 29
10 Program Start 5 35 User input 30
11 Program No. selection bit 0 6 36 User input 31
18 Program No. selection parity bit 13 43 User input 38
19 Motor Power ON 14 44 User input 39
20 CAL Execution 15 45 User input 40
21 Reserved. 16 46 User input 41
22 SP100 17 47 User input 42
23 External Mode Change 18 48 User input 43
24 Program Reset 19 49 User input 44
25 Clear Robot Error 20 50 User input 45
Note: Terminal numbers with asterisks (*) are NOT used in the dual-safety emergency stop circuit version.
135

8.5.3 OUTPUT (CN10) in I/O-Box Standard Mode
No. No. No. No.
4 Servo ON 75 38 User output 109
5 Robot Initialized 76 39 User output 110
6 Auto Mode 77 40 User output 111
7 External Mode 78 41 User output 112
8 Battery Warning 79 42 User output 113
9 Robot Warning 80 43 User output 114
10 Continue Start Permission 81 44 User output 115
11 SS Mode 82 45 User output 116
15 Command Processing Completed 86 49 User output 120
16 Status area odd parity 87 50 User output 121
17 Status area bit 0 88 51 User output 122
23 Status area bit 6 94 57 Not used. ⎯
24 Status area bit 7 95 58 Not used. ⎯
25 Status area bit 8 96 59* ⎯
26 Status area bit 9 97 60* (Robot Stop 1) ⎯
27 Status area bit 10 98 61*
28 Status area bit 11 99 62* (Robot Stop 2) ⎯
29 Status area bit 12 100 63* (Emergency Stop 1 (+)) ⎯
30 Status area bit 13 101 64* (Emergency Stop 1 (-)) ⎯
31 Status area bit 14 102 65 Emergency Stop 2 (+) ⎯
32 Status area bit 15 103 66 Emergency Stop 2 (-) ⎯
136

8.5.4 INPUT (CN8) in I/O-Box Standard Mode
No. No. No. No.
Power supply for Robot Stop
1* ⎯ 26 Data area 2 bit 7 21
(Internal +24V)
2* Robot Stop ⎯ 27 Data area 2 bit 8 22
3
(Internal +24V) ⎯ 28 Data area 2 bit 9 23
4 Enable Auto ⎯ 29 Data area 2 bit 10 24

5 Step Stop (All tasks) 0 30 Data area 2 bit 11 25
6 Reserved. 1 31 Data area 2 bit 12 26
7 Instantaneous Stop (All tasks) [Halt] 2 32 Data area 2 bit 13 27
8 Strobe Signal 3 33 Data area 2 bit 14 28
9 Interruption Skip 4 34 Data area 2 bit 15 29
10 Command data area odd parity 5 35 Command area bit 0 30
11 Data area 1 bit 0 6 36 Command area bit 1 31
14 Data area 1 bit 3 9 39 User input 34
137

8.5.5 OUTPUT (CN10) in I/O-Box All User I/O Mode
No. No. No. No.
4 User output 75 38 User output 109
23 User output 94 57 Not used. ⎯
24 User output 95 58 Not used. ⎯
25 User output 96 59* ⎯
26 User output 97 60* (Robot Stop 1) ⎯
27 User output 98 61*
28 User output 99 62* (Robot Stop 2) ⎯
29 User output 100 63* (Emergency Stop 1 (+)) ⎯
30 User output 101 64* (Emergency Stop 1 (-)) ⎯
31 User output 102 65 Emergency Stop 2 (+) ⎯
32 User output 103 66 Emergency Stop 2 (-) ⎯
138

8.5.6 INPUT (CN8) in I/O-Box All User I/O Mode
No. No. No. No.
Power supply for Robot stop
1* ⎯ 26 User input 21
(Internal +24V)
2* Robot stop ⎯ 27 User input 22
3
(Internal +24V) ⎯ 28 User input 23
4 Enable Auto ⎯ 29 User input 24

5 User input 0 30 User input 25
139

8.5.7 DeviceNet Slave Board in I/O-Box Compatible Mode
518 Not used. 774 Reserved.
519 Not used. 775 Reserved.
528 Motor Power ON 784 Error in the units place, bit 0
535 Not used. 791 Error in the tens place, bit 3
544 INPUT 544 800 OUTPUT 800
545 INPUT 545 801 OUTPUT 801
546 INPUT 546 802 OUTPUT 802
547 INPUT 547 803 OUTPUT 803
548 INPUT 539 804 OUTPUT 804
549 to 763 INPUT 549 to INPUT 763 805 to 1019 OUTPUT 805 to OUTPUT 1019
764 INPUT 764 1020 OUTPUT 1020
765 INPUT 765 1021 OUTPUT 1021
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
140

8.5.8 DeviceNet Slave Board in I/O-Box Standard Mode
517 Not used. 773 Auto Mode
518 Not used. 774 External Mode
533～540 Data area 2 bit 5 to 789 Status area bit 5
Data area 2 bit 12
544 Command area bit 0 793 Status area bit 9
548 Not used. 797 Status area bit 13
551 Not used. 800 OUTPUT 800
552 INPUT 552 801 OUTPUT 801
553 INPUT 553 802 OUTPUT 802
554 INPUT 554 803 OUTPUT 803
555 INPUT 555 804 OUTPUT 804
556 to 763 INPUT 556 to INPUT 763 805 to 1019 OUTPUT 805 to OUTPUT 1019
764 INPUT 764 1020 OUTPUT 1020
765 INPUT 765 1021 OUTPUT 1021
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
141

8.5.9 CC-Link Board (2 stations occupied) in I/O-Box Compatible Mode
Remote
Remote input
Port No. Signal name output. Port No. Signal name
(Note 1)
(Note 1)
512 Step Stop (All tasks) RYn0 768 ⎯ RXn0
[Halt]
518 Reserved. RYn6 774 Reserved. RXn6
522 Program No. selection bit 2 RYnA 778 CAL Completed RXnA
526 Program No. selection bit 6 RYnE 782 Robot Warning RXnE
Program No. selection parity
527 RYnF 783 Continue Start Permission RXnF
bit
536 RY(n+1)8 792 RX(n+1)8
bit 0
User input (INPUT m) Error in the hundreds place,
: : 793 RX(n+1)9
(Note 2) bit 1
559 RY(n+2)F 794 RX(n+1)A
bit 2
560 RY(n+3)0 795 RX(n+1)B
Not used. bit 3
: : 796 SS Mode RX(n+1)C
800 RX(n+2)0
: :
(Note 2)
815 RX(n+2)F
816 RX(n+3)0
: Not used. :
825 RX(n+3)9
828 RX(n+3)C
: Not used. :
831 RX(n+3)F

142

Remote
Remote input.
(Note 1)
(Note 1)
[Halt]
518 Reserved. RYn6 774 Not used. RXn6
519 Reserved. RYn7 775 Not used. RXn7
bit
536 RY(n+1)8 792 RX(n+1)8
bit 0
: : 793 RX(n+1)9
(Note 2) bit 1
591 RY(n+4)F 794 RX(n+1)A
bit 2
592 RY(n+5)0 795 RX(n+1)B
Not used. bit 3
800 RX(n+2)0
: :
(Note 2)
847 RX(n+4)F
848 RX(n+5)0
: Not used. :
857 RX(n+5)9
860 RX(n+5)C
: Not used. :
863 RX(n+5)F

143

Remote
I/O port I/O port Remote input.
Signal number output. Signal number
number number (Note 1)
(Note 1)
[Halt]
bit
536 RY(n+1)8 792 RX(n+1)8
bit 0
: : 793 RX(n+1)9
(Note 2) bit 1
623 RY(n+6)F 794 RX(n+1)A
bit 2
624 RY(n+7)0 795 RX(n+1)B
Not used. bit 3
800 RX(n+2)0
: :
(Note 2)
879 RX(n+6)F
880 RX(n+7)0
: Not used. :
889 RX(n+7)9
892 RX(n+7)C
: Not used. :
895 RX(n+7)F

144

8.5.12 CC-Link Board (2 stations occupied) in I/O-Box Standard Mode
Remote
Remote input
(Note 1)
(Note 1)
[Halt]
519 RYn7 775 Battery Warning RXn7
parity
522 Data area 1 bit 2 RYnA 778 SS Mode RXnA
Command Processing
526 Data area 1 bit 6 RYnE 782 RXnE
Completed
(Note 2)
(Note 4)
552 RY(n+2)8 828 RX(n+3)C
: : : Not used. :
(Note 2)
559 RY(n+2)F 829 RX(n+3)F
560 RY(n+3)0
: Not used. :
575 RY(n+3)F

145

Remote Remote
Port No. Signal name output Port No. Signal name output
(Note 1) (Note 1)
[Halt]
parity
Command Processing
526 Data area 1 bit 6 RYnE 782 RxnE
Completed
(Note 2)
(Note 4)
552 RY(n+2)8 860 RX(n+5)C
: : : Not used. :
(Note 2)
591 RY(n+4)F 863 RX(n+5)F
592 RY(n+5)0
: Not used. :
607 RY(n+5)F

146

Remote
Remote input
(Note 1)
(Note 1)
[Halt]
parity
Command Processing
526 Data area 1 bit 6 RYnE 782 RxnE
Completed
(Note 2)
(Note 4)
552 RY(n+2)8 892 RX(n+7)C
: : : Not used. :
(Note 2)
623 RY(n+6)F 895 RX(n+7)F
624 RY(n+7)0
: Not used. :
639 RY(n+7)F

147

8.5.15 PROFIBUS-DP Slave Board in I/O-Box Compatible Mode
512 Step Stop (All tasks) 768 ⎯
518 Reserved. 774 Reserved.
519 Reserved. 775 Reserved.
528 Motor power ON 784 Error in the units place, bit 0
535 Reserved. 791 Error in the tens place, bit 3
544 INPUT 544 800 OUTPUT 800
545 INPUT 545 801 OUTPUT 801
546 INPUT 546 802 OUTPUT 802
547 INPUT 547 803 OUTPUT 803
548 INPUT 548 804 OUTPUT 804
549 INPUT 549 805 OUTPUT 805
: :
: :
765 INPUT 765 1021 OUTPUT 1021
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
148

8.5.16 PROFIBUS-DP Slave Board in I/O-Box Standard Mode
548 to 551 Reserved. 804 OUTPUT 804
552 INPUT 552 805 OUTPUT 805
553 INPUT 553 806 OUTPUT 806
: :
: :
766 INPUT 766 1022 OUTPUT 1022
767 INPUT 767 1023 OUTPUT 1023
149

8.5.17 Parallel I/O Board in I/O-Box Al User I/O Mode
Terminal Terminal
Signal name Port No. Direction Signal name Port No. Direction
No. No.
1 3840 OUT 49 3864 OUT
2 3841 OUT 50 3865 OUT
3 3842 OUT 51 3866 OUT
4 3843 OUT 52 3867 OUT
5 3844 OUT 53 3868 OUT
6 3845 OUT 54 3869 OUT
7 3846 OUT 55 3870 OUT
8 3847 OUT 56 3871 OUT
9 3848 OUT 57 3872 OUT
10 3849 OUT 58 3873 OUT
11 3850 OUT 59 3874 OUT
12 3851 OUT 60 3875 OUT
13 3852 OUT 61 3876 OUT
14 3853 OUT 62 3877 OUT
15 3854 OUT 63 3878 OUT
16 3855 OUT 64 3879 OUT
17 3856 OUT 65 3880 OUT
18 3857 OUT 66 3881 OUT
19 3858 OUT 67 3882 OUT
20 3859 OUT 68 3883 OUT
21 3860 OUT 69 3884 OUT
22 3861 OUT 70 3885 OUT
23 3862 OUT 71 3886 OUT
24 3863 OUT 72 3887 OUT
25 3584 IN 73 3604 IN
26 3585 IN 74 3605 IN
27 3586 IN 75 3606 IN
28 3587 IN 76 3607 IN
29 3588 IN 77 3608 IN
30 3589 IN 78 3609 IN
31 3590 IN 79 3610 IN
32 3591 IN 80 3611 IN
33 3592 IN 81 3612 IN
34 3593 IN 82 3613 IN
35 3594 IN 83 3614 IN
36 3595 IN 84 3615 IN
37 3596 IN 85 3616 IN
38 3597 IN 86 3617 IN
39 3598 IN 87 3618 IN
40 3599 IN 88 3619 IN
41 3600 IN 89 3620 IN
42 3601 IN 90 3621 IN
43 3602 IN 91 3622 IN
44 3603 IN 92 3623 IN
150

8.5.18 DeviceNet Master Board in I/O-Box All User I/O Mode
Note: The table below applies also to the allocation of the master area on the

1024 INPUT 1024 2048 OUTPUT 2048
1025 INPUT 1025 2049 OUTPUT 2049
1026 INPUT 1026 2050 OUTPUT 2050
1027 INPUT 1027 2051 OUTPUT 2051
1028 INPUT 1028 2052 OUTPUT 2052
1029 INPUT 1029 2053 OUTPUT 2053
1030 INPUT 1030 2054 OUTPUT 2054
1031 INPUT 1031 2055 OUTPUT 2055
1032 INPUT 1032 2056 OUTPUT 2056
1033 INPUT 1033 2057 OUTPUT 2057
1034 INPUT 1034 2058 OUTPUT 2058
1035 INPUT 1035 2059 OUTPUT 2059
1036 INPUT 1036 2060 OUTPUT 2060
1037 INPUT 1037 2061 OUTPUT 2061
1038 INPUT 1038 2062 OUTPUT 2062
1039 INPUT 1039 2063 OUTPUT 2063
1040 INPUT 1040 2064 OUTPUT 2064
1041 INPUT 1041 2065 OUTPUT 2065
1042 INPUT 1042 2066 OUTPUT 2066
1043 INPUT 1043 2067 OUTPUT 2067
1044 INPUT 1044 2068 OUTPUT 2068
1045 INPUT 1045 2069 OUTPUT 2069
1046 INPUT 1046 2070 OUTPUT 2070
1047 INPUT 1047 2071 OUTPUT 2071
1048 INPUT 1048 2072 OUTPUT 2072
1049 INPUT 1049 2073 OUTPUT 2073
1050 INPUT 1050 2074 OUTPUT 2074
1051 INPUT 1051 2075 OUTPUT 2075
1052 INPUT 1052 2076 OUTPUT 2076
1053 INPUT 1053 2077 OUTPUT 2077
1054 INPUT 1054 2078 OUTPUT 2078
1055 INPUT 1055 2079 OUTPUT 2079
1056 INPUT 1056 2080 OUTPUT 2080
1057 INPUT 1057 2081 OUTPUT 2081
1058 INPUT 1058 2082 OUTPUT 2082
1059 INPUT 1059 2083 OUTPUT 2083
1060 INPUT 1060 2084 OUTPUT 2084
1061 INPUT 1061 2085 OUTPUT 2085
2045 INPUT 2045 3069 OUTPUT 3069
2046 INPUT 2046 3070 OUTPUT 3070
2047 INPUT 2047 3071 OUTPUT 3071
151

8.5.19 S-Link V Master Board in I/O-Box All User I/O Mode
3072 INPUT 3072 3328 OUTPUT 3328
3073 INPUT 3073 3329 OUTPUT 3329
3074 INPUT 3074 3330 OUTPUT 3330
3075 INPUT 3075 3331 OUTPUT 3331
3076 INPUT 3076 3332 OUTPUT 3332
3077 INPUT 3077 3333 OUTPUT 3333
3078 INPUT 3078 3334 OUTPUT 3334
3079 INPUT 3079 3335 OUTPUT 3335
3080 INPUT 3080 3336 OUTPUT 3336
3081 INPUT 3081 3337 OUTPUT 3337
3082 INPUT 3082 3338 OUTPUT 3338
3083 INPUT 3083 3339 OUTPUT 3339
3084 INPUT 3084 3340 OUTPUT 3340
3085 INPUT 3085 3341 OUTPUT 3341
3086 INPUT 3086 3342 OUTPUT 3342
3087 INPUT 3087 3343 OUTPUT 3343
3088 INPUT 3088 3344 OUTPUT 3344
3089 INPUT 3089 3345 OUTPUT 3345
3090 INPUT 3090 3346 OUTPUT 3346
3091 INPUT 3091 3347 OUTPUT 3347
3092 INPUT 3092 3348 OUTPUT 3348
3093 INPUT 3093 3349 OUTPUT 3349
3094 INPUT 3094 3350 OUTPUT 3350
3095 INPUT 3095 3351 OUTPUT 3351
3096 INPUT 3096 3352 OUTPUT 3352
3097 INPUT 3097 3353 OUTPUT 3353
3098 INPUT 3098 3354 OUTPUT 3354
3099 INPUT 3099 3355 OUTPUT 3355
3100 INPUT 3100 3356 OUTPUT 3356
3101 INPUT 3101 3357 OUTPUT 3357
3102 INPUT 3102 3358 OUTPUT 3358
3103 INPUT 3103 3359 OUTPUT 3359
3104 INPUT 3104 3360 OUTPUT 3360
3105 INPUT 3105 3361 OUTPUT 3361
3106 INPUT 3106 3362 OUTPUT 3362
3107 INPUT 3107 3363 OUTPUT 3363
3108 INPUT 3108 3364 OUTPUT 3364
3109 INPUT 3109 3365 OUTPUT 3365
3325 INPUT 3325 3581 OUTPUT 3581
3326 INPUT 3326 3582 OUTPUT 3582
3327 INPUT 3327 3583 OUTPUT 3583
152

RC7M CONTROLLER
INTERFACE MANUAL
First Edition July 2005
Eighth Edition March 2008
Ninth Edition September 2008
DENSO WAVE INCORPORATED 9K**C

The purpose of this manual is to provide accurate information in the handling and operating
of the robot. Please feel 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 DENSO WAVE INCORPORATED be liable for any direct or indirect damages
resulting from the application of the information in this manual.


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ROBOT

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Robot controller covered by this manual

Caution in connecting/disconnecting the motor & encoder cable

Release the lock carefully

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GENERAL INFORMATION ABOUT ROBOT

INSTALLATION & MAINTENANCE GUIDE

PROGRAMMER'S MANUAL I, Program Design and Commands

PROGRAMMER'S MANUAL II, PAC Library

RC7M CONTROLLER MANUAL - this book -

ERROR CODE TABLES

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Chapter 1 Outline of the RC7M Controller

Chapter 2 General Information about the Interface

Chapter 3 System I/O Signals

Chapter 4 I/O Circuits and Connectors (NPN type)

Chapter 5 I/O Circuits and Connectors (PNP type)

Chapter 6 Installation & Maintenance for the RC7M controller

Chapter 7 I/O Allocation for I/O Extension Board(s)

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WARNING Alerts you to those conditions, which could result

CAUTION Alerts you to those conditions, which could result

Terminology and Definitions

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Warning label Instructions printed on the label

<Except HM> For UL-Listed robot units only

Risk of electrical shock.

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3.1 Insuring the proper

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

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

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

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3.15 Affixing the warning Place the warning label packaged

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4. Precautions Touching the robot while it is in

1) Do not enter the robot's restricted space when the robot

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4.7 Precautions for (1) At start-up

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8. Battery Recycling DENSO Robot uses lithium batteries.

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How the documentation set is organized ........................................................................................................................ii

Chapter 1 General Information about RC7M Controller............................................................................................. 1

Chapter 2 General Information about the Interface ................................................................................................... 12

Chapter 3 System I/O Signals ........................................................................................................................................ 16

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Chapter 5 Connector Pin Assignment and I/O Circuits (PNP type)........................................................................... 65

Chapter 6 Installation and Maintenance of the RC7M Controller ............................................................................ 82

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Chapter 7 I/O Allocation for I/O Extension Board(s) ................................................................................................ 103

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