Denso RC7M User Manual

ROBOT

RC7M

CONTROLLER MANUAL

Copyright © DENSO WAVE INCORPORATED, 2005-2008

All rights reserved. No part of this publication may be reproduced in any form or by any means without
permission in writing from the publisher.

Specifications are subject to change without prior notice.

All products and company names mentioned are trademarks or registered trademarks of their respective
holders.

i

Preface

Thank you for purchasing this high-speed, high-accuracy assembly robot.

This manual describes the RC7M controller configured in the **-G robot system. It also covers interfacing
required when you integrate your robot system into your facilities, as well as providing the maintenance &
inspection procedures.

Before use, read this manual carefully together with related manuals to safely get the maximum benefit
from your robot in your assembling operations.

Note: The name of this manual has changed from the "RC7M Controller INTERFACE MANUAL" to the
"RC7M CONTROLLER MANUAL."

Robot controller covered by this manual

RC7M controller

Caution in connecting/disconnecting the motor & encoder cable

The CN7 (MOTOR) connector for the motor & encoder cable on the RC7M controller uses a rigid
structure.

Connection: Lock the connector properly.
Disconnection: Release the lock carefully and safely. It cannot be easily released.

Connection Disconnection

Release the lock carefully

and safely.

Important

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

ii

How the documentation set is organized

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

GENERAL INFORMATION ABOUT ROBOT

Provides the packing list of the robot and outlines of the robot system, robot unit, and robot
controller.

INSTALLATION & MAINTENANCE GUIDE

Provides instructions for installing the robot components and customizing your robot, and
maintenance & inspection procedures.

STARTUP HANDBOOK

Introduces you to the DENSO robot system and guides you through connecting the robot unit
and controller with each other, running the robot with the teach pendant, and making and
verifying a program. This manual is a comprehensive guide to starting up your robot system.

SETTING-UP MANUAL

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

For the panel designer functions, refer to the Panel Designer User's Manual (SUPPLEMENT).

WINCAPSII GUIDE

Provides instructions on how to use the teaching system WINCAPSII which runs on the PC
connected to the robot controller for developing and managing programs.

PROGRAMMER'S MANUAL I, Program Design and Commands

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

PROGRAMMER'S MANUAL II, PAC Library

Describes the program libraries that come with WINCAPSII as standard.

RC7M CONTROLLER MANUAL - this book -

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

ERROR CODE TABLES

List error codes that will appear on the teach pendant, mini-pendant, or PC screen if an error
occurs in the robot series or WINCAPSII. These tables provide detailed description and
recovery ways.

OPTIONS MANUAL

Describes the specifications, installation, and use of optional devices.

For the extension board "conveyer tracking board," refer to the OPTIONS MANUAL
(SUPPLEMENT).

iii

How this book is organized

This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS
and chapters one through eight.

SAFETY PRECAUTIONS

Defines safety terms and related symbols and provides precautions that should be observed. Be sure to
read this section before operating your robot.

Chapter 1 Outline of the RC7M Controller

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

Chapter 2 General Information about the Interface

Introduces you to the interface required for connecting the robot controller with a PLC or other external
equipment.

Chapter 3 System I/O Signals

Describes system I/O signals, and describes I/O signals that execute I/O commands.

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

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

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

Describes the I/O circuits and connector pin layout of a PNP I/O board (sink input and source output).

Chapter 6 Installation & Maintenance for the RC7M controller

Provides instructions for installing the robot controller, and maintenance & inspection procedures.

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

Lists the I/O allocation tables to apply when I/O extension boards are mounted.

Chapter 8 I/O Allocation for I/O Conversion Box (only for standard type of controller)

Lists the I/O allocation tables to apply when the I/O conversion box is mounted.
Using the I/O conversion box on the RC7M controller with an optional parallel I/O board mounted allows

the "INPUT (CN8)," "OUTPUT (CN10)," and "I/O POWER (CN7)" used on the RC5 controller to be used
on the RC7M controller as is.

Note: The I/O conversion box cannot be used for the global type of the controller.

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

Be sure to observe all of the following safety precautions.

Strict observance of these warning and caution indications are a MUST for preventing accidents, which
could result in bodily injury and substantial property damage. Make sure you fully understand all
definitions of these terms and related symbols given below, before you proceed to the text itself.

WARNING

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

CAUTION

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

Terminology and Definitions

Maximum space: Refers to the space which can be swept by the moving parts of the robot as defined by

the manufacturer, plus the space which can be swept by the end-effector and the workpiece. (Quoted
from the ISO 10218-1:2006.)

Restricted space: Refers to the portion of the maximum space restricted by limiting devices (i.e.,
mechanical stops) that establish limits which will not be exceeded. (Quoted from the ISO 10218-1:2006.)

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

Operating space: Refers to the portion of the restricted space that is actually used while performing all
motions commanded by the task program. (Quoted from the ISO 10218-1:2006.)

Task program: Refers to a set of instructions for motion and auxiliary functions that define the specific
intended task of the robot system. (Quoted from the ISO 10218-1:2006.)

1. Introduction

This section provides safety precautions to be observed for the
robot system.

The installation shall be made by qualified personal and should
confirm to all national and local codes.

The robot unit and controller have warning labels. These labels
alert the user to the danger of the areas on which they are
pasted. Be sure to observe the instructions printed on those
labels.

Warning label Instructions printed on the label

Label (1)

Risk of injury.

Never enter the restricted space.

<Except HM>

<HM>

Label (2)

For UL-Listed robot units only

Risk of injury.

This label alerts the user that pressing
the brake release switch could drop the
arm.

Label (3)

Risk of electrical shock.

Never open the controller cover when
the power is on.

Never touch the inside of the controller
for at least 3 minutes even after turning
the power off and disconnecting the
power cable.

2. Warning Labels

(Example: Location of labels)

Label (4)

Risk of injury.

Be sure to perform lockout/tagout
before starting servicing.

Turning the power ON when a person is
inside the safety fence may move the
arm, causing injuries.

SAFETY PRECAUTIONS

3. Installation Precautions

3.1 Insuring the proper
installation environment

 For standard type and

cleanroom type

The standard and cleanroom type have 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 material,

(4) there is a mist,

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

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

 For dust- & splash-proof

type

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

Note that the robot controller is not a dust- or splash-proof
structure. Therefore, when using the robot controller in an
environment exposed to mist, put it in an optional protective box.

The dust- & splash-proof type should not be installed in any
environment where:

(1) there are any flammable gases or liquids,

(2) there are any acidic, alkaline or other corrosive material,

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

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

(4) it may likely be submerged in fluid,

(5) there are any grinding or machining chips or shavings,

(6) any machining oil not specified in this manual is in use, or

Note: Yushiron Oil No. 4C (non-soluble) is specified.

(7) there is sulfuric cutting or grinding oil mist.

3.2 Service space

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

3.3 Control devices
outside the robot's
restricted space

The robot controller, teach pendant and mini-pendant should be
installed outside the robot's restricted space and in a place where
you can observe all of the robot’s movements and operate the
robot easily.

3.4 Positioning of gauges

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

3.5 Protection of electrical
wiring and
hydraulic/pneumatic
piping

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

3.6 Grounding resistance

The grounding resistance of the robot power supply should not
be more than 100Ω.

3.7 Positioning of
emergency stop
switches

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.

(3) Emergency stop switches should be separate from the

power switch.

3.8 Positioning of
operating status
indicators

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

Note: The UL-Listed robot units have motor ON lamps on their
robot arms.

SAFETY PRECAUTIONS

3.9 Setting-up a safety
fence

A safety fence should be set up so that no one can easily enter
the robot's restricted space.

(1) The fence should be constructed so that it cannot be easily

moved or removed.

(2) The fence should be constructed so that it cannot be easily

damaged or deformed through external force.

(3) Establish the exit/entrance to the fence. Construct the fence

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

(4) The fence should be constructed to ensure that it is not

possible for hands or any other parts of the body to get
through it.

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

exit of the fence:

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

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

When making a test run, before setting up the fence,

place an overseer in a position outside the robot’s
restricted space and one in which he/she can see all of
the robot’s movements. The overseer should prevent
workers from entering the robot's restricted space and be
devoted solely to that task.

3.10 Setting the robot's
motion space

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, Chapter

2.

3.11 No robot modification
allowed

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

3.12 Cleaning of tools

If your robot uses welding guns, paint spray nozzles, or other
end-effectors requiring cleaning, it is recommended that the
cleaning process be carried out automatically.

3.13 Lighting

Sufficient illumination should be assured for safe robot operation.

3.14 Protection from objects
thrown by the
end-effector

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.

3.15 Affixing the warning
label

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.

SAFETY PRECAUTIONS

4. Precautions

while Robot 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

4.1 and onwards are followed
when any work is being
performed.

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

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

3) When it is necessary to enter the robot's restricted space
to perform teaching or maintenance work while the robot
is running, ensure that the steps described in Section 4.3
"Ensuring safety of workers performing jobs within the
robot's restricted space" are taken.

4.1 Creation of working
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 4.2 on the next
page.)

2) Assuring the safety of workers performing jobs within the
robot's restricted space (See Section 4.3 on the next
page.)

3) Maintaining worker position and stance

Position and stance that enables the worker to confirm

normal robot operation and to take immediate refuge if a
malfunction occurs.

4) Implementation of measures for noise prevention

5) Signaling methods for workers of related equipment

6) Types of malfunctions and how to distinguish them

Please ensure "working regulations" are appropriate to the robot
type, the place of installation and to the content of the work.

Be sure to consult the opinions of related workers, engineers at
the equipment manufacturer and that of a labor safety consultant
when creating these "working regulations".

4.2 Display of operation
panel

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 operation
panel or teach pendant. Take any other steps as appropriate,
such as locking the cover.

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

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

immediately upon a malfunction.

 Do not permit anyone other than the worker engaged for

that job to enter the robot’s restricted space.

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

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

4.4 Inspections before
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.

SAFETY PRECAUTIONS

4.5 Release of residual air
pressure

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

4.6 Precautions for test
runs

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

4.7 Precautions for
automatic operation

(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 to be taken when a malfunction occurs

Should a malfunction occur with the robot or related

equipment and it is necessary to enter the robot's restricted
space to perform emergency maintenance, stop the robot’s
operation by activating the emergency stop device. Take any
necessary steps such as placing a display on the starter
switch to indicate work is in progress to prevent anyone from
accessing the robot.

4.8 Precautions in repairs

(1) Do not perform repairs outside of the designated range.

(2) Under no circumstances should the interlock mechanism be

removed.

(3) When opening the robot controller's cover for battery

replacement or any other reasons, always turn the robot
controller power off and disconnect the power cable.

(4) Use only spare tools specified in this manual.

5. Daily and Periodical
Inspections

(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.

6. Management of
Floppy Disks

(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.

7. Safety Codes

The safety standards relating to robot systems are listed below.

As well as observing the safety precautions given in this manual,
ensure compliance with all local and national safety and
electrical codes for the installation and operation of the robot
system.

Standards Title

ANSI/RIA R15.06-1999 Industrial Robots and Robot Systems--Safety Requirements

ANSI/UL1740: 1998 Safety for Robots and Robotic Equipment

CAN/CSA Z434-03 Industrial Robots and Robot Systems--General Safety Requirements

ISO10218-1: 2006 Robots for industrial environments--Safety requirements--Part 1: Robot

NFPA 79: 2002 Electrical Standard for Industrial Machinery

8. Battery Recycling

DENSO Robot uses lithium batteries.

Discard batteries according to your local and national recycling
law.

Contents

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

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

SAFETY PRECAUTIONS

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

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

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

1.2.1 Controller Components.............................................................................................................................. 4

1.2.2 Warning and Caution Labels...................................................................................................................... 5

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

1.4 Controller System Configuration........................................................................................................................... 10

1.4.1 Internal Circuits of the Controller (Typical configuration)...................................................................... 10

1.4.2 Typical Robot System Configuration....................................................................................................... 11

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

2.1 Types and General Information about I/O Signals ................................................................................................ 12

2.1.1 Types of System I/O Signals (Standard type of controller)...................................................................... 12

2.1.2 Types of System I/O Signals (Global type of controller)......................................................................... 13

2.2 Usage of User I/O Signals ..................................................................................................................................... 14

2.2.1 I/O Type Variable Declaration.................................................................................................................. 14

2.2.2 I/O Type Global Variables........................................................................................................................ 14

2.2.3 I/O Type Local Variables ......................................................................................................................... 14

2.2.4 User Input Commands .............................................................................................................................14

2.2.5 User Output Commands........................................................................................................................... 15

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

3.1 Types and Functions of System Output Signals .................................................................................................... 16

3.2 Usage of System Output Signals ........................................................................................................................... 17

3.2.1 Robot Initialized (output)......................................................................................................................... 17

3.2.2 Auto Mode (output).................................................................................................................................. 18

3.2.3 Operation Preparation Completed (output)............................................................................................. 19

3.2.4 Robot Running (output)............................................................................................................................20

3.2.5 CPU Normal (output) .............................................................................................................................. 21

3.2.6 Robot Error (output) ................................................................................................................................ 22

3.2.7 Battery Warning (output) .........................................................................................................................23

3.2.8 Continue Start Permission (output): Selectable by I/O hardware setting...................................... 24

3.2.9 Emergency Stop Circuit Contact Outputs (Standard type of controller).................................................. 25

3.2.10 Safety Circuit Contact Outputs (Global type of controller) .....................................................................28

3.3 Types and Functions of System Input Signals ....................................................................................................... 31

3.4 Usage of System Input Signals.............................................................................................................................. 32

3.4.1 Step Stop (All tasks) (input)...................................................................................................................... 32

3.4.2 External Emergency Stop (input) .............................................................................................................33

3.4.3 Enable Auto (input) (Standard type of controller).................................................................................... 34

3.4.4 Enable Auto (input) (Global type of controller)....................................................................................... 35

3.4.5 Protective Stop (input): Global type of controller ............................................................................ 36

3.5 Command Execution I/O Signals .......................................................................................................................... 37

3.5.1 General Information about Commands.................................................................................................... 37

3.5.2 Processing I/O Commands....................................................................................................................... 38

3.5.3 I/O Commands Details............................................................................................................................. 41

3.6 Example of Using System I/O Signals .................................................................................................................. 44

Chapter 4 Connector Pin Assignment and I/O Circuits (NPN type) .......................................................................... 48

4.1 Connector Pin Assignment (NPN type)................................................................................................................. 48

4.1.1 RS-232C (CN1): RS-232C connector...................................................................................................... 48

4.1.2 HAND I/O (CN9) ....................................................................................................................................49

4.1.3 Mini I/O (CN5): User- or System-I/O connector..................................................................................... 50

4.1.4 Safety I/O (CN10)：System-I/O connecter (Global type of controller).................................................. 52

4.2 Robot Controller I/O Circuits (NPN type)............................................................................................................. 53

4.2.1 Setting up Mini I/O Power Supply........................................................................................................... 53

4.2.2 User-Input, System-Input and Hand-Input Circuits (NPN type).............................................................. 54

4.2.3 User-Output, System-Output, and Hand-Output Circuits (NPN type)..................................................... 56

4.2.4 Configuration of Emergency Stop Circuitry (Standard type of controller)............................................. 59

4.2.5 Configuration of Safety Circuit (Global type of controller).....................................................................61

4.3 Wiring Notes for Controller I/O Connectors (NPN type)...................................................................................... 63

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

5.1 Connector Pin Assignment (PNP type).................................................................................................................. 65

5.1.1 RS-232C (CN1): RS-232C connector...................................................................................................... 65

5.1.2 HAND I/O (CN9) ....................................................................................................................................66

5.1.3 Mini I/O (CN5): User- or System-I/O connector..................................................................................... 67

5.1.4 Safety I/O (CN10)：System-I/O connecter (Global type of controller).................................................. 69

5.2 Robot Controller I/O Circuits (PNP type) ............................................................................................................. 70

5.2.1 Setting up Mini I/O Power Supply........................................................................................................... 70

5.2.2 User-Input, System-Input and Hand-Input Circuits (PNP type)............................................................... 71

5.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP type)...................................................... 73

5.2.4 Configuration of Emergency Stop Circuitry (Standard type of controller)............................................. 76

5.2.5 Configuration of Safety Circuit (Global type of controller).....................................................................78

5.3 Wiring Notes for Controller I/O Connectors (PNP type)....................................................................................... 80

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

6.1 Supplies for the Controller .................................................................................................................................... 82

6.2 Mounting the Controller ........................................................................................................................................ 82

6.2.1 Installation Requirements for the Controller............................................................................................ 82

6.2.2 Mounting the Robot Controller................................................................................................................ 83

6.3 I/O and AC Input Wiring ....................................................................................................................................... 85

6.3.1 Multi-core Cables with Connectors .........................................................................................................85

6.3.2 Wiring of Primary Power Source ............................................................................................................. 86

6.3.3 Disconnecting the Robot from the Power Source.................................................................................... 88

6.4 Cleaning the Air Intake Filters............................................................................................................................... 89

6.5 Replacing the Memory Backup Battery ................................................................................................................ 91

6.5.1 Replacing procedures............................................................................................................................... 91

6.5.2 Setting the Next Battery Replacement Date............................................................................................. 94

6.6 Replacing Fuses and Output ICs ........................................................................................................................... 95

6.6.1 Positions of Fuses and Output ICs ........................................................................................................... 95

6.6.2 Replacing procedures............................................................................................................................... 97

6.7 Replacing IPM Boards ........................................................................................................................................ 100

6.7.1 Location of IPM Boards......................................................................................................................... 100

6.7.2 Replacing the IPM board ....................................................................................................................... 101

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

7.1 Combination of I/O Extension Boards and Allocation Modes ............................................................................ 103

7.2 I/O Allocation in Individual Allocation Modes ................................................................................................... 104

7.3 Notes on Using I/O Extension Boards................................................................................................................. 104

7.4 Hand I/O (CN9): Common to All Allocation Modes........................................................................................... 105

7.5 I/O Allocation Tables for Individual Allocation Modes....................................................................................... 106

7.5.1 Mini I/O Board (CN5 on standard type of controller) in Mini I/O Dedicated Mode ............................. 106

7.5.2 Mini I/O Board (CN5 on global type of controller) in Mini I/O Dedicated Mode................................. 107

7.5.3 Mini I/O Board (CN5 on standard type of controller) in Compatible,

Standard and All User I/O Modes ..........................................................................................................

108

7.5.4 Mini I/O Board (CN5 on global type of controller) in Compatible, Standard,

and All User I/O Modes.........................................................................................................................

109

7.5.5 Parallel I/O Board in Compatible Mode ................................................................................................ 110

7.5.6 Parallel I/O Board in Standard Mode..................................................................................................... 111

7.5.7 Parallel I/O Board (1st) in All User I/O Mode ....................................................................................... 112

7.5.8 Parallel I/O Board (2nd) in All User I/O Mode...................................................................................... 113

7.5.9 DeviceNet Slave Board in Compatible Mode........................................................................................ 114

7.5.10 DeviceNet Slave Board in Standard Mode ............................................................................................ 115

7.5.11 DeviceNet Slave Board in All User I/O Mode....................................................................................... 116

7.5.12 CC-Link Board (2 stations occupied) in Compatible Mode................................................................... 117

7.5.13 CC-Link Board (3 stations occupied) in Compatible Mode................................................................... 118

7.5.14 CC-Link Board (4 stations occupied) in Compatible Mode................................................................... 119

7.5.15 CC-Link Board (2 stations occupied) in Standard Mode ....................................................................... 120

7.5.16 CC-Link Board (3 stations occupied) in Standard Mode ....................................................................... 121

7.5.17 CC-Link Board (4 stations occupied) in Standard Mode ....................................................................... 122

7.5.18 CC-Link Board (2 stations occupied) in All User I/O Mode .................................................................123

7.5.19 CC-Link Board (3 stations occupied) in All User I/O Mode .................................................................124

7.5.20 CC-Link Board (4 stations occupied) in All User I/O Mode .................................................................125

7.5.21 PROFIBUS-DP Slave Board in Compatible Mode................................................................................ 126

7.5.22 PROFIBUS-DP Slave Board in Standard Mode .................................................................................... 127

7.5.23 PROFIBUS-DP Slave Board in All User I/O Mode............................................................................... 128

7.5.24 DeviceNet Master Board in All User I/O Mode..................................................................................... 129

7.5.25 S-Link V Master Board in All User I/O Mode....................................................................................... 130

Chapter 8 I/O Allocation for I/O Conversion Box (only for standard type of controller)...................................... 131

8.1 I/O Allocation Modes with I/O Conversion Box Mounted.................................................................................. 131

8.2 I/O Allocation in Individual Allocation Modes ................................................................................................... 132

8.3 Notes on Using the I/O Conversion Box ............................................................................................................. 132

8.4 Allocation Common to All Allocation Modes ..................................................................................................... 133

8.4.1 I/O POWER (CN9): Common to All Modes .........................................................................................133

8.4.2 HAND I/O (CN9): Common to All Modes............................................................................................ 133

8.5 I/O Allocation Tables for Individual Allocation Modes....................................................................................... 134

8.5.1 OUTPUT (CN10) in I/O-Box Compatible Mode...................................................................................134

8.5.2 INPUT (CN8) in I/O-Box Compatible Mode ........................................................................................135

8.5.3 OUTPUT (CN10) in I/O-Box Standard Mode....................................................................................... 136

8.5.4 INPUT (CN8) in I/O-Box Standard Mode ............................................................................................. 137

8.5.5 OUTPUT (CN10) in I/O-Box All User I/O Mode .................................................................................138

8.5.6 INPUT (CN8) in I/O-Box All User I/O Mode .......................................................................................139

8.5.7 DeviceNet Slave Board in I/O-Box Compatible Mode.......................................................................... 140

8.5.8 DeviceNet Slave Board in I/O-Box Standard Mode.............................................................................. 141

8.5.9 CC-Link Board (2 stations occupied) in I/O-Box Compatible Mode ....................................................142

8.5.10 CC-Link Board (3 stations occupied) in I/O-Box Compatible Mode ....................................................143

8.5.11 CC-Link Board (4 stations occupied) in I/O-Box Compatible Mode ....................................................144

8.5.12 CC-Link Board (2 stations occupied) in I/O-Box Standard Mode......................................................... 145

8.5.13 CC-Link Board (3 stations occupied) in I/O-Box Standard Mode......................................................... 146

8.5.14 CC-Link Board (4 stations occupied) in I/O-Box Standard Mode......................................................... 147

8.5.15 PROFIBUS-DP Slave Board in I/O-Box Compatible Mode.................................................................. 148

8.5.16 PROFIBUS-DP Slave Board in I/O-Box Standard Mode...................................................................... 149

8.5.17 Parallel I/O Board in I/O-Box Al User I/O Mode .................................................................................. 150

8.5.18 DeviceNet Master Board in I/O-Box All User I/O Mode ......................................................................151

8.5.19 S-Link V Master Board in I/O-Box All User I/O Mode......................................................................... 152

1

Chapter 1

General Information about RC7M Controller

The RC7M controller is available in several models which differ in detailed
specifications to match robot models.

1.1 Controller Model Name on Nameplate

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

Coding of Controller Model Name

RC7M - VSG 6 B A - B P

(a) (b) (c) (d) (e) (f) (g)

Position

Code

sample

Denotes: Coding

(a) VSG Robot model name VMG: VM-G series, VSG: VS-G series,

VPG: VP-G series, HMG: HM-G series,
HSG: HS-G series, XRG: XR-G series

(b) 6 No. of controllable axes 4: 4 axes, 5/6: 5 or 6 axes, 6: 6 axes

(c) B Engineering symbol 1 B: Encoder B

C: Encoder C

(d) A Engineering symbol 2 A: 24V brake

(e) Engineering symbol 3 Blank: 200 VAC power

A: 100 VAC power

(f) B Controller type (Note) Blank: Standard type

B: Global type (with safety board)
C: Global type (with safety box)
D: UL-Listed（with safety board）
E: UL-Listed(with safety box)

(g) P I/O type Blank or N: NPN I/O

P: PNP I/O

(Note) For the differences between the global and standard types, see the next page.

2

Differences between Global and Standard Types of Robot Controllers

The global type of the robot controller has either a safety board or safety box which the
standard type has not. Described below are the functional differences between the
global and standard types.

[ 1 ] Deadman switch function (Enable switch function)

The global type controls the deadman switch provided on the teach pendant or
mini-pendant in a partially different way than the standard type does. When reading the
instruction manuals that are prepared for the standard type, be careful with the
following differences.

(1) Location of deadman switches (enable switches) on the teach pendant and mini-pendant

Deadman
switch
(Enable
switch)

Mini-pendant

(2) Difference in deadman switch operation

The table below lists the functional differences of the teach pendant and mini-pendant
between the global and standard types in Manual mode and Teach check mode.

Global type

Standard type

(described in the instruction manuals)

(1) Unless the deadman switch is held down, you

can neither

operate the robot nor turn the motor

power ON.

(1) Unless the deadman switch is held down, you

cannot operate the robot, but you can 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.

(2) When the robot is in operation, releasing the

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

Deadman switch
(Enable switch)

Teach pendant

3

[ 2 ] "Single point of control" function

The global type of the robot controller supports the "single point of control" function,
while other types do not.

(1) Single point of control

The "single point of control" function, which is one of the robot safety functions, limits
the robot control sources (command sources) to only one. This function is specified by
the parameter "Single point of control" that limits the control to either "Internal Auto" or
"External Auto" limited mode.

 Internal Auto limited mode

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

 External Auto limited mode

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

Note: In this mode, the teach pendant operation panel editor "Panel Designer" cannot
be used in External Auto.

(2) Setting the Internal/External Auto Limited Mode Parameters

Using the teach pendant, set the parameters with the following access.

Note 1: The "Internal Auto Limited Mode" is the factory default.
Note 2: The global type displays letter "A" following the robot type on the teach pendant

screen.

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

In Ver. 2.3 or later:
Access: [Top screen]—[F4 I/O]—[F6 Aux.]—[F4 Int/Ext]

"A" displayed

Setting on the "I/O Hardware Settings" window

"A" displayed

Setting on the "Single point of control" window

(Ver. 2.3 or later)

4

1.2 Names of the Controller Components

1.2.1 Controller Components

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

Front Panel

Connector No. Marking Name

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

(only on the global type)

Names of RC7M Robot Controller

5

1.2.2 Warning and Caution Labels

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

Location of Labels on the Controller

6

Warning and Caution Labels on the Robot Controller

Warning and caution labels on the controller Contents

Warning label 1

(For maintenance of the controller)
Risk of electrical shock.
Never open the controller cover when the power is ON.
Never touch the inside of the controller for at least 3

minutes even after turning the power OFF and
disconnecting the power cable.

Warning label 2

(For controller power switch)
Risk of injury.
Be sure to perform lockout/tagout before starting

servicing.
Turning the power ON may move the arm, causing injuries

if a person is inside the safety fence.

Caution label

(For cooling fans)
Risk of injury.
Do not insert fingers, sticks or other foreign objects

through the openings.

Caution label

The controller is not designed to be dust-, splash-, or
explosion-proof. Before installation, be sure to read the
user's manual.

Do not put anything on the controller or apply any impact
or shock to it.

Caution label

When using an external power source, never apply the
voltage not specified. Doing so can result in a controller
failure.

Caution label

After turning the power switch OFF, do not turn it ON for at
least six seconds.

7

1.3 Controller Specifications

[ 1 ] Specifications

The table below lists the robot controller specifications.

RC7M Robot Controller Specifications

Item Specifications

Robot series

VM-G series VS-G series VP-G series HM-G series HS-G series

XYC-4G

series

XR-G

series

Model (RC7M-)

VMG-

6∗∗∗-∗∗

VSG-

6∗∗∗-∗∗

VPG-

5/6∗∗∗-∗∗

HMG-

4∗∗∗-∗∗

HSG-

4∗∗∗-∗∗

XYCG-

4∗∗∗-∗∗

XR-

43***G*

Controllable axes 6 axes 5 or 6 axes

4 axes

Control system PTP, CP 3-dimensional linear, 3-dimensional circular

Drive system All axes: Full-digital AC servo

Language used DENSO robot language (conforming to SLIM)

Memory capacity 3.25 MB (equivalent to 10,000 steps, 30,000 points)

Teaching system

1) Remote teaching

2) Numerical input (MDI)

1) Direct teaching

2) Remote teaching

3) Numerical input (MDI)

1) Remote teaching

2) Numerical input
(MDI)

Mini I/O

Input: 8 user open points + 11 fixed system points
Output: 8 user open points + 14 fixed system points
(Note: The global type of the controller cannot use system-fixed emergency stop I/Os.)

Standard

I/O

HAND I/O

Input: 8 user open points
Output: 8 fixed system points

SAFETY I/O

(only on global type)

Input: 6 fixed system points
Output: 5 fixed system points

2 boards
mounted

Input: 80 user open points
Output: 96 user open points (addition possible)

Parallel I/O

extension

boards

(option)

Single

board

mounted

Input: 40 user open points
Output: 48 user open points (addition possible)

Master/

Slave

Input: 1024 points (master) + 256 points (slave)
Output: 1024 points (master) + 256 points (slave)

Master

Input: 1024 points
Output: 1024 points

DeviceNet

board

(option)

Slave

Input: 256 points
Output: 256 points

External

signals

(I/O)

CC-Link

board

(option)

Slave

Input: 128 points
Output: 128 points

External communication

RS-232C: 1 line
Ethernet: 1 line
USB: 2 lines (Supporting flash memory)

Extension slots 3 (For optional boards)

Self-diagnosis function Overrun, servo error, memory error, input error, etc.

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

Error display

Error codes will be outputted on the external I/O.
Error messages will be displayed in English on the teach pendant (option).
Error codes will be displayed on the mini-pendant (option).

Robot control
cable (option)

Standard: 4 m, 6 m,
12 m (Standard
type/splash-proof type)

Standard:
4 m, 6 m,
12 m

Standard: 4 m, 6 m,
12 m (Standard
type/splash-proof type)

Standard:

4 m, 6 m

Standard:
4 m, 6 m,
12m

I/O cable (option) 8 m, 15 m (for Mini I/O, HAND I/O, parallel I/O extension boards, safety I/O board)

Cables

Power cable 5 m

8

Item Specifications

Environmental conditions

(in operation)

Temperature: 0 to 40°C
Humidity: 90% RH or less (no condensation allowed) Altitude: 1,000m or less

VM-G series Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 3.3 kVA

VS-G series

Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1.85 kVA
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1.85 kVA

200 VAC type

Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1 kVA
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1 kVA

VP-G

series

100 VAC type Single-phase, 100 VAC -10% to 110 VAC +10%, 50/60 Hz, 1 kVA

HM-G series

Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 2.45 kVA
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 2.45 kVA

HS-G series

Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1.8 kVA
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1.8 kVA

XYC-4G series

Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1.15 kVA
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1.15 kVA

Power

source

XR-G series

Three-phase, 200 VAC -15% to 230 VAC +10%, 50/60 Hz, 1.8 kVA
Single-phase, 230 VAC -10% to 230 VAC +10%, 50/60 Hz, 1.8 kVA

External power
source

A 24 VDC ±10% should be supplied from external equipment.

I/O power

source

Internal power
source

A 24 VDC ±10% should be supplied internally in the robot
controller.

Note: Refer to Sections

4.2.1 and 5.2.1 "Setting
up Mini I/O Power
Supply."

Rated output current

VM-G series: Approx. 20 A , VS-G series: Approx. 11 A , VP-G series: Approx. 5 A ,
HM-G series: Approx. 19 A , HS-G series: Approx. 14 A, XR-G series:Approx. 10A

Safety category

With safety board: Compliant with safety category 3
With safety box: Compliant with safety category 4
(Only the controller with safety box is available to the XYC-4G series of robots.)

Degree of protection

IP20

Weight (Mass)

4-axis standard type: Approx. 17 kg
6-axis standard type: Approx. 18 kg
4-axis global type, UL-Listed (w/ safety board): Approx. 18 kg
6-axis global type, UL-Listed (w/ safety board): Approx. 19 kg
4-axis global type, UL-Listed (w/ safety box): Approx. 21 kg
6-axis global type, UL-Listed (w/ safety box): Approx. 22 kg

Note: When handling the controller, be sure to observe the following.

Controller Handling Notes

WARNING

- DO NOT touch fins. Their hot surfaces may cause severe burns.

- DO NOT insert fingers or foreign objects into openings. Doing so may cause

bodily injury.

- Before opening the controller cover and accessing the inside of the controller

for maintenance, be sure to turn off the power switch, disconnect the power
cable, and wait 3 minutes or more. This is for protecting you from electric shock.

- DO NOT connect or disconnect connectors to/from the controller when the AC

power or the 24 VDC power for I/O is being supplied. Doing so may cause
electric shock or controller failure.

CAUTION IN INSTALLATION

- This controller is not designed to be dust-, splash-, or explosion-proof.

- Read operation manuals before installation.

- Do not place anything on the controller or apply an impact or shock to the

controller.

- Avoid mounting the controller in an environment where excessive vibration is
applied to the controller.

CAUTION: The robot controller connectors are of a screw-lock type or ring-lock type.

Lock the connectors securely. If even one of the connectors is not locked,
weak contact may result thereby causing an error.

Be sure to turn the robot controller OFF before connecting/ disconnecting the

power connector or motor connector. Otherwise, the internal circuits of the
robot controller may be damaged.

9

[ 2 ] Outer Dimensions

The outer dimensions of the robot controller are shown below.

Outer Dimensions of RC7M Robot Controller

10

1.4 Controller System Configuration

1.4.1 Internal Circuits of the Controller (Typical configuration)

The block diagram below shows the internal circuits of the RC7M controller designed
for a 6-joint robot.

Block Diagram of the RC7M Controller

11

1.4.2 Typical Robot System Configuration

The block diagram below shows a typical robot system configuration.

Robot System Configuration

12

Chapter 2

General Information about the Interface

2.1 Types and General Information about I/O Signals

This section describes the I/O signals for the Robot Controller.
The I/O signals are grouped into user I/O signals and system I/O signals.

Note: For the interface to apply when an I/O extension board or I/O conversion box is
mounted, refer to Chapter 7 or 8 in this manual, respectively, and the OPTIONS
MANUAL.

2.1.1 Types of System I/O Signals (Standard type of controller)

Seven input points for command execution are used to direct program start and other
instructions as I/O commands.

The table below lists the types of system I/O signals.

Types of System I/O Signals (Standard type of controller)

Fixed by system

Type

No. of

points

Function

System input 4

External Emergency Stop 1, External Emergency Stop 2,
Enable Auto, Step Stop (All tasks)

System output

13

(Note)

Auto Mode, Robot Initialized, Robot Running, CPU Normal,
Robot Error, Operation Preparation Completed, Battery Warning,
Emergency Stop 1, Emergency Stop 2,
Deadman SW 1 [Enable SW 1], Deadman SW 2 [Enable SW 2],
Pendant Emergency Stop 1, Pendant Emergency Stop 2,
Continue Start Permission (selectable by I/O hardware setting)

(See Note below.)

Input for command
execution

7 Command (3 bits), data area (3 bits), and Strobe Signal

Output for command
execution

1 Command Processing Completed

Controlled by user program

Type

No. of

points

Function

User input 8

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

8

(Note)

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

HAND input

8

Inputs to read the external I/O status with an IN command or IO [ ] variable.
Used for checking the hand status.

HAND output 8

Outputs to issue signals to the external devices with SET and RESET
commands, etc.
Used for controlling the hand to open or close.

Note: Terminal #53 on CN5 (port 24) is assigned a user output by factory default. It can be assigned the
Continue Start Permission output signal with the I/O hardware setting.

13

2.1.2 Types of System I/O Signals (Global type of controller)

The global type of the controller concentrates emergency stop related system I/Os on
the safety I/O (CN10), so it does not use the Mini I/O (CN5). (Refer to Sections 4.1.3,

4.1.4, 5.1.3, and 5.1.4.)

It issues PROGRAM START commands as I/O commands by using seven command
execution inputs.

The table below lists the types of system I/O signals.

Types of System I/O Signals (Global type of controller)

Fixed by system

Type

No. of

points

Function

System input 7

External Emergency Stop 1, External Emergency Stop 2, Enable Auto 1,
Enable Auto 2, Step Stop (All tasks), Protective Stop 1, Protective Stop 2

System output

12

(Note)

Auto Mode, Robot Initialized, Robot Running, CPU Normal,
Robot Error, Operation Preparation Completed, Battery Warning,
Pendant Emergency Stop 1, Pendant Emergency Stop 2,
Deadman SW 1 [Enable SW 1], Deadman SW 2 [Enable SW 2],
Contactor Contact Monitor, Continue Start Permission (selectable by I/O

hardware setting) (Note)

Input for command
execution

7 Command (3 bits), data area (3 bits), and Strobe Signal

Output for command
execution

1 Command Processing Completed

Controlled by user program

Type

No. of

points

Function

User input 8

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

7

(Note)

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

HAND input 8

Inputs to read the external I/O status with an IN command or IO [ ] variable.
Used for checking the hand status.

HAND output 8

Outputs to issue signals to the external devices with SET and RESET
commands, etc.

Used for controlling the hand to open or close.

Note: Terminal #53 on CN5 (port 24) is assigned a user output by factory default. It can be assigned the
Continue Start Permission output signal with the I/O hardware setting.

14

2.2 Usage of User I/O Signals

User I/O signals are used as I/O type variables. Access the user I/O by writing it to the
I/O type variables or reading it.

2.2.1 I/O Type Variable Declaration

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

2.2.2 I/O Type Global Variables

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

I/O type global variables are expressed in either of the following two ways:

IO [nn] (nn denotes I/O port number) Example: IO [104]
IOnn (nn denotes I/O port number) Example: IO104

2.2.3 I/O Type Local Variables

I/O type local variables are used to collectively refer to or change 1-bit, 8-bit, 16-bit or
32-bit user I/O signals starting from a specified terminal number.

I/O type local variables require a declaration, which will be made with a DEFIO
command, before they are used. For further information about declarations with a
DEFIO command, refer to the PROGRAMMER'S MANUAL (I), Chapter 9, Section 9.7
"DEFIO (Statement) [Conforms to SLIM]."

2.2.4 User Input Commands

There are two types of user input commands, IN and WAIT. The IN command
substitutes the input result for a variable. The WAIT command waits until the input
result meets specified conditions.

• IN Command

The IN command inputs a signal from the user input specified by an IO type variable
and substitutes it for an arithmetic variable.

For further information about the IN command, refer to the PROGRAMMER'S MANUAL
(I), Chapter 13, Section 13.1 "IN."

• WAIT Command

The WAIT command suspends the execution of the program until specified conditions
are met. If an I/O type variable is used for the conditional statement, this command
suspends the execution of the program until the status of the signal from a specified
user input is checked and meets the specified conditions. For further information about
the WAIT command, refer to the PROGRAMMER'S MANUAL (I), Chapter 12, Section

12.5 "WAIT."

15

2.2.5 User Output Commands

There are three types of user output commands, SET, RESET and OUT. The SET and
RESET commands turn ON and OFF all user outputs specified by I/O type variables.
The OUT command outputs data to a specified user output.

• SET Command

The SET command turns ON all user outputs specified by I/O type variables.

For further information about the SET command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "SET."

• RESET Command

The RESET command turns OFF all user outputs specified by I/O type variables.

For further information about the RESET command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "RESET."

• OUT Command

The OUT command outputs data to the user output specified by an I/O type variable.

For further information about the OUT command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "OUT."

16

Chapter 3 System I/O Signals

3.1 Types and Functions of System Output Signals

The table below lists the system output signals.

Types and Functions of System Output Signals

Application Output signal name Function

Robot Initialized

Outputs to the external device that the
OPERATION PREPARATION command is
executable.

Auto Mode Outputs when the robot is in Auto mode.

Start-up

Operation Preparation
Completed

Outputs when the motor power is turned on and the
robot is in External auto mode.

Program execution Robot Running

Outputs when the robot is in operation (one or
more tasks are being executed).

CPU Normal

Outputs when the CPU of the robot controller is
normal.

Robot Error

Outputs when a servo error, program error, or any
other serious error occurs.

Error/Warning

Battery Warning

Outputs when the voltage of the encoder or
memory backup battery drops below the specified
level.

Continue

Continue Start Permission

Note: It is necessary to specify
this output signal by I/O
hardware setting beforehand.

Outputs when Continue Start is permitted.

Emergency Stop
(dual line)

Outputs when the robot is emergency-stopped.

Pendant Emergency Stop
(dual line)

Outputs the status of the emergency stop button
on the teach pendant or mini-pendant.

Emergency stop circuit

(Standard type of
controller)

Deadman SW [Enable SW]
(dual line)

Outputs the status of the deadman switch (enable
switch) on the teach pendant or mini-pendant.

Pendant Emergency Stop
(dual line)

Outputs the status of the emergency stop button
on the teach pendant or mini-pendant.

Deadman SW [Enable SW]
(dual line)

Outputs the status of the deadman switch (enable
switch) on the teach pendant or mini-pendant.

Safety circuit

(Global type of
controller)

Contactor Contact Monitor

Outputs the status of the auxiliary contact of the
motor contactor in the robot controller.

This signal comes on when the motor is turned on;
it comes off when the motor is turned off.

17

3.2 Usage of System Output Signals

The usage of each system output signal is described below:

3.2.1 Robot Initialized (output)

(1) Function

This signal tells the external device that the OPERATION PREPARATION
command is ready to execute.

(2) Terminal number

#48 on connector CN5

(3) Usage

With this signal and Auto Mode output signal being ON, the OPERATION
PREPARATION command must be executed.

(4) ON conditions

This signal will be turned ON when:

(a) Turning the controller power on normally starts the system program in it

and the OPERATION PREPARATION command becomes ready to
execute.

(b) A robot error is cleared by the OK or Cancel key on the teach pendant or

mini-pendant or by Clear Robot Error (001) after this signal has been
turned OFF.

(5) OFF condition

This signal will be turned OFF when a robot error occurs.

Robot Initialized Output

Robot error

- Pressing the OK or Cancel key on the teach
pendant of mini-pendant has cleared a robot error.

- Entry of

Clear Robot Error (001) from an external

device has cleared a robot error.

After the power was turned ON,
the system has started normally.

18

3.2.2 Auto Mode (output)

(1) Function

This signal tells the external device that the robot is in Auto mode.

(2) Terminal number

#49 on connector CN5

(3) Usage

With this signal being ON, the OPERATION PREPARATION or PROGRAM
START command must be executed.

(4) ON condition

This signal will be turned ON when the robot controller enters Auto mode by
turning the mode selector switch on the teach pendant or mini-pendant to
AUTO with the Enable Auto input signal being ON.

(5) OFF conditions

This signal will be turned OFF under the following conditions.

(a) The operation mode is switched to the Manual or Teach check mode by

using the teach pendant or mini-pendant.

(b) The Enable Auto input signal is OFF.

Note: The Enable Auto input signal will not be turned OFF in the
pendantless state described in the OPTIONS MANUAL, Chapter 1,
Section 1.3.3.

Caution: The Auto Mode output signal will not be turned OFF with

INSTANTANEOUS STOP, STEP STOP or CYCLE STOP
commands.

Auto Mode Output

- The mode selector switch on the teach pendant or
mini-pendant is set to MANUAL or TEACH CHECK.

- Enable Auto OFF

19

3.2.3 Operation Preparation Completed (output)

(1) Function

This signal tells that the motor power is ON and the robot is in External auto
mode.

(2) Terminal number

#50 on connector CN5

(3) Usage

With this signal being ON, the robot must be in External auto mode and the
motor power must be ON to run the robot from the external device.

(4) ON conditions

The signal will be turned ON under the External auto mode and motor ON.

Operation to switch to External auto mode

(a) When the External mode is selected on the teach pendant or

mini-pendant.

(b) When the External mode is turned ON by the OPERATION

PREPARATION command from the external device.

Operation to switch the motor ON

(a) When the motor key is pushed on the teach pendant or mini-pendant.
(b) When the motor is turned ON by the OPERATION PREPARATION

command from the external device.

(5) OFF conditions

The signal will be turned OFF under the following conditions;

- Out of the External auto mode

- Under the motor OFF.

Operation to exit External auto mode

(a) When internal mode is selected on the teach pendant or mini-pendant.
(b) When the mode selector switch of the teach pendant or mini-pendant is

set to MANUAL or TEACH CHECK in External mode.
(c) When an Emergency Stop input signal is turned ON.
(d) When a Robot Error output signal is turned ON. (Except level 2 error)
(e) When an Enable Auto input signal is turned OFF.
(f) When a Protective Stop input signal is turned OFF. (Only for the global

type of controller)

Operation to switch the motor OFF

(a) When the motor power is turned off with the MOTOR key or the

emergency stop button is pressed on the teach pendant or mini-pendant.

(b) When a Robot Error output signal is turned ON.

Note: If any of ERROR 6071 to 607B, 6671 to 667B and 607F occurs in
the Manual mode or Teach check mode, the motor power will not be
turned OFF.

(6) Note for software version 2.00 or later

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

20

Operation Preparation Completed Output

3.2.4 Robot Running (output)

(1) Function

This signal tells the external device that the robot is in operation (that is, one

or more tasks are being executed).

(2) Terminal number

#46 on connector CN5

(3) Usage

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

Performing the "Stop all programs" operation* turns this signal OFF, allowing
you to check that all programs are stopped.

(4) ON conditions

This signal will be turned ON during execution of the program and also in the

WAIT STATE with a conditional branch or timer command.

(5) OFF conditions

This signal will be turned OFF with the "Stop all programs" operation*.

* "Stop all programs" operation
This operation includes the following: Depression of the emergency stop
button and STOP key and input of Step Stop (All task) and External
Emergency Stop signals.

Robot Running Output

Robot Running ON
(output) OFF

21

3.2.5 CPU Normal (output)

(1) Function

This signal tells the external device that the CPU of the robot controller is
normal.

(2) Terminal number

#45 on connector CN5

(3) Usage

(a) This signal is used to light the robot controller error indicator lamp on the

external operating panel.

(b) If this signal is turned OFF, perform the error recovery with the PLC.

(4) ON conditions

This signal will be turned ON by the hardware when the CPU of the robot
controller operates normally.

(5) OFF conditions

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

Caution: The OFF state of this signal indicates that the robot controller

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

CPU Normal Output

22

3.2.6 Robot Error (output)

(1) Function

This signal tells the external device that a servo error, program error, or any
other serious error has occurred in the robot.

(2) Terminal number

#47 on connector CN5

(3) Usage

(a) This signal is used to light the robot error indicator lamp on the external

operating panel.

(b) If this signal is turned ON, perform the error recovery with the PLC.

(4) ON conditions

When a level 2 error or higher one occurs.
Note: Except the error caused by the wrong operation of the teach pendant
or mini-pendant.

(5) OFF conditions

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

(a) When a Clear Robot Error (001) signal is inputted and the existing error

is cleared.

(b) When the existing error is cleared by operating the OK or Cancel key on

the teach pendant or the mini-pendant.

Robot Error Output

Robot Error ON
(output) OFF

- Input of Clear Robot Error (001)

- OK or CANCEL key operation on the
teach pendant or mini-pendant

23

3.2.7 Battery Warning (output)

(1) Function

This signal tells the external device that the voltage of the encoder or
memory backup battery has dropped below the specified level.

(2) Terminal number

#51 on connector CN5

(3) Usage

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

(4) Output condition

This signal will be issued when the voltage of the encoder or memory
backup battery has dropped below the specified level.

Note: The teach pendant or mini-pendant shows any of ERROR64A1 to
64A6 when the encoder backup battery voltage is low. Meanwhile, the
teach pendant shows ERROR6103 when the memory backup battery
voltage is low.

(5) OFF condition

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

Battery Warning Output

24

3.2.8 Continue Start Permission (output): Selectable by I/O hardware setting

Terminal #53 on CN5 (port 24) is assigned a user output by factory default. It
can be assigned the Continue Start Permission output signal with the I/O
hardware setting.

When the "Continue Start Permission" is set:

(1) Function

The controller will output this signal when Continue Start is permitted.

(2) Terminal number

#53 on connector CN5

(3) Usage

Use this signal when you want to know whether Continue Start is permitted.

(4) ON condition

This signal comes on when Continue Start is permitted. For details, refer to
the SETTING-UP MANUAL, Chapter 3, Section 3.4.5 "Continue Function."

(5) OFF condition

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

25

3.2.9 Emergency Stop Circuit Contact Outputs (Standard type of
controller)

3.2.9.1 Emergency Stop (output) (Standard type of controller)

(1) Function

This signal outputs the emergency stop status (dual line).

(2) Terminal number

Signal name Terminal number

Emergency Stop 1 #6 and #40 on CN5
Emergency Stop 2 #7 and #41 on CN5

(3) Usage

This signal is used to confirm that an Emergency Stop input has been
entered. For details about the emergency stop circuits, refer to Sections

4.2.4 and 5.2.4.

This signal can emergency-stop the external device when the emergency
stop button on the teach pendant or mini-pendant is pressed. Turning the
controller power OFF is functionally equivalent to the Emergency Stop
output.

Note: Do not enter this signal into the controller's External Emergency Stop
input circuit. Doing so makes it impossible to reset the emergency stop
state.

(4) Output conditions

Turning an External Emergency Stop input signal OFF or pressing the
emergency stop button on the teach pendant or mini-pendant turns OFF the
Emergency Stop output signal (mini relay contact in the controller).

Emergency Stop Output (Standard type of controller)

26

3.2.9.2 Pendant Emergency Stop Output (Standard type of controller)

(1) Function

This signal outputs the status of the emergency stop button on the teach
pendant or mini-pendant (dual line).

(2) Terminal number

Signal name Terminal number

Pendant Emergency Stop 1 #28 and #62 on CN5
Pendant Emergency Stop 2 #29 and #63 on CN5

(3) Usage

This signal is used to emergency-stop the external device when the
emergency stop button on the teach pendant or mini-pendant is pressed.
This signal is issued independently of the controller ON/OFF state.

For details about the emergency stop circuits, refer to Sections 4.2.4 and

5.2.4.

(4) Output conditions (Normal close type, b contact)

Two contacts of the emergency stop button (4b) on each of the teach
pendant or mini-pendant are connected each other. Pressing the
emergency stop button turns the Pendant Emergency Stop output signal
(contacts) OFF.

Pendant Emergency Stop Output (Standard type of controller)

27

3.2.9.3 Deadman SW [Enable SW] (output) (Standard type of controller)

(1) Function

This signal outputs the status of the deadman switch (enable switch) on the
teach pendant or mini-pendant (dual line).

(2) Terminal number

Signal name Terminal number

Deadman SW 1 [Enable SW 1] #8 and #42 on CN5
Deadman SW 2 [Enable SW 2] #9 and #43 on CN5

(3) Usage

This signal is used to display the operation status of the deadman switch or
interlock the deadman switch with other device (e.g., stopping or running the
conveyor).

For details about the emergency stop circuits, refer to Sections 4.2.4 and

5.2.4.

(4) Output conditions

Holding down the deadman switch closes the mini relay contact in the
controller, turning ON the Deadman SW output signal (Contact output:
close).

Deadman SW Output (Enable SW Output) (Standard type of controller)

28

3.2.10 Safety Circuit Contact Outputs (Global type of controller)

3.2.10.1 Pendant Emergency Stop (output) (Global type of controller)

(1) Function

This signal outputs the status of the emergency stop button on the teach
pendant or mini-pendant (dual line).

(2) Terminal number

Signal name Terminal number

Pendant Emergency Stop 1 #13 and #31 on CN10
Pendant Emergency Stop 2 #14 and #32 on CN10

(3) Usage

This signal is used to emergency-stop the external device when the
emergency stop button on the teach pendant or mini-pendant is pressed.
This signal is issued independently of the controller ON/OFF state.

For details about the safety circuits, refer to Sections 4.2.5 and 5.2.5.

(4) Output conditions (Normal close type, b contact)

Two contacts of the emergency stop button (4b) on each of the teach
pendant or mini-pendant are connected each other. Pressing the
emergency stop button turns the Pendant Emergency Stop output signal
(contacts) OFF.

Pendant Emergency Stop Output (Global type of controller)

29

3.2.10.2 Deadman SW [Enable SW] (output) (Global type of controller)

(1) Function

This signal outputs the status of the deadman switch (enable switch) on the
teach pendant or mini-pendant (dual line).

(2) Terminal number

Signal name Terminal number

Deadman SW 1 [Enable SW 1] #15 and #33 on CN10
Deadman SW 2 [Enable SW 2] #16 and #34 on CN10

(3) Usage

This signal is used to display the operation status of the deadman switch or
interlock the deadman switch with other device (e.g., stopping or running the
conveyor).

For details about the safety circuits, refer to Sections 4.2.5 and 5.2.5.

(4) Output conditions

Holding down the deadman switch closes the safety relay contact in the
controller, turning ON the Deadman SW output signal (Contact output:
close).

Deadman SW Output (Enable SW Output) (Global type of controller)

30

3.2.10.3 Contactor Contact Monitor (output) (Global type of controller)

(1) Function

This signal outputs the status of the auxiliary contact of the motor contactor
in the robot controller. The contact output signal comes on when the motor is
turned on; it comes off when the motor is turned off.

(2) Terminal number

#17 and #35 on CN10

(3) Usage

This signal is used to confirm the ON/OFF state of the motor on the monitor.

For details about the safety circuits, refer to Sections 4.2.5 and 5.2.5.

Contactor Contact Monitor Output (Global type of controller)

31

3.3 Types and Functions of System Input Signals

The table below lists the system input signals.

Types and Functions of System Input Signals

Use to:

Applicable

controller type

Signal name Function

Step Stop (All tasks)

Releasing the signal step-stops all programs
being executed.

Any type

Instantaneous Stop
(All tasks)

(Note 2)

Releasing this signal instantaneously stops all
programs being executed.

Standard type External Emergency

Stop (dual line)

Releasing this signal stops the robot in an
emergency.

Stop

(Note 1)

Global type External Emergency

Stop (dual line)

Releasing this signal stops the robot in an
emergency.

Standard type Enable Auto Short-circuiting this signal enables switching to

Auto mode.

Enable Auto
(dual line)

Select mode

Global type

Protective Stop
(dual line)

Short-circuiting this signal enables switching to
Auto mode.

The Enable Auto and Protective Stop input
signal circuits are connected in series in the
controller, so two types of inputs are available
as an automatic operation permission signal.

Strobe Signal This signal initiates the processing of the I/O

commands set in the data and command areas.

Data areas
(3 bits)

Prepare for
operation

Start program

Clear error

Any type

Command areas
(3 bits)

These areas are used to specify I/O commands
that enable the following:

- Start/stop each task program.

- Prepare for operation

- Clear robot errors.

Note: For details, refer to Section 3.5.3 "I/O
Commands Details

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

- The moment each of these signals is released, the corresponding stop processing starts.

- As long as it is not necessary to stop the robot, these stop signals should be short-circuited.

(Note 2)
The Instantaneous Stop signal becomes available only when an I/O extension board is used and the

allocation mode is changed to Standard or Compatible mode. Like other stop signals, this signal should be
short-circuited as long as it is not necessary to stop the robot.

32

3.4 Usage of System Input Signals

The usage of each system input signal is described below.

3.4.1 Step Stop (All tasks) (input)

(1) Function

This signal allows the external device to step-stop all tasks being executed,
except supervisory tasks.

(2) Terminal

#11 on connector CN5

(3) Input conditions and operation

(a) Turning (opening) this signal OFF stops all tasks upon completion of the

on-going step and turns OFF the Robot Running output signal.

(b) For resuming the program after a step stop, see Chapter 3, Section

3.5.3.2 "OPERATION PREPARATION (000)."

Step Stop (All tasks) Input

33

3.4.2 External Emergency Stop (input)

(1) Function

This signal allows the external device to emergency-stop the robot.

(2) Terminal number

Controller type Signal name Terminal number

External Emergency Stop 1 #2 and #36 on CN5

Standard type

External Emergency Stop 2 #3 and #37 on CN5
External Emergency Stop 1 #1 and #19 on CN10

Global type*

External Emergency Stop 2 #2 and #20 on CN10

* The global type of controller must use two separate contacts to control two

External Emergency Stop input signals. Two circuits connected in parallel using a
single contact or an always-shorted circuit will be interpreted as an external circuit
failure so that the circuitry will not operate.

(3) Input conditions and operation

(a) Turning (opening) this signal OFF emergency-stops the robot.

1) The OFF signal turns the motor power OFF irrespective of whether the
robot is in Manual, Internal auto, or External auto mode.

2) During execution of programs (Robot Running signal ON), the OFF
signal turns the motor power OFF and places the robot in internal
mode after decelerating the robot to a stop. It also resets programs so
as not to execute the subsequent and the following steps.

3) When the program is stopped in Manual or Auto mode, the OFF signal
produces nothing except it turns the power to the motor OFF.

(b) This signal must be turned ON (shorted) in order to turn the motor power

ON and run the robot in Manual or Auto mode.

(c) Opening the External Emergency Stop input is functionally equivalent to

pressing the emergency stop button on the teach pendant or
mini-pendant.

(4) Input timing

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

Notes

(1) The different status between two emergency stop circuits, if kept for

at least approx. one second, will be interpreted as an occurrence of
trouble, triggering an error "279E: Inconsistent robot stop input" and
shutting down the motor power.

(2) The global type of controller should control two external emergency

stop inputs with separate contacts. Two circuits connected in parallel
with a single contact or either one circuit always short-circuited will
be interpreted as an external circuit error, producing no circuit
operation.

34

3.4.3 Enable Auto (input) (Standard type of controller)

(1) Function

(a) Turning this signal ON (shorting) enables switching to Auto mode.
(b) Turning this signal OFF (opening) enables switching to Manual or Teach

check mode.

(2) Terminal number

#1 and #35 on connector CN5

(3) Usage

This signal is used to connect the Auto/Teaching selector switch of an
external operating panel.

(4) Input conditions and operation

(a) As shown below, the selectable operation mode depends on whether this

input is shorted or open.

(b) If the input becomes open during automatic operation, the mode will be

switched to Manual mode and ERROR21FC will be displayed.

(c) If manual operation or a teach check is conducted with this input shorted,

ERROR21F2 will be displayed.

(d) With this signal being opened, turning the mode selector switch on the

teach pendant or mini-pendant from the MANUAL or TEACH CHECK to
AUTO position triggers ERROR21F3.

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

displayed until the robot exits this state.

(e) Although ERROR21FD or ERROR21FC will be displayed when the state

is changed from

 to Δ or ×, they will not be displayed when the state is

changed from Δ or × to .

(f) Turning this signal OFF (open) in External mode switches to the internal

mode and turns the Operation Preparation Completed output signal OFF.

Relationship Between Enable Auto Input and Selectable Mode

Enable Auto

Operation mode Application

ON (shorted) OFF (open)

Manual mode

Manual operation with the teach pendant or
mini-pendant.

Δ 

Teach check mode Program check with the teach pendant or mini-pendant. Δ 

Internal auto mode

Automatic operation with the teach pendant or
mini-pendant.

 ×

External auto mode Automatic operation with the external device.  ×

Note:  = Mode selectable × = Mode not selectable
Δ = Mode selectable but manual operation program not executable

Caution: In the pendantless state, auto mode is valid even if the Enable Auto input is open. (The External

mode cannot be switched and the program cannot begin execution.)

Perform the following when operating the robot in the pendantless state:

(a) Set the robot so that it will not start to operate when the Enable Auto input is open.
(b) Enable Auto input open state and Auto Mode output (See Section 3.2.2 "Auto Mode

(output).")

Set the equipment to make an emergency stop in an AND state.

35

3.4.4 Enable Auto (input) (Global type of controller)

(1) Function

(a) Turning this signal ON (shorting) enables switching to Auto mode. (Dual

line)

Note: The Enable Auto and Protective Stop input signal circuits are

connected in series in the controller and those signals are used as an
automatic operation permission signal when turned ON (closed).

(b) Turning this signal OFF (opening) enables switching to Manual or Teach

check mode.

(2) Terminal number

Signal name Terminal number

Enable Auto input 1 #7 and #25 on CN10

Enable Auto input 2 #8 and #26 on CN10

Note: For the circuit configuration, refer to Sections 4.2.5 and 5.2.5. Two
Enable Auto input signal circuits must be controlled with two separate
contacts each. Two circuits connected in parallel using a single contact or
an always-shorted circuit will be interpreted as an external circuit error so
that the circuitry will not operate.

(3) Usage

This signal is used to connect the AUTO/TEACHING selector switch of an
external operating panel.

(4) Input conditions and operation (with Protective Stop input signal ON)

(a) As shown below, the selectable operation mode depends on whether this

input is shorted or open.

(b) Turning this signal OFF (open) during automatic operation turns the motor

power OFF (Continue stop) and displays ERROR21FC.

(c) If manual operation or a teach check is conducted with this input shorted,

ERROR21F2 will be displayed.

(d) With this signal being opened, turning the mode selector switch on the

teach pendant or mini-pendant from the MANUAL or TEACH CHECK to
AUTO position triggers ERROR21F3.

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

displayed until the robot exits this state.

(e) Although ERROR21FD or ERROR21FC will be displayed when the state

is changed from

 to Δ or ×, they will not be displayed when the state is

changed from Δ or × to .

(f) Turning this signal OFF (open) in External mode turns the motor and the

Operation Preparation Completed output signal OFF.

Relationship Between Enable Auto Input and Selectable Mode

(With Protective Stop input signal ON)

Enable Auto

Operation mode Application

ON (shorted) OFF (open)

Manual mode Manual operation with the teach pendant or mini-pendant. Δ 

Teach check mode Program check with the teach pendant or mini-pendant. Δ 

Internal auto mode

Automatic operation with the teach pendant or
mini-pendant.

 ×

External auto mode Automatic operation with the external device.  ×

Note:  = Mode selectable × = Mode not selectable
Δ = Mode selectable but manual operation program not executable

36

Caution: In the pendantless state, Auto mode is valid even if the Enable Auto input is open. (The

External mode cannot be switched and the program cannot begin execution.)

Perform the following when operating the robot in the pendantless state:

(a) Set the robot so that it will not start to operate when the Enable Auto input is open.
(b) Enable Auto input open state and Auto Mode output (See Section 3.2.2 "Auto Mode

(output).")

Set the equipment to make an emergency stop in an AND state.

3.4.5 Protective Stop (input): Global type of controller

(1) Function

Opening this input signal circuit in Auto mode allows the external device to
continue-stop the robot. (dual line)

Note: The Enable Auto and Protective Stop input signal circuits are
connected in series in the controller and those signals are used as an
automatic operation permission signal when turned ON (closed).

(2) Terminal number

Signal name Terminal number

Protective Stop input 1 #5 and #23 on CN10

Protective Stop input 2 #6 and #24 on CN10

(3) Usage

This signal is used for a safety door switch and other safety devices.

(4) Input conditions and operation (with Enable Auto input signal ON)

Note: The Enable Auto and Protective Stop input signal circuits are
connected in series in the controller and have the same function. (See
Section 3.4.4.)

(a) Turning this signal OFF (open) in Auto mode turns the motor power OFF

and continue-stops the robot.

(b) Turning this signal OFF (open) in Manual mode turns the motor power

OFF.

Note: For the circuit configuration, refer to Sections 4.2.5 and 5.2.5. Two

Protective Stop input signal circuits must be controlled with two separate
contacts each. Two circuits connected in parallel using a single contact or
an always-shorted circuit will be interpreted as an external circuit error so
that the circuitry will not operate.

(5) Input timing

In Auto mode, this signal will be processed prior to other input signals and all
commands.

Note: Switching the Protective Stop and Enable Auto input signals from

open to close does not require temporal conditions, but requires any
action to switch.

37

3.5 Command Execution I/O Signals

The I/O commands can be executed using command execution I/O signals.
I/O commands execute the following.

⋅ Start/stop each task program.
⋅ Enable running the robot from the external device.
⋅ Clear robot errors.

3.5.1 General Information about Commands

The table below shows the I/O commands functions.

I/O Command Functions

Command Description of function

Program Operation

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

⋅ Resets the program (specified program/all programs).

Operation Preparation

⋅ Enables running the robot from the external device.

Clear Robot Error

⋅ Clears a robot error from the external device.

38

3.5.2 Processing I/O Commands

3.5.2.1 General Information about Processing

I/O commands to be executed are processed as shown below.

Outline of I/O Command Processing

(1) Set a command area and a data area (if necessary) for the command

execution I/O signal from the external device to the robot controller.

Note: The data to be set must be defined at least 1 ms before the Strobe

Signal is turned ON

(2) After completion of setting, turn the Strobe Signal ON.
Note: The command input with a Strobe Signal should be preceded by the

output of the Robot Initialized. If a Robot Error signal has been issued,
however, execute a Clear Robot Error (001) since no Robot Initialized will
be issued.

39

(3) The controller reads the command area and the data area according to the

input of Strobe Signal.

(4) The controller starts processing based on the command read.

(5) After completion of command processing, the controller turns ON the

Command Processing Completed signal.

If an error has occurred during processing, a Robot Error signal will be

outputted together with the Command Processing Completed signal.

Note: If the Strobe Signal is turned OFF before the Command Processing

Completed signal is turned ON, the Command Processing Completed
signal will be output and then turned OFF within 100 ms

(6) The PLC waits until the Command Processing Completed signal is input.

In this case, confirm that no error exists with the robot.

(7) The PLC turns OFF the command and data areas and the Strobe Signal.

(8) As soon as the Strobe Signal is turned OFF, the controller turns OFF the

Command Processing Completed signal.

The Robot Error signal, which is outputted due to a command processing

error, remains ON until Clear Robot Error (001) is executed.

Note: The maximum allowable time from when the Strobe Signal is turned

OFF until the Command Processing Completed signal is turned OFF, is 100
ms.

3.5.2.2 Using Each Signal Line

[ 1 ] Command and Data Areas

This section describes the usage of the command area (3 bits, input) and data
area (3 bits, input).

(1) Function

Specifies the commands to be executed by the Robot Controller.
Sets the command area at all times, and data area if necessary.

(2) Terminal numbers

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

(3) Input conditions and operation

(a) Set the command area whenever I/O commands are to be executed. Set

data for data area if commands require them.
(b) "Shorted" represents the bit value = 1.
"Open" represents the bit value = 0.
(c) Input the command area and data area before the Strobe Signal (1 ms or

more). Retain the status until the Command Processing Completed signal

is output.

40

[ 2 ] Strobe Signal (input)

(1) Function

This signal informs the Robot Controller that the command area and data
area have been set. Additionally it directs the start of command processing.

Caution: Perform command (Except Clear Robot Error (001)) input with a

Strobe Signal after the system output signal "Robot Initialized"

is output.

(2) Terminal number

#12 on connector CN5.

(3) Input conditions and operation

By turning ON this input in Auto or External mode, the robot controller reads
the command area and data area, and starts processing.

[ 3 ] Command Processing Completed (output)

(1) Function

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

(2) Terminal number

#52 on connector CN5.

(3) Usage

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

(4) ON conditions

(a) The signal will be turned ON upon completion of processing the I/O

command given.

(b) If an error occurs as a result of executing an I/O command, the Robot

Error signal and the Command Processing Completed signal will be
turned simultaneously ON.

(5) OFF conditions

(a) The signal will be turned OFF when the Strobe Signal is turned OFF.
(b) If the Strobe Signal is turned OFF before command processing is

completed, the Command Processing Completed signal will be output

and then turned OFF within 100 ms.

41

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

000
Operation Preparation

001 Motor Power ON, CAL Execution
010 External speed 100
100 External Mode switching
111 Execution of all above
(Motor Power
ON→CAL→SP100→External)

001

Clear Robot Error

⎯

010
Program Start

Program number

011
Continue Start

⎯

100
Specified Program Reset

Program number

101
All Programs Reset

⎯

3.5.3.2 OPERATION PREPARATION (000)

(1) Function

Prepares to operate the robot by switching the operation mode from the
external devices.

(2) Format

Command area (3 bits, input)
000

Data area (3 bits, input)

0 bit: Motor Power ON, CAL Execution
1 bit: External speed 100
2 bit: External mode switching

These bits can be set at the same time and can be executed. If plural bits are
set, the commands are executed in order.
For example: If the 0 bit, 1 bit and 2 bit are set, commands are executed as
follows;
Motor Power ON, CAL Execution, External speed 100 and External mode
switching

(3) Description

This command can be executed in Auto mode. In other modes, an error

occurs at execution. When executing this command, select the Internal auto
mode on the teach pendant or mini-pendant beforehand.

42

3.5.3.3 CLEAR ROBOT ERROR (001)

(1) Function

This command clears a robot error that has been caused.

(2) Format

Command area (3 bits, input)
001

Data area (3 bits, input):
Nothing will be input.

(3) Description

If a robot error occurs, this command clears it. When there is no failure, no
processing will take place
When an error is displayed, the same processing as when the OK or Cancel
key of the teach pendant or the mini-pendant is operated will be performed.

3.5.3.4 PROGRAM START (010)

(1) Function

This command starts the specified program in the data area.

(2) Format

Command area (3 bits, input)
010

Data area (3 bits, input)
Program number: Program number to be started.
If the specified number is "n", PRO n starts.

(3) Description

This command is executable only in External mode. An error will occur in other
modes. This command starts the program of the program number specified in
data area. PRO 0 to PRO 7 can be started.

One of the following operations takes place according to the operating status
of the program.

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

beginning.

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

following the suspended step.

⋅ If the specified program is instantaneously stopped (Halt), it will resume

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

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

displayed, and the program will stop.

43

3.5.3.5 CONTINUE START (011)

(1) Function

This command starts Continue Start.

(2) Format

Command area (3 bits, input)
011

Data area (3 bits, input):
Nothing will be input.

(3) Description

This command is executable only in External mode. An error will occur in
other modes.
An attempt to execute this command when the Continue Start Permission
signal is off, will cause an error (ERROR 27A8).

3.5.3.6 SPECIFIED PROGRAM RESET (100)

(1) Function

This command immediately stops and also initializes the program of the
program number specified in data area.

(2) Format

Command area (3 bits, input)
100

Data area (3 bits, input):
Program number: The program number to be reset.
If the number "n" is specified in data area, resets PRO n.

(3) Description

This command can reset the programs for PRO 0 to PRO 7.

One of the following operations takes place according to the operating
status of the program.

⋅ When the specified program is terminated (stopped), nothing will

happen.

⋅ When the specified program is step-stopped or immediately stopped

(halt), it will be initialized. The initialized program will resume from the
beginning.

⋅ When the specified program is running, it will immediately stop (halt)

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

44

3.5.3.7 ALL PROGRAMS RESET (101)

(1) Function

This command immediately stops all programs and also initializes them.

(2) Format

Command area (3 bits, input)
101

Data area (3 bits, input):
Nothing will be input.

(3) Description

This command can reset all programs.

One of the following operations takes place according to the operating
status of the program.

⋅ When the specified program is terminated (stopped), nothing will

happen.

⋅ When the specified program is step-stopped or immediately stopped

(halt), it will be initialized. The initialized program will resume from the
beginning.

⋅ When the specified program is running, it will immediately stop (halt)

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

3.6 Example of Using System I/O Signals

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

(1) Equipment setup example

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

Example of Equipment Setup Using a Robot

45

Function Example of External Equipment Operating Panel

Classification Part Application

Display

Display Displays messages, such as ROBOT PREPARATION OK.

(1) Automatic operation

indicator

- Lights during automatic operation.

- Turned OFF when the robot is not in automatic operation.

(2) Robot external

running OK indicator

- Lights when the Operation Preparation Completed signal
is ON.

- Turned OFF when the Operation Preparation Completed
signal is OFF.

(3) Operation OK

indicator

- Lights when the Enable Auto input signal is ON.

- Turned OFF when the Enable Auto input signal is OFF.

Lamp

(4) Robot home

position indicator

- Lights when the robot is in the home position for working.

- Turned OFF when the robot is out of the home position
for working.

(By programming with an user-output)

(1) Robot preparation

button

Starts the preparation of the robot.

(2) Automatic start

button

Starts the operation of the equipment.

(3) Cycle stop button

Stops the equipment after a cycle of operations is
completed.

Switch

(4) Operation/

Adjustment selector
switch

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 necessary functions.

(2) Outline of procedure

Described below is the outline of the procedure for using the equipment
taken as an example shown on the previous page.
Follow steps (a) to (d).

(a) Operation preparation

The OPERATION PREPARATION command brings to be able to operate
the robot into external automatic operation mode. This operation will be
completed when the Operation Preparation Completed signal is turned

ON.
(b) Operation start area check
When the robot arm is in the home position for working, the robot home

position indicator lights and "ROBOT PREPARATION OK" displays.

(c) Automatic operation

Start the program by which the robot starts from the home position for

working, performs operations, and returns to the home position.
(d) Operation end

Terminate the day’s operations with a cycle stop, and turn OFF the

power.

(3) Start and stop procedure, and system I/O signals

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

46

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

Step

Worker’s operation and display on

equipment’s operation panel

PLC processing Robot operation

(a) Operation preparation

(b) Operation start area check

(Continued on following page)

Equipment power ON

Setting
operation/adjustment
selector switch to
operation

Enable Auto ON

Operation OK indicator
ON

Setting Mode selector
switch of the teach
pendant or the
mini-pendant to AUTO

Robot preparation
button ON

(Note 1)

Command area input ON

Executing Operation
Preparation command

Setting SP100

Robot external running
OK indicator ON

Switching mode to

external mode

(Internal processing)

Operation Preparation

Com

p

leted signal ON

Robot external running OK
indicator

Run the user program for moving
robot arm close to the home
position, when the robot home

p

osition indicator is OFF.

Robot home position
indicator ON

Robot preparation OK
display

(Internal processing)

When both are ON

(Internal processing)

Motor power ON

(Internal processing)

User output signal ON

(for robot home position)

47

(Continued from preceding page)

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

Step

Worker’s operation and display on

equipment’s operation panel

PLC processing Robot operation

(c) Automatic operation

(Note 2)

(d) Operation end

Note 1: Refer to Section 3.5.3.2, "OPERATION PREPARATION (000)."

Note 2: Refer to Section 3.5.3.4, "PROGRAM START (010)."

Note 3: Symbol signification

: System I/O signal : Flow of signal

Equipment’s Automatic

Start Button ON

Executing Program
Operation Command
(Program start)

Automatic Operation
indicator ON

Program Number
selection

Program start
command ON

Equipment power OFF

(Internal processing)

Robot Running signal

OFF

Equipment’s Cycle
Stop button ON

Automatic operation
indicator OFF

Data area input ON

Robot Running signal

OFF

Re

p

eated

Executing 1-cycle

END

END

Program start

Cycle Stop ON

Program Number
selection

48

Chapter 4

Connector Pin Assignment and I/O Circuits

(NPN type)

This chapter explains the connector pin assignment and circuits of NPN type (source
input and sink output) on an I/O board. I/O boards designed for the use in Japan are of
an NPN type.

For a PNP type (sink input and source output), refer to Chapter 5, "Connector Pin
Assignment and I/O Circuits (PNP type)."

4.1 Connector Pin Assignment (NPN type)

This section describes the pin assignment of I/O connectors on the robot controller.

4.1.1 RS-232C (CN1): RS-232C connector

RS-232C (CN1) Pin Assignment

Terminal No. Name Terminal No. Name

1

⎯

6 DSR

2

RXD 7 RTS

3

TXD 8 CTS

4

DTR 9

⎯

5

SG

49

4.1.2 HAND I/O (CN9)

HAND I/O (CN9) Pin Assignment (NPN type)

View from the cable side

Wire color Wire color

Termin al

No.

Name

Port

No.

Standard

Reinforced

Termin al

No.

Name

Port

No.

Standard

Reinforced

1 Hand output 64 Black Blue 11 Hand input 50 Pink White

2 Hand output 65 Brown Yellow 12 Hand input 51 Pink White

3 Hand output 66 Black Green 13 Hand input 52 White White

4 Hand output 67 Brown Red 14 Hand input 53 White White

5 Hand output 68 Red Violet 15 Hand input 54 White White

6 Hand output 69 Orange Blue 16 Hand input 55 White Brown

7 Hand output 70 Yellow Yellow 17 Internal power

source output
+24V

⎯ White Brown

8 Hand output 71 Green Green 18 Internal power

source output
0V

⎯ White Brown

9 Hand input 48 Blue Red 19 NC ⎯ White Brown

10 Hand input 49 Violet Violet 20 NC ⎯ White Brown

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #11, #2 and #12, #10 and #20.

Note 2: The unused pins should be prevented from direct contact with other pins or conductive part. Direct contact could result in a

controller failure or damage.

50

4.1.3 Mini I/O (CN5): User- or System-I/O connector

[ 1 ] Standard type of controller

Mini I/O (CN5) Pin Assignment (For standard type of controller)

View from the cable side

Ter mi na l

No.

Signal name

Port

No.

Wire

color

Ter mi na l

No.

Signal name

Port

No.

Wire

color

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

2

External Emergency Stop 1, b-1 (input)
(Internal +24V)

⎯ Brown 36 External Emergency Stop 1, b-2 (input) ⎯ Pink

3

External Emergency Stop 2, b-1 (input)
(Internal +24V)

⎯ Red 37 External Emergency Stop 2, b-2 (input) ⎯ Pink

4 Reserved. ⎯ Orange 38 Reserved. ⎯ Pink
5 Reserved. ⎯ Yellow 39 Reserved. ⎯ Pink

6

Emergency Stop 1, -1 (output)
(Mini relay)

⎯ Black 40

Emergency Stop 1, -2 (output)
(Mini relay)

⎯ White

7

Emergency Stop 2, -1 (output)
(Mini relay)

⎯ Brown 41

Emergency Stop 2, -2 (output)
(Mini relay)

⎯ White

8

Deadman SW 1, -1 (output)
[Enable SW 1, -1] (Mini relay)

⎯ Red 42

Deadman SW 1, -2 (output)
[Enable SW 1, -2] (Mini relay)

⎯ White

9

Deadman SW 2, -1 (output)
[Enable SW 2, -1] (Mini relay)

⎯ Orange 43

Deadman SW 2, -2 (output)
[Enable SW 2, -2] (Mini relay)

⎯ White

10 ⎯ ⎯ Yellow 44 ⎯ ⎯ White

11 Step Stop (All tasks) (input) 0 Green 45 CPU Normal (No monitor allowed) (output) 16 White

12 Strobe Signal (input) 1 Blue 46 Robot Running (output) 17 White

13 Data area bit 0 (input) 2 Violet 47 Robot Error (output) 18 White

14 Data area bit 1 (input) 3 Gray 48 Robot Initialized (output) 19 White

15 Data area bit 2 (input) 4 Pink 49 Auto Mode (output) 20 White

16 Command area bit 0 (input) 5 Black 50 Operation Preparation Completed (output) 21 Gray

17 Command area bit 1 (input) 6 Black 51 Battery Warning (output) 22 Violet

18 Command area bit 2 (input) 7 Brown 52 Command Processing Completed (output) 23 Violet

19 User input 8 Red 53

User output/
Continue Start Permission (output)

24 Violet

20 User input 9 Orange 54 User output 25 Violet

21 User input 10 Yellow 55 User output 26 Violet

22 User input 11 Green 56 User output 27 Violet

23 User input 12 Blue 57 User output 28 Violet

24 User input 13 Gray 58 User output 29 Violet

25 User input 14 Pink 59 User output 30 Violet

26 User input 15 Brown 60 User output 31 Gray
27 ⎯ ⎯ Red 61 ⎯ ⎯ Gray

28

Pendant Emergency Stop 1, b-1 (output)
(Dry output)

⎯ Orange 62

Pendant Emergency Stop 1, b-2 (output)
(Dry output)

⎯ Gray

29

Pendant Emergency Stop 2, b-1 (output)
(Dry output)

⎯ Yellow 63

Pendant Emergency Stop 2, b-2 (output)
(Dry output)

⎯ Gray

30

Dedicated to conveyor tracking board
(when JP12 on mini I/O board is shorted.
Internal power source +24V)

⎯ Green 64

Dedicated to conveyor tracking board
(when JP13 on mini I/O board is shorted.
Internal power source 0V)

⎯ Gray

31 ⎯ ⎯ Blue 65 ⎯ ⎯ Gray
32 ⎯ Pink 66 ⎯ Gray

33 ⎯ Black 67 ⎯ Blue

34

DC power input +24V (when external
power source is used)

DC power output +24V (when internal
power source is used)

⎯ Brown 68

DC power input 0V (when external power
source is used)

DC power output 0V (when internal power
source is used)

⎯ Blue

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35, #2 and #36, #34 and #68.
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could

result in a controller failure or damage.

Note 3: To use Pendant Emergency Stop output signals, be sure to supply 24 V to terminals #28 and #29.

51

[ 2 ] Global type of controller (with safety board or safety box)

The global type of the controller handles stop-related I/Os by using the safety I/O
(CN10) given on the next page.

Mini I/O (CN5) Pin Assignment (For global type of controller)

View from the cable side

Ter mi na l

No.

Signal name

Port

No.

Wire

color

Ter mi na l

No.

Signal name

Port

No.

Wire
color

1 Reserved. ⎯ Black 35 Reserved. ⎯ Pink

2 Reserved. ⎯ Brown 36 Reserved. ⎯ Pink
3 Reserved. ⎯ Red 37 Reserved. ⎯ Pink

4 Reserved. ⎯ Orange 38 Reserved. ⎯ Pink
5 Reserved. ⎯ Yellow 39 Reserved. ⎯ Pink

6 Reserved. ⎯ Black 40 Reserved. ⎯ White
7 Reserved. ⎯ Brown 41 Reserved. ⎯ White

8 Reserved. ⎯ Red 42 Reserved. ⎯ White

9 Reserved. ⎯ Orange 43 Reserved. ⎯ White

10 ⎯ ⎯ Yellow 44 ⎯ ⎯ White

11 Step Stop (All tasks) (input) 0 Green 45

CPU Normal (No monitor allowed)
(output)

16 White

12 Strobe Signal (input) 1 Blue 46 Robot Running (output) 17 White

13 Data area bit 0 (input) 2 Violet 47 Robot Error (output) 18 White

14 Data area bit 1 (input) 3 Gray 48 Robot Initialized (output) 19 White

15 Data area bit 2 (input) 4 Pink 49 Auto Mode (output) 20 White

16 Command area bit 0 (input) 5 Black 50

Operation Preparation Completed
(output)

21 Gray

17 Command area bit 1 (input) 6 Black 51 Battery Warning (output) 22 Violet

18 Command area bit 2 (input) 7 Brown 52

Command Processing Completed
(output)

23 Violet

19 User input 8 Red 53

User output /
Continue Start Permission (output)

24 Violet

20 User input 9 Orange 54 User output 25 Violet

21 User input 10 Yellow 55 User output 26 Violet

22 User input 11 Green 56 User output 27 Violet

23 User input 12 Blue 57 User output 28 Violet

24 User input 13 Gray 58 User output 29 Violet

25 User input 14 Pink 59 User output 30 Violet

26 User input 15 Brown 60 Reserved. 31 Gray

27

⎯ ⎯

Red 61

⎯ ⎯

Gray

28 Reserved.

⎯

Orange 62 Reserved.

⎯

Gray

29 Reserved.

⎯

Yellow 63 Reserved.

⎯

Gray

30

Dedicated to conveyor tracking board
(when JP12 on mini I/O board is shorted.
Internal power source +24V)

⎯

Green 64

Dedicated to conveyor tracking board
(when JP13 on mini I/O board is shorted.
Internal power source 0V)

⎯

Gray

31

⎯ ⎯

Blue 65

⎯ ⎯

Gray

32

⎯

Pink 66

⎯

Gray

33

⎯

Black 67

⎯

Blue

34

DC power input +24V (when external
power source is used)

DC power output +24V (when internal
power source is used)

⎯

Brown 68

DC power input 0V (when external power
source is used)

DC power output 0V (when internal power
source is used)

⎯

Blue

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35, #2 and #36, #34 and #68.
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could

result in a controller failure or damage.

52

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

Safety I/O (CN10) Pin Assignment

View from the cable side

Ter mi na l

No.

Signal name

Port

No.

Wire
color

Ter mi na l

No.

Signal name

Port

No.

Wire

color

1 External Emergency Stop 1, b-1 (input)

Black 19 External Emergency Stop 1, b-2 (input)

Pink

2 External Emergency Stop 2, b-1 (input)

Brown 20 External Emergency Stop 2, b-2 (input)

Pink

3 Reserved.

Red 21 Reserved.

Pink

4 Reserved.

Orange 22 Reserved.

Pink

5 Protective Stop 1, -1 (input)

Yellow 23 Protective Stop 1, -2 (input)

Pink

6 Protective Stop 2, -1 (input)

Green 24 Protective Stop 2, -2 (input)

Pink

7 Enable Auto 1, -1 (input)

Blue 25 Enable Auto 1, -2 (input)

Pink

8 Enable Auto 2, -1 (input)

Black 26 Enable Auto 2, -2 (input)

Gray

9 ⎯

Brown 27 ⎯

Gray

10 Reserved.

Red 28 Reserved.

Gray

11 Reserved.

Orange 29 Reserved.

Gray

12 Reserved.

Yellow 30 Reserved.

Gray

13

Pendant Emergency Stop 1, b-1

(output)

Green 31

Pendant Emergency Stop 1, b-2

(output)

Gray

14

Pendant Emergency Stop 2, b-1

(output)

Blue 32

Pendant Emergency Stop 2, b-2

(output)

Gray

15

Deadman SW 1, -1 (output)

[Enable SW 1, -1]

(Safety relay)

Violet 33

Deadman SW 1, -2 (output)

[Enable SW 1, -2]

(Safety relay)

Gray

16

Deadman SW 2, -1 (output)

[Enable SW 2, -1]

(Safety relay)

Black 34

Deadman SW 2, -2 (output)

[Enable SW 2, -2]

(Safety relay)

White

17

Contactor Contact Monitor 1, -1

(output)

Brown 35

Contactor Contact Monitor 1, -2

(output)

White

18

Reserved.

Red 36 Reserved.

White

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #19, #2 and #20, #18 and #36.
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could

result in a controller failure or damage.

Note 3: To use Pendant Emergency Stop output signals, be sure to supply 24 V to terminals #13 and #14.

53

4.2 Robot Controller I/O Circuits (NPN type)

4.2.1 Setting up Mini I/O Power Supply

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

Power supply

for I/O

Jumper switches JP1 and JP3 on the

controller printed circuit board

Description

External
source

Short-circuit
pins 2 and 3
(factory
default)

Do not change the
factory default setting.

Internal
source

Short-circuit
pins 1 and 2,
and pins 3
and 4

Remove the controller
top cover and change
the JP1 and JP3
settings with short
sockets that come with
the robot.

Note: Switching the power supply setting for I/O from external to internal changes the
assignment to terminals #32 to #34 and #66 to #68 on CN5 from external DC power input to
internal DC power output. For details, refer to the circuit configuration examples in Sections

4.2.2 and 4.2.3.

54

4.2.2 User-Input, System-Input and Hand-Input Circuits (NPN type)

The figure below shows examples of the user-input, system-input and hand-input circuit
configurations and connections of the robot controller.

Notes

(1) In addition to PLCs, proximity switches and relay contacts can be directly

connected to the input terminals of the robot controller. Note that the leakage
current from the proximity switches should be 1 mA or below.

(2) Use multi-core shielding cables for protecting the controller from external noise and

ground them at the controller side.

(When the external power source is used)

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

55

(When the internal power source is used)

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

56

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

The following pages show examples of the configuration and connection of the robot
controller's user-output, system-output and hand-output circuits.

(1) The User-Output, System-Output and Hand-Output Circuits are open

collector output circuits.

(2) The maximum allowable source current is 70 mA.

Keep the current consumption of a device to be connected to the Robot

Controller, such as a PLC and a relay coil, below the allowable current.

(3) Select an induction load, such as a relay coil, which has a built-in diode (for

absorbing inverse electromotive force).

To use an induction load without a built-in diode, add a diode equivalent to

the 1S1888 (Toshiba) in close vicinity to the coil.

Caution: When externally attaching a diode, connect it with correct

polarity. Incorrect polarity may damage the Output circuit.

(4) Connecting a lamp requires a circuit through which dark current flows and

use a lamp whose rating is 0.5W or less.

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

circuit may be damaged by rush current that flows when the
lamp lights. To reduce rush current, select and connect a
resistor R that allows dark current 1/3 or less of the rated
current to flow when the lamp goes OFF.

Refer to next page.

(5) Use a multi-core shielding cable for the purpose of protecting the devices

from external noise. Ground it to the robot controller.

(6) +24V internal power source of the robot controller must not be grounded.

Caution: If the output terminal +24V of internal power source is

grounded, there may be a case where the controller is
damaged.

(7) For three seconds after the controller power is turned on, the I/O board will

be in a transient state, so do not use its output as valid signals.

57

(When the external power source is used)

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

58

(When the internal power source is used)

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

Example of Circuit with Lamp (NPN type)

59

4.2.4 Configuration of Emergency Stop Circuitry
(Standard type of controller)

4.2.4.1 External Emergency Stop and Enable Auto Input Circuits

(Standard type of controller)

The External Emergency Stop and Enable Auto input signals are important for safety.
Be sure to configure their circuits with contacts as shown below.

Note: For the overall configuration sample of an emergency stop circuit, refer to
Section 4.2.4.2 "Emergency Stop Circuit."

External Emergency Stop and Enable Auto Input Circuits (Standard type of controller)

60

4.2.4.2 Emergency Stop Circuit (Standard type of controller)

The following figure shows the example of configuration and connection of emergency
stop circuit on the standard type of the controller. In the RC7M controller, the
emergency stop circuit consists of dual safety circuits.

The emergency stop button on the teach pendant can be used also as an emergency
stop switch of the equipment.

Emergency Stop and Pendant Emergency Stop output signals

(1) Emergency Stop output signal

The internal relay receives the External Emergency Stop input signal and the

emergency stop input from the teach pendant to output this signal. When the power
is turned OFF, the controller is in the emergency stop state.

(2) Pendant Emergency Stop output signal (Dry output)

The two contacts on the emergency stop button (4b) on the teach pendant are

connected. This signal will be issued independent of the ON/OFF state of the
controller power.

Emergency Stop Circuit in the RC7M Controller (Standard type of controller)

61

4.2.5 Configuration of Safety Circuit (Global type of controller)

4.2.5.1 Input Circuit to the Safety Circuit

Input signals to the safety circuit are important for safety. Be sure to configure their
circuits with contacts as shown below, observing the notes given below.

Note: For the overall configuration sample of a safety circuitry, refer to Section 4.2.5.2
"Safety Circuit."

Precautions on Connecting the Safety I/O (CN10)

(1) Two External Emergency Stop input signals must be controlled with separate contacts. Two circuits

connected in parallel using a single contact or an always-shorted circuit will be interpreted as an
external circuit failure so that the emergency stop state cannot be reset.

(2) Two Protective Stop input signals and two Enable Auto input signals each must be controlled with

separate contacts. Two circuits connected in parallel using a single contact or an always-shorted
circuit will be interpreted as an external circuit failure so that the circuitry will not operate.

(3) The Enable Auto and Protective Stop input signals are connected in series in the controller, so two

types of inputs are available as an automatic operation permission signal.

(4) Switching the External Emergency Stop, Protective Stop, and Enable Auto input signals from open

to close does not require temporal conditions, but requires any action to switch.

Input Circuits to the Safety Circuits (Global type of controller)

62

4.2.5.2 Safety Circuit (Global type of controller)

The figure below shows an internal connection equivalent circuit for the safety circuit in

the global type of the controller. The actual safety circuit is configured with safety relays
and others.

Safety Circuit in the RC7M Controller (Global type of controller)

Note: Different stop states resulting from emergency stop input, Protective Stop, and Enable Auto (OFF)

(1) The emergency stop input (External Emergency Stop or teach pendant/mini-pendant input) shuts down

the power to the motor and resets the program, provided that the Continue parameter is set to the default
(0: Disable) in Continue setting.

(2) The Protective Stop or Enable Auto (OFF) input signal shuts down the power to the motor and places the

robot in the Continue Stop state.

63

4.3 Wiring Notes for Controller I/O Connectors (NPN type)

After the wiring of the controller's I/O connectors is completed, check the following
before turning ON the power:

Check point (1)

Using a circuit tester, check across the "+24V terminal" and "0V terminal" of each
connector and across the "E24V terminal" and the "E0V terminal" to see that there is
no continuity.

Caution: If the connector wiring between the Robot Controller's "+24V terminal" and "0V

terminal" and between the "E24V terminal" and the "E0V terminal" is shorted,
damage to the power circuit of the Robot Controller will result.

Check point (2)

Using a circuit tester, check across "each signal output terminal" and "+24V
terminal" or "E24V terminal" of each connector to see that there is no continuity.

Caution: If the wiring between "each signal output terminal" and "+24V terminal" or "E24V

terminal" of each connector is shorted, damage to the output circuit and power
circuit of the Robot Controller will result.

Caution: Wind adhesive vinyl tape around all ends of the unconnected wiring of each

connector to prevent them from contacting other wiring and parts, which results in
shorting.

Robot
controller

Circuit tester

"+24V terminal" and
"E24V terminal" of
the controller

"0V terminal" and "E0V terminal"
of the controller

External
device

Checking Example

64

Mini I/O connector (CN5)

View from the cable side

Terminal Number Name Meaning Check point

1 to 3 +24V internal power source terminal +24V internal power output (1)

45 to 60 Signal output terminal 0V (GND) at output (2)

External power
source

+24 VDC power source input 24 VDC power input (1)

32 to 34

Internal power
source

+24 VDC power source output 24 VDC power output (1)

External power
source

0 VDC power source input DC power input (GND) (1)

66 to 68

Internal power
source

0 VDC power source output DC power output (GND) (1)

HAND I/O connector (CN9)

View from the cable side

Terminal Number Name Meaning Check point

1 to 8 Hand output terminal 0V (GND) at output (2)

17 Internal power source output (+24V) 24 VDC power output (1)

18 Internal power source output (0V) DC power output (GND) (1)

65

Chapter 5

Connector Pin Assignment and I/O Circuits

(PNP type)

This chapter explains the connector pin assignment and circuits of PNP type (sink input
and source output) on an I/O board.

For an NPN type (source input and sink output), refer to Chapter 4, "Connector Pin
Assignment and I/O Circuits (NPN type)."

5.1 Connector Pin Assignment (PNP type)

This section describes the pin assignment of I/O connectors on the robot controller.

5.1.1 RS-232C (CN1): RS-232C connector

RS-232C (CN1) Pin Assignment

Terminal No. Name Terminal No. Name

1 ⎯

6 DSR

2

RXD 7 RTS

3

TXD 8 CTS

4

DTR 9

⎯

5 SG

66

5.1.2 HAND I/O (CN9)

HAND I/O (CN9) Pin Assignment (PNP type)

View from the cable side

Wire color Wire color

Term inal

No.

Name

Port

No.

Standard

Reinforced

Term inal

No.

Name

Port

No.

Standard

Reinforced

1 Hand output 64 Black Blue 11 Hand input 50 Pink White

2 Hand output 65 Brown Yellow 12 Hand input 51 Pink White

3 Hand output 66 Black Green 13 Hand input 52 White White

4 Hand output 67 Brown Red 14 Hand input 53 White White

5 Hand output 68 Red Violet 15 Hand input 54 White White

6 Hand output 69 Orange Blue 16 Hand input 55 White Brown

7 Hand output 70 Yellow Yellow 17 Internal power

source output
(0V)

⎯ White Brown

8 Hand output 71 Green Green 18 Internal power

source output
(+24V)

⎯ White Brown

9 Hand input 48 Blue Red 19 NC ⎯ White Brown

10 Hand input 49 Violet Violet 20 NC ⎯ White Brown

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #11, #2 and #12, #10 and #20.

Note 2: The unused pins should be prevented from direct contact with other pins or conductive part. Direct contact could result in a

controller failure or damage.

67

5.1.3 Mini I/O (CN5): User- or System-I/O connector

[ 1 ] Standard type of controller

Mini I/O (CN5) Pin Assignment (For standard type of controller)

View from the cable side

Ter mi na l

No.

Signal name

Port

No.

Wire

color

Ter mi na l

No.

Signal name

Port

No.

Wire

color

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

2

External Emergency Stop 1, b-1 (input)
(Internal +24V)

⎯ Brown 36 External Emergency Stop 1, b-2 (input) ⎯ Pink

3

External Emergency Stop 2, b-1 (input)
(Internal +24V)

⎯ Red 37 External Emergency Stop 2, b-2 (input) ⎯ Pink

4 Reserved. ⎯ Orange 38 Reserved. ⎯ Pink
5 Reserved. ⎯ Yellow 39 Reserved. ⎯ Pink

6

Emergency Stop 1, -1 (output)
(Mini relay)

⎯ Black 40

Emergency Stop 1, -2 (output)
(Mini relay)

⎯ White

7

Emergency Stop 2, -1 (output)
(Mini relay)

⎯ Brown 41

Emergency Stop 2, -2 (output)
(Mini relay)

⎯ White

8

Deadman SW 1, -1 (output)
[Enable SW 1, -1] (Mini relay)

⎯ Red 42

Deadman SW 1, -2 (output)
[Enable SW 1, -2] (Mini relay)

⎯ White

9

Deadman SW 2, -1 (output)
[Enable SW 2, -1] (Mini relay)

⎯ Orange 43

Deadman SW 2, -2 (output)
[Enable SW 2, -2] (Mini relay)

⎯ White

10 ⎯ ⎯ Yellow 44 ⎯ ⎯ White

11 Step Stop (All tasks) (input) 0 Green 45 CPU Normal (No monitor allowed) (output) 16 White

12 Strobe Signal (input) 1 Blue 46 Robot Running (output) 17 White

13 Data area bit 0 (input) 2 Violet 47 Robot Error (output) 18 White

14 Data area bit 1 (input) 3 Gray 48 Robot Initialized (output) 19 White

15 Data area bit 2 (input) 4 Pink 49 Auto Mode (output) 20 White

16 Command area bit 0 (input) 5 Black 50 Operation Preparation Completed (output) 21 Gray

17 Command area bit 1 (input) 6 Black 51 Battery Warning (output) 22 Violet

18 Command area bit 2 (input) 7 Brown 52 Command Processing Completed (output) 23 Violet

19 User input 8 Red 53

User output/
Continue Start Permission (output)

24 Violet

20 User input 9 Orange 54 User output 25 Violet

21 User input 10 Yellow 55 User output 26 Violet

22 User input 11 Green 56 User output 27 Violet

23 User input 12 Blue 57 User output 28 Violet

24 User input 13 Gray 58 User output 29 Violet

25 User input 14 Pink 59 User output 30 Violet

26 User input 15 Brown 60 User output 31 Gray
27 ⎯ ⎯ Red 61 ⎯ ⎯ Gray

28

Pendant Emergency Stop 1, b-1 (output)
(Dry output)

⎯ Orange 62

Pendant Emergency Stop 1, b-2 (output)
(Dry output)

⎯ Gray

29

Pendant Emergency Stop 2, b-1 (output)
(Dry output)

⎯ Yellow 63

Pendant Emergency Stop 2, b-2 (output)
(Dry output)

⎯ Gray

30

Dedicated to conveyor tracking board
(when JP12 on mini I/O board is shorted.
Internal power source output +24V)

⎯ Green 64

Dedicated to conveyor tracking board
(when JP13 on mini I/O board is shorted.
Internal power source output 0V)

⎯ Gray

31 ⎯ ⎯ Blue 65 ⎯ ⎯ Gray
32 ⎯ Pink 66 ⎯ Gray

33 ⎯ Black 67 ⎯ Blue

34

DC power input +24V (when external
power source is used)

DC power output +24V (when internal
power source is used)

⎯ Brown 68

DC power input 0V (when external power
source is used)

DC power output 0V (when internal power
source is used)

⎯ Blue

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35, #2 and #36, #34 and #68.
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could

result in a controller failure or damage.

Note 3: To use Pendant Emergency Stop output signals, be sure to supply 24 V to terminals #28 and #29.

68

[ 2 ] Global type of controller (with safety board or safety box)

The global type of the controller handles stop-related I/Os by using the safety I/O
(CN10) given on the next page.

Mini I/O (CN5) Pin Assignment (For global type of controller)

View from the cable side

Ter mi na l

No.

Signal name

Port

No.

Wire

color

Ter mi na l

No.

Signal name

Port

No.

Wire

color

1 Reserved. ⎯ Black 35 Reserved. ⎯ Pink

2 Reserved. ⎯ Brown 36 Reserved. ⎯ Pink

3 Reserved. ⎯ Red 37 Reserved. ⎯ Pink
4 Reserved. ⎯ Orange 38 Reserved. ⎯ Pink

5 Reserved. ⎯ Yellow 39 Reserved. ⎯ Pink
6 Reserved. ⎯ Black 40 Reserved. ⎯ White

7 Reserved. ⎯ Brown 41 Reserved. ⎯ White

8 Reserved. ⎯ Red 42 Reserved. ⎯ White
9 Reserved. ⎯ Orange 43 Reserved. ⎯ White

10 ⎯ ⎯ Yellow 44 ⎯ ⎯ White

11 Step Stop (All tasks) (input) 0 Green 45

CPU Normal (No monitor allowed)
(output)

16 White

12 Strobe Signal (input) 1 Blue 46 Robot Running (output) 17 White

13 Data area bit 0 (input) 2 Violet 47 Robot Error (output) 18 White

14 Data area bit 1 (input) 3 Gray 48 Robot Initialized (output) 19 White

15 Data area bit 2 (input) 4 Pink 49 Auto Mode (output) 20 White

16 Command area bit 0 (input) 5 Black 50

Operation Preparation Completed
(output)

21 Gray

17 Command area bit 1 (input) 6 Black 51 Battery Warning (output) 22 Violet

18 Command area bit 2 (input) 7 Brown 52

Command Processing Completed
(output)

23 Violet

19 User input 8 Red 53

User output /
Continue Start Permission (output)

24 Violet

20 User input 9 Orange 54 User output 25 Violet

21 User input 10 Yellow 55 User output 26 Violet

22 User input 11 Green 56 User output 27 Violet

23 User input 12 Blue 57 User output 28 Violet

24 User input 13 Gray 58 User output 29 Violet

25 User input 14 Pink 59 User output 30 Violet

26 User input 15 Brown 60 Reserved. 31 Gray

27

⎯ ⎯

Red 61

⎯ ⎯

Gray

28 Reserved.

⎯

Orange 62 Reserved.

⎯

Gray

29 Reserved.

⎯

Yellow 63 Reserved.

⎯

Gray

30

Dedicated to conveyor tracking board
(when JP12 on mini I/O board is shorted.
Internal power source output +24V)

⎯

Green 64

Dedicated to conveyor tracking board
(when JP13 on mini I/O board is shorted.
Internal power source output 0V)

⎯

Gray

31

⎯ ⎯

Blue 65

⎯ ⎯

Gray

32

⎯

Pink 66

⎯

Gray

33

⎯

Black 67

⎯

Blue

34

DC power input +24V (when external
power source is used)

DC power output +24V (when internal
power source is used)

⎯

Brown 68

DC power input 0V (when external power
source is used)

DC power output 0V (when internal
power source is used)

⎯

Blue

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35, #2 and #36, #34 and #68.
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could

result in a controller failure or damage.

69

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

Safety I/O (CN10) Pin Assignment

View from the cable side

Ter mi na l

No.

Signal name

Port

No.

Wire

color

Ter mi na l

No.

Signal name

Port

No.

Wire

color

1 External Emergency Stop 1, b-1 (input)

Black 19 External Emergency Stop 1, b-2 (input)

Pink

2 External Emergency Stop 2, b-1 (input)

Brown 20 External Emergency Stop 2, b-2 (input)

Pink

3 Reserved.

Red 21 Reserved.

Pink

4 Reserved.

Orange 22 Reserved.

Pink

5 Protective Stop 1, -1 (input)

Yellow 23 Protective Stop 1, -2 (input)

Pink

6 Protective Stop 2, -1 (input)

Green 24 Protective Stop 2, -2 (input)

Pink

7 Enable Auto 1, -1 (input)

Blue 25 Enable Auto 1, -2 (input)

Pink

8 Enable Auto 2, -1 (input)

Black 26 Enable Auto 2, -2 (input)

Gray

9 ⎯

Brown 27 ―

Gray

10 Reserved.

Red 28 Reserved.

Gray

11 Reserved.

Orange 29 Reserved.

Gray

12 Reserved.

Yellow 30 Reserved.

Gray

13

Pendant Emergency Stop 1, b-1

(output)

Green 31

Pendant Emergency Stop 1, b-2

(output)

Gray

14

Pendant Emergency Stop 2, b-1

(output)

Blue 32

Pendant Emergency Stop 2, b-2

(output)

Gray

15

Deadman SW 1, -1 (output)

[Enable SW 1, -1]

(Safety relay)

Violet 33

Deadman SW 1, -2 (output)

[Enable SW 1, -2]

(Safety relay)

Gray

16

Deadman SW 2, -1 (output)

[Enable SW 2, -1]

(Safety relay)

Black 34

Deadman SW 2, -2 (output)

[Enable SW 2, -2]

(Safety relay)

White

17

Contactor Contact Monitor 1, -1

(output)

Brown 35

Contactor Contact Monitor 1, -2

(output)

White

18 Reserved.

Red 36 Reserved.

White

Note 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #19, #2 and #20, #18 and #36.
Note 2: The reserved pins and output pins should be prevented from direct contact with other pins or conductive part. Direct contact could

result in a controller failure or damage.

Note 3: To use Pendant Emergency Stop output signals, be sure to supply 24 V to terminals #13 and #14.

70

5.2 Robot Controller I/O Circuits (PNP type)

5.2.1 Setting up Mini I/O Power Supply

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

Power supply

for I/O

Jumper switches JP1 and JP3 on the

controller printed circuit board

Description

External
source

Short-circuit
pins 2 and 3
(factory default)

Do not change the
factory default setting.

Internal
source

Short-circuit
pins 1 and 2,
and pins 3 and
4

Remove the controller
top cover and change
the JP1 and JP3
settings with short
sockets that come with
the robot.

Note: Switching the power supply setting for I/O from external to internal changes the
assignment to terminals #32 to #34 and #66 to #68 on CN5 from external DC power input to
internal DC power output. For details, refer to the circuit configuration examples in Sections 5.2.2
and 5.2.3.

71

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

The figure below shows examples of the user-input, system-input and hand-input circuit
configurations and connections of the robot controller.

Notes

(1) In addition to PLCs, proximity switches and relay contacts can be directly

connected to the input terminals of the robot controller. Note that the leakage
current from the proximity switches should be 1 mA or below.

(2) Use multi-core shielding cables for protecting the controller from external noise and

ground them at the controller side.

(When the external power source is used)

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

72

(When the internal power source is used)

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

73

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

The following pages show examples of the configuration and connection of the robot
controller's user-output, system-output and hand-output circuit.

(1) The User-Output, System-Output and Hand-Output Circuits are open

collector output circuits.

(2) The maximum allowable source current is 70 mA.

Keep the current consumption of a device to be connected to the Robot

Controller, such as a PLC and a relay coil, below the allowable current.

(3) Select an induction load, such as a relay coil, which has a built-in diode (for

absorbing inverse electromotive force).

To use an induction load without a built-in diode, add a diode equivalent to

the 1S1888 (Toshiba) in close vicinity to the coil.

Caution: When externally attaching a diode, connect it with correct

polarity. Incorrect polarity may damage the output circuit.

(4) Connecting a lamp requires a circuit through which dark current flows and

use a lamp whose rating is 0.5W or less.

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

circuit may be damaged by rush current that flows when the
lamp lights. To reduce rush current, select and connect a
resistor R that allows dark current 1/3 or less of the rated
current to flow when the lamp goes OFF.

Refer to next page.

(5) Use a multi-core shielding cable for the purpose of protecting the devices

from external noise. Ground it to the robot controller.

(6) +24V internal power source of the robot controller must not be grounded.

Caution: If the output terminal +24V of internal power source is

grounded, there may be a case where the controller is
damaged.

(7) For three seconds after the controller power is turned on, the I/O board will

be in a transient state, so do not use its output as valid signals.

74

(When the external power source is used)

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

75

(When the internal power source is used)

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

Example of Circuit with Lamp (PNP type)

76

5.2.4 Configuration of Emergency Stop Circuitry
(Standard type of controller)

5.2.4.1 External Emergency Stop and Enable Auto Input Circuits

(Standard type of controller)

The External Emergency Stop and Enable Auto input signals are important for safety.
Be sure to configure their circuits with contacts as shown below.

TIP: For the overall configuration sample of an emergency stop circuitry, refer to
Section 5.2.4.2 "Emergency Stop Circuit."

External Emergency Stop and Enable Auto Input Circuits (Standard type of controller)

77

5.2.4.2 Emergency Stop Circuit (Standard type of controller)

The following figure shows the example of configuration and connection of emergency
stop circuit on the standard type of the controller. In the RC7M controller, the
emergency stop circuit consists of dual safety circuits.

The emergency stop button on the teach pendant can be used also as an emergency
stop switch of the equipment.

Emergency Stop and Pendant Emergency Stop output signals

(1) Emergency Stop output signal

The internal relay receives the External Emergency Stop input signal and the

emergency stop input from the teach pendant to output this signal. When the power
is turned OFF, the controller is in the emergency stop state.

(2) Pendant Emergency Stop output signal (Dry output)

The two contacts on the emergency stop button (4b) on the teach pendant are

connected. This signal will be issued independent of the ON/OFF state of the
controller power.

Emergency Stop Circuit in the RC7M Controller (Standard type of controller)

78

5.2.5 Configuration of Safety Circuit (Global type of controller)

5.2.5.1 Input Circuit to the Safety Circuit

Input signals to the safety circuit are important for safety. Be sure to configure their
circuits with contacts as shown below, observing the notes given below.

Note: For the overall configuration sample of a safety circuitry, refer to Section 5.2.5.2
"Safety Circuit."

Precautions on Connecting the Safety I/O (CN10)

(1) Two External Emergency Stop input signals must be controlled with separate contacts. Two circuits

connected in parallel using a single contact or an always-shorted circuit will be interpreted as an
external circuit failure so that the emergency stop state cannot be reset.

(2) Two Protective Stop input signals and two Enable Auto input signals each must be controlled with

separate contacts. Two circuits connected in parallel using a single contact or an always-shorted
circuit will be interpreted as an external circuit failure so that the circuitry will not operate.

(3) The Enable Auto and Protective Stop input signals are connected in series in the controller, so two

types of inputs are available as an automatic operation permission signal.

(4) Switching the External Emergency Stop, Protective Stop, and Enable Auto input signals from open

to close does not require temporal conditions, but requires any action to switch.

Input Circuits to the Safety Circuits (Global type of controller)

79

5.2.5.2 Safety Circuit (Global type of controller)

The figure below shows an internal connection equivalent circuit for the safety circuit in

the global type of the controller. The actual safety circuit is configured with safety relays
and others.

Safety Circuit in the RC7M Controller (Global type of controller)

Note: Different stop states resulting from emergency stop input, Protective Stop, and Enable Auto (OFF)

(1) The emergency stop input (External Emergency Stop or teach pendant/mini-pendant input) shuts down

the power to the motor and resets the program, provided that the Continue parameter is set to the default
(0: Disable) in Continue setting.

(2) The Protective Stop or Enable Auto (OFF) input signal shuts down the power to the motor and places the

robot in the Continue Stop state.

80

5.3 Wiring Notes for Controller I/O Connectors (PNP type)

After the wiring of the controller's I/O connectors is completed, check the following
before turning ON the power:

Check point (1)

Using a circuit tester, check across the "+24V terminal" and "0V terminal" of each
connector and across the "E24V terminal" and the "E0V terminal" to see that there is
no continuity.

Caution: If the connector wiring between the Robot Controller's "+24V terminal" and "0V

terminal" and between the "E24V terminal" and the "E0V terminal" is shorted,
damage to the power circuit of the Robot Controller will result.

Check point (2)

Using a tester, check across "each signal output terminal" and "+24V terminal" or
"E24V terminal" of each connector to see that there is no continuity.

Caution: If the wiring between "each signal output terminal" and "+24V terminal" or "E24V

terminal" of each connector is shorted, damage to the Output circuit and power
circuit of the Robot Controller will result.

Caution: Wind adhesive vinyl tape around all ends of the unconnected wiring of each

connector to prevent them from contacting other wiring and parts, which results in
shorting.

Robot
controller

Circuit tester

"+24V terminal" and
"E24V terminal" of
the controller

"0V terminal" and "E0V terminal"
of the controller

External
device

Checking Example