Denso RC5 User Manual

ROBOT

RC5 CONTROLLER

INTERFACE MANUAL

Copyright © DENSO WAVE INCORPORATED, 2002
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 covers interfacing required when you integrate your robot system configured with the RC5

robot controller into your facilities.
Before use, read this manual carefully together with related manuals to safely get the maximum benefit

from your robot in your assembling operations.

Robot models covered by this manual

All robot models configured with RC5 controller

Important

T o ensure operator safety , be sure to read the precautions and instructions in "SAFETY PRECAUTIONS."

i

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.

BEGINNER'S GUIDE

Introduces you to the DENSO robot. Taking an equipment setup example, this book guides you
through running your robot with the teach pendant, making a program in WINCAPSII, and
running your robot automatically.

SETTING-UP MANUAL

Describes how to set-up or teach your robot with the teach pendant, operating panel, or
mini-pendant.

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), (II)

Describes the PAC programming language, program development, and command
specifications in PAC.

RC5 CONTROLLER
INTERFACE MANUAL - this book -

Describes the RC5 controller, 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, operating panel, 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.

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 nine.

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 RC5 Controller

Provides an outline of the RC5 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. It describes two I/O allocation modes available--standard mode and compatible mode, and
the switching procedure between those modes.

Describes declaration of I/O variables and user I/O signals.

Chapter 3 System I/O Signals in Standard Mode

Describes system I/O signals available in standard mode, and describes I/O signals that execute I/O
commands.

Chapter 4 System I/O Signals in Compatible Mode

Describes the functions, terminal numbers, and on/off conditions of system I/O signals in compatible
mode.

Chapter 5 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 6 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 7 I/O Wiring

Describes I/O cables and wiring.

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

CAUTION

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

Alerts you to those conditions, which could result
in minor bodily injury or substantial property
damage if the instructions are not followed
correctly.

Terminology and Definitions

Maximum space: Refers to the volume of space encompassing the maximum designed movements of

all robot parts including the end-effector, workpiece and attachments. (Quoted from the RIA*
Committee Draft.)

Restricted space: Refers to the portion of the maximum space to which a robot is restricted by limiting
devices (i.e., mechanical stops). The maximum distance that the robot, end-effector, and workpiece
can travel after the limiting device is actuated defines the boundaries of the restricted space of the
robot. (Quoted from the RIA Committee Draft.)

Motion space: Refers to the portion of the restricted space to which a robot is restricted by software
motion limits. The maximum distance that the robot, end-effector, and workpiece can travel after the
software motion limits are set defines the boundaries of the motion space of the robot. (The "motion
space" is DENSO WAVE-proprietary terminology.)

Operating space: Refers to the portion of the restricted space (or motion space in Denso robot) that is
actually used by the robot while performing its task program. (Quoted from the RIA Committee Draft.)

Task program: Refers to a set of instructions for motion and auxiliary functions that define the specific
intended task of the robot system. (Quoted from the RIA Committee Draft.)

(*RIA: Robotic Industries Association)

1. Introduction

This section provides safety precautions to be observed during
installation, teaching, inspection, adjustment, and maintenance
of the robot.

2. Installation Precautions

2.1 Insuring the proper
installation environment

2.1.1 For standard type The standard type has not been designed to 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 gases,
(4) there is cutting or grinding oil mist,
(5) it may likely be submerged in fluid,
(6) there is sulfuric cutting or grinding oil mist, or

2.1.2 For dust-proof, splash­proof type

(7) there are any large-sized inverters, high output/high

frequency transmitters, large contactors, welders, or other
sources of electrical noise.

The dust-proof, splash-proof type is an IP54-equivalent
structure, but it has not been designed to withstand explosions.
(The HS-E-W and the wrist of the VM-D-W/VS-E-W are an
IP65-equivalent dust-proof 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-proof, 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 gases,
(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,

2.2 Service space

(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.

The robot and peripheral equipment should be installed so that
sufficient service space is maintained for safe teaching,
maintenance, and inspection.

SAFETY PRECAUTIONS

2.3 Control devices
outside the robot's
restricted space

2.4 Positioning of gauges

2.5 Protection of electrical
wiring and
hydraulic/pneumatic
piping

2.6 Positioning of
emergency stop
switches

The robot controller, teach pendant, and operating panel should
be installed outside the robot's restricted space and in a place
where you can observe all of the robot’s movements when
operating the robot controller, teach pendant, or operating
panel.

Pressure gauges, oil pressure gauges and other gauges should
be installed in an easy-to-check location.

If there is any possibility of the electrical wiring or
hydraulic/pneumatic piping being damaged, protect them with a
cover or similar item.

Emergency stop switches should be provided in a position
where they can be reached easily should it be necessary to
stop the robot immediately.

(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.

2.7 Positioning of
operating status
indicators

(3) Emergency stop switches should be separate from the

power switch.

Operating status indicators should be positioned in such a way
where workers can easily see whether the robot is on
temporary halt or on an emergency or abnormal stop.

2.8 Setting-up the safety
fence or enclosure

A safety fence or enclosure should be set up so that no one can
easily enter the robot's restricted space. If it is impossible,
utilize other protectors as described in Sect ion 2. 9.

(1) The fence or enclosure should be constructed so that it

cannot be easily moved or removed.

(2) The fence or enclosure should be constructed so that it

cannot be easily damaged or deformed through external
force.

(3) Establish the exit/entrance to the fence or enclosure.

Construct the fence or enclosure so that no one can easily
get past it by climbing over the fence or enclosure.

(4) The fence or enclosure should be constructed to ensure

that it is not possible for hands or any other parts of the
body to get through it.

(5) Take any one of the following protections for the entrance/

exit of the fence or enclosure:

1) Place a door, rope or chain across the entrance/exit of
the fence or enclosure, and fit it with an interlock that
ensures the emergency stop device operates
automatically if it is opened or removed.

2) Post a warning notice at the entrance/exit of the fence
or enclosure stating "In operation--Entry forbidden" or
"Work in progress--Do not operate" and ensure that
workers follow these instructions at all times.

2.9 Positioning of rope or
chain

When mak ing a test run, before setting up the fence or
enclosure, place an overseer in a position outside the
robot’s restricted space and one in which he/she can
see all of the robot’s movements. The overseer should
prevent workers from entering the robot's restricted
space and be devoted solely to that task.

If it is not possible to set up the safety fence or enclosure
described in Section 2.8, hang a rope or chain around the
perimeter of the robot’s restricted space to ensure that no one
can enter the restricted space.

(1) Ensure the support posts cannot be moved easily.
(2) Ensure that the rope or chain’s color or material can easily

be discerned from the surrounds.

(3) Post a warning notice in a position where it is easy to see

stating "In operation--Entry forbidden" or "W ork in progress

--Do not operate" and ensure that workers follow these
instructions at all times.

(4) Set the exit/entrance, and follow the instructions given in

Section 2.8, (3) through (5).

SAFETY PRECAUTIONS

2.10 Setting the robot's
motion space

2.11 No robot modification
allowed

2.12 Cleaning of tools

2.13 Lighting

The area required for the robot to work is called the robot's
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."

Never modify the robot unit, robot controller, teach pendant or
other devices.

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.

Sufficient illumination should be assured for safe robot
operation.

2.14 Protection from objects
thrown by the end­effector

2.15 Affixing the warning
label

If there is any risk of workers being injured in the event that the
object being held by the end-effector is dropped or thrown by
the end-effector, consider the size, weight, temperature and
chemical nature of the object and take appropriate safeguards
to ensure safety.

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

3. Precautions

while r obot is
running

Warning

Touching the robot while it is
in operation can lead to
serious injury. Please ensure
the following conditions are
maintained and that the
cautions listed from Section

3.1 onwards are followed
when any work is being
performed.

1) Do not enter the robot's restricted space when the robot
is in operation or when the motor power is on.

2) As a precaution against malfunction, ensure that an
emergency stop device is activated to cut the power to
the robot motor upon entry into the robot's restricted
space.

3) When it is necessary to enter the robot's restricted
space to perform teaching or maintenance work while
the robot is running, ensure that the steps described in
Section 3.3 "Ensuring safety of workers performing jobs
within the robot's restricted space" are taken.

3.1 Creation of working
regulations and
assuring worker
adherence

When entering the robot’s restricted space to perform teaching
or maintenance inspections, set "working regulations" for the
following items and ensure workers adhere to them.

(1) Operating procedures required to run the robot.
(2) Robot speed when performing teaching.
(3) Signaling methods to be used when more than one worker

is to perform work.

(4) Steps that must be taken by the worker in the event of a

malfunction, according to the contents of the malfunction.

(5) The necessary steps for checking release and safety of the

malfunction status, in order to restart the robot after robot
movement has been stopped due to activation of the
emergency stop device

(6) Apart from the above, any steps below necessary to

prevent danger from unexpected robot movement or
malfunction of the robot.

1) Display of the control panel (See Section 3.2 on the
following page)

2) Assuring the safety of workers performing jobs within
the robot's restricted space (See Section 3.3 on the
following page)

SAFETY PRECAUTIONS

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".

3.2 Display of operation
panel

3.3 Ensuring safety of
workers performing
jobs within the robot's
restricted space

To prevent anyone other than the worker from accessing the
start switch or the changeover switch by accident during
operation, display something to indicate it is in operation on the
operating panel or teach pendant. Take any other steps as
appropriate, such as locking the cover.

When performing jobs within the robot’s restricted space, take
any of the following steps to ensure that robot operation can be
stopped immediately upon a malfunction.

(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

Q

immediately upon a malfunction.

R Do not permit anyone other than the worker engaged

for that job to enter the robot’s restricted space.

(2) Ensure a worker within the robot's restricted space carries

the portable emergency stop switch so he/she can press it
(the robot stop button on the teach pendant) imm ediately if
it should be necessary to do so.

3.4 Inspections before
commencing work
such as teaching

Before starting work such as teaching, inspect the following
items, carry out any repairs immediately upon detection of a
malfunction and perform any other necessary measures.

(1) Check for any damage to the sheath or cover of the

external wiring or to the external devices.

(2) Check that the robot is functioning normally or not (any

unusual noise or vibration during operation).
(3) Check the functioning of the emergency stop device.
(4) Check there is no leakage of air or oil from any pipes.
(5) Check there are no obstructive objects in or near the

robot’s restricted space.

3.5 Release of residual air
pressure

3.6 Precautions for test
runs

3.7 Precautions for
automatic operation

Before disassembling or replacing pneumatic parts, first release
any residual air pressure in the drive cylinder.

Whenever possible, have the worker stay outside of the robot's
restricted space when performing test runs.

(1) At start-up

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 t o 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.

SAFETY PRECAUTIONS

3.8 Precautions in repairs

4. Daily and periodical
inspections

5. Management of
floppy disks

(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.

(1) Be sure to perform daily and periodical inspections. Before

starting jobs, always check that there is no problem with the
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.

(1) Carefully handle and store the "Initial settings" floppy disks

packaged with the robot, which store special data
exclusively 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.

Contents

Preface.........................................................................................................................................................i

How the documentation set is o rganized...................................................................................................ii

How this bo ok is organized .......................................................................................................................iii

SAFETY PRECAUTIONS

Chapter 1 General Information about RC5 Controller

1.1 Controller Model Name on Nameplate..........................................................................................1

1.2 Names of the Robot Controller Components ................................................................................. 4

1.3 Robot Controller Specifications......................................................................................................7

1.4 Controller System Configuration..................................................................................................11

1.4.1 Internal Circuits of the Controller (Typical configuration)..................................................11

1.4.2 Typica l Robot System Configurations..................................................................................12

Chapter 2 General Information about the Interface

2.1 Standard Mode and Compatible Mode ........................................................................................ 14

2.2 Switching between Modes............................................................................................................ 14

2.3 Types and General Information about I/O Signals ..................................................................... 22

2.3.1 Standard Mode...................................................................................................................... 22

2.3.2 Compatible Mode..................................................................................................................23

2.4 Using User I/O Signals (common to both modes)........................................................................24

2.4.1 I/O Type Variable Declaration.............................................................................................. 24

2.4.2 I/O Type Global Variables..................................................................................................... 24

2.4.3 I/O Type Local Variables....................................................................................................... 24

2.4.4 User Input Commands.......................................................................................................... 24

2.4.5 User Output Commands.......................................................................................................25

Chapter 3 System I/O Signals Standard Mode

3.1 Types and Functions of System Output Signals (Standard Mode)............................................. 26

3.2 Usage of System Output Signals (Standard Mo de).....................................................................27

3.2.1 Robot Initialization Complete (Outpu t)...............................................................................27

3.2.2 Auto Mode (Output).............................................................................................................. 28

3.2.3 External Mode (Output)....................................................................................................... 29

3.2.4 Servo ON (Output)................................................................................................................ 30

3.2.5 Robot-in-operation (Output)................................................................................................. 31

3.2.6 Normal CPU (Output)...........................................................................................................32

3.2.7 Robot Failure (Output).........................................................................................................33

3.2.8 Robot Warning (Output).......................................................................................................34

3.2.9 Dead Battery Warning (Output)........................................................................................... 35

3.2.10 Continue Start Permitted (Output)...................................................................................... 36

3.2.11 SS mode (Output).................................................................................................................. 36

3.2.12 Emergency Stop (Output from a contact)............................................................................. 37

3.3 Types and Functions of System Input Signals (Standard Mode)................................................ 38

3.4 Usage of System Input Signals (Standard Mode) ....................................................................... 39

3.4.1 Enable Auto (Input) .............................................................................................................. 39

3.4.2 Robot Stop (Input)................................................................................................................. 40

3.4.3 Step Stop (All Tasks) (Input)................................................................................................41

3.4.4 Instantaneous Stop (All Tasks) (Input)................................................................................ 42

3.4.5 Interrupt Skip (Input)...........................................................................................................43

3.5 Command Execution I/O Signals Dedicated to Standard Mode.................................................45

3.5.1 General Information about Commands................................................................................ 45

3.5.2 Processing I/O Commands....................................................................................................46

3.5.3 I/O Commands Details..........................................................................................................52

3.6 Example of Using System I/O Signal s in St andard Mode .......................................................... 65

Chapter 4 System I/O Signals Compatible Mode

4.1 Types and Functions of System Output Signals (Compatible Mode)......................................... 69

4.2 Usage of System Output Signals in the Compatible Mode......................................................... 70

4.2.1 Robot Power ON Complete................................................................................................... 70

4.2.2 Auto Mode (Output).............................................................................................................. 71

4.2.3 Servo ON (Output)................................................................................................................ 72

4.2.4 CAL Complete (Output)........................................................................................................ 73

4.2.5 External Mode (Output)....................................................................................................... 74

4.2.6 Teaching (Output).................................................................................................................75

4.2.7 Program Start Reset (Output).............................................................................................. 76

4.2.8 Robot-in-operation (Output)................................................................................................. 77

4.2.9 Single-Cycle End (Output)....................................................................................................78

4.2.10 Normal CPU (Output)........................................................................................................... 79

4.2.11 Robot Failure (Output).........................................................................................................80

4.2.12 Robot Warning (Output) ....................................................................................................... 81

4.2.13 Dead Battery Warnin g (Output)........................................................................................... 82

4.2.14 Error No. (Output)................................................................................................................83

4.2.15 Continue Start Permitted (Output)...................................................................................... 84

4.2.16 SS mode (Output).................................................................................................................. 84

4.2.17 Emergency Stop (Output from a contact)............................................................................. 85

4.3 Types and Functions of System Input Signals (Compatible Mode)........................................... 86

4.4 Usage of System Input Signals in C o mpatible Mode..................................................................87

4.4.1 Enable Auto (Input) .............................................................................................................. 87

4.4.2 Operation Preparation Start (Input).................................................................................... 88

4.4.3 Program No. Select (Input)...................................................................................................90

4.4.4 Program Start (Input)........................................................................................................... 92

4.4.5 Program Reset (Input).......................................................................................................... 98

4.4.6 Robot Stop (Input)............................................................................................................... 100

4.4.7 Step Stop (All Tasks) (Input)..............................................................................................101

4.4.8 Instantaneous Stop (All Tasks) (Inpu t ).............................................................................. 102

4.4.9 Clear Robot Failure (Input)................................................................................................ 103

4.4.10 Interrupt Skip (Input).........................................................................................................104

4.4.11 Continue Start (Input) ........................................................................................................ 105

4.5 Example of Using Syste m I/O Signals in Compatible Mode..................................................... 106

Chapter 5 Connector Pin Assignment and I/O Circuits (NPN type)

5.1 Connector Pin Assignment (NPN type)......................................................................................110

5.1.1 Connector Pin Assignment Common to Both Modes (NPN type ).......................................110

5.1.2 Connector Pin Assignment in Standard Mode....................................................................112

5.1.3 Connector Pin Assignment in Compatible Mode................................................................114

5.2 Robot Controller I/O Circuits (NP N type) ..................................................................................116

5.2.1 User-Input, System-Input and Hand-Input Circuits (NPN type)......................................116

5.2.2 Robot Stop and Enable Auto Input Circuits........................................................................119

5.2.3 User-Output, System -Output, and Hand-Output Circuits (NPN type)............................ 120

5.2.4 Emergency Stop Circuit...................................................................................................... 124

5.2.5 I/O Power Connector (NPN type) ....................................................................................... 126

5.3 Wiring No tes for Robot Controller I/O Connectors (NPN type)................................................128

Chapter 6 Connector Pin Assignment and I/O Circuits (PNP type)

6.1 Connector Pin Assignment (PNP type)...................................................................................... 130

6.1.1 Connector Pin Assignment Common to Both Modes (PNP type) ...................................... 130

6.1.2 Connector Pin Assignment in Standard Mo de................................................................... 132

6.1.3 Connector Pin Assignment in Compatible Mode ............................................................... 134

6.2 Robot Controller I/O Circuits (PNP type)..................................................................................136

6.2.1 User-Input, System-Input and Hand-Input Circuits (PN P type)...................................... 136

6.2.2 Robot Stop and Enable Auto Input Circuits.......................................................................139

6.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP type)............................. 140

6.2.4 Emergency Stop Circuit...................................................................................................... 144

6.2.5 I/O Power Connector (PNP type)........................................................................................ 146

6.3 Wiring Notes for Robot Controller I/O Connectors (PNP type)................................................. 148

Chapter 7 I/O Wiring

7.1 Multi-core Cables with Connectors............................................................................................150

7.2 Wiring of Primary Power Source ............................................................................................... 152

Index

Chapter 1

General Information about RC5 Controller

The RC5 controller is available in several models which differ in detailed
specifications to mat ch robot models of **-D/-E series.

1.1 Controller Model Name on Nameplate

The model name of the controller is printed on the nameplate attached to the side of
the controller as shown below. The model name is coded as listed below.

Nameplate
(Sample)

Coding of Controller Model Name

RC5 - VSE 6 B A - P

(a) (b) (c) (d) (e)

Position

(a) VSE Robot model name VM: VM-D, VS: VS-D, VSE: VS-E, VC: VC-E,

(b) 6 No. of controllable axes 4: 4 axes, 5: 5 axes, 6: 6 axes
(c) B Engineering symbol 1 A: Encoders connected via parallel interface to CN13

(d) A Engineering symbol 2 Blank or A
(e) P Types Blank: I/O of NPN type

Code

sample

Denotes: Coding

H: HM/HS-D, HSE: HS-E, HME: HM-E, HC: HC-D,
XYC:XYC-D
EAH: HM/HS-D with extended-joint support

EAHC: HC-D with extended-joint support
EAXYC: XYC-D with extended-joint support
EAVS: VS-D with extended-joint support

B: Encoders connected via bus to CN12

P: I/O of PNP type
AN: Robot System “Type A” and I/O of NPN type
(Note: For Robot System “Type A” refer to next page.)
AP: Robot System “Type A” and I/O of PNP type
BN: Global type (:Dual emergency stop type +

Robot System “Type A”) and I/O of NPN type

BP: Global type (:Dual emergency stop type +

Robot System “Type A”) and I/O of PNP type

1

<Notes for Robot System “ Type A”>

1 Modified Deadman Switch Functions in Robot System "Type A"

In Robot System "Type A" designed for the RC5 controller, the functions of the
deadman switches provided on the optional devices have been partially modified
regarding the motor power ON/OFF control. Accordingly, the description given in the
instruction manuals that come with "Type A" is different from the actual functions.
When reading the deadman switch related sections, be careful with the following
modification.

1.1 Deadman switches on optional devices

(Teach pendant, operating panel, and mini-pendant)

Deadman switches are locat ed as shown below.

Deadman switches

Teach pendant

1.2 Modified deadman switch functions

When you operate the teach pendant, operating panel, or mini-pendant in Manual
mode or Teach check mode, the deadman switch controls the motor power ON/OFF
function in Robot System "Type A," while it does not in the description given in the
instruction manuals.

Robot System "Type A" Description given in the instruction manuals

Deadman switch

Operating panel

Deadman
switch

Mini-pendant

(1) Unless t he deadman switch is held down,

you may neither operate the robot nor turn
the motor power ON.

(2) When the robot is in operation, releasing

the deadman switch will stop not only the
robot but also turn the motor power OFF.

(1) Unless t he deadman switch is held down,

you may not operate the robot, but you may
turn the motor power ON.

(2) When the robot is in operation, releasing

the deadman switch will stop the robot but
not turn the motor power OFF (servo lock).

How to identify your robot system as "Type A"

Check the controller model on the nameplate located on the side of the robot controller or the
robot model shown on the status bar of the teach pendant screen. The model name of "Type A"
contains letter "A" as shown below.

Robot controller example: RC5-H4A-A N
Robot example: HM-40702D A Symbol denoting "Ty pe A"

2

2 “Single point of control” function

r

The “Single point of control” function is added only for Robot System “Type A”.
This function limits the robot-start that other equipments except specified one device
(for example: Teach Pendant) cannot en able to start the robot.
The “Auto mode” of this function is usable in either “Internal Auto Limited Mode” or
“External Auto Limited Mode” by set t ing the parameter.

2.1 Internal Auto Limited Mode

The operational permit of “Internal Auto Limited Mode” is the same range as the
“Internal Auto Mode”. Program Start can be executed from the teach pendant, but
cannot be executed from the external device.
The switching between Internal Auto and External Auto cannot be operated by the
teach pendant.

2.2 External Auto Limited Mode

The operational permit of “External Auto Limited Mode” is the same range as the
“External Auto Mode”. Program Start can be executed from the external device, but
cannot be executed from the teach pendant.
The switching between Internal Auto and External Auto cannot be operated by the
teach pendant.

2.3 Setting the parameter

Access: [Top screen] - [F4 I/O] - [F6 Aux.] - [F1 Set H/W] - [F3 Jump To] - “31”

Select the Internal Auto Limited Mode (Int:0) or the External Auto Limited Mode

(Ext:1).

TIP: Before shipping from the factory, the single point of control is set to 0
(Internal Auto Limited Mode) by default .

Type A

Setting paramete

3

1.2 Names of the Robot Controller Components

x

x

r

The following figures show the names of the robot controller components.

n

n For VM-D/HM-E series

nn

<Front>

Floppy disk drive (option)

CN1 CN2 CN3 CN4 CN5

Robot stop button

Memory backup
battery holder

FG
terminal

Pilot lamp

Filters (air intake)

Output IC bo

<Left side>

CN8

CN6

CN9

CN7

CN10

Fuse bo

Power
switch

<Right side>

Names of Robot Controller Components (VM-D/HM-E series)

CN11

CN12

Filte

s (exhaust)

Radiating fin

4

n

x

r

x

n For robot series except VM-D/HM-E

nn

<Front>

Floppy disk drive (option)

Robot stop button

Memory backup
battery holder

Pilot lamp

s (air intake)

Filte

<Left side>

Output IC bo

Fuse bo

Filters (exhaust)

FG terminal

Power switch

<Right side>

Radiating fin

Note: CN13 is not provided on the VS-E and HS-E series.

Names of Robot Controller Components (Robot series except VM-D/HM-E)

5

Connectors for the VM-D, VS-E, and H∗∗∗∗-E series (Encoders connected via bus)

Connector

No.

CN1 RS232C

CN2 CRT

CN3 KEYBD

CN4 MOUSE

CN5 PENDANT

CN6 PRINTER

Connectors for the VS-D, VC-E, H∗∗∗∗-D and XYC-D series (Encoders connected via parallel interface)

Connector

No.

CN1 RS232C

Marking Name Connector

No.

Serial interface
connector

CRT connector

Keyboard connector

Connector for PS/2
mouse

Connector for teach
pendant

Printer connector
(Not used.)

Marking Name Connector

Serial interface
connector

CN7 I/O

CN8 INPUT

CN9 HAND I/O

CN10 OUTPUT

CN1 1 INPUT AC

CN12 MOTOR

No.

CN8 INPUT

Marking Name

Power connector for

POWER

Marking Name

I/O
Connector for user input

or system input
Connector for end-

effector I/O
Connector for user output

or system output
Power connector

Connector for
motor/encoder

Connector for user input
or system input

CN2 CRT

CN3 KEYBD

CN4 MOUSE

CN5 PENDANT

CN6 PRINTER

CN7 I/O

POWER

CRT connector

Keyboard connector

Connector for PS/2
mouse

Connector for teach
pendant

Printer connector
(Not used.)

Power connector for
I/O

CN9 HAND I/O

CN10 OUTPUT

CN1 1 INPUT AC

CN12 MOTOR

CN13 ENCODER

Connector for end­effector I/O

Connector for user
output or system output

Power connector

Motor connector

Encoder connector

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.

6

1.3 Robot Controller Specifications

[ 1 ] Specifications

The table below lists the robot controller specifications.

Robot Controller Specifications

Item Specifications

Control system

(NOTE 1)

No. of controllable axes

(NOTE 1)

Drive system All axes: Full-digital AC servo

Memory capacity

Language used

No. of teach programs

loadable to the memory

Teaching system

Input signal 20 user open points (PLC 12, hand input 8) + 36 fixed system pointsExternal

signals

(I/O)

Output signal 32 user open points (PLC 24, hand output 8) + 33 fixed system points

External

communication

Timer function 0.02 to 10 sec. (in units of 1/60 sec.)
Self-diagnosis

function

Error display

PTP, CP 3-dimensional linear, 3-dimensional circular
H∗-D/-E, XYC-D: Up to four axes simultaneously

VC-E (5-axis models): Up to five axes simultaneously
V∗-D/-E: Up to six axes simultaneously

1.25 MB (equivalent to 5000 steps, 13,000 points)
DENSO robot language (conforming to SLIM)

255

1) Remote teaching 2) Numerical input (MDI)

RS-232C: 1 line
Ethernet: 1 line (option)

Overrun, servo error, memory error, input error, etc.

Error codes will be displayed on the external I/O or the operating panel (option).
Error messages will be displayed in English on the teach pendant (option).

Power source

Power capacity

(NOTE 1)

Environmental conditions

(in operation)

Degree of protection IP20

Robot control

Cables

(option)

cable

I/O cable 8 m, 15 m
Power cable 5 m

Weight

NOTE 1: For extended-joint support controllers, refer to the manual "SUPPLEMENT
Extended-Joints Support" separately issued.

All RC5 models: 3-phase, 200 VAC-15% to 230 VAC+10%, 50/60 Hz

RC5 for VS-D/-E, H∗-D/-E, XYC-D: Single-phase, 230 VAC-10% to 230 VAC+10%,

50/60 Hz

RC5 for VC-E: Single-phase, 200 VAC-10% to 230 VAC+10%,

50/60 Hz

VM-D/HM-E: 3.3 kVA H∗-D: 2.0 kVA VS-E: 1.9 kVA HS-E: 1.8 kVA
VS-D, XYC-D: 1.5 kVA VC-E: 0.6 kVA

Temperature: 0 to 40°C
Humidity: 90% RH or less (no condensation allowed)

VM-D, VS-E, H∗-E: Standard: 4 m, 6 m High strength: 6 m, 12 m (selectable)
VS-D, H∗-D, XYC-D: 3 m, 6 m (selectable)
VC-E: 4 m, 6 m (selectable)

VM-D: Approx. 19 kg (excluding attached cables)
VS-D/-E, VC-E, HS-E: Approx. 17 kg (excluding attached cables)
H∗-D/E, XYC-D: Approx. 16 kg (excluding attached cables)

7

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 controll er f or m aintenance, be sure to turn off
the power switch, discon nect the power cable, and wait 3
minutes or more. T hi s is for protecting you from electr i c
shock.

⋅⋅⋅⋅ DO NOT connect or disconnect connectors to/f rom th e

controller while the power switch is on. Doing so may cause
electric shock or controller failure.

CAUTION IN INSTALLATION

⋅⋅⋅⋅ This controller is not designed to b e dust-proof, splash-

proof, or explosio n- pr oof.

⋅⋅⋅⋅ Read operation manuals before instal l ati on.
⋅⋅⋅⋅ Do not place anything on the controller.

8

[ 2 ] Outer Dimensions

The outer dimensions of the robot cont roller are shown below.

Outer Dimensions of Robot Controller (for VM-D/HM-E series and extended-joint support)

Outer Dimensions of Robot Controller (for robot series except VM-D/HM-E)

9

n

p

)

p

)

p

)

p

)

p

)

p

)

p

)

p

)

p

)

p

)

n Location of IPM boards

nn

The table below shows the location of IPM boards for robot series or models.

Rear view of the controller

Series &

models

VM-6070D

VM-6083D/

VM-60B1D

VS-D

VS-E

VC-E

HM/HS-D

HM-E

HS-E

HC-D

XYC-D

Location

(8) (7) (6) (5) (4) (3) (2) (1)

Item

Joints -165432-

IPM model - M SS SS SS S L -

Motor ca

Motor ca

Motor ca

Motor ca

Motor ca

Motor ca

Motor ca

Motor ca

Motor ca

Motor ca

acity (W

Joints -265431-

IPM model - M SS SS SS S L -

acity (W

Joints --654321

IPM model - - SS SS SS S S S

acity (W

Joints --654321

IPM model - - SS SS SS S S M

acity (W

Joints --654321

IPM model - - SS SS SS SS SS SS

acity (W

Joints ----4321

IPM model ----SSSMM

acity (W

Joints - - 4 3 2 1

IPM model - - M M LL LL

acity (W

Joints ----4321

IPM model ----SSML

acity (W

Joints ----4321

IPM model ----SSSSSM

acity (W

Joints ----4321

IPM model ----SSSSS

acity (W

- 750 100 200 200 400 1500 -

- 750 100 200 200 400 1500 -

- - 50 50 50 200 400 400

- - 50 80 100 200 400 750

- - 30 30 30 80 80 80

----200200750750

- - 300 300 600 1000

----150200400750

----50100400750

----50200400200

NOTE 1: No IPM board are installed to locations marked with "-." Those locations

are covered with blank caps.

NOTE 2: For details about extended-joint support controllers, refer to the manual

"SUPPLEMENT Ext ended-Joints Support."

10

1.4 Controller System Configuration

1.4.1 Internal Circuits of the C ontroller (Typical config uration)

The block diagram below show s t he internal circuits of an RC5 controller designed for
a 6-joint robot.

11

1.4.2 Typical Robot System Configurations

The block diagrams below show t ypical robot system configurations.
To connect encoders via a time-division multiplexed bus: Connect the robot controller

(CN12) to the robot unit with a motor/enc oder cable (see below).
To connect encoders via parallel interface: Connect the robot controller (CN12 and

CN13) to the robot unit with a motor cable a nd encoder cable, respectively.

n

n Robot system configuration with encoders connected via a multiplexed bus

nn

(VM-D, VS-E, HS-E, and HM-E)

Robot System Configuration

12

n

n Robot system configuration with encoders connected via a parallel interface

nn

(VS-D, VC-E, H*-D, and XYC-D)

System Configuration Example

13

Chapter 2

General Information about the Interface

2.1 Standard Mode and Compatible Mode

The robot controller can be operated in two different modes – standard mode and
compatible mode. The default is standard mode. Select either mode before operating
the robot controller.

In the standard mode, all of the advantages can be expected from the new model of
the robot controller by simultaneously running two or more programs with
multitasking.

The compatible mode focuses on compatibility with conventional DENSO robots. Use
this mode whenever compatibility is required. For example, when replacing a
conventional robot with a new model. However, there are some restrictions on the
use of new functions, such as mu lt itasking, in this mode.

2.2 Switching between Modes

Switch from one mode to the other using the teach pendant or the PC teaching
system.

Caution: After switching between those modes, restart the robot controller to

make the new setting go into effect.

14

[ 1 ] Switching from the Teach Pendant

Follow the procedure below when switching from one mode to the other from
the teach pendant:

On the top screen, press [F4 I/O].

STEP 1

"

The I/O Monitor window appears.

F6

STEP 2

"

Press [F6 Aux.].

The Auxiliary Functions (I/O) window appears as shown below.

F2

Press [F2 I/O Assign]. (For Version 1.6 or later)
NOTE: For Version 1.5 or earlier, press [F1 Set H/W] and select the

Allocation mode field in the I/O Hardware Settings window.

15

STEP 3

"

The Choose allocation win dow appears as shown below.
NOTE: If your robot controller has a built-in DeviceNet master, the Select

Port Assignment window will appear instead of the Select I/O Assignment
Mode window. Refer to the DeviceNet Master Unit user's manual, Chapter
3, "I/O Assignment."

Using the jog dial or cursor keys, select the desired assignment
mode. Then press OK.

STEP 4

"

STEP 5

"

The following system message appears.

Press OK.

The screen returns to the Auxiliary Functions (I/O) window.

Turn the controller power OFF.

STEP 6

"

Turn the controller power ON again.

The I/O assignment mode is switched.

16

[ 2 ] Switching from the Computer

Follow the procedure below when switching from one mode to the other from
the computer.

Start WINCAPSII on the computer. Log in with Programmer.

STEP 1

"

STEP 2

"

Start WINCAPSII according to the procedure given in WINCAPSII GUID E,
Chapter 3, Section 3.1.

For details on the user level of Programmer, refer to the WINCAPSII
GUIDE, Chapter 1, Sect ion 1.3.

Click on the DIO Manager b utton in the System Manager.

DIO Manager starts an d t he DI O Manager window opens.

17

STEP 3

"

STEP 4

"

Select the SETTING command from the Tools menu of DIO Manager.

The Options window will ap pear as shown below.

Click on the Hardware tab in the Options window.

The hardware settings will a ppear.

18

STEP 5

"

STEP 6

"

Select the desired assignment mode from the right-hand popup menu
in the I/O Allocation frame (Ver. 1.6 or later).

Click on OK in the Options window.

The Options window closes.

STEP 7

"

Click on the Connect button to connect the computer to the robot
controller.

The Connect button appears in a pressed state.

19

STEP 8

"

STEP 9

"

Click on the Transfer button.

The Transfer Environment Table window appears.

Check off the check box by clicking on the Hard setting field.

STEP 10

"

Click on the Transfer button.

The following message window appears confirming that you are sure to
update the data.

Click on the Yes button.

20

STEP 11

"

STEP 12

"

STEP 13

"

The Transmitting hard setting table window appears displaying a bar graph
that indicates the transfer progres s.

After the Transmitting hard setting table window disappears, turn the
controller power OFF.

Turn the controller power ON.

The I/O assignment mode is switched.

21

2.3 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.
User I/O signals are compatible with conventional signals, including the pin

pattern, in compat ibl e mode. Note that the connector pin meanings are dif ferent
between standard mode and compatible mode. Some of the signal lines used
for user I/O in compatible mode are used for system input in standard mode.

Additionally, part of the signal lines used for system I/O in compatible mode is
used for command execution I/O signals in standard mode.

2.3.1 Standard Mode

In standard mode, 30 input points for command execution are used to direct
program start and other instructions as I/O commands.
The table below lists the types of I/O signals used in standard mode.

Ty pes of System I/O Signals Used in Standard Mode

Fixed by system

Type

System input 5

System output 12

Input for command
execution

Output for command
execution

Type

User input 12

No. of

points

30

18

No. of

points

Function

Robot stop, Enable Auto, interrupt skip, instantaneous stop (all tasks),
step stop (all tasks)

Robot initialization complete, automatic operation mode, external mode,
servo ON, robot-in-operation, normal CPU, robot failure, robot warning,
dead battery warning, continue start permitted, SS mode, emergency
stop

Command (4 bits) data area 1 (8 bits), data area 2 (16 bits), odd parity
bit, strobe signal

Command processing complete, status area (16 bits), odd parity bit

Controlled by user program

Function

Inputs to read the external I/O status with an IN command or IO [ ]
variable.
Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.

User output 24

Hand input 8

Hand output 8

Outputs to issue a signal to the external device during program execution
with a SET command, RESET command, etc.

Inputs to read the external I/O status with an IN command or IO [ ]
variable.
Used to confirm the end-effector check status, etc.

Outputs to issue a signal to the external device with a SET command,
RESET command, etc.
Used to control the opening and closing of the end-effector.

22

2.3.2 Compatible Mode

In the compatible mode, the input and output points are arranged in disregard
of compatibility with conventional VS series robots.

The table below lists the types of I/O signals used in compatible mode.

Types of I/O Signals Used in Compatible Mode

Fixed by system

Type

System input 22

System output 27

Type

User input 25

User output 24

Hand input 8

No. of

points

No. of

points

Function

Inputs to turn ON the power to the robot from the external device (PLC),
start CAL or select and start a program instead of operations by the
operating panel or teach pendant.

Outputs to inform the external device (PLC) of the robot status, such as
robot-in-operation or occurrence of an error.

Controlled by user program

Function

Inputs to read the external I/O status with an IN command or IO [ ]
variable.
Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.

Outputs to issue a signal to the external device during program execution
with a SET command, RESET command, etc.

Inputs to read the external I/O status with an IN command or IO [ ]
variable.
Used to confirm the end-effector check status, etc.

Hand output 8

Outputs to issue a signal to the external device (valve) with a SET
command, RESET command, etc.
Used to control the opening and closing of the end-effector.

23

2.4 Using User I/O Signals (common to both modes)

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

2.4.1 I/O T ype 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.

2.4.2 I/O T ype Global Variables

I/O type global variables are used to refer to or change user I/O signals bit by bi t.
Since they are global variab les, they can be used without any declaration.

I/O type global variables are expressed in either of the following two ways:
IO[nn] (nn: terminal number) Example: IO[104]

IOnn (nn: terminal number) Example: IO104

2.4.3 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]."

2.4.4 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 arith meti c variable.

For further information about the IN command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Sect ion 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 u sed for the condition al 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."

24

2.4.5 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 co mma nd 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."

25

Chapter 3

System I/O Signals Standard Mode

3.1 Types and Functions of System Output Signals (Standard

Mode)

The table below lists the system output signals used in standard mode.

Types and Functions of System Output Signals to be Used in Standard Mode

Application Signal name Function

Robot initialization

complete

Auto mode

Start-up

External mode Outputs when the robot is in external mode.

Servo ON

Program execution Robot-in-operation

Normal CPU

Robot failure

Error/Warning

Robot warning Outputs wh en a slight err or occ urs .

Dead battery warning

Continue start

Continue start

permitted

Outputs when preparations for operation are ready to
start.

Outputs when the robot is in Auto mode.

Outputs when the power to the motor is turned ON.
Outputs when the robot is in operation (the program is

being executed).
Outputs when the CPU (hardware) of the Robot

Controller is normal.
Outputs when a serious error, such as a servo error

and a program error, occurs.

Outputs when the voltage of the encoder back-up
battery or memory back-up battery dangerously low.

Outputs when Continue Start is enabled.

Safe start function SS mode

Emergency stop Emergency stop

Outputs when the robot is in SS mode. Refer to the
SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6
"SS (Safe Start) Function."

Outputs from a contact exclusively designed for an
emergency stop circuitry.

26

3.2 Usage of System Output Signals (Standard Mode)

L

T

o

The usage of each system output signal in standard mode is described below :

3.2.1 Robot Initialization Complete (Output)

(1) Function

The signal outputs to the external device that a MODE SWITCHING
COMMAND is ready to execute from the device.

(2) Terminal number

No.5 of connector CN10.

(3) Usage

The "mode switching command" will be executed as soon as this signal and
the auto mode signal are turned ON, aft er t he power is turned ON.

(4) ON conditions

 The signal will be turned ON when the system program for the Robot

Controller normally starts, after the power, is turned ON and the mode
switching command is ready to execute.

 The signal will be turned ON when a robot failure is cleared by the

CANCEL key of the operating panel or teach pendant or by a CLEAR
ROBOT FAILURE command, after the power is turned OFF.

ROBOT PO WER ON
COM P LET E output

(5) OFF condition

The signal will be turned OFF when a robot failure or robot warning signal
is turned ON.

⋅ A robot error is cleared with the OK or CANCE

⋅ The system properly started t

operate after the power was
turned ON.

⋅ Robot error or robot warning

Robot Power ON Complete Output

key of the operating panel or teach pendant.

⋅ A robot error is clear ed wi th a CLEAR ROBO

FA ILURE com m and from an ex ternal device.

27

3.2.2 Auto Mode (Output)

L

(1) Function

The signal outputs to t he ext ernal device that the robot is in auto mode.

(2) Terminal number

No.6 of connector CN10.

(3) Usage

Starting the program from the external device requires an EXTERNAL
MODE SWITCHING BY MODE SWITCHING COMMAND input and a
PROGRAM START BY PROGRAM OPERATION COMMAND input. The
signal is used to monitor the auto mode output signal and determine
whether to execute the command.

(4) ON condition

The signal will be output when the robot enters auto mode by setting the
mode selector switch of the operating panel or teach pendant to AUTO.

(5) OFF conditions

The signal will be turned OFF under the following conditions.
 The mode selector switch of the operating panel is set to MANUAL or the

teach pendant is set to MAN UAL or TEACH CHECK.

 The Enable Auto OFF is input..

(Note: The signal will not be turned OFF in the pendantless state
described in the OPTIONS MANUAL, Chapter 1, Subsection 1.3.3.)

Auto mode
output

Caution: Th e signal will not b e turned OFF w ith INSTANTANEOUS STOP,

STEP ST OP or CYCLE STOP commands.

⋅ When the mode selector switch of the operating panel or teach

pendant is set to AUTO.

⋅ When the mode selector switch of the operating panel is set

to MANUAL or that of the teach pendant is set to MANUA
or TEACH CHECK.

⋅ When Enable Auto OFF is input

Auto mode Output

28

3.2.3 External Mode (Output)

(1) Function

The signal outputs to t he ext ernal device that the robot is in external mode.

(2) Terminal number

No.7 of connector CN10.

(3) Usage

Starting the program from the external device requires an EXTERNAL
MODE SWITCHING BY MODE SWITCHING COMMAND input and a
PROGRAM START BY PROGRAM OPERATION COMMAND input. The
signal is used to confirm that the robot is in external mode.

(4) ON conditions

 The signal will be turned ON under the follow i ng conditions.

The external mode is selecte d on t he t each pendant.

 The EXTERNAL/INTERNAL is input on the operating panel in AUTO

MODE and in the INTER NA L CONTROL ON state.

 The EXTERNAL MODE SWITCHING BY MODE SWITCHING

COMMAND is input from the external device.

(5) OFF conditions

The signal will be turned ON under the following conditions.

 When internal mode is selected on the teach pendant.
 W hen the mode selector switch of the teach pendant is set to MANUAL

or TEACH CHECK in ex t ernal mode.

 W hen EXTERNAL/INTERNAL is input on the operating panel in AUTO

MODE and in the INTER NA L CONTROL OFF state.

 When ROBOT STOP is input.
 When ROBOT FAILURE is outputted.

External mode
output

Caution: Th e signal will not b e turned OFF w ith INSTANTANEOUS STOP,

STEP STOP or CYCLE STOP.

 When an Enable Auto input is turned OFF.

⋅

When the mode is switched to external mode on the teach pendant.

⋅

When EXTERNAL/INTERNAL is input on the operating panel.

⋅

When a MODE SWITCHING COMMAND (EXTERNAL MODE SWITCHING)
is input from an external device.

⋅

When internal mode is selected on the teach pendant.

⋅

When the mode selector switch of the teaching pendant is set to
MANUAL or TEACH CHECK.

⋅

When EXTERNAL/INTERNAL is input on the operating panel.

⋅

ROBOT STOP or ROBOT ERROR

⋅

When an Enable Auto input is turned OFF.

External Mode Output

29

3.2.4 Servo ON (Output)

(1) Function

The signal outputs to the external device that the power to the motor of the
robot is turned ON.

(2) Terminal number

No.4 of connector CN10.

(3) Usage

Start i ng t he program requires the power to the motor to be turned ON. This
signal is used to light the motor power ON indicator lamp on an external
operating panel.

(4) ON conditions

The signal will be turned O N when t he power to the motor is turned ON.
 When the MOTOR key of the operating panel or teach pendant is

activated; or

 When the motor runs with a MOTOR ON AND CAL EXECUTION BY

MODE SWITCHING COMMAND input from the external device.

(5) OFF conditions

The signal will be turned OFF when the power to the motor is turned OFF.
 When the MOTOR key of the operating panel or teach pendant is

deactivated and the ROBOT STOP button is oper ated;

 When ROBOT STOP is input from the external device; or
 When a ROBOT FAILURE is outputted. If errors 0 × 6071 to 607B, 0 ×

6671 to 667B, 0 × 607F occur, the servo will be turned OFF in automatic
or external mode but will not be turned OFF in the manual or the teach
check mode.

ON

Servo ON output OFF

⋅ When the MOTOR key of the operating panel or teach pendant is activated.
⋅ When MOTOR ON AND CAL EXECUTION WITH MODE SWITCHING

COMMAND is input from an external device.

⋅ When the MOTOR key of the operating panel or teach pendant is

deactivated and the ROBOT STOP button is operated.

⋅ When ROBOT STOP is input from an external device.
⋅ When a ROBOT FAILURE occurs.

Servo ON Output

30

3.2.5 Robot-in-operation (Output)

(1) Function

This signal outputs t o t he external device that the robot is in operation.

(2) Terminal number

No.2 of connector CN10.

(3) Usage

The signal is used to light the robot operating indicator lamp of an external
operating panel.

Since the signal is turned OFF with STOP ALL PROGRAMS, outputs to
the external device that all programs are stopped.

(4) ON conditions

The signal will be turned ON during execution of the program and also
while in the WA I T STATE with a condition branch or t imer command.

(5) OFF conditions

The signal will be turned OFF with STOP ALL PROGRAMS.

Caution: STOP ALL PROGRAMS means the operation of the ROBOT

STOP or STOP button of the operating panel or teach pendant
and INSTANTANEOUS STOP (ALL TASKS), STEP STOP (ALL
TASKS) and ROBOT STOP inputs.

31

3.2.6 Normal CPU (Output)

A

(1) Function

The signal outputs to the external device that the Robot Controller CPU
(hardware) is normal.

(2) Terminal number

No.1 of connector CN10.

(3) Usage

 The signal is used to light the Robot Controller external operating panel

error indicator lamp.

 The signal is used when a normal CPU SIGNAL is turned OFF because

of an error and the PLC corrects it.

(4) ON conditions

The signal will be turned ON by the hardware when the Robot Controller
CPU operates normally with the power turned ON.

(5) OFF conditions

The signal will be turned OFF by the hardware when the CPU does not
operate normally.

Normal CPU output

Caution: The OFF state of this signal indicates that the Robot Controller

internal arithmetic circuit may be damaged. Therefore, ROBOT
ERROR, ERROR NUMBER, and other outputs may not be
correct.

⋅ Power ON (CPU operating properly)

bnormal CPU (hardware error)

Normal CPU Output

32

3.2.7 Robot Failure (Output)

(1) Function

The signal outputs to the external device that a problem (such as a servo
error or a program error) occurs with the robot.

(2) Terminal number

No.3 of connector CN10.

(3) Usage

 The signal is used to light the robot external operating panel error

indicator lamp of an.

 The signal is used to help the PLC clear an error in response to a

ROBOT FAILURE signal.

(4) ON conditions

As shown below, the signal will be turned ON under the following
conditions.

 When an error, such as a servo error, a program error or program

undefined, occurs at the start of the program and during execution of
the program.

 When an error occurs during execution of the program in internal

operation by the operating panel or the teach pendant or in external
operation by the PLC.

Robot failure

Caution: The signal will not be outputted when an error, such as a

program input error occurs in manual operation, except when
a servo error occurs in manual operation. For further
information, see the "ERRO R CODE TABLES. "

(5) OFF conditions

As shown below, the signal will be turned OFF under the following
conditions.

 When a CLEAR ROBOT FAILURE command is inputted and the

existing error is cleared.

 W hen the existing error is cleared by operating the OK or Cancel key

on the operating pane l or t he t each pendant.

⋅ Program number, parity error, or undefined program number, at

external start.

⋅ Robot failure during automatic operation (both internal operation

and external operation)

⋅ When a CLEAR ROBOT FAILURE command is inputted.
⋅ W hen the OK or Cancel key of the operating panel or teach

pendant is operated.

ƒpƒŠƒeƒB [ƒGƒ‰ [ A

Robot Failure Output

33

3.2.8 Robot W arning (Output)

(1) Function

The signal outputs to the external device that a minor error occurs with an
I/O command or during servo processing.

Caution: The signal will not be outputted if a minor error, such as a

program selection error occurs by the operation of the teach
pendant or operatin g panel.

(2) Terminal number

No.9 of connector CN10.

(3) Usage

⋅ The signal is used to light t he robot warning indi cator lamp of the external

operating panel.

⋅ The signal is used to help the PLC clear an error in response to a

ROBOT WA RN ING signal.

(4) ON condition

As shown below, the signal will be turned ON if a minor error occurs
during I/O processing, execution of the program or servo processing,
irrespective of the operation mode.

Robot warning

(5) OFF conditions

As shown below, the robot-warning signal will be turned OFF under the
following conditi ons.
⋅ When a CLEAR ROBOT WARNING command is inputted from the

external device and the existing error is cleared.

⋅ When operating the OK or Cancel key on the operating panel or the

teach pendant clears the exist in g error.

⋅ W hen a slight error occurs during I/O processing, execution of the

program or servo processing.

⋅ When a CLEAR ROBOT WARNING command is inputted from an

external device and the existing error is cleared .

⋅ W hen the existing error is cleared by operating the OK or Cancel key

of the operating panel or teach pendant.

Robot Warning Output

34

3.2.9 Dead Battery Warning (Output)

(1) Function

The signal will be output when the voltage of the encoder back-up battery
or memory back-up battery becomes lower than acceptable.

(2) Terminal number

No.8 of connector CN10.

(3) Usage

The signal is used to check the timing battery replacement. For example,
the battery voltage beco me s lower than acceptable.

(4) ON condition

The signal will be turned ON when the voltage of the encoder back-up
battery or memory back-up battery beco mes lower t han acceptable.

Caution: The operating panel shows any of ERROR64A1 to 64A6 when

the encoder back-up battery voltage is low. Meanwhile, the
teach pendant shows ERROR6103 when the memory back-up
battery voltage is low.

(5) OFF condition

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

Robot power ON state

Dead battery
warning output

Power ON

⋅ The voltage of the

encoder backup
battery or memory
back-up battery
becomes dangerously
low.

Dead Battery Warning Output

Power OFF

Power ON

Power OFF

⋅ Battery replaced

Power ON

35

3.2.10 Continue Start Permitted (Output)

(1) Function

The controller will output t his signal when the continue start is per mit ted.

(2) Terminal number

No.10 of connector CN10.

(3) Usage

Use this signal when you want to know whether the continue start is
permitted.

(4) ON condition

This signal comes on when the continue start is permitted. For details,
refer to the SETTING-UP MANUAL.

(5) OFF condition

This signal goes of f by carrying out the "Task Status Change Operation."

3.2.11 SS mode (Output)

(1) Function

The controller will output t his signal during the SS mode.
This mode is effective when the slow mode is selected.

(2) Terminal number

No.11 of connector CN10

(3) Usage

This signal is used to warn workers that the robot is in the SS mode by
beeping or lighting the lamp.

(4) ON condition

This signal comes on when th e SS mode is selected.

(5) OFF condition

The signal goes off when the TS time passes so as to cancel SS mode.
This function is eff ect ive when the slow mode is selected.

Note: If the TS time passes, this signal goes off even when the robot is
operation in the slow mode. After this signal goes off, the robot runs at the
original speed.

36

3.2.12 Emergency Stop (Output from a contact)

(1) Function

This signal outputs from a contact exclusively designed for an emergency
stop circuitry you may configure. It allows red mushroom buttons provided
on the front panel of the robot controller, on the teach pendant, and on the
operating panel to be us ed as emergency stop buttons of the facilities.

A 0.3A fuse is built in the contact.

(2) Terminal number

No. 65 of connector CN10: Emerge ncy stop (+)
No. 66 of connector CN10: Emerge ncy stop (-)

(3) Usage

This signal is used to stop the facilities or robot in an emergency. (Refer
to Subsection 5.2.4 "Emergency Stop Circuit.")

(4) Contact

This contact is a normal close one (b contact). If any of the emergency
stop buttons is pressed, then the contact turns off to output an emergency
stop signal.

37

3.3 Types and Functions of System Input Signals (Standard

Mode)

The table below lists the system input signals to be used in standard mode:

Types and Functions of System Input Signals to be Used in Standard Mode

Application Signal Name Function

Start-up Enable Auto

Robot stop Stops the robot with canceling signals.

Stop

Program interrupt Interrupt skip

Instantaneous

stop (all ta sks)

Step stop (all

tasks)

Enables switching to automatic operation.

Immediately stops all programs being executed with
canceling signals.

Step-stops all programs being executed with canceling
signals.

Interrupts the execution of the current step and starts
executing the next step.

38

3.4 Usage of System Input Signals (Standard Mode)

The usage of each system in put signal in standard mode is described below.

3.4.1 Enable Auto (Input)

(1) Function

 The signal enables switching of the robot mode to auto mode (shorted

state).

 The signal enables switching of the robot mode to manual mode or

teach check mode (open state).

(2) Terminal number

No. 4 of connector CN8.

(3) Usage

The signal is used for the AUTO/TEACHING selector switch of an external
operating panel and can be combined with a safety fence switch.

(4) Input conditions and operation

 As shown below, the selectable operation mode depends on whether

this input is shorted or open.

 If the input becomes open during automatic operation, the mode will be

switched to manua l mode and ERROR21FC will be displayed.

 If manual operation or a teach check is conducted with this input

shorted, ERROR21F2 w ill be displayed.

 If the mode selector switch of the teach pendant or operating panel is

set to AUTO wit h t h is input open, ERROR21F3 will be displayed.

Since this state is shown as × in the table below, this error will remain

displayed until the robot exits this state.

 Although ERROR21FD or ERROR21FC will be displayed when the

state is changed from
state is changed fro m ∆ or × to

 When the input is turned OFF (open) in external mode, the external

mode output will also be turned O FF.

Relationship Between Enable Auto Input and Selectable Mode

¡ to ∆ or ×, they will not be displayed when the

¡.

Operation mode Application

Manual mode

Teach check mode Program check with the teach pendant. ∆ ¡
Internal auto mode

External auto mode Automati c operation with the external device. ¡ ×

Note: ¡ = Mode selectable × = Mode not selectable

∆ = Mode selectable but manual o peration program not executable

Manual operation with the operating panel or the teach
pendant.

Automatic operation with the operating panel or teach
pendant.

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:

QQQQ

Set the robot so that it will not start to operate when the Enable
Auto input is open.

RRRR

Enable Auto input open state and auto mode output (See
Subsections 4.2.2 and 6.2.2 "Auto Mode".)
Set the equipment to make an emergency stop in an AND state.

Add

QQQQ

and

RRRR

with the external sequence circuit.

ON (shorted) OFF (open)

Enable Auto

∆ ¡

¡ ×

39

3.4.2 Robot St op (Input)

(1) Function

 The signal stops the robot from the external device by opening the

robot stop input.

 The signal readies the power to the robot motor to be turned ON by

shorting the robot stop input.

(2) Terminal number

No.2 of connector CN8.

(3) Input conditions and operation

 The robot stops with this input OFF (open).
 The power to the robot motor is made ready to be turned ON with this

input ON (shorted).

 Irrespective of whether internal mode, operation by the teach pendant,

or external mode, remote operation by the external device, is selected,
the power to the robot motor cannot be turned ON with this input OFF
(open) and neither manual nor automatic operation can be performed
until this input is turned ON (s horted). (ERROR2008 will be displayed.)

 By turning OFF (open) this input the following co nditions may result.

1) The power to the motor will be turned OFF irrespective of whether

2) During execution of the program (Robot-in-operation signal ON), the

3) When the program is not executed in manual and auto modes in

 Opening the ROBOT STOP input and pressing the ROBOT STOP

button of the operating p anel or the teach pendant function is the same.

manual, automatic, internal or external mode is selected.
power to the motor will be turned OFF and the mode will be

switched to internal mode a f ter the robot decelerates to a stop;
manual and auto modes, everything will be the same except the

power to the motor will be turned OFF. The power to the motor can
be turned ON and the suspended operation can, therefore, be
resumed by shorting the ROBOT STOP input. (However, the
program will be executed from the beginning.)

(4) Timing of the input

This input will be processed prior to all commands and input signals.

40

3.4.3 Step Stop (All Tasks) (Input)

(1) Function

Input this signal to step-stop the program being executed from the
external device. All t asks will be step-stopped.

(2) Terminal

No.5 of connector CN8.

(3) Input conditions and operation

 If the state of this signal is changed from ON (shorted) to OFF (open),

the robot will stop all tasks as soon as the ongoing step is completed,
and the Robot-in-operation signal will be turned OFF. However, auto
mode or external m ode will remain valid, and the suspended program
will be resumed by inputting a program operation command (start). See
the figure given below.

 For resuming the program after a step stop, see Chapter 5, Subsection

5.3.2 "Program Operation Command (000 1)".

Robot status

Program start signal (input) ON (shorted)

OFF (open)

Step-stop signal (input) ON (shorted)

OFF (open)

Robot-in-operation (output) ON (shorted)

OFF (open)

Operating halfway

Step Stop Signal

1-cycle operation

At step-stop

Performing
Remaining operation

41

3.4.4 Instantaneous Stop (All Tasks) (Input)

(1) Function

Input this signal to instantaneously stop the running programs from an
external device. All tasks will stop.

(2) Terminal number

No.7 of connector CN8.

(3) Input conditions and operation

 If the state of this signal is turned from ON (shorted) to OFF (open), the

robot will immediately stop in the middle of the ongoing step, and the
Robot-in-operation signal will be turned OFF. However, auto mode or
external mode will remain valid, and the suspended programs will be
resumed by inputting Program start signal.

 For resuming the program after an instantaneous stop, see Chapter 5,

Subsection 5.3.2 "Program Operation Command (0001)".

 The minimum required pulse width is 50 milliseconds (msec.) or more.

ON (shorted)

Halt OFF (open)

50 ms. or more required

Minimum Instantaneous Stop Pulse Width

42

3.4.5 Interrupt Skip (Input)

(1) Function

If this signal is turned ON (shorted) during execution of the robot operation
command, within the range between INTERRUPT ON and INTERRUPT
OFF in the program, the correct step operation will immediately stop and
the next step will start.

Caution: For further information about the INTERRUPT ON and OFF

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

(2) Terminal number

No.9 of connector CN8.

(3) Usage

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

(4) Input conditions and operation

If this signal is turned ON (shorted), the robot will immediately stop the
current operation and start executing the next step.

Robot status

Interrupt skip signal (input) ON (shorted)

OFF (open)

Input Conditions and Operation of Interrupt Skip

INTERRUPT ON

Command

Operating halfway

Next operation

50 ms. or more required

43

Caution: When turning ON (shorting) the interrupt skip signal, at a

minimum either the program reset signal or the program
start signal must be turned OFF (open). If the interrupt
skip signal is turned ON, the robot interprets the program
start signal as immediatel y turned OFF (open).
Consequently, the program selected with the program No.
selection signal will be executed from the beginning. (See
the figure given below.)

Robot status

Interrupt skip signal (input) ON (shorted)

OFF (open)

Program start signal (input) ON (shorted)

OFF (open)

Program reset signal (input) ON (shorted)

OFF (open)

Program No. select signal (input) ON (shorted)

OFF (open)

Example of Operation When an Interrupt Skip is Input

Executing cycle halfway

WRONG

Executing cycle from beginning

44

3.5 Command Execution I/O Signals

Dedicated to Standard Mode

In standard mode the I/O commands can be executed using command execution I/O
signals. I/O commands execute the following.

⋅ Operate (start and stop) a program for each t ask.
⋅ Refer to or change variables from the external device.
⋅ Refer to or change inputs and out puts from the external device.

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).
⋅ Step-stops the program (specified program/all programs).

Program operation

⋅ Immediately stops the program (specified program/all

programs).

Speed setting

Error number read

Type I variable write

Type I variable read

Mode switching

Clear robot failure

Internal I/O write
Internal I/O read

⋅ Resets the program (specified program/all programs).
⋅ Sets the external speed.
⋅ Sets the external acceleration.
⋅ Sets the external deceleration.
⋅ Outputs the error number to the system I/O area.

⋅ Reads a value from the system I/O area and substitutes it for a

Type I variable.

⋅ Outputs a Type I variable to the system I/O area.
⋅ Switches the robot operation mode.
⋅ Clears a robot failure from the external device.
⋅ Sets the state of internal inputs and outputs.
⋅ Outputs the state of internal inputs and outputs to the system I/O

area.

45

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.

⋅ Command Area (input)
⋅ Data Area (input)
⋅ Command and Data Area

Odd Parity (input)

⋅

Strobe Signal (input)

⋅

Status Area (output)

⋅ Status Parity (output)

⋅ Command processing complete (output)

Q

Note  1 ms or more

X

S

X

R

U

Y

Y

V

⋅ Robot Error (output)

Note  100 ms. or less

V

Outline of I/O Command Processing

46

 Set a command area, a data area (if necessary) and command and data

area odd parity for the command execution I/O signal from the external
device to the Robot Controller.

 After the setting is completed, turn ON the strobe s ign al.

Caution: QQQQ The data to be set in QQQQ must be defined more at least 1

msec. before the strobe signal is turned O N.

R

R Perform command input with a strobe signal after the

RR

system output signal ROBOT INITIALIZATION COMPLETE is
output.

 The controller reads the command area, the data area and the command

and data area odd par ity as the strobe signal is input.

 The controller starts processing based on the command it read.

 If the command is one that outputs a status, the controller sets the status

area and status parity.

 After command processing has been completed and a status area has

been set, the controller turns ON the command processing complete
signal.

If an error occurs in the while processing, a robot failure signal will be
outputted together with the command processing complete signal.

 The PLC waits until the command processing complete signal is input, and

receives the status of the status area, if necessary. In this case,
confirmation that no error exists with the robot.

 After the PLC has read the status, it turns OFF the command and data

areas and the strobe signal.

 As soon as the strobe signal is turned OFF, the controller turns OFF the

status area and the command processing complete signal.
The robot failure signal, which is outputted due to a command processing

error, rema ins ON until a CLEAR ROBOT FAILURE command is executed.

Caution: SSSS The maximum time taken until the status area and the

command processing complete signal are turned OFF, after
the strobe signal is turned OFF in XXXX, is 100 msec.

T

T If the strobe signal is turned OFF before the command

TT

processing complete signal is turned ON in VVVV, the
command processing complete signal and the status area
will be output and then turned OFF within 100 msec.

47

3.5.2.2 Using Each Signal Line

[ 1 ] Command and Data Areas

This section describes the usage of the command area (4 bits, input), data
area 1 (8 bits, input), data area 2 (16 bits, input) and command and data area
odd parity (input).

(1) Function

Specif ies t he commands to be executed by the Robot Controller.
Sets the command area at all times, and data areas 1 and 2, if necessary.

(2) Terminal numbers

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

(3) Input conditions and operation

 Set the command area whenever I/O commands are to be executed.

Set data for data areas 1 and 2 if commands require them.

 "Shorted" represents the bit value = 1.

"Open" represents the bit value = 0.
"Parity bit " is odd parity.

 Input the command area, data areas 1 and 2, and command and data

area odd parity before the strobe signal (1 msec. or more). Retain the
status until the command processing complete signal is output.

 Input 1 or 0 as the parity bit so that the total of 1s existing in the

command area, data areas 1 and 2 and the command and data area
odd parity will be odd
The data areas count even commands, which do not require any data
area, in a check sum calculation.

 Checksum can be set valid or invalid using a parameter. When

checksum is invalid, no checksum check will be performed.

48

[ 2 ] Strobe Signal (Input)

(1) Function

This signal informs the Robot Controller that the command area, data
areas 1 and 2, and the command and data area odd parity bit have been
set. Additionally it directs the start of command processing.

Caution: Perform command input with a strobe signal after the system

(2) Terminal number

No. 8 of connector CN8.

(3) Input conditions and operation

 By turning ON this input in automatic or external mode, the Robot

Controller reads the command area, data areas 1 and 2, and the
command and data area odd parity bit starts processing.

 Retain the status until a command processing complete signal is output

and the necessary status data is read. If the strobe signal is turned
OFF before a command processing complete signal is output, the
status area will not be output.

 By turning OFF this input after the status is read, the command

processing complete output, the status area and the status parity will
be turned OFF.

output signal ROBOT INITIALIZATION COMPLETE is output.

49

[ 3 ] Command Processing Complete (Output)

(1) Function

The signal outputs to the external device that I/O command processing is
completed.

(2) Terminal number

No. 15 of connector CN10.

(3) Usage

The signal is used to confi rm that I/O command processing is complete, or
as a timing signal for obtaining the result of I/O command processing.

(4) ON conditions

 The signal will be turned ON upon completion of processing the I/O

command given and determination of outputting the status area.

 If an error occurs a s a result of executing an I/O co mmand, the result

will not be output to the status area, but the robot failure signal and the
command processing complete signal will be turned simultaneously
ON.

(5) OFF conditions

 The signal will be turned OFF when the strobe signal is turned OFF.
 If the strobe signal is turned OFF, before command processing is

completed, the command processing complete signal will be output and
then turned OFF within 100 msec.

50

[ 4 ] Status Are a

This section describes the usage of the status area (16 bits, output) and of
status area odd parity (output).

(1) Function

The signal outputs the result of I/O command processing to the external
device.

(2) Terminal numbers

Nos. 17 to 32 of connector CN10.

(3) Usage

The signal is used to execute an I/O command and obtain the result of the
PLC.

(4) ON conditions

 When processing of the I/O given is completed, the status

corresponding to the command will be set.

 "ON" represents the bit value = 1.

"OFF" represents the bit value = 0.
"Parity bit" is odd parity.

 Input 1 or 0 as the parity bit so that the total of 1s existing in the

command area and status area parity will be odd.

The status area counts even commands, which do not require any data

area, in a parity calculation.

 Parity can be set valid or invalid with a parameter. When parity is

invalid, no parity check will be performed.

(5) OFF conditions

 The signal will be turned OFF when the strobe signal is turned OFF.
 If the strobe signal is turned OFF, before command processing is

completed, the status signal will be output and then turned OFF within
100 msec.

51

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 1 Data area 2 Status area

0001
Program operation

0010
External speed and

acceleration setting

0100
Error read
0101
Type I variable

write
0110
Type I variable read

0111
Mode switching

1000
Clear robot failure
1001
I/O write
1010
I/O read

00000001 Program reset start
00000010 Program start
00000100 Continue start
00010000 Step stop
00100000 Instantaneous stop
01000000 Reset
00000001 Speed setting
00000010 Acceleration setting
00000100 Deceleration setting

Error

Type I variable number

Type I variable number 

00000001 Motor ON, CAL execution
00000010 External speed 100
10000000 External mode switching
10000011 Execution of all above
(Motor ON→CAL→SP100→External)



Set I/O value First internal I/O port

 First internal I/O port

Program number
Program number

(Note)

Program number
Program number
Program number
Set speed value
Set acceleration

value
Set deceleration

value

Set variable value
(lower 16 bits)



address

address











number



Variable
value (lower
16 bits)



I/O

(Note) In execution of Continue Start command, program numbers will be ignored.

52

3.5.3.2 Program Operation Command (0001)

(1) Function

This command controls the operating state of the program specified in
data area 2 based on the setti ng of data area 1.

(2) Format

Command area (4 bits, input)
0001

Data area 1 (8 bit s, input)
00000001: Program reset start
00000010: Program start
00000100: Continue start
00010000: Step stop
00100000: Instant aneous stop
01000000: Reset
An error (ERROR2032) will occur if dat a i s ot her t han t he above is set.

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

Stat us area (16 bits, output)
Nothing will be output.

(3) Description

 Program reset start

This command is execut able only in external mode. If executed in other
mode an error will occur.
This command initializes and starts the program of the program
number specified in data area 2. PRO0 to PRO32767 can be started.
If the program number specified in data area 2 is negative, an error
(ERROR73E4) will occur.
Either of the following operations takes place according to the
operating status of the program:

⋅ If the specified program is terminated (stopped), step-stopped or

immediately stopped, it will start from the beginning.

⋅ If the specified program is running, an error (ERROR21F5) will be

displayed, and the program w ill stop.

53

 Program start

This command is executable only in external mode. An error
(ERROR2032) will occur in ot her modes.
This command starts the program of the program number specified in
data area 2. PRO0 to PRO32767 can be started.
If the program number specified in data area 2 is negative, an error
(ERROR73E4) will occur.
One of the following operations takes place according to the operating
status of the program.

⋅ If the specified program is terminated (stopped), it will start from the

beginning.

⋅ If the specified program is step-stopped, it will resume from the step

following the suspended step.

⋅ If the specified program is immediately stopped, it will resume from

the step following the suspended step. When the program is
instantaneously stopped in while in execution of an operation
command, it will resume from the o peration still undone.

⋅ If the specified program is running, an error (ERROR21F5) will be

displayed, and the program w ill stop.

 Continue start

This command is executable only in external mode when the Continue
Start Permitted signal is on. The data area will be ign ored.

 Step stop

This command step-stops the program of the program number
specified in data area 2. PRO0 to PR032767 can be step-stopped.
If the program number specified in data area 2 is negative, all
programs being executed will step-stop.
Either of the following operations takes place according to the
operating status of the program.

⋅ If the specified program is terminated (stopped), step-stopped or

immediately stopped, not hing will happen.

⋅ If the specified program is running, it will step-stop. If started after a

step stop, the stopped program will resume from the step following
the suspended step.

 Instantaneous top

This command immediately stops the program of the program number
specified in data area 2. PRO0 to PR032767 can be stopped
immediately.
If the program number specified in data area 2 is negative, all
programs being executed will step-stop.
Either of the following operations takes place according to the
operating status of the program:

⋅ If the specified program is terminated (stopped), step-stopped or

immediately stopped, not hing will happen.

⋅ If the specified program is running, it will immediately stop. If

started after an instantaneous stop, the stopped program will
resume from the suspended step. If the program is immediately
stopped in the middle of execution of an operation command, it will
resume, starting from the last uncompleted operation.

54

 Reset

This command immediately stops and also initializes the program of
the program number specified in data area 2. PRO0 to PR032767 can
be stopped.
This command cannot be used together with the program start
command.
To start a step-stopped or cycle-stopped program from the beginning,
use the program reset start command.
If the program number specified in data area 2 is negative, all
programs being executed will be reset.
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, it will be initialized. The initialized program will resume
from the beginning.

⋅ W hen the specified program is running, it will immediately stop and

also be initialized. If started after an instantaneous stop, the
stopped program will resume from the beginning.

55

3.5.3.3 External Speed and Acceleration Setting (0010)

(1) Function

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

(2) Format

Command area (4 bits, input)
0010

Data area 1 (8 bit s, input)
00000001: Speed setting
00000010: Accelerat ion setting
00000100: Deceleration set t ing
An error (ERROR2032) will occur if dat a ot her t han the above is set.

Data area 2 (16 bits, input)
Set values: Speed, acceleration and deceleration to be set
Enter any of the external speed, acceleration and deceleration values
specified in dat a area 1.
The values must be between 1 and 100. If they are out of this range, an
error (ERROR2003) will occur.

Stat us area (16 bits, output)
Nothing will be output.

(3) Description

 Speed setting

The external speed is set to the value specified in data area 2. The
value must be between 1 and 100. An error (ERROR2003) will occur if
the value is out of this range.
The external acceleration and deceleration will be set simultaneously
as shown below by setting the external speed:
External acceleration and external deceleration = External speed
(minimum value: 1)

 Acceleration setting

The external acceleration is set to the value specified in data area 2.
The value must be between 1 and 100. An error (ERROR2003) will
occur if the value is out of this range.

 Deceleration setting

The external deceleration is set to the value specified in data area 2.
The value must be between 1 and 100. An error (ERROR2003) will
occur if the value is out of this range.

2

/100

56

3.5.3.4 Error Read (0100)

(1) Function

This command outputs the ex ist i ng error number to the status area.
This command is output to the status area only when the strobe signal
remains ON.

Caution: This command will not be output if a minor erro r occurs, such

as a program selection error, caused by the operation of the
teach pendant or the operating panel.

(2) Format

Command area (4 bits, input)
0100
Data area 1 (8 bit s, input)
Nothing will be input.
Data area 2 (16 bits, input)
Nothing will be input.
Stat us area (16 bits, output)
The existing error code will be out put .

(3) Hexadecimal codes

Refer to the figure given below.

Thousands of error

Terminal No.
(Connector CN10)

ERROR

The following figure shows an example of error number output when
ERROR6174 (overload error with t he fourth axis) occurs.

32 31 30 29

× ¡¡ ×

6

(4) Description

×××× → 0 סס → 5 ¡×¡×→ A
××ס → 1 ס¡×→ 6 ¡×¡¡ → B
×ס×→ 2 ס¡¡ → 7 ¡¡×× → C
×ס¡ → 3 ¡××× → 8 ¡¡×¡ → D
ס×× → 4 ¡×ס → 8 ¡¡¡×→ E ¡⋅⋅⋅ON

¡¡¡¡ → F ×⋅⋅⋅⋅OFF

Hundreds of error No.

28 27 26 25

×× ×¡

1

Example of Error Number Output

Tens of error No.

24 23 22 21

× ¡¡ ¡

7

Units of error No.

20 19 18 17

× ¡ ××

4

If a command is executed when a robot failure or the robot warning signal
is output, the error number, which caused the robot failure or robot
warning signal to be output, will be output to the status area.
If no error exists after an error has been cleared, 0 will be output to the
status area. Also, when there is an error that does not output any robot
failure or robot warning signal, 0 w il l be o ut putted.

57

3.5.3.5 T ype I Variable W rite (0101)

(1) Function

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

(2) Format

Command area (4 bits, input)
0101

Data area 1 (8 bit s, input)
The number of the Type I variable for which a value will be substituted.
Any number between I[0] and I[255] can be specified. When the input data
in data area 1 is nn, the value specified in data area 2 will be substituted
for the Ty pe I variable I [nn].

Data area 2 (16 bits, input)
The value to be substituted for the Type I variable specified in data area 1.
Any value between -32768 and 32767 can be set.

Stat us area (16 bits, output)
Nothing will be output.

(3) Description

The value specified in data area 2 is substituted for the Type I variable
specified in dat a area 1.
Although the type I variable has a storage area of 32 bits, the 16-bit data
in data area 2 will be substituted for the lower 16 bits. Zero will be
substituted for the upper 16 bits of the Type I variable.

58

3.5.3.6

Type I Variable Read (011 0)

(1) Function

This command outputs to the status area the value of the Type Ι (integer
type) global variable o f the number specified in data area 1.

(2) Format

Command area (4 bits, input)
0110

Data area 1 (8 bit s, input)
The number of the Type I variable for which a value will be substituted.
Any number between I [0] and I [255] can be specified. When the input
data in data area 1 is nn, the value specified in data area 2 will be
substituted for the Type I variable I [nn].

Data area 2 (16 bits, input)
Nothing will be input.

Stat us area (16 bits, output)
The lower 16 bit value of the Type I variable specified in data area 1 will
be output.

(3) Description

The value of the Type I variable specified in data area 1 is output to the
status area.
Although the Type I variable has a storage area of 32 bits, the lower 16
bits will be output t o t he status area.
Therefore, any value between -32768 and 32767 can be output properly.
However, if the value is out of this range, only the lower 16 bits of the data
will be output.

59

3.5.3.7 Mode Switching (0111)

(1) Function

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

(2) Format

Command area (4 bits, input)
0111

Data area 1 (8 bit s, input)
Bit 0 (00000001): Motor ON, CAL execution
Bit 1 (00000010): External speed 100
Bit 7 (10000000): External mo de sw it ching
These bits can be set together to execute commands. When two or more
bits are set, commands will be ex ecut ed one after another.

For example, when bits 0, 1 and 7 are set, motor ON, CAL execution,
external speed 100 and external mode will be executed in this order.
If bits other than the above are set, an error will result.

Data area 2 (16 bits, input)
Nothing will be input.

Stat us area (16 bits, output)
Nothing will be output.

(3) Description

This command is used for equipment using the robot to switch the
operation mode of the robot to externa l mod e from the external device

The processing operations to be executed are specified by the bits set in
data area 1 and will be executed from bit 0 to bit 7.

 Motor ON, CAL execution (bit 0)

When this bit is set, the power to the Robot Controller motor will be
turned ON and CAL will be executed. If CAL is executed once after the
power is turned ON, no processing wil l take place.

60

 External speed 100 (bit 1)

When this bit is set, the external speed, external acceleration and
external deceleration of the Robot Controller will be set to 100.

 External mode switching (bit 7)

When this bit is set, the mode of the Robot Controller will be switched
from automatic to external.

61

3.5.3.8 Clear Robot Failure (1000)

(1) Function

This command clears a robot failure that has been caused.

(2) Format

Command area (4 bits, input)
1000

Data area 1 (8 bit s, input)
Nothing will be input.

Data area 2 (16 bits, input)
Nothing will be input.

Stat us area (16 bits, output)
Nothing will be output.

(3) Description

If a robot failure occurs, this command clears it. When there is no failure,
no processing will ta ke pl ace
When an error is displayed, the same processing as when the OK or
Cancel key of the operating panel or the teach pendant is operated will be
performed.

62

3.5.3.9 I/O Write (1001)

(1) Function

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

(2) Format

Command area (4 bits, input)
1001

Data area 1 (8 bit s, input)
The status to be set will be specified in the internal I/O area starti ng from
the number specified in data area 2.

Data area 2 (16 bits, input)
This is first number of th e internal I/O (8-bi t) area for which the status wil l
be substituted. The number can be set between 128 and 504. If the
number is out of this range, an error (ERROR2034) will occur.

Stat us area (16 bits, output)
Nothing will be output.

(3) Description

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

63

3.5.3.10 I/O Read (1010)

(1) Function

This command outputs to the lower 8 bits of the status area the status of
the 8-bit internal I/O area starting from the numbe r specified in data area

2.

(2) Format

Command area (4 bits, input)
1010

Data area 1 (8 bit s, input)
Nothing will be input.

Data area 2 (16 bits, input)
This is the first numbe r of the i nternal I/O (8-bi t) are a whose status wil l be
output. The number can be set between 128 and 504. If the number is out
of this range, an error (ERROR2034) w i ll occur.

Stat us area (16 bits, output)
The status of the 8-bit i nternal I/O a rea startin g f rom the number specifie d
in data area 2 will be output to the lower 8 bits of this area.

(3) Description

This command outputs to the lower 8 bits of the status area the status of
the 8-bit internal I/O area starting from the numbe r specified in data area

2. Zero will be output to the upper 8 bit s.

64

3.6 Example of Using System I/O Signals in Standard Mode

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

(1) Equipment 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 operation panel has
a display, lamps and switches listed on t he next page.

Robot

Robot
controller

Other equipment

(e.g. conveyor)

Operating panel

Example of Equipment Setup Using a Robot

PLC

65

Function Example of Equipment Operating Panel

Classificati

on

Display

Lamp

Switch

Part Application

Display

Q Automatic operation

indicator lamp

R Robot external mode

indicator lamp

S Operation OK indicator
lamp

Q Robot preparation button Starts the preparation of the robot.

R Automatic start button Starts the operation of the equipment.

S Cycle stop button

T Operation/Adjustment

selector switch

Displays messages, such as ROBOT PREPARATION
OK.

⋅ Lights during automatic operation.
⋅ Turned OFF when the robot is not in automatic

operation.

⋅ Lights when the robot is in external mode.
⋅ Turned OFF when the robot is not in external mode.

⋅ Lights when the Enable Auto signal is ON.
⋅ Turned OFF when the Enable Auto signal is OFF.

Stops the equipment after a cycle of operations is
completed.

Automatic operation of the robot possible when
OPERATION is selected.
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 nece ssary functions.

(2) Outline of procedure

Described below is the outline of the procedure when using the equipment
taken as an example shown on the previous page.
Follow steps  to .

 Operation preparation start

After setting the MOTOR ON, CAL EXECUTION, EXTERNAL SPEED
100 and EXTERNAL MODE SWITCHING bits, execute the mode
switching command to bring the robot into external automatic operation
mode. This operation will be completed when the EXTERNAL MODE
output signal is turned ON.

 Automatic operation

Start the program by which the robot starts from the operation origin,
performs operations, and return s t o t he operat ion origin.

 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 si gnals
for start and stop, worker’s operation, display on the equipment operation
panel, PLC procee di ng, and robot motion.

66

Step

r

r

g

K

Worker’s operation and display on

equipment’s operation panel

Equipment power ON

Setting
operation/adjustment
selector switch to
operation

Operation OK indicato
lamp ON

Setting Mode selecto
switch of the operating
panel or the teach
pendant to AUTO

PLC processing Robot operation

Enable Auto ON

(Note )

(Internal processing)

Q

Q Operation preparation start

Q

Q

Robot preparation
button ON

Robot external mode
indicator lamp ON

Moving robot arm close
to operation origin,
when external mode
indicator lamp is ON
and operation position
1 indicator lamp is OFF.

Data area 1 input ON

Executing mode
switchin

(Internal processing)

command

Motor power ON

Executing CAL

Setting SP 100

Switching mode to

external mode

External mode ON

R

R Operation start area check

R

R

Robot operation origin
indicator lamp ON

Robot preparation O
display

(Internal processing)

When both are ON

(Internal processing)

Operation position 1

Start and Stop Procedure and System I/O Signals-1

(Continued on following page)

67

(Continued from preceding page)

Step

Worker’s operation and display on

equipment’s operation panel

PLC processing Robot operation

S

S Automatic operation

S

S

Equipment’s Automatic

Start Button ON

Automatic Operation
indicator lamp ON

Equipment’s Cycle
Stop button ON

Program No. Select ON

Regular operation
program is selected
and output to data
area 2.

Executing Program
Operation Command
(Program start)

Program No. select ON

Regular operation
program is selected
and output to data
area 2.

Program start ON

Cycle Stop ON

Program start

END

Robot-in-operation

signal OFF

Repeated

Executing 1-cycle

END

T

T Operation end

T

T

Automatic operation
indicator lamp OFF

Equipment power OFF

(Internal processing)

Robot-in-operation

signal OFF

Note SSSS In data area 1, the bit to each of "motor ON , CAL execution," "ex ternal spe ed 100" an d

"External Mode switching" will be turned ON. Refer to Chapter 5, Subsection 5.3.7
"Mode Switching (0111)".

T

T in the above figure indicates a system I/O signal, and ←←←←represents the flow of

TT

signals.

Start and Stop Procedure and System I/O Signals-2

68

Chapter 4

System I/O Signals Compatible Mode

4.1 Types and Functions of System Output Signals (Compatible

Mode)

The table below lists the system output signals used in the compatible mode.

Types and Functions of System Output Signals to be Used in Compatible Mode

Application Signal name Function

Robot power ON

complete

Auto mode Outputs when the robot is in auto mode.

Start-up

Program
pre-execution check

Program execution

Program end Single cycle end Outputs when the program completes a cycle.

Servo ON Outputs when the power to the motor is turned ON.

CAL complete Outputs when calibration is completed.

External mode Outputs when the robot is in external mode.

Teaching

Program start reset

Robot-in-operation

Continue start

permitted

Normal CPU

Outputs when preparations for operation are ready
to start.

Outputs when the robot is in manual or teach ch eck
mode.

Outputs when execution of the program starts in
response to the program start signal received.

Outputs when the robot is in operation (the pr ogram
is being executed).

Outputs when the continue start is permitted.

Outputs when the CPU (hardware) of the Robot
Controller is normal.

Robot failure

Error/warning

Continue start Continue start permitted Outputs when Continue Start is enabled.

Safe start function SS mode

Emergency stop Emergency stop

Robot warning Outputs when a slight error occur s.

Dead battery warning

Error No.

Outputs when a failure (such as a servo f ailure and
program error) occurs in the robot.

Outputs when the voltage of the encoder backup
battery or memory backup battery lowers.

An error number wil l be outputted in BCD code if an
error occurs.

Outputs when the robot is in SS mode. Refer to the
SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6
"SS (Safe Start) Function."

Outputs from a contact exclusively designed for an
emergency stop circuitry.

69

4.2 Usage of System Output Signals in the Compatible Mode

r

The usage of each system output signal in the compatible mode is described
below.

4.2.1 Robot Power ON Complete

(1) Function

The signal outputs to the external device that OPERATION
PREPARATION START is possible.

(2) Terminal number

No.9 of connector CN10.

(3) Usage

OPERATION PREPARAT ION START will be executed after this signal and
the auto mode signal are turned ON after the power was turned ON.

(4) ON conditions

 The signal will be turned ON when the Robot Controller system

program properly starts. Preparations for operation can be started after
the power was turned ON.

 The signal will be turned ON when the robot failure is cleared by the

OK or Cancel key of the operating panel or the teach pendant or by
CLEAR ROBOT FAILURE and OPERATION PREPARATION START
signals, after the power was turned O F F.

ROBOT POWER ON
COMPLETE output

(5) OFF conditions

The signal will be turned OFF when a robot failure or robot warning signal
is turned ON.

⋅ A robot error is cleared by the OK or Cancel

key of the operating panel or teach

⋅ When a robot error was cleared with CLEAR

⋅ The system properly

starts to operate after
the power is turned
ON.

⋅ Robot erro

Robot Power ON Complete Output

ROBOT FAILURE and OPERATION PRE­PARATION START signals from the external
device.

pendant.

70

4.2.2 Auto Mode (Output)

r

p

A

(1) Function

The signal outputs to the external device that the robot is in the auto
mode.

(2) Terminal number

No.4 of connector CN10.

(3) Usage

Starting the program from the external device requires an SW ITCH EXT
MODE input, a PROGRAM NO. SELECT input and a PROGRAM START
input. The signal is used t o confirm that the robot is in the auto mode.

(4) ON conditions

The signal will be output when the robot enters the auto mode under the
following conditi ons.

 The mode selector switch of the operating panel or the teach pendant

is set to AUTO.

(5) OFF conditions

The signal will be turned OFF under the following conditions.
 When the mode selector switch of the operating panel is set to

MANUAL or t he teach pendant is set to MANUAL or TEAC H CHECK.

 When Enable Auto OFF is input.

(Caution: The signal will not be turned OFF in the pendantless state
described in the OPTIONS MANUAL, Chapter 1, Subsection 1.3.3.)

uto mode output

Caution: The signal will not be turned OFF with INSTANTANEOUS

STOP, STEP STOP or CYCLE STOP.

⋅The Mode selector switch of the operating panel or the teach pendant is

set to AUTO.

⋅ SWITCH AUTO MODE and OPERATION PREPARATION START are

in

ut from the external device.

⋅ The mode selector switch of the operating panel is set to

MANUAL or that of the teach pendant is set to MANUAL o
TEACH CHECK.

⋅ Enable Auto OFF is input.

Auto Mode Output

71

4.2.3 Servo ON (Output)

F

(1) Function

The signal outputs to the external device that the power to the robot motor
is turned ON.

(2) Terminal number

No. 10 of connector CN10.

(3) Usage

Executing CAL from the external device or starting the program requires
the power to the motor to be turned ON. This signal is used to confirm that
the power to the motor is turned ON and to light the motor power ON
indicator lamp on an external operat ing panel.

(4) ON conditions

The signal will be turned ON when the power to the motor is turned ON
under the following condit ions.
 The MOTOR switch on the operating panel or the teach pendant is

activated.

 MOTOR POWER ON + OPERATION PREPARATION START signals

are input from the external device.

(5) OFF conditions

The signal will be turned OFF when the power to the motor is turned OFF
under the following condit ions.
 The MOTOR switch of the operating panel or the teach pendant is

deactivated and the ROBOT STOP button is operated.

 ROBOT STOP is input from the external device.
 ROBOT FAILURE is outputted. If any of errors 0 × 6071 to 607B, 0 ×

6671 to 667B, 0 × 607F occurs, the servo ON signal will be turned OFF
in External Auto mode but will not be turned OFF in manual or teach
check mode.

Servo ON output

⋅ W hen th e MOTOR button of the operating panel or the teach pendant is

turned ON.

 uMOTOR vON ‘ € ì

⋅ W hen MOTOR POWER ON and OPERATION PREPARATION START

signals are input from the external device.

⋅ W hen the MOTOR button of the operating panel or the teach pendant is

turned OFF and the ROBOT STOP button is operated.

 uMOTOR vOF

⋅ When a ROBOT STOP signal is input from an external device.
⋅ When a ROBOT FAILURE occurs.

Servo ON Output

72

4.2.4 CAL Complete (Output)

(1) Function

The signal outputs to t he ext ernal device that CAL is compl et ed.

(2) Terminal number

No. 11 of connector CN10.

(3) Usage

This signal is used to deter mine whether to execute CAL.
Once CAL is completed, it does not need to be executed again as long as
the power to the Robot Controller is turned ON.

(4) ON conditions

The signal will be turned ON upon proper completion of CAL under the
following conditi ons.

 When CAL is performed by the operating panel or t each pendant.
 When CAL EXECUTION and OPERATION PREPARATION START

signals are input from the ext ernal device.

(5) OFF conditions

The signal will be turned OFF when CAL is not properly completed as
shown below.
It will remain O FF until CAL is perfor med again and properly completed.

CAL complete

⋅ CAL is performed by the teach pendant.
⋅ CAL EXECUTION and OPERATION

PREPARATION START commands are
input from the external device.
(Prerequisite: MOTOR POWER ON)

⋅ Normal CAL end

CAL Complete Output

⋅ CAL is executed again.

When CAL has properly ended

When a CAL error occurs.

73

4.2.5 External Mode (Output)

p

(1) Function

The signal outputs to the external device that the robot is in the external
mode.

(2) Terminal number

No. 5 of connector CN10.

(3) Usage

Starting the program from the external device requires an SW ITCH EXT
MODE input, PROGRAM NO. SELECT input and a PROGRAM START
input. The signal is used to confirm to the external device that the robot is
in external mode.

(4) ON conditions

The signal will be turned ON under the following conditions.
 When INTERNAL/EXTERNAL is input on the teach pendant and the

external mode is selected.

 W hen EXTERNAL/INTERNAL is input on the operating panel in AUTO

MODE and in the INTER NA L CONTROL ON state.

 When SW ITCH EXT MODE and OPERATION PREPARATION START

signals are input from the ext ernal device.

(5) OFF conditions

The signal will be turned OFF under the following conditions.
 W hen the mode selector switch of the teach pendant is set to MANUAL

or TEACH CHECK in ex t ernal mode.

 When EXTERNAL/INTERNAL is input on the teach pendant and

external mode is selected.

 W hen EXTERNAL/INTERNAL is input on the operating panel in AUTO

MODE and in the INTER NA L CONTROL OFF state.

 When ROBOT STOP is input.
 When ROBOT F AI L URE is outp utt ed.

Caution: The signal will not be turned OFF with STEP STOP.

 When an Enable Auto inp ut is t urned OFF.

⋅ When INTERNAL/EXTERNAL is input on the teach pendant and external mode is selected.
⋅ When INTERNAL/EXTERNAL is input on the operating panel in AUTO MODE and in the

INTERNAL CONTROL ON state.

⋅ When EXTERNAL MODE SWITCHING and OPERATION PREPARATION START signals are

input from the external device.

ON

External mode output OFF

⋅ When internal mode is selected on the teach pendant.
⋅ When INTERNAL/EXTERNAL is input on the teach pendant

and external mode is selected.

⋅ When INTERNAL/EXTERNAL is input on the operating panel in

AUTO MODE and in the INTERNAL CONTROL ON state.

⋅ When ROBOT STOP is input.
⋅ When ROBOT ERROR is output.
⋅ When an Enable Auto in

External Mode Output

ut is turned OFF.

74

4.2.6 Teaching (Output)

h

Š

Ž

(1) Function

The signal outputs to the external device that the robot is in the manual
mode or teaches check mode.

(2) Terminal number

No. 12 of connector CN10.

(3) Usage

This signal is used to inf orm an exter nal operatin g panel that the robot is
teaching when they are inst alled separately from each other.

(4) ON conditions

The signal will be turned ON when the mode selector switch of the
operating panel or the teach pendant is set to MANUAL or TEACH
CHECK, as shown below.

(5) OFF conditions

The signal will be turned OFF when the mode selector switch of the
operating panel or teach pendant is set to AUTO and the Enable Auto
input is turned ON.

Teaching

 EƒIƒyƒŒ [ƒeƒBƒ“ƒOƒpƒlƒ‹‚Å uManual v‘€ ì

⋅ When the mode selector switch of the operating panel is set to

 EƒeƒB [ƒ`ƒ“ƒOƒyƒ“ƒ_ƒ“ƒg‚Å uMANUAL v E uTeac

MANUAL.

Check v‘€ ì

⋅ When the mode selector switch of the teach pendant is set to

MANUAL or TEACH CHECK.

⋅ When the mode selector switch of the operating panel or the

 EƒIƒyƒŒ [ƒeƒBƒ“ƒOƒpƒlƒ‹‚Ü‚½‚̓eƒB [ƒ`ƒ“ƒ

teach pendant is set to AUTO and the Enable Auto input is
turned ON from the external device.

Teaching Output

ƒyƒ“ƒ_ƒ“ƒg‚Å uAuto v‘€ ì A‚©‚
“®‰^“]ƒCƒl [ƒuƒ‹“ü—Í‚ªON

O•”‚æ‚è

75

4.2.7 Program Start Reset (Output)

(1) Function

This signal is output to the external device when the robot receives a start
signal from the external device and starts to operate.

(2) Terminal number

No. 6 of connector CN10.

(3) Usage

 The signal is used to prompt the external device to receive information

that the robot program has started to run, and to process subsequent
sequence programs.

 The signal is used as a condition to turn OFF the PROGRAM START

signal sent from the external device to the robot.

(4) ON conditions

The signal will be turned ON immediately after the robot program starts to
run, as shown below.

(5) OFF conditions

The signal will be turned OFF automatically when the PROGRAM START
signal sent to the robot is turne d O FF.

Robot status

Program start signal (input) ON (shorted)

OFF (open)

Program start Reset (output)

Program Start Reset Output ON Condition

Single-cycle operation

Single-cycle operation

76

4.2.8 Robot-in-operation (Output)

(1) Function

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

(2) Terminal number

No. 2 of connector CN10.

(3) Usage

The signal is used to light the robot operating indicator lamp of the
external operating panel.
Since the signal is turned OFF with STOP ALL PROGRAMS, it outputs to
the external device that all programs are stopped.

(4) ON conditions

The signal will be turned ON while executing the program and also in the
Wait State with a condition branch or t i mer co mmand.

(5) OFF conditions

The program will be turned OFF with STOP ALL PROGRAMS.

Caution: STOP ALL PROGRAMS means the operation of the ROBOT

STOP or STOP button of the operating panel or the teach
pendant and INSTANTANEOUS TOP (ALL TASKS), STEP STOP
(ALL TASKS) and ROBO T STOP input s.

77

4.2.9 Single-Cycle End (Output)

(1) Function

The signal outputs to the external device that a single-cycle of the
program is completed.

Caution QQQQ The single-cycle end signal will be output upon reading

END of the program. However, it will be output earlier th an
the end of the actual robot operation because the Robot
Controller pre-reads the program.

R

R The single-cycle end signal will be output on the premise

RR

that only one program is executed at a time. If two or more
programs are executed simultaneously (multi-tasks), the
single-cycle end signal w ill be turned ON immediately after
any of the programs reads an E ND command.

(2) Terminal number

No. 13 of connector CN10.

(3) Usage

The signal is used to operate another equipment in synchronization with a
single-cycle end of the program.

(4) ON conditions

(5) OFF conditions

Robot status

PROGRAM START input

1-CYCLE END

The signal will be turned ON when the program is read to the end.

The signal will be turned O FF i mmediately after the program starts to run.

Single-cycle
operation

Single-Cycle End Output

Wait for start

Single-cycle
operation

78

4.2.10 Normal CPU (Output)

(1) Function

The signal outputs to the external device that the CPU (hardware) of the
Robot Control ler is normal.

(2) Terminal number

No. 1 of connector CN10.

(3) Usage

 The signal is used to light the Robot Controller error indicator lamp of

an external operating pa nel.

 The signal is used when the NORMAL CPU signal is turned OFF

because of an error and the PLC correct s it .

(4) ON conditions

The signal will be turned ON by the hardware when the CPU of the Robot
Controller operates normally w ith t he pow er t urned ON.

(5) OFF conditions

The signal will be turned OFF by the hardware when the CPU does not
operate normally.

Normal CPU output

Caution: The OFF state of this signal indicates that the internal

arithmetic circuit of t he Robot Controller may be damaged and
ROBOT ERROR, ERROR NUMBER and other outputs may not
be correct.

⋅ Power ON (CPU operates properly)

⋅ CPU error (hardware error)

Normal CPU Output

79

4.2.11 Robot Failure (Output)

(1) Function

The signal outputs to the external device that a problem, such as a servo
error and a program error, occurs with the robot.

(2) Terminal number

No. 3 of connector CN10.

(3) Usage

 The signal is used to light the robot failure indicator lamp of an external

operating panel.

 The signal is used to help the PLC clear an error in response to a

ROBOT FAILURE signal.

(4) ON conditions

As shown below, the signal will be turned ON under the following
conditions.
 W hen an error, such as a servo error, a program error and undefined

program, occurs at the start of the program and during execution of the
program.

 When an error occurs during execution of the program in internal

operation by the operating panel or the teach pendant or in external
operation by the PLC.

 W hen an error, such as undefined program, occurs at the start of the

program only in external operati on.

Robot failure

Caution: The signal will not be output when an error, such as a

program input error occurs in manual operation, except when
a servo error occurs in manual operation. For further
information, see "ERROR CODE TABL ES. "

(5) OFF conditions

As shown below, the signal will be turned OFF under the following
conditions.
 W hen a CLEAR ROBOT FAILURE command is input from the external

device and the existing error is c leared.

 W hen the existing error is cleared by operating the Cancel key of the

operating panel or the teach pendant.

⋅ Program number, parity error, or an undefined program number at

external start.

⋅ The robot errors during automatic operation (both internal operation and

external operation).

⋅ When CLEAR ROBOT FAILURE and OPERATION PREPARATION

START signals are input.

⋅ When the Cancel key of the operating panel or the teach pendant is

operated.

 uCancel vƒL [‘€ ì

ƒoƒŠƒeƒB [ƒGƒ‰ [ A

Robot Failure Output

80