FANUC CRX Operators Manual

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< Robot CRX series

MECHANICAL UNIT

OPERATOR'S MANUAL

© FANUC CORPORATION, 2020

B-84194EN/04

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•

Original Instructions

• The appearance and specifications of this product are subject to change without notice.

e and

Trade Law". The export from Japan may be subject to an export license by the

Should you wish to export or re-export these products, please contact FANUC for advice.

There are, however, a very

and if the manual

that any operations that are not explicitly described as being possible are "not possible".

Thank you very much for purchasing FANUC Collaborative Robot.

Before using the Robot, be sure to read the "SAFETY PRECAUTIONS" in this manual and
understand the content.

• No part of this manual may be reproduced in any form.

The products in this manual are controlled based on Japan's “Foreign Exchang
Foreign
government of Japan. Further, re-export to another country may be subject to the license
of the government of the country from where the product is re-exported. Furthermore, the
product may also be controlled by re-export regulations of the United States government.

In this manual, we endeavor to include all pertinent matters.
large number of operations that must not or cannot be performed,
contained them all, it would be enormous in volume. It is, therefore, requested to assume

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SAFETY PRECAUTIONS

This chapter explains cautions for safety usage of FANUC collaborative robot.

Robot cannot work without the end effector or peripheral equipment. By combined with the end effector
and peripheral equipment and assembling the system, robot can demonstrate works. In other words the
robot is one part of the system.

FANUC is not and does not represent itself as an expert in safety systems, safety equipment, or the specific
safety aspects of your company and/or its workplace. It is the responsibility of the owner, employer, or user
to take all necessary steps to guarantee the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation can best be determined by safety system
professionals.

FANUC therefore, recommends that each customer consult with such professionals in order to provide a
safe application.

Additionally, robot system owner, it is your responsibility to arrange for the training of the operator of a
robot system to recognize and respond to known hazards associated with robot to be aware of the
recommended operating procedures. Because FANUC prepare for the professional training course of the
robot, please use it.

It is recognized that the operational characteristics of robots can be significantly different from those of
other machines and equipment.
Robots are capable of high energy movements through a large volume beyond the base of robots.
Although, robot is substitution for work at dangerous zone or harmful zone, but it may cause work-related
accident by mistake. So perfect safety precautions for usage is required when installing it.
In order to prevent work-related accident by robot, as indicators of the steps that an employer should take
each safe standard (JIS, ISO, IEC) are provided, these shows the contents for during installation and
usage.

This chapter provides some hints and guidelines for the robot system safety design.

Before using the FANUC collaborative robot, be sure to read this manual to become familiar with those
contents.

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SAFETY PRECAUTIONS B-84194EN/04

1 DEFINITION OF WARNING AND CAUTION

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on
safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is
indicated by "NOTE". Please read each "WARNING", "CAUTION" and "NOTE" before using the
robots.

Symbol Definitions

WARNING

CAUTION

NOTE

• Check this manual thoroughly, and keep it handy for the future reference.

Used if hazard resulting in the death or serious injury of the user will be expected to
occur if he or she fails to follow the approved procedure.
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
damage may be expected to occur if he or she fails to follow the approved
procedure.
Used if a supplementary explanation not related to any of WARNING and CAUTION
is to be indicated.

2 FANUC COLLABORATIVE ROBOT

SYSTEM

2.1 OVERVIEW

The collaborative robot means the robot that work with workers.
The robot system that is designed with following this manual, can admit the safety work of person near the
moving robot.

System example：
Robot hands parts to person

This chapter explains cautions for safety usage of collaborative robot. So unless otherwise specified, in this
manual, “robot” means “collaborative robot”.

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If the robot contacts to person,
The robot stops.

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2.2 PURPOSE OF ROBOT

FANUC Robot series can be used for the following applications.

- Arc welding

- Handling

- Assembling

Required functionality for these applications is implemented by selecting an appropriate TOOL software.
Please consult your FANUC sales representative if you want to use the robot for any application other than
listed above.

Even when you use the robot for the purpose of any of the applications listed above, the robot must not be
under any of the conditions listed below. Inappropriate usage of robots may cause not only damage to the
robot system, but also serious injury or even death of the user in the premises.

• Flammable atmosphere

• Explosive atmosphere

• Radioactive environment

• In water or any kind of liquid

• Use of robot for the purpose of transferring human or animals

• Use of robot as a step (climbing upon the robot)

• Outdoor

• Use of robot under conditions not in accordance with FANUC recommended installation or usage

FANUC is not responsible for any damage caused by misuse of the robots.
Before using the robot, check the specifications of the robot, and then take adequate safety measures to
prevent hazardous conditions.

2.3 CONFIGURATION OF ROBOT SYSTEM

The following elements has been verified their safety.

• Robot

• Robot controller

• Robot teach pendant

• End effector

• Other peripheral devices (machine)

• Workpiece

Users conduct risk assessment of robot system, and the following elements must be prepared by the user
according to system configuration as the need arises.

• Safeguard

• Interlocked gate

• Interlocking device

Except the robot, the robot controller and the robot teach pendant depend on the system, so please them by
users. FANUC Robot has an interface to connect interlocking devices. So confirm the specifications and
design the interlock system.

Security is already confirmed against following components.

• Robot

• Robot controller and teach pendant

FANUC can not guarantee safety for end effector, other peripheral equipment and workpiece.
System designer must design the system in consideration of security according to safety standard.
Robot system designer must design the robot system to secure the security according to EN ISO 10218
(ANSI RIA ISO 10218) and Annex I of Machinery Directive.

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2.4 DEFNITION OF THE USER

The user can be classified as follows.

Collaborative worker

• Enter collaborative workspace, work with the robot

• Change the robot attitude by forcing robot directly, example push to escape function

• Restart the program with operator button set for collaborative worker.

Operator:

• Turns robot controller power ON/OFF

• Starts robot program from operator’s panel

Programmer:

• Operates the robot and performs the teaching using a teach pendant.

• Operates the robot and performs the teaching using the direct teach.

Maintenance engineer:

• Operates the robot

• Teaches robot inside the safety fence

• Maintenance (repair, adjustment, replacement)

Programmer and maintenance engineer must be trained specialized training for the robot.

Collaborative worker that may contact to robot must be informed regularly about the risks,
emergencies and necessary safety measures.

Table 2.4 (a) shows the workings to the collaborative robot. In this table, the symbol “” means the
working allowed to be carried out by the personnel.

Table 2.4 (a) List of workings to the collaborative robot

Power ON/OFF for Robot controller
Select operating mode (AUTO, T1, T2)
Select Remote/Local mode
Select robot program with teach pendant
Select robot program with external device
Start robot program with operator’s panel
Start robot program with teach pendant
Reset alarm with operator’s panel
Reset alarm with teach pendant
Set data on the teach pendant
Teaching with teach pendant
Teaching with direct teach
Emergency stop with operator’s panel
Emergency stop with teach pendant
Maintenance for operator’s panel
Maintenance for teach pendant
Enter collaborative workspace,
work with the robot
Restart the program with operator button
which is set for collaborative worker

Collaborative

worker

   
   

   

   

Operator

  

  

Programmer

or Teaching

operator

 
 
 
 

 
 
 
 
 
 

Maintenance

technician




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The collaborative worker, programmer and maintenance engineer take care of their safety using the
following safety protectors as the need arises, for example.

• Adequate clothes, uniform, overall for operation

• Safety shoes

• Helmet

• Protective glasses

In addition, a user in this manual means collaborative worker, programmer, teaching operator and
maintenance engineer

2.4.1 Robot Training

When people access the robot, the collaborative robot may move not stop. All people that may enter the
area where the collaborative robots are placed, must be trained following training

- The worker must be trained for the characteristic of the collaborative robot. The characteristic of the
collaborative robot is described in the whole this manual. Especially, refer to Section 3.6 in SAFETY
PRECAUTIONS in particular.

- Collaborative worker, operator work with collaborative robot may contact with the collaborative robot.
The workers must periodically trained for its danger and method to secure safety in emergency.

The programmer, teaching operator and maintenance engineer must be trained for the robot operating and
maintenance.
The required items are:

• Robot basic knowledge,

• Robot safety (laws, ordinances labor security hygiene rule, safety precautions)

• Practice of jog feed,

• Practice of robot manual operation and teaching

• Programming practice, teaching and playback practice,

• Practice of automatic operation,

• Explanation of configuration and function of robot,

• Explanation and practice of setting up frame,

• Explanation of interface between robot and peripheral device,

• Explanation and practice of initial setting,

• Explanation and practice of troubleshooting

• Explanation and practice of periodic checks and periodic replacement

• Explanation and practice of file input/output

• Explanation and practice of mastering, and

• Explanation and practice of disassemble and assemble of robots.

Some training courses for these items for the maintenance engineer or system engineer are provided in the
robot school and each technical service center. Contact your local FANUC representative

WARNING

Robot operating personnel such as programmers, teaching operators or

maintenance engineers must be properly trained. Without appropriate training,
any operation inside the safety fence may cause very severe injury or even
death of personnel due to the multiple and various hazards caused by the robot
arm.

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2.4.2 Safety of the working person

Working person safety is the primary safety consideration. As it is very dangerous to enter the operating
area of the robot during its automatic operation, adequate safety precautions must be observed.

The following lists the general safety precautions. Careful consideration must be made to ensure working
person safety.

(1) We obligate the Working person to take a FANUC training courses.

FANUC provides various training courses. Contact your local FANUC representative for details.

(2) Even when the robot is stationary during operation, it is possible that the robot is still in a ready to

move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To
ensure working person safety, provide the system with an alarm to indicate visually or aurally that the
robot is in motion.

(3) Implement the Risk assessment, if necessary, install a safety fence with a gate so that no working

person can enter the work area without passing through the gate. Install an interlocking device, a
safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this
signal is received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). For connection, refer to below Fig. 2.4.2 (b).

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Recommend to install the peripheral device outside of the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such

as a hand.

(7) Implement the Risk assessment, if necessary, install a mat switch or photoelectric switch on the floor

with an interlock to a visual or aural alarm that issues alarm with light, buzzer, or stops the robot when
a working person enters the work area.

(8) If necessary, install a safety lock so that no one except the working person in charge can turn the power

on the robot controller.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with
a padlock.

(9) When adjusting each peripheral device independently, make sure to turn the power off the robot

controller.

(10) Operators must take the gloves off while manipulating the operator’s panel or teach pendant.

Operation with gloved fingers may cause an operation error.

(11) Programs, system variables, and other information can be saved on memory card or USB memories.

Be sure to save the data periodically in case the data is lost in an accident. (Refer to Controller
maintenance manual.)

(12) The robot must be transported and installed by accurate procedure recommended by FANUC. Wrong

transportation or installation may cause the robot to fall, resulting in severe injury to workers.

(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.

Then, the speed should be gradually increased to check the operation of the robot.

(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the

same time, a check must be made to ensure that there is no risk of hazardous situations. If detected,
such a situation should be eliminated before the operation.

(15) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external

emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong
connection.

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(16) In preparing the trestle, please secure the maintenance worker safety at high place in reference to Fig.

2.4.2 (c). Design with the Scaffolding and Safety-belt with circumspection.

RP1
Pulsecoder
RI/RO,XHBK,XROT

RM1
Motor power/brake

EARTH

Safety fence

Interlocking device and safety plug that are activated if the
gate is opened.

Fig. 2.4.2 (a) Safety fence and safety gate

WARNING

1 When you close a fence, Make sure that no one is around the robot in closing

the safety fence.

2 After the door interlock switch is actuated , robot slows down and stops within 2

seconds, and then servo power is cut off. Before cutting off the servo power,
never enter the safeguarded area (inside of safety fence, etc.).

Main board

EAS1

24V-2

EAS2

For the R-30iB Mini Plus

EAS1, 24V-2, EAS2, 0V are on the main board.

Refer to the 3. ELECTRICAL CONNCETIONS of II. CONNECTION
in
R-30iB Mini Plus CONTROLLER
MAINTENANCE MANUAL (B-84175EN) for details.

0V

Fig. 2.4.2 (b) Connection diagram for the signal of the safety fence

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Hook for safety belt

Fence

Steps

Trestle

Footstep
for maintenance

Fig. 2.4.2 (c) Footstep for maintenance

2.4.3 Safety of the Collaborative Worker

A collaborative workers indicates the personnel who work with collaborative robot, and if necessary,
perform the start operation of the program with operator button for collaborative worker. Because they may
contact with the collaborative robot, they must periodically be trained about its danger and securing safety
method at emergency.

2.4.4 Safety of the Operator

An “Operator” indicates a person who turns on and off the power to the robot system, and starts a robot
the program with operator’s panel (in a daily operation.). Prohibit operators from working inside the safety
fence.

(1) If you don’t need to operate the robot, turn the power off the robot controller, or press the

“EMERGENCY STOP” button, and then proceed your work.

(2) Install a safety fence with a safety gate to prevent any worker other than the operator from entering

the work area unexpectedly and the worker from entering a hazardous area.

(3) Install one or more necessary quantity of EMERGENCY STOP button(s) within the operator’s reach

in appropriate location(s) based on the system layout.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this
connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type), when the external EMERGENCY STOP button is pressed. See the
diagram below for connection.

Emergency stop button

外部非常停止ボタン

Main board

EES1

24V-2

EES2

0V

Fig. 2.4.4 (a) Connection diagram for external emergency stop button

(Note)
Connect EES1 and 24V-2, EES2 and 0V.

For the R-30iB Mini Plus

EES1, 24V-2, EES2, 0V are on the main board.

Refer to the 3. ELECTRICAL CONNCETIONS of II.
CONNECTION in
R-30iB Mini Plus CONTROLLER
MAINTENANCE MANUAL (B-84175EN) for details.

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2.4.5 Safety of the Programmer

While teaching the robot, the operator must enter the work area of the robot. Especially the teach pendant
operator must secure own safety.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other

conditions of the safety devices (such as the EMERGENCY STOP button, the Enabling device
(DEADMAN switch) on the teach pendant) before entering the area.

(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
(5) Programming must be done outside of the safety fence as far as possible. If programming needs to be

done in the area of the safety fence, the programmer must take the following precautions:

- Before entering the safety fence area, ensure that there is no risk of hazardous situation in the

area.

- Be ready to press the emergency stop button whenever it is necessary.

- Operate the Robot at low speed.

- Before starting programming, check the entire system status to ensure that no remote instruction

to the peripheral equipment or motion would harm working person.
(6) Operator must work under the condition of Contact Stop function activates.
(7) Required to deactivate the Contact Stop temporally, take measure to disseminate Contact Stop function

deactivates.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent
other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is
opened with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is
disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other
people from entering the inside of the safety fence.

Our teach pendant is provided with an enabling device (DEADMAN switch) as well as an emergency stop button.
These button and switch function as follows:
(1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY

PRECAUTIONS for detail of stop type) when pressed.

(2) Enabling device (DEADMAN switch) : Functions differently depending on the teach pendant enable/disable

switch setting status.
(a) Enable: Servo power is turned off when the operator releases the enabling device (DEADMAN switch)

or when the operator presses the switch strongly.
(b) Disable: The enabling device (DEADMAN switch) is disabled.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or

presses the pendant strongly in case of emergency. The R-30iB employs a 3-position enabling device

The programmer intention of starting teaching is determined by the controller through the dual operation of setting
the teach pendant enable/disable switch to the enable position and pressing the enabling device (DEADMAN
switch). The programmer should make sure that the robot could operate in such conditions and be responsible in
carrying out tasks safely.

Based on the risk assessment by FANUC, number of operation of enabling device (DEADMAN switch) should not
exceed about 10000 times per year.

(DEADMAN switch), which allows the robot to operate when the 3-position enabling device (DEADMAN
switch) is pressed to its intermediate point. When the operator releases the enabling device
(DEADMAN switch) or presses the switch strongly, the robot stops immediately.

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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the
validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator
panel, the teach pendant enable switch and the remote condition on the software.

In case of operating the robot as a collaborative robot without safety fence, there may be a possibility that robot will
not stop even personnel approach. In that case, the robot will suspend when personnel contact.

Mode

AUTO

mode

T1, T2

mode

T1,T2 mode: Enabling device (DEADMAN switch) is effective.

(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and

that there are no abnormal conditions in the robot work area.

(7) When a program is completed, be sure to carry out the test operation according to the following

procedure.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate

(d) Run the program for one operation cycle in the continuous operation mode at the normal

(e) After checking the completeness of the program through the test operation above, execute it in

(8) While operating the system in the automatic operation mode, the teach pendant operator must leave

the robot work area.

Teach pendant

enable switch

On

Off

On

Off

speed and check that no abnormalities occur due to a delay in timing.

operating speed, and check that the system operates automatically without trouble.

the automatic operation mode.

2.4.6 Safety of the Maintenance Engineer

Software remote

condition

Local Not allowed Not allowed Not allowed

Remote Not allowed Not allowed Not allowed

Local Not allowed Allowed to start Not allowed

Remote Not allowed Not allowed Allowed to start

Local Allowed to start Not allowed Not allowed

Remote Allowed to start Not allowed Not allowed

Local Not allowed Not allowed Not allowed

Remote Not allowed Not allowed Not allowed

Teach pendant Operator panel

Peripheral

device

For the safety of maintenance engineer personnel, pay utmost attention to the following.

(1) Must never be in the area during its operation.
(2) A hazardous situation may occur when the robot or the system, are kept with their power-on during

maintenance operations. Therefore, for any maintenance operation, the robot and the system must be
put into the power-off state. If necessary, a lock should be in place in order to prevent any other person
from turning on the robot and/or the system. In case maintenance needs to be executed in the power­on state, the emergency stop button must be pressed.

(3) If it becomes necessary to enter the robot operation area while the power is on, press the emergency

stop button on the operator panel, or the teach pendant before entering the area. The maintenance
personnel must indicate that maintenance work is in progress and be careful not to allow other people
to operate the robot carelessly. (See Section 4.5.)

(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire

system in order to make sure that there is no dangerous situation around. In case the worker needs to
enter the safety area whilst a dangerous situation exists, extreme care must be taken, and entire system
status must be carefully monitored.

(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and

the pressure in the piping should be reduced to zero.

(6) Before teaching, check the robot and its peripheral devices are all in the normal condition.

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(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) Make certain that their escape path is not obstructed inside the safety fence, or the robot operation

area. Provided, however, that the robot secure the operation as a collaborative robot.

(9) When a tool is mounted on the robot, or any moving device other than the robot is installed, such as

belt conveyor, careful attention required for those motion.

(10) Assign an expert near the operator panel who can press the EMERGENCY STOP button whenever he

sees the potential danger.

(11) In case of replacing a part, please contact your local FANUC representative. Wrong procedure may

cause the serious damage to the robot and the worker.
(12) Make sure that no impurity into the system in while (in) replacing or reinstalling components.
(13) Turn off the circuit breaker to protect again electric shock in handling each unit or printed circuit board

in the controller during inspection. If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction

or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.

Such a fuse may cause a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that there

is no person in the work area and that the robot and the peripheral devices are not abnormal.
(16) In case of remove the motor or brake, suspend the arm by crane or other equipment beforehand to

avoid falling.
(17) Whenever grease is spilled on the floor, remove them as soon as possible to prevent from falling.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated state,

the worker should wear heat-resistant gloves or use other protective tools.

• Servo motor

• Inside of the controller

• Reducer

• Gearbox

• Wrist unit

(19) Maintenance must be done with appropriate lightning. Be careful that those lightning will not cause

any further danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to

protect maintenance workers from excessive load. Otherwise, the maintenance workers would be

severely injured.
(21) Must never climb or step on the robot even in the maintenance. If it is attempted, the robot would be

adversely affected. In addition, a misstep can cause injury to the worker.
(22) Secure footstep and wear the safety belt in performing the maintenance work in high place.
(23) Remove all the spilled oil or water and metal chips around the robot in the safety fence after

completing the maintenance.
(24) All the related bolts and components must return to the original place in replacing the parts. If some

parts are missing or left (remained), repeat the replacement work until complete the installation.
(25) In case robot motion is required during maintenance, the following precautions should be taken :

• Secure an escape route. And during the maintenance motion itself, monitor continuously the
whole system so that your escape route will not become blocked by the robot, or by peripheral
equipment.

• Keep vigilant attention for the potential danger. and to press the emergency stop button whenever

(26) Periodic inspection required. (Refer to the robot mechanical manual and controller maintenance

(27) After replacing some parts, a test run required by the predetermined method. (See TESTING section

(28) Make certain that their escape path is not obstructed inside the safety fence, or the robot operation

it is necessary.

manual.) A failure to do the periodical inspection can may adversely affect the performance or service
life of the robot and may cause an accident

of “Controller operator’s manual”. During the test run, the maintenance staff must work outside
the safety fence as the need arises.

area. Provided, however, that the robot secure the operation as a collaborative robot.

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2.5 RELEVANT STANDARDS

FANUC robot series meets following standards.

[For CE marking : Machinery/Low voltage Directives]

- EN ISO 10218-1

- EN 60204-1

- EN/ISO 13849-1

[For NRTL]

- UL 1740

- CAN/CSA Z434

- CSA C22.2 No.73

NOTE

For ISO 13849-1 the following safety categories have been applied.

Controller model

R-30iB Mini Plus

Controller model

R-30iB Mini Plus

[CE marking : For EMC Directive]

- EN 55011 (Group 1, Class A)

- EN 61000-6-2

For the above standards, FANUC robot systems have been certified by the following third parties.

- CE marking : TÜV Rheinland Japan, TÜV SÜD

- NRTL : TÜV SÜD America

Emergency

stop

[7DF5 or later]
Cat.4
PL e
SIL 3

Collaborative robot function

(Collaborative robot safety function)

Cat.3
PL d

Dual Check Safety (optional functions)

Position/

Speed check

[7DF5 or later]
Cat.3
PL d
SIL 2

Safe I/O
connect

[7DF5 or later]
Cat.4
PL e
SIL 3

EN ISO 13849-1:2015

Safety

Network

Applied

standard

Applied

standard

EN ISO
13849-1:2015

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3 ROBOT SYSTEM DESIGN

In this chapter, requirements for robot system design are described.

- Placement of Equipment

- Power Supply and Protective Earth Connection

- Other Precautions

In addition, the basic requirements for end effector, workpiece, and peripheral equipment are outlined in

3.5 in SAFETY PRECAUTIONS. The characteristic of collaborative robot are outlined in 3.6 in SAFETY
PRECAUTIONS.
About the safety fence, safety gate and other protection devices, refer to Section 4.5 to 4.7 in SAFETY
PRECAUTIONS.

Collaborative robot applications are different from traditional robot systems because of the capability of
the robot to operate in close proximity to a person in the robot’s operating space without an enabling device.
Guidance in ISO 10218-2 (ANSI/RIA R15.06-2012) should be followed in the construction of the robot
system using collaborative robots.

In ISO10218-2, carrying out risk assessment (a dangerous evaluation) for the whole robot system is
demanded. Depending on a result of the risk assessment (a dangerous evaluation), please carry out
appropriate safe protection plan to reduce the risk that a person injures.

3.1 GENERAL

The robot system must be designed, constructed, and implemented so that in case of a foreseeable failure
of any single component, whether electrical, electronic, mechanical, pneumatic, or hydraulic, safety
functions are not affected or when they are, the robot system is left in a safe condition (“Failure to safety”).

Under the intended conditions of use, the discomfort, fatigue and psychological stress faced by the operator
must be reduced to the minimum possible, taking into account ergonomic principles such as:

- allowing for the variability of the collaborative worker and operator’s physical dimensions, strength
and stamina,

- providing enough space for movements of the parts of the collaborative worker and operator’s body,

- avoiding a machine-determined work rate,

- avoiding monitoring that requires lengthy concentration,

- adapting the man/machinery interface to the foreseeable characteristics of the collaborative worker
and operators.

ISO10218-2 requires performing risk assessment for the whole robot system. The application of the
electrical equipment of the robot system must be accordance with IEC/ EN60204-1 or NFPA70/NFPA79.

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3.2 PLACEMENT OF EQUIPMENT

Please make sure the following requirements are all satisfied for each component of a robot system.

• Be sure to perform the risk assessment and be sure to design the appropriate safeguarding measures.

• An appropriate safety fence/guard must be placed according to the safety standards. Please refer to

section 3.5 and 3.6 in SAFETY PRECAUTIONS for the basic requirement of the safety fence/guard
and protection devices.

• As the need arises, the additional space are required beyond the restricted space to define the
safeguarded space.

• The operator panel must be located at a safe place:

- outside the safety fence, and cannot be reached from inside the safety fence, if the robot system

has safety fence.

- where it can be easily seen, and easily operated by the operator,

- where the operator can operate it without hesitation or loss of time and without ambiguity,

- where collaborative worker or operator can confirm the emergency stop button easily and can

operate it easily, and

- where no dangerous situation is created by operating it.

• If the robot controller is placed inside or near the robot operating space, the distance between the
maintenance space of robot controller and robot operating space should be sufficient (over 1.22m from
the opening section of robot controller, or opening section of robot controller is placed to opposite
direction of robot operating space.

• The operating position must be designed and constructed in such a way as to avoid any risk due to
exhaust gases and/or lack of oxygen.

• If the robot system is intended to be used in a hazardous environment presenting risks to the health
and safety of the collaborative worked and operator or if the robot system itself gives rise to a
hazardous environment, adequate means must be provided to ensure that the operator has good
working conditions and is protected against any foreseeable hazards.

• Where appropriate, the operating position must be fitted with an adequate cabin designed, constructed
and/or equipped to fulfill the above requirements. The exit must allow rapid evacuation. Moreover,
when applicable, an emergency exit must be provided in a direction which is different from the usual
exit.

• A large space must be secured around each component enough for the maintenance and inspection of
the robot system.

• The robot system must be designed and constructed in such a way as to allow access in safety to all
areas where intervention is necessary during operation, adjustment and maintenance.

• The space inside or near the robot operating space for maintenance and inspection, must be designed
to protect the user from falling off or slipping off the step, and where appropriate, handholds that are
fixed relative to the operator and that enable them to maintain their stability should be prepared.

• The robot system must be secured on a stable floor. Especially the robot mechanical unit must be
attached to the stable place according to the instructions in the maintenance manual or operator’s
manual.

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• The robot system must be designed to avoid trapping and collision between the moving parts of the
robot and other fixed or moving objects.

• The layouts must be designed in such a way that between moving parts of the robot and objects in the
environment (e.g. pillars of the structure, ceiling joists, fences, supply leads) sufficient clearance is
available.

• When T2 mode is used, the following clearance is required for robot system installation.

- 0.5m or more from readily accessible areas of buildings, structures, utilities, other machines and

equipment not specifically supporting the robot function that may create trapping or a pinch point

Where this minimum clearance is not provided, additional safeguarding devices is required.

- Stop robot motion while personnel are within 0.5m of the trapping or pinch hazard
If these actions are not applied, it may cause injury of the users.

• When a limitation of the restricted space, by limiting the range of motion of the primary axes (J1, J2,
J3-axes), is required by the plan, limiting devices must be provided. They should not injury to a person
and must comply with one of the following.

- Mechanical stopper which are capable of stopping the robot at any adjusted position when it is

carrying its rated load at maximum velocity.

- Alternative methods of limiting the range of motion may be provided only if they are designed,

constructed, and installed to achieve the same level of safety as the mechanical stoppers.

This may include using the robot controller and limit switches according to IEC/EN 60204-1 or

NFPA70/NFPA79.

Note that the limiting devices must be correctly adjusted and secured.

• When it is intended that collaborative worker or operators will perform manual operations associated
with the robot, such as loading and unloading of parts, this must be taken into account in the
arrangement of the robot system, either by providing part loading devices so that the operator cannot
access the hazardous area, or by providing appropriate safeguards for the manual activity.

• Where appropriate and where the working conditions so permit, work stations constituting an integral
part of the robot system must be designed for the installation of seats.

• The operator’s seat must enable him or her to maintain a stable position. Furthermore, the seat and its
distance from the operator's panel must be capable of being adapted to the operator.

• If the robot system is subject to vibrations, the seat must be designed and constructed in such a way
as to reduce the vibrations transmitted to the operator to the lowest level that is reasonably possible.
The seat mountings must withstand all stresses to which they can be subjected, where there is no floor
beneath the feet of the operator, footrests covered with a slip-resistant material must be provided.

• On transportation of robot mechanical unit or controller, proper transportation procedure described on
operator’s or maintenance manual for each models have to be followed.

WARNING

Follow the procedure specified by FANUC when transporting the robot

mechanical unit or controller. Otherwise, it may fall over due to the loss of the
mechanical stability (balance), resulting in serious injury or death of personnel.

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3.3 POWER SUPPLY AND PROTECTIVE EARTH

CONNECTION

• The power supply and the grounding must be connected according to the maintenance manual.

• Unsafe conditions must be avoided in the event of a power down, power recovery after a power down

or supply voltage fluctuations. Unsafe conditions to be avoided are;

- Dropping workpiece or any material,

- Safety equipment not functioning, etc.

WARNING

Dropping workpiece or any material may result in personal injury.

• The robot system must have means to isolate its power sources. These means must be located in such
a way that no person will be exposed to any hazard, as well as must have a lockout/tagout capability.

WARNING

The robot mechanical unit and controller have to be properly connected by PE

(Protective Earth). Without PE connection, electric shock can occur.

3.4 OTHER PRECAUTIONS

• Shutdown (removal of power) to the robot system or any peripheral equipment must not result in a
hazardous condition.

• All environmental conditions must be evaluated to ensure compatibility of the robot and the robot
system with the anticipated operational conditions. These conditions include, by are not limited to,
explosive mixtures, corrosive conditions, humidity, dust, temperature, electromagnetic interference
(EMI), radio frequency interference (RFI), and vibration.

• The control position where the operator stands must be predetermined.
The control position must satisfy the following conditions.

- The operator can easily operate the operator panel or the teach pendant.

- The operator can easily make sure that nobody is inside or near the robot operating space or

inside the safety fence (if safety fence is placed).

- The operator can easily verify the operation of the system.

- The operator can immediately stop the entire or partial system in the event a malfunction of the

system or any dangerous condition.

• The following safety measure must be used if the operator cannot easily verify nobody is inside the
safety fence, or as required by the risk-assessment result.

- A visible/audible warning (complying EN/ISO/IEC standards or OSHA) is used before robot

starts moving.

- A measure for the collaborative worker inside or near the robot operating space to stop the robot

system or a measure for the person to evacuate outside the robot operating space.

- The control system is designed and constructed in such a way that starting is prevented while

someone is in the danger zone.

• If necessary, means must be provided to ensure that the robot system can be controlled only from
control positions located in one or more predetermined zones or locations.

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• Where there is a more than one control position, the control system must be designed in such a way
that the use of one of them precludes the use of the others, except for stop controls and emergency
stops.

• When the robot system has two or more operating positions, each position must be provided with all
the required control devices without the operators hindering or putting each other into a hazardous
situation.

• The manual intervention and reset procedure to restart the robot system after an emergency stop must
take place outside the restricted space.

• A warning device must be such that the operator and people in dangerous area can easily recognize it.

• For UL standard compliance, “a yellow or amber visual indicator” specified by CL 36.1 of UL 1740

was to be installed by the end-user or system manufacturer. SYSRDY or PROGRUN output signals
are available for installing such a visual indicator.

• The area must be appropriately lighted, especially for maintenance and inspection.

The lighting must not create a new dangerous situation (e.g. dazzled).

CAUTION

Operation inside of the safety fence (teaching, maintenance, etc.) without

suitable ambient lighting can cause hazards of collision (with some obstacles
inside of the safety fence) or slipping/falling down of personnel.

• It is recommended that adjustment, greasing or oiling, and other maintenance work can be performed
from outside the dangerous area while the system is stopping.

If it is not feasible, a method to perform these operations safely must be established.

• If the robot and the peripheral equipment synchronously move in the robot system, an appropriate
measure must be provided to avoid unsafe condition by stopping the entire system in the event any of
the equipment stops due to malfunction.

• Any robot that can be controlled from a remote location must be provided with an effective means that
must prevent hazardous conditions of the robot being initiated from any other location.

• It is recognized that for certain phases of the robot system life (e.g. commissioning, process
changeover, cleaning, and maintenance) it may not be possible to design completely adequate
safeguards to protect against every hazard or that contain safeguards may be suspended.

Under these conditions, appropriate safe working procedures must be used.

• A robot system manufacturer must provide an operation manual according to EN ISO 10218 etc.

• Requirements of each safety standard (EN ISO, IEC, JIS etc.) and labor security hygiene rule must be

considered when a robot application system is designed.

• Keep the component cells of the robot system clean, operate the robot where insulated from the
influence of grease, water, and dust.

• Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.

• Adopt limit switches or mechanical stoppers to limit the robot motion, and avoid the robot from

collisions against peripheral devices or tools.

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• Observe the following precautions about the mechanical unit cables. Failure to follow precautions may
cause mechanical troubles.

- Use mechanical unit cable that have required user interface.

- Do not add user cable or hose to inside of mechanical unit.

- Please do not obstruct the movement of the mechanical unit cable when cables are added to

outside of mechanical unit.

- In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a

protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.

- When installing user peripheral equipment on the robot mechanical unit, please pay attention that

equipment does not interfere with the robot itself.

• The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid
the system construction that power-off stop would be operated routinely. (Refer to bad case example.)
Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or
cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type.)

(Bad case example)

- Whenever poor product is generated, a line stops by emergency stop and power-off of the robot

is executed.

- When alteration was necessary, safety switch is operated by opening safety fence and power-off

stop is executed for the robot during operation.

- An operator pushes the emergency stop button frequently, and a line stops.

- An area sensor or a mat switch connected to safety signal operates routinely and power-off stop

is executed for the robot.

- Power-off stop is regularly incurred due to an inappropriate setting for Dual Check Safety
(DCS).

• Power-off stop of Robot is executed when collision detection alarm (SRVO-050) etc. occurs. Please
try to avoid unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the
causes of the alarm.

• Operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the
robot in any eventuality.

• Before pressing the jog key, be sure to comprehend the robot movement by the key in advance.

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3.5 END EFFECTOR, WORKPIECE AND PERIPHERAL

EQUIPMENT

It is the responsibility of the robot system manufacturer to perform the risk assessment of the end effector,
workpiece and peripheral equipment.

This section outlines the basic requirement for the risk assessment of these components.

End Effector

• End effectors must be designed and constructed, or safeguarded, so that

- power failure does not cause release of the load (workpiece) or result in a hazardous condition.

- The static and dynamic forces created by the load (workpiece) and the end effector together are

within the load capacity and dynamic response of the robot.

- Shape or motion of the end effector does not harm the personnel.

• We recommend to protect the hard part with sponges, and relax the force when the personnel contact
it.

• If it is equipped with a tool that can function with several different conditions (speed, etc.), the
selection of the condition must be safely and securely done.

Workpiece

• The material and its shape must not be dangerous and if unsafe, safety measures must be provided.

• If the workpiece is in extreme high or low temperature, safety measures must be provided to avoid

personnel from touching or getting too close to it.

WARNING

Dropping workpiece or any material may result in personal injury.

Peripheral Equipment (including end effector)

• The material and shape must not be dangerous.

• If any component could break down during operation, it must be placed so that it will not scatter if it

breaks down.

• Pipes (for liquid/gas) must have enough strength for its internal / external pressure.

• Pipes must be secured and protected from the external pressure or tension.

• Be sure to provide measures to avoid a dangerous situation if a pipe is broken causing sudden

movement of the pipe or the high speed flow of material.

• If a pneumatic device is used, be sure to install an air valve which shuts off the air supply to the robot.

• If a power source other than the electricity (e.g. pneumatic, water, heat) is used in the system, be sure

to perform appropriate risk-assessment, and be sure to provide appropriate safety measures.

• Be sure to provide safety measures to avoid swapping of components that cause unsafe conditions, by

- design to avoid mount mistakes,

- indication of necessary information on the parts.

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• Be sure to provide safety measures to avoid inferior contacts, by

- design,

- displaying the information on the connectors, pipes and cables.

• Be sure to provide safety measures to avoid an unsafe condition by touching an extremely high/low
temperature parts (if any).

• Be sure to provide safety measures to avoid fire or explosion through sufficient amount of
investigation.

• Vibration and sound noise must be kept to a minimum.

• For place where personnel may contact, get rid of sharp points and rough surfaces, because those may

harm personnel by contact.

• If a laser equipment is used, the following must be considered.

- avoid unexpected emission of laser light

- direct/indirect emission of light must give no harm to the health

- laser light must give no harm to health during maintenance / adjustment.

3.6 THE CHARACTERISTIC OF COLLABORATIVE ROBOT

AND LIMITATIONS AND USAGE NOTES

This section describes that the characteristic of collaborative robot and limitations and usage notes.
Refer to Collaborative Robot Function OPERATOR’S MANUAL (B-83744EN) about the detail of each
function.

CONTACT STOP FUNCTION

• When the external force exceeds the external force limit, the robot stops. Example, when a person
contacts to robot and big external force add to robot, the robot stops. This function does not guarantee
safety in the all situation. The notice must be followed and additional appropriate safeguarding
measures must be placed as the need arises.

※External force：Force to act on the robot at the time of contact by the robot motion.

• The external force is calculated by the torque acting on each axis. Therefore, when the robot contacts
at the point near the each axis, the robot may not stop even if the external force is more than the
external force limit. On the other hand, when the robot contacts at the point far from the each axis, the
robot may stop even if the external force is smaller than the external force limit.

• A default value of external force limit is 150N. The sensitivity of contact stop can be increased by
decreasing the external force limit. But in case of increasing sensitivity, the robot may stop by
misdetecting the contact depending on the motion of the robot. The external force limit can’t increase
more than 150N.

• There is a function which resume the program automatically after contact stop. If this function is
effective, Even if the robot stops, program is restarted automatically when required condition is met.

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WARNING

Motion groups other than Collaborative robot are outside of the scope of the

contact stop function. If a person comes into contact with the motion group other
than Collaborative robot, a serious personal injury could result. If the robot
system is designed to include the motion group other than Collaborative robot,
adequate risk assessment for the whole robot system is necessary to verify that
the motion group other than Collaborative robot are outside of the scope of the
contact stop function.

ACCEPTABLE MOTION SPEED FOR BODY REGIONS

• Be sure to set motion speed in order to prevent injury caused by the force of contact to a sensitive area
as determined by the risk assessment. Please note that a default value of collaborative motion speed is
250mm/s, and the maximum setting value is 1000mm/s. For reference, acceptable motion speed for
body regions are shown below.

Body region

Face, Neck Not applicable
Arm, Hand, Fingers 1000
Thigh, knee 300 250
Lower legs Not applicable
Body region excluding the above region 300 280

RESTART AFTER CONTACT STOP

• Restart by the switch installed near the robot is possible. In that case, be sure to install the emergency
stop button near the restart switch.

PUSH TO ESCAPE

• When a person pushes the robot, the robot escapes. Only J1 axis, J2 axis and J3 axis can respectively
escape by pushing. The robot stops after certain distance escape. In this case, release your hand for a
moment and push again. When the robot escapes, the attitude of TCP changes.

RETREAT AFTER CONTACT STOP

• When the robot was stopped by the contact stop and if strong force to robot remains, the robot will
retreat slightly.

NOTE TO DESIGN THE COLLABORATIVE WORKSPACE

When the designer of a robot application system design the workspace where person work near robot, the
designer must follow the following notes.

WARNING

When person is pinched between the robot and the other object (wall, floor, etc.),

and the robot arm, it may result in personal injury.

• The space where a person escapes at contacting to robot must be placed between collaborative
workspace and wall, floor, etc. If the space can’t be placed, the robot system must be designed to use
additional appropriate safeguarding measures. Example, when a person access to dangerous space, the
robot stops.

• The following countermeasure is effective as a measure to reduce the generation force when pinching
between the robot and the other object.

- Reduce the robot's motion speed near the place where pinching is occurred.

- Cover the object or the table with a soft material because the lower the rigidity of the contact

point, the smaller the generated force.

CRX-5iA CRX-10iA, CRX-10iA/L, CRX-20iA/L CRX-25iA

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SAFETY PRECAUTIONS

• The collaborative workspace shall be marked appropriately.(floor marking, signs, etc.)
Access or admittance restrictions shall be marked be placement of appropriate signs, such as “Active
Robotic Collaborative workspace; authorized persons only”, “Caution, robot can move at any time”.

• Untrained (according to Subsection 2.4.1) people must not enter collaborative workspace.

• The ambient working space in which people may collide with the collaborative robot shall be arranged

so they can move safely.

WARNING

Inappropriate collaborative workspace may result in personal injury.

WORKING NOTE INSIDE THE COLLABORATIVE WORKSPACE

• Please don't put any objects on the robot. Foreign objects may cause an improper detection of the
external contact seen by the robot.

• When people enter the collaborative workspace, please take care of their safety using the personal
protective equipment (helmet, safety shoes, protective glasses etc.), as the need arises.

INDICATION OF COLLABORATION MODE

• The visual indication, for example lamp, indicating that the robot is in collaborative operation is
necessary. The LED installed on the robot is set for this purpose. The LED color differs depending on
the robot status according to the following table.

Green Collaborative mode
Flash green Direct teaching
Yellow High speed mode
Red Alarm occurrence

LED color Robot status

B-84194EN/04

Fig. 3.6 (a) LED on the robot

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PROTECT OF HEAD, NECK

WARNING

An impact force to the head or neck from contact with the robot may cause death

or heavy injury of the users.

• The robot system must be designed not to contact robot to head or neck of person with frequency.

WARNING

If a part of body is pinched, it might cause heavy injury.

• When wrist unit or J3 arm approaches J1 base or J2 base, a part of your body may be pinched.

EXTERNAL FORCE AGAINST THE ROBOT

• If force generated from the end effector, force of pushing direction or pulling direction generated from
the cables and hoses connected to the end effector exceeds the restriction value of the external force
Design a system during considering to avoid force mentioned above is applied to the robot.

For information of the external force and load monitoring method, refer to Subsection 4.2.2 “Payload

Monitor” of the OPERATOR’S MANUAL (Collaborative Robot Function) (B-83744EN).

HIGH SPEED MODE

• By default, the collaborative robots can also be used as a no-collaborative robot (in a no-
collaborativemode) in a high speed mode. The maximum speed of each model for both collaborative
and no-collaborative mode is shown in the table. If the robots are operated in the high speed mode,
risk assessment for traditional robot (no-collaborative) is required and additional appropriate
safeguarding measures is required as the need arises. The basic safeguarding measures is safeguarding
fence, but other safeguarding measures that is result of risk assessment may be admitted.

Model

CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-25iA
CRX-20iA/L

• Contact stop function is not available with this mode.

Maximum speed in

collaborative mode (mm/s)

1000 2000
1000 1000

Maximum speed in

high speed mode (mm/s)

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4 SAFETY DEVICES

4.1 STOP TYPE OF ROBOT

There are following three types of Stop Category.

Stop Category 0 following IEC 60204-1 (Power-off Stop)

Servo power is turned off, and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
“Stop Category 0” performs following processing.

• An alarm is generated, and then the servo power turns off. Instantly the robot stops.

• Execution of the program is paused.

Frequent Category 0 Stop of the robot during operation can cause mechanical problems of the robot.
Avoid system designs that require routine or frequent Category 0 Stop conditions.

Stop Category 1 following IEC 60204-1 (Controlled Stop, Smooth Stop)

The robot is decelerated until it stops, and servo power is turned off.
“Stop Category 1” performs following processing.

• The alarm "SRVO-199 Controlled stop" or "SRVO-289 Smooth Stop" occurs along with a
decelerated stop. The program execution is paused.

• An alarm is generated, and then the servo power turns off.

In Smooth stop, the robot decelerates until it stops with the deceleration time shorter than Controlled stop.
The stop type of Stop Category 1 is different according to the robot model or option configuration. Please
refer to the operator's manual of a particular robot model.

Stop Category 2 following IEC 60204-1 (Hold)

The robot is decelerated until it stops, and servo power remains on.
“Stop Category 2” performs following processing.

• The robot operation is decelerated until it stops. Execution of the program is paused.

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WARNING

1 The stopping distance and time of Stop Category 1 are longer than those of Stop

Category 0. A risk assessment for the whole robot system which takes into
consideration the increased stopping distance and stopping time is necessary
when Stop Category 1 is used. Please refer to the operator's manual of a
particular robot model for the data of stopping distance and time.

2 In multi arm system, the longest stopping distance and time of Stop Category 1

among each robot are adopted as those for the system. A risk assessment for
the whole robot system which takes into consideration a possibility that the
stopping distance and time increase, is necessary on the multi arm system.

3 In the system which has extended axis, the longer stopping distance and time of

Stop Category 1 among robot and extended axis are adopted as those for the
system. A risk assessment for the whole robot system which takes into
consideration a possibility that the stopping distance and time increase, is
necessary on the system which has extended axis. Please refer to the extended
axis setup procedure of the controller operator’s manual for considering the
stopping distance and time of the extended axis.

4 When Stop Category 1 occurs during deceleration by Stop Category 2, the stop

type of robot is changed to Stop Category 0.

5 In case of Stop Category 1, motor power shutdown is delayed for a maximum of

2 seconds. In this case, a risk assessment for the whole robot system is
necessary, including the 2 seconds delay.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Stop Category
0 or Stop Category 1. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the option configuration.

There is the following 1 Stop pattern.

Stop

pattern

AUTO Category 1 Category 1 Category 1 Category 1 -

D T1 Category 1 Category 1 - Category 1 Category 1

T2 Category 1 Category 1 - Category 1 Category 1

Category 0: Stop Category 0
Category 1: Stop Category 1

-: Disable

(*) The stop pattern of NTED input is same as enabling device (Deadman switch).

The following table indicates the Stop pattern according to the controller type or option configuration.

Standard D(**)

(**) R-30iB Mini Plus does not have SVOFF input.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer
to "Software version" in operator's manual of controller for the detail of software version screen.

Mode

Emergency

stop

button

Option

External

Emergency

stop

FENCE open

SVOFF

input

Enabling device

(Deadman
switch) (*)

R-30iB Mini Plus

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4.2 EMERGENCY STOP

This robot has following emergency stop devices.

• emergency stop button (They are on the operator panel and teach pendant.)

• external emergency stop (input signal)

When emergency stop button is pushed, the robot stops immediately (refer to Section 3.1).
The external emergency stop input signal is input from peripheral devices.
The signal terminal is inside of the robot controller.

4.3 MODE SELECT SWITCH

The MODE SELECT SWITCH is installed on the robot controller. (This is an option for some
controllers.)You can select one of the operation modes using this switch. The selected operation mode can
be locked by removing its key.
When the mode is changed by this switch, the robot system stops and a message is shown in teach pendant
LCD.

AUTO

T1

T2

Fig. 4.3 (a) Example of mode select switch

4.3.1 Operating Modes

There are two or three operating modes.

CAUTION

When high speed mode (contact stop function is disabled) is applied, contact
stop function, push to escape function, retreat function after contact stop are set
to disabled.

AUTO: Automatic Mode

• The operator panel/box becomes enable.

• The robot program can be started by the operator panel/box start button or peripheral device I/O.

• If the robot system has safety fence, safety fence is enabled.

• The robot can be operated at the specified maximum speed.

• The contact stop function is enabled.

• The push to escape function is enabled

• The retreat function after contact stop is enabled

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T1: Test Mode 1

• Program can be activated from the teach pendant only.

• The robot cannot be operated at speeds higher than 250mm/s at both of tool center point (tool

coordinate origin) or wrist flange center.

• If the robot system has safety fence, safety fence is disabled. (Robot does not stop when fence is
opened.)

• The contact stop function is enabled.

• The push to escape function is disabled

• The retreat function after contact stop is disabled at jogging

T2: Test Mode 2(Optional)

• Program can be activated from the teach pendant only.

• The robot can be operated at the specified maximum speed.

• If the robot system has safety fence, safety fence is disabled. (Robot does not stop when fence is

opened.)

• The contact stop function is enabled.

• The push to escape function is disabled

• The retreat function after contact stop is disabled at jogging

Please refer to the operator’s manual of robot controller for detail.

4.4 ENABLING DEVICE (DEADMAN SWITCH)

The enabling device (deadman switch) is used as an “enabling device”.
When the teach pendant is enabled, robot motion is allowed only while at least one of enabling devices
(deadman switches) is gripped. If you release or hard grip switches, the robot stops immediately.
In case of the tablet TP, if you release or hard push the enabling device (deadman switch), the robot stops
immediately.

Enabling device

デットマンスイッチ

(Deadman switch)

Fig. 4.4 (a) Enabling device (Deadman switch) (Tablet TP)

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Enabling device

(Deadman switch)

Fig. 4.4 (b) Enabling device (Deadman switch) (iPendant)

Based on the risk assessment by FANUC, number of operation of enabling device (DEADMAN switch)
must not exceed about 10000 times per year.

4.5 SAFEGUARDS

The safeguards consists of:

• safety fence (fixed guard),

• safety gate (with interlocking devices),

• safety plug and socket, and

• other protection devices.

These safety devices must be complied with EN ISO, IEC and so on In addition, system designers must
install these devices according to the risk assessment.

This section describes the basic requirements for these devices. Please refer to EN ISO 10218 and so on for
detail. Note that these safety devices must be fitted to the robot system by the system house, etc.

WARNING

Suitable safety guards are installed around robot system as the need arises.

Robot operation without safety guards required from the result of risk
assessment can cause serious injury or death of personnel.

4.5.1 Safety Fence

The basic requirements for Safety Fence are as follows.

• The fence is constructed to withstand foreseeable operational and environmental forces.

• The fence is free of sharp edges and projection and is not themselves a hazard.

• The fence prevents access to the safeguarded space except through openings associated with

interlocking devices.

• The fence is permanently fixed in position and is removable only with the aid of tools.

• Fixing system of the safety fence must remain attached to the safety fence or to the robot system when

they are removed.

• Where possible, safety fence must be incapable of remaining in place without their fixings.

• The fence cause minimum obstruction to the view of the production process. (wire mesh, lattice, panel

etc.)

• The fence is located at an adequate distance from the maximum space.

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• The fence should be connected to PE (protective Earth) to prevent the electric shock with accident.

• Please refer to the following and their related standards for detail of safety fence aperture size,

minimum size of grids and so on.

- EN ISO 13855

- EN ISO 13857

- ANSI B11.19

4.5.2 Safety Gate and Plugs

The basic requirements for Safety Gate are as follows.

• The gate prevents the robot system from automatic operation until the gate is closed.

• The closure of the gate is not the control to restart automatic operation. This must be a deliberate

action at a control station.

• The gate has plug and socket for interlock. The plug and socket must be selected appropriate things
for safety.

This gate must be the one either it remains locked closed until the risk of injury from the hazard has passed
(interlocking guard with guard locking) or opening the guard while the robot system is working gives a stop
or emergency stop instruction (interlocking guard).

Please refer to EN ISO 14119 or ANSI B11.19 for detail of interlocking system.

If a personnel whole body can enter the safeguard space via the interlocking door, installing a device that
the door does not close without intending.

Care should be taken to ensure that actuation of an interlock installed to protect against on hazard (e.g.
stopping hazardous motion of the robot system) does not create a different hazard (e.g. the release of
hazardous substances into the work zone).

4.5.3 Other Protection Devices

Protection devices must be designed and incorporated into the control system so that:

• they can be adjusted only by means of an intentional action, such as the use of a tool, key, etc.,

• the absence or failure of one of their components prevents starting or stops the moving parts.

As the need arises, the robot system must be designed so that

• moving parts cannot start up while they are within the operator’s reach,

• the exposed person cannot reach moving parts once they have started up.

If some presence sensing devices are used for safety purposes, they must comply with the following.

• A presence sensing device must be installed and arranged so that persons cannot enter and reach into
a hazardous area without activating the device.

• A presence sensing device must be installed and arranged so that persons cannot reach the restricted
space before the hazardous conditions have ceased.

• Barriers used in conjunction with the presence-sensing device may be required to prevent persons
from bypassing the device.

• Their operation must not be adversely affected by any of the environmental conditions for which the
system was intended.

• When a presence-sensing device has been activated, it may be possible to restart the robot system from
the stopped position provided that this does not create other hazards.

• As the need arises, resumption of robot motion must require the removal of the sensing field
interruption. The result of risk assessment may require that this must not be the control to restart
automatic operation.

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4.6 OPERATION INSIDE OF THE SAFETY FENCE

When some workers (programmer, maintenance engineer) have to enter the safety fence, the following care
has to be taken into account.

• Make sure that the robot system has been completely stopped before entering the safety fence. Never
enter the safety fence during the robot moving. If the robot is moving, stop the robot by hold button
(or input signal), and after "controlled stop" it (servo power off), then you can enter the safety fence.
(In case a safety fence is installed.)

• Make sure that an indicator lamp for stop condition (to be suitably installed by the end user) shows
the stopped status of the robot, and enter the safety fence from the safety gate.

• To inform you are working in the safety fence, display “working”. During robot teaching or test
operation, robot may move to an unexpected direction. So exercise special care, and perform teaching
in the position where you can escape from the robot in case of dangerous situation.

• Set "Safe speed" signal enabled.

• When more than one worker collaborates for their operation, a user in charge should be equipped with

teach pendant, and other users have to follow his order.

Any operations from the external interface and robot controller operation panel without his order have

to be prohibited.

• All users inside of the safety fence always have to secure the escape zone to avoid hazards from
unintended movement of the robot.

• Care should be taken by all workers not to close off the escape routes for each other.

• Do not operate the robot resting against the wall, apparatus installed inside of the safety fence, etc.

those take away escape zone from the operator.

• Keep watching the robot during operation in jogging, program verification, etc.

• Stop the robot immediately by E-stop SW when somebody recognizes dangerous situation.

Whenever possible, other user who is readily accessible to the E-stop SW keeps watch from the outside

of the safety fence.

• Make sure that deadman switches on teach pendant are operated only by hand.

• Make sure that nobody still exists inside of the safety fence when the safety gate is going to be closed.

• Do not leave tools etc. inside of the operating space of robot or peripheral devices, when operation

inside of the safety fence has been finished.

WARNING

1 Safety procedures of entering the safety fence have to be established and

observed. Improper procedure of entering the safety fence can cause serious
injury or death of personnel who enter the safety fence.

2 During teaching or maintenance of robot system with safety fence opened,

special care shall be take not to enter any other personnel who is not work for
these operations. Unauthorized entry to inside of safety fence can cause serious
injury or death of personnel who enter the safety fence.

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4.7 THE SAFETY SEQUENCE FOR FENCE ENTRY

This section describes the safety procedure of entering the safety fence.

Note that only a programmer or a maintenance person can enter the safety fence. A general person
CANNOT enter the safety fence.

Entering into the SAFETY FENCE

0. The robot is moving automatically (in AUTO mode).

1. Stop the robot by pressing HOLD buttons or HOLD input signal.

2. Change the operating mode to T1 or T2 from AUTO.

3. Remove the operating mode key switch for mode lock to prevent other persons change the operating
mode.

4. Remove the plug2 from socket 2.

5. Open the gate of the safety fence, and put the plug2 to socket4.

6. Remove the plug1 from socket1

7. Enter inside of the safety fence, and put the plug 1 to socket 3.

Please refer to Fig. 4.7 (a) for details of safety fence and safety plug configurations.

The key of operating mode key switch and the safety plug1 must be carried into the safety fence.
The safety plug1 must be put to the socket3 inside fence.

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Safety Fence

Maximum space

Controller (operator panel)

Operator’s box

and

Mode switch key

Mode switch key

Teach pendant

and

Safety gate

Safety Fence

Safety gate

Restriction space

Safeguard distance

Safety Fence

Plug 1

Socket 1
Socket 2

Plug 2

Socket 1
Socket 2

Plug 1
Plug 2

FENCE1 FENCE2 EMGIN1 EMGIN2

Socket 1

Plug 1

Safety fence

Safety gate
(CLOSED)

«Inside of safety fence»

Socket 3

Socket 3

Socket 4

Outside of safety fence»

«

Safety gate

Socket 3 (inside of safety fence)

Socket 4

Plug 1

S

a

(

O

P

Socket 3

f

e

t

y

g

a

t

E

N

E

D

)

e

Plug 1

Safety fence

Socket 1
Socket 2

FENCE1 FENCE2 EMGIN1 EMGIN2

Socket 1

Socket 4

Plug 2

Socket 3

Socket 4

Plug 2

Socket 2

When the safety gate is CLOSED When the safety gate is OPENED

Fig. 4.7 (a) SAFETY FENCE and SAFETY GATE example

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5 GENERAL CAUTIONS

In this chapter, the requirements for safety during the following situations are described:

• Installation (5.1)

• Commissioning and functional testing (5.2)

• Programming (5.3)

• Program verification (5.4)

• Troubleshooting (5.5)

• Saving programmed data (5.6)

• Automatic operation (5.7)

• Maintenance (5.8)

• Dismantling / scrapping (5.9)

• Procedure to move arm without drive power in emergency or abnormal situations (5.10)

• Warning & Caution label (5.11)

The user must ensure that the safeguarding methods are provided, utilized, and maintained for each
operation associated with the robot system and in particular for personnel other than those utilizing the
teach pendant or enabling device.

The user must ensure that a teach pendant not connected to the robot controller must be inaccessible.

WARNING

1 Safety procedures of entering the safety fence have to be established and

observed. Improper procedure of entering the safety fence can cause serious
injury or death of personnel who enter the safety fence.

2 During teaching or maintenance of robot system, special care shall be take not

to access any other personnel who is not work for these operations.
Unauthorized entry to inside of safety fence can cause serious injury or death of
personnel who enter the safety fence.

3 The servo motors, the regenerative resistor units and the isolated transformers

on the AC power supply may be hot even after robot operation. Touching the
surface of these components should be therefore avoided as much as possible.

When touching any of these components is nonetheless required (ex.: for

maintenance purposes), special care must be applied in order to avoid burn
injury.

5.1 INSTALLATION

Be sure to install the robot system in accordance with FANUC’s requirements. The safeguarding methods
must be identified by the hazard analysis and the risk assessment. The user must review the safety
requirements to ensure that the appropriate safeguards are applied and operational prior to use in production.

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5.2 COMMISSIONING AND FUNCTIONAL TESTING

During the testing of robots or robot systems after installation or relocation, be sure to follow the following
procedures. These procedures are also applied to robots or robot systems after modifications (e.g. changes
in hardware or software, replacement of parts, adjustments) and after maintenance or repairs that can
adversely affect their operation.

5.2.1 Designation of the Restricted Space and Restriction of User

During the commissioning and functional testing, if the contact stop function is enabled, it is admitted that
people they are trained about collaborative robot access the robot

During the commissioning and functional testing, if the contact stop function is disabled or untrained people
may access the robot, and the safeguarding methods are not in place, interim means of designating the
restricted space must be in place before proceeding. And users must not be allowed in the safeguarded space
until the safeguards are functional.

5.2.2 Safety and Operational Verification

For commissioning and testing of the robot or the robot system, follow the instruction by the manufacturer
(FANUC). At the initial start-up, be sure to include the following procedure (but not limited to).

Before applying power, verify that

• the robot has been properly mechanically mounted and is stable,

• the electrical connections are correct and the power (i.e. voltage, frequency, interference levels) is

within specified limits,

• the other utilities (e.g. water, air, gas) are properly connected and within specified limits,

• the peripheral equipment is properly connected,

• the limiting devices that establish the restricted space (when utilized) are installed,

• the safeguarding means are applied, and

• the physical environment is as specified (e.g. lighting and noise levels, temperature, humidity,

atmospheric contaminants).

After applying power, verify that

• the start, stop, and mode selection (including key lock switches) control devices function as intended,

• each axis moves and is restricted as intended,

• emergency stop circuits and devices are functional,

• the safeguards and interlocks function as intended (when installing the controller),

• Contact stop function correctly,

• it is possible to shut out the outer power source,

• Teaching and restarting function correctly,

• other safeguarding is in place (e.g. barriers, warning devices),

• in reduced speed, the robot operates properly and has the capability to handle the product or workpiece,

and

• in automatic (normal) operation, the robot operates properly and has the capability to perform the
intended task at the rated speed and load.

5.2.3 Robot System Restart Procedures

A procedure for the restart of the robot system after hardware, software or task program modification, repair,
or maintenance must include but not necessarily be limited to the following:

• check any changes or additions to the hardware prior to applying power;

• functionally test the robot system for proper operation.

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5.3 PROGRAMMING

Whenever possible, programming must be performed with all persons outside the safeguarded space or the
robot operating space and neighborhood. When it is necessary to perform programming with personnel
inside the safeguarded space, the following safety procedures are necessary.

WARNING

No other personnel than programmer or teaching operator enter inside of safety

fence during teaching. Unauthorized entry to inside of safety fence can cause
serious injury or death of personnel who enter the safety fence.

5.3.1 Prior to Programming

The following conditions must be met before making taught program.

• The programmer must be trained on the type of robot used in the actual robot system and must be
familiar with the recommended programming procedures including all of the safeguarding methods.

• The programmer must visually check the robot system and safeguarded space to ensure that extraneous
conditions which can cause hazardous do not exist.

• When using the teach pendant to make taught program, the teach pendant must be tested to ensure
proper operation.

• Any faults or failures of the robot system must be corrected prior to teaching the robot.

• Before entering the safeguarded space or robot operating space and neighborhood, the programmer

must ensure that all necessary safeguards are in place and functioning.

• The programmer must set the operating mode to taught mode prior to entering the safeguarded space
or robot operating space and neighborhood. Take measure to prevent the third person starting auto
operation.

• The results of risk assessment may admit that people they are not programmer but trained about
collaborative robot access to the robot operating space and neighborhood easily, during programming.
In this case, confirm that the contact stop function is enabled.

5.3.2 During Programming

During programming, only the programmer must be allowed in the safeguarded space and the following
conditions must be met.

• The robot system must be under the sole control of the programmer within the safeguarded space or
robot operating space or neighborhood.

• The controls of the teach pendant must be used as intended.

• The robot system must not respond to any remote commands or conditions that would cause hazardous

conditions.

• All robot system emergency stop devices must remain functional. If it is impossible, take measures to

secure security of users in safeguard space or robot operating space or neighborhood.

The results of risk assessment may admit that people they are not programmer but trained about
collaborative robot access to the robot operating space and neighborhood easily, during programming. In
this case, confirm that the contact stop function is enabled. If the programmer changes the contact stop
function to disable temporary, indicate to the surrounding people

5.3.3 Returning to Automatic Operation

The programmer must return the suspended safeguards to their original effectiveness prior to initiating
automatic operation of the robot system.

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5.3.4 Other Cautions for Programming

• Adopt a limit switch or other sensor to detect a dangerous state and, if necessary, design the program
to stop the robot when the sensor signal is received.

• Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.

• For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming in order not to interfere with each other.

• Provide a suitable interface between the robot and its peripheral devices so that the robot can detect
the states of all devices in the system, and can be stopped according to the states.

• Design to arrange avoiding mutual interfere when various robot’s operation space crossover
significantly.

• Be sure to specify the predetermined work origin in a motion program so that the robot starts from the
origin and terminates at the origin. Make it possible for the operator to distinguish easily that the robot
motion has terminated at a glance.

• Circumspect program with sufficient delay required for the program after executing some control

command in adopting actuators (pneumatic, hydraulic, and electric)

• Adopt limit switches for the end effector, and control the robot system by monitoring the state.

5.4 PROGRAM VERIFICATION

When visual examination of the robot system response to the task program is necessary as part of the
verification procedure, it should be made with all persons outside the safeguarded space and its
neighborhood. When it is necessary to perform program verification with personnel inside the safeguarded
space or the robot operating space and neighborhood, apply the following contents.

• Program verification must initially be performed at reduced speed.
Special care is required when override is specified in the program.

• When it is necessary to examine the movement of the robot at full (operational) speed, apply the
following contents:

- Only the programmer can change safety operation mode to normal operation mode by means

which requires careful operation;

- Workers in safeguard space or robot operating space and its neighborhood always can use enable

device or other devices with an equivalent safety level if necessary;

- safe working procedures are established to minimize the exposure of personnel to hazards within

the safeguarded space or robot operating space and its neighborhood.

5.5 TROUBLESHOOTING

When troubleshooting is performed from within the safeguarded space or the robot operating space and
neighborhood, be sure to follow the following contents.

• personnel responsible for trouble shooting are specifically authorized and trained for these activities;

• personnel entering the safeguarded space or robot operating space must operate the robot with the

enable machine;

• safe working procedures are established to minimize the exposure of personnel to hazards within the
safeguarded space or robot operating space and its neighborhoood.

5.6 SAVING PROGRAMMED DATA

A record of the task programs together with any modifications must be maintained. The programmed date
which is saved in portable media must be stored in a suitably protected environment when not in use.

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5.7 AUTOMATIC OPERATION

Automatic operation must only be permissible when

• the intended safeguards are in place and functioning,

• proper safe working procedures are followed.

The results of risk assessment may require to check following items before automatic operation

• no personnel are present within the safeguarded space,

WARINIG

Please make sure that nobody remained inside of the safety fence before

starting up automatic operation of robot systems. If somebody remained inside
of the safety fence exists, trapped personnel inside of the safety fence might
meet serious situation, which can lead them to serious injury or death.

5.8 MAINTENANCE

The robot and robot system must have an inspection and maintenance program to ensure continued safe
operation of the robot system.
The inspection and maintenance program must take into account the robot and robot system manufacturer’s
recommendations.

Personnel who perform maintenance or repair on robots or a robot system must be trained in the procedures
necessary to perform safely the required tasks.

Personnel who maintain and repair robot systems must be safeguarded from hazards.
Where possible, maintenance must be performed from outside the safeguarded space or robot operating
space or neighborhood by placing the robot arm in a predetermined position.

The results of risk assessment may admit that people they don’t maintain or repair but trained about
collaborative robot access to the robot operating space and neighborhood easily, during maintenance. In
this case, confirm that the contact stop function is enabled.

The following is the safety procedure of entering safeguarded space for maintenance.

WARNING

Make sure the Main breaker must be shut down in the robot maintenance with

the exception of following.

- Replacing batteries of the Robot

- Demand of operating the peripheral equipment in maintenance operation

- Safety maintenance disturbance

Maintenance without disconnecting the electric power supply may cause the

serious electric shock.

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Entering safeguarded space for maintenance

1 Stop the robot system.

2 Shut off the power of the robot system, and lock the main breaker to prevent powering on during

maintenance, by mistake.

If you have to enter the safeguarded space while power is available to the robot system, you must do
the following things prior to entering the safeguarded space:

- check the robot system to determine if any conditions exist that are likely to cause malfunctions,

- check if the teach pendant works correctly, and

- if any damage or malfunction is found, complete the required corrections and perform retest

before personnel enter the safeguarded space.

3 Enter the safeguarded space (see Section 4.7 “The Safety Sequence for Fence Entry”).

4 After the maintenance working, check if the safeguard system is effective. If it has been suspended to

perform the maintenance working, return their original effectiveness.

5.9 DISMANTLING / SCRAPPING

Do not start dismantling the robot before contacting such as FANUC Europe Corporation , FANUC
America Corporation, SHANGHAI-FANUC Robotics CO., LTD. or FANUC Corporation in Japan.
Please contact us when you have to dismantle/scrap FANUC robot systems.

WARNING

When dismantling and/or scrapping robot mechanical units equipped with spring

balancers, the robot arm may move unexpectedly due to the stored elastic
energy of the springs inside the balancer(s), and subsequently lose its balance.

Dismantling and scrapping of such robot system must be done only after

releasing the stored energy and according to the instructions provided by
FANUC. Very severe injury or death of personnel may occur in case any of
these instructions is not followed

CAUTION

Robot batteries used for memory and/or encoder backup must be disposed of

appropriately. Failure to do so may cause short circuit during
dismantling/scrapping, which potentially can cause ignition or explosion.

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B-84194EN/04 SAFETY PRECAUTIONS

5.10 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER

IN EMERGENCY OR ABNORMAL SITUATIONS

(1) For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), brake release

unit can be used to move the robot axes without drive power.

Please order following unit and cable.

Name Specification

Brake release unit A05B-2695-J350

A05B-2695-J360 (5m) (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L)
Robot connection
cable

Power cable

(2) Prepare and store adequate numbers of brake release units which are ready and readily accessible for

robot system before installation.

(3) Regarding how to use brake release unit, please refer to “Robot controller maintenance manual”.

WARNING

Robot arm would fall down by releasing its brake because of the gravity.

Therefore, it is strongly recommended to take adequate measures such as
hanging Robot arm by a crane before releasing a brake.

CAUTION

Robot systems installed without adequate number of brake release units or

similar means are neither in compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the CE marking.

A05B-2695-J361(10m) (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L)

A05B-2695-J362 (5m) (CRX-25iA)

A05B-2695-J363 (10m) (CRX-25iA)

A05B-2690-J101 (5 m) (AC200-240V single phase, right angle, round terminal M5)

A05B-2690-J102(10m) (AC200-240V single phase, right angle, round terminal M5)

A05B-2695-J101 ( 5m) (AC100-120V single phase, right angle, Power plug)

A05B-2695-J102(10m) (AC100-120V single phase, right angle, Power plug)

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SAFETY PRECAUTIONS

B-84194EN/04

5.11

(1) Operation space and payload label

WARNING & CAUTION LABEL

Fig. 5.11 (a) Operating space and payload label (CRX-5iA)

Fig. 5.11 (b) Operating space and payload label (CRX-10iA, CRX-10iA/L, CRX-20iA/L)

Fig. 5.11 (c) Operating space and payload label (CRX-25iA)

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B-84194EN/04 SAFETY PRECAUTIONS

6 DAILY MAINTENANCE

6.1 MECHANICAL UNIT

To keep the robot system safe, please perform periodic maintenance those are specified in operator’s
manual or maintenance manual.
In addition, please clean each part of the system and visually check them for any damage or cracks.
Daily check items are as follows (but not limited to).

• Input power voltage

• Pneumatic pressure

• Damage of connection cables

• Looseness of connectors

• Lubrication

• Emergency stop functions

• Effectiveness of deadman switch on teach pendant

• Safety gate interlocks (in case the robot system has safety gate interlocks)

• Vibration, noise by the robot movement

• Functions of peripheral devices

• Fixtures of robot and peripheral devices

6.2 CONTROL UNIT

Before operating the system each day, clean each part of the system and check the system parts for any
damage or cracks.

Also, check the following:

(a) Before service operation

- Check the cable connected to the teach pendant for excessive twisting.

- Check the controller and peripheral devices for abnormalities.

- Check the safety function.

(b) After service operation
At the end of service operation, return the robot to the proper position, then turned off the controller.

Clean each part, and check for any damage or cracks.
If the ventilation port and the fan motor of the controller are dusty, wipe off the dust.

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B-84194EN/04 PREFACE

PREFACE

This manual explains operation procedures for the following mechanical units:

Model name Mechanical unit specification No. Maximum load

FANUC Robot CRX-5iA

FANUC Robot CRX-10iA

FANUC Robot CRX-10iA/L

FANUC Robot CRX-20iA/L
FANUC Robot CRX-25iA

The label stating the mechanical unit and force sensor specification number is affixed in the following
position. Before reading this manual, verify the specification number of the mechanical unit.

A05B-1703-B201 5kg
A05B-1702-B201
A05B-1702-B203
A05B-1702-B202
A05B-1702-B204
A05B-1702-B212 20kg
A05B-1704-B201 25kg

10kg

10kg

Position of label indicating mechanical unit and force sensor specification number

TABLE 1 (a) Mechanical unit

CONTENTS (1) Model name (2) TYPE (3) No. (4) DATE

LETTERS

FANUC Robot
CRX-5iA

FANUC Robot
CRX-10iA

FANUC Robot
CRX-10iA/L

FANUC Robot
CRX-20iA/L

FANUC Robot
CRX-25iA

A05B-1703-B201

A05B-1702-B201
A05B-1702-B203

A05B-1702-B202
A05B-1702-B204

A05B-1702-B212 41

A05B-1704-B201 135

p-1

TYPE
NO.
DATE

SERIAL NO. IS
PRINTED

(4)

(1)

(2)

(3)

PRODUCTION
YEAR AND
MONTH ARE
PRINTED

W E I G H T

Kg

(5)

(5) WEIGHT kg

(Without controller)

25

40

40

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PREFACE B-84194EN/04

RELATED MANUALS

For the FANUC Robot series, the following manuals are available:

R-30iB Mini Plus
controller

This manual uses following terms.

Connection cable between robot and controller Robot connection cable
Robot mechanical unit Mechanical unit

OPERATOR’S MANUAL
(Basic Operation)

B-83284EN

OPERATOR’S MANUAL
(Alarm Code List)

B-83284EN-1

OPERATOR’S MANUAL
(Optional Function)

B-83284EN-2
ARC Welding Function
OPERATOR’S MANUAL

B-83284EN-3

Dispense Function
OPERATOR’S MANUAL

B-83284EN-5

Collaborative Robot Function
OPERATOR’S MANUAL

B-83744EN
MAINTENANCE MANUAL

B-84175EN

Name Terms in this manual

Intended readers :

Operator, programmer, Teaching operator,
Maintenance technician, System designer

Topics :

Robot functions, Operations, Programming, Setup,
Interfaces, Alarms

Use :

Robot operation, Teaching, System design

Intended readers :

Maintenance technician, System designer

Topics :

Installation, Start-up, Connection, Maintenance

Use :

Installation, Start-up, Connection, Maintenance

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B-84194EN/04 TABLE OF CONTENTS

TABLE OF CONTENTS

SAFETY PRECAUTIONS ............................................................................ s-1

1 DEFINITION OF WARNING AND CAUTION ....................................... s-2

2 FANUC COLLABORATIVE ROBOT SYSTEM .................................... s-2

2.1 OVERVIEW ................................................................................................ s-2

2.2 PURPOSE OF ROBOT .............................................................................. s-3

2.3 CONFIGURATION OF ROBOT SYSTEM .................................................. s-3

2.4 DEFNITION OF THE USER ....................................................................... s-4

2.4.1 Robot Training ...................................................................................................... s-5

2.4.2 Safety of the working person ................................................................................. s-6

2.4.3 Safety of the Collaborative Worker ....................................................................... s-8

2.4.4 Safety of the Operator ........................................................................................... s-8

2.4.5 Safety of the Programmer ...................................................................................... s-9

2.4.6 Safety of the Maintenance Engineer .................................................................... s-10

2.5 RELEVANT STANDARDS ........................................................................ s-12

3 ROBOT SYSTEM DESIGN ................................................................ s-13

3.1 GENERAL ................................................................................................ s-13

3.2 PLACEMENT OF EQUIPMENT ................................................................ s-14

3.3 POWER SUPPLY AND PROTECTIVE EARTH CONNECTION ............... s-16

3.4 OTHER PRECAUTIONS .......................................................................... s-16

3.5 END EFFECTOR, WORKPIECE AND PERIPHERAL EQUIPMENT ........ s-19

3.6 THE CHARACTERISTIC OF COLLABORATIVE ROBOT AND

LIMITATIONS AND USAGE NOTES ........................................................ s-20

4 SAFETY DEVICES ............................................................................. s-24

4.1 STOP TYPE OF ROBOT .......................................................................... s-24

4.2 EMERGENCY STOP ................................................................................ s-26

4.3 MODE SELECT SWITCH ......................................................................... s-26

4.3.1 Operating Modes ................................................................................................. s-26

4.4 ENABLING DEVICE (DEADMAN SWITCH) ............................................. s-27

4.5 SAFEGUARDS ......................................................................................... s-28

4.5.1 Safety Fence ........................................................................................................ s-28

4.5.2 Safety Gate and Plugs .......................................................................................... s-29

4.5.3 Other Protection Devices ..................................................................................... s-29

4.6 OPERATION INSIDE OF THE SAFETY FENCE ...................................... s-30

4.7 THE SAFETY SEQUENCE FOR FENCE ENTRY .................................... s-31

5 GENERAL CAUTIONS ...................................................................... s-33

5.1 INSTALLATION ........................................................................................ s-33

5.2 COMMISSIONING AND FUNCTIONAL TESTING ................................... s-34

5.2.1 Designation of the Restricted Space and Restriction of User .............................. s-34

5.2.2 Safety and Operational Verification .................................................................... s-34

5.2.3 Robot System Restart Procedures ....................................................................... s-34

5.3 PROGRAMMING ...................................................................................... s-35

5.3.1 Prior to Programming .......................................................................................... s-35

5.3.2 During Programming ........................................................................................... s-35

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TABLE OF CONTENTS B-84194EN/04

5.3.3 Returning to Automatic Operation ...................................................................... s-35

5.3.4 Other Cautions for Programming ........................................................................ s-36

5.4 PROGRAM VERIFICATION ..................................................................... s-36

5.5 TROUBLESHOOTING .............................................................................. s-36

5.6 SAVING PROGRAMMED DATA .............................................................. s-36

5.7 AUTOMATIC OPERATION ...................................................................... s-37

5.8 MAINTENANCE ........................................................................................ s-37

5.9 DISMANTLING / SCRAPPING ................................................................. s-38

5.10 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN

EMERGENCY OR ABNORMAL SITUATIONS ......................................... s-39

5.11 WARNING & CAUTION LABEL ................................................................ s-40

6 DAILY MAINTENANCE ..................................................................... s-41

6.1 MECHANICAL UNIT ................................................................................. s-41

6.2 CONTROL UNIT ....................................................................................... s-41

PREFACE ....................................................................................................p-1

1 TRANSPORTATION AND INSTALLATION ........................................... 1

1.1 TRANSPORTATION ...................................................................................... 1

1.2 INSTALLATION ............................................................................................. 5

1.2.1 Angle of Mounting Surface Setting ........................................................................ 12

1.3 MAINTENANCE AREA ................................................................................ 18

1.4 INSTALLATION CONDITIONS .................................................................... 20

1.5 SWITCHING INPUT POWER SUPPLY 100V 200V (CRX-25iA) ................. 20

2 CONNECTION WITH THE CONTROLLER .......................................... 22

3 BASIC SPECIFICATIONS .................................................................... 26

3.1 ROBOT CONFIGURATION ......................................................................... 26

3.2 MECHANICAL UNIT EXTERNAL DIMENSIONS AND OPERATING SPACE

..................................................................................................................... 29

3.3 ZERO POINT POSITION AND MOTION LIMIT ........................................... 33

3.4 WRIST LOAD CONDITIONS ....................................................................... 39

4 EQUIPMENT INSTALLATION TO THE ROBOT .................................. 44

4.1 END EFFECTOR INSTALLATION TO WRIST ............................................ 44

4.2 LOAD SETTING .......................................................................................... 45

4.3 30kg PAYLOAD MODE (CRX-25iA) ............................................................ 49

5 PIPING AND WIRING TO THE END EFFECTOR ................................ 50

5.1 INTERFACE FOR OPTION CABLE ............................................................ 51

5.2 AIR SUPPLY (CRX-25iA) ............................................................................ 56

5.3 AIR PIPING (OPTION) ................................................................................ 57

6 AXIS LIMIT SETUP ............................................................................... 58

6.1 CHANGE AXIS LIMIT BY DCS .................................................................... 58

6.2 RISK ASSESSMENT FOR J5-AXIS MOTION RANGE ............................... 61

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B-84194EN/04 TABLE OF CONTENTS

7 CHECKS AND MAINTENANCE ........................................................... 62

7.1 PERIODIC MAINTENANCE ........................................................................ 62

7.1.1 Daily Checks .......................................................................................................... 62

7.1.2 Periodic Check and Maintenance ........................................................................... 63

7.2 CHECK POINTS .......................................................................................... 64

7.2.1 Confirmation of Oil Seepage .................................................................................. 64

7.2.2 Confirmation of the Air Control Set (option) ......................................................... 65

7.2.3 Check the Mechanical Unit Connectors ................................................................. 66

7.3 MAINTENANCE ........................................................................................... 67

7.3.1 Replacing the Batteries ........................................................................................... 67

7.4 STORAGE ................................................................................................... 69

8 MASTERING ......................................................................................... 70

8.1 OVERVIEW ................................................................................................. 70

8.2 RESETTING ALARMS AND PREPARING FOR MASTERING ................... 71

8.3 ZERO POSITION MASTERING .................................................................. 72

8.4 QUICK MASTERING ................................................................................... 75

8.5 QUICK MASTERING FOR SINGLE AXIS ................................................... 79

8.6 SINGLE AXIS MASTERING ........................................................................ 81

8.7 MASTERING DATA ENTRY ........................................................................ 83

8.8 VERIFYING MASTERING ........................................................................... 85

9 TROUBLESHOOTING .......................................................................... 86

9.1 TROUBLESHOOTING ................................................................................. 86

APPENDIX

A PERIODIC MAINTENANCE TABLE ..................................................... 95

B MOUNTING BOLT TORQUE LIST ....................................................... 98

C EU DECLARATION OF CONFORMITY ............................................... 99

D CONTACTS ......................................................................................... 100

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

A

1 TRANSPORTATION AND INSTALLATION

1.1 TRANSPORTATION

When transporting the robot, sure to change the posture of the robot to that shown below and pack it in the
transport box (except CRX-25iA). Please perform packing the robot in two people. Refer to specification
of Section 1.2 about unpacking and installation
The transport kit and the carrying support can be purchased from FANUC. Refer to Table 1.1 (a) and (b)
about specification.

WARNING

The robot becomes unstable when it is transported with the end effector applied

to wrist. Please be sure to remove the end effector when the robot is
transported.

Carrying support
CRX-5iA:

97L-0318-0710#5IA-1

One worker supports the arm, and the
other worker takes off the bolts fixing
the robot to the base.

Please tighten the box
with PP bands.

Transport kit
CRX-5iA :A97L-0318-0710#5IA

Fig. 1.1 (a) Transportation using transport box (CRX-5iA)

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1. TRANSPORTATION AND INSTALLATION

A

A

Carrying support
CRX-10iA:

97L-0318-0710#10IA-1

CRX-10iA/L, CRX-20iA/L:

97L-0318-0710#10IAL-1

One worker supports the arm, and the
other worker takes off the bolts fixing
the robot to the base.

B-84194EN/04

Please tighten the box
with PP bands.

Transport kit
CRX-10iA
CRX-10iA/L, CRX-20iA/L:A97L-0318-0710#10IAL

Fig. 1.1 (b) Transportation using transport box (CRX-10iA, CRX-10iA/L, CRX-20iA/L)

:A97L-0318-0710#10IA

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

Table 1.1 (a) Specification related to transportation.

Model Name Specification

CRX-5iA

CRX-10iA

CRX-10iA/L, CRX-20iA/L

Note) The transport kit includes the carrying support.

Use a crane to transport CRX-25iA. Before transporting the robot, be sure to change the posture of the robot
to that shown Fig. 1.1(c).

CAUTION

When hoisting or lowering the robot with a crane, move it slowly and with great

care. When placing the robot on the floor, exercise care to prevent the
installation surface of the robot from striking the floor with too much force.

When hoisting or lowering the robot, be sure to perform it with the robot only. Do

not hoist or lower the robot with a pedestal, or an installation plate and skid for
transportation.

If these cautions are not followed, the internal sensor might break.

WARNING

1 The robot becomes unstable when it is transported with the end effector applied

to wrist. Please be sure to remove the end effector when the robot is
transported.

2 Do not lift at showing point with transportation skid.

Transport kit A97L-0318-0710#5IA

Carrying support A97L-0318-0710#5IA-1

Transport kit A97L-0318-0710#10IA

Carrying support A97L-0318-0710#10IA-1

Transport kit A97L-0318-0710#10IAL

Carrying support A97L-0318-0710#10IAL-1

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B-84194EN/04

Transport posture

o

J1:0

J4:180o

o

J2:0

J5:0o

o

J3:-90

J6:90o

Crane

Sling

Note)

1. Mechanical unit mass : 135kg

2. Load capacity of crane : 300kg or more

3. Load capacity of sling : 250kg or more

Fig. 1.1 (c) Transportation using a crane (CRX-25iA)

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

1.2 INSTALLATION

Please perform unpacking and the installation of the robot in two people (except CRX-25iA). Fig. 1.2 (a)
and (b) show how to unpack and to install.

One worker supports the arm, and the
other worker fixes the robot arm to the
base using bolts.

Fig. 1.2 (a) Unpacking and the installation of the robot (CRX-5iA)

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1. TRANSPORTATION AND INSTALLATION

B-84194EN/04

One worker supports the arm, and the
other worker fixes the robot arm to the
base using bolts.

Fig. 1.2 (b) Unpacking and the installation of the robot (CRX-10i A, CRX-10iA/L, CRX-20iA/L)

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

Fig. 1.2 (c) to (f) show the robot base dimensions.

CAUTION

Flatness of robot installation surface must be less than or equal to 0.5mm.
Inclination of robot installation surface must be less than or equal to 0.5°.
If robot base is placed on uneven ground, it may result in the base breakage or

low performance of the robot.

Fig. 1.2 (c) Dimensions of the robot base (CRX-5iA back side connector)

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1. TRANSPORTATION AND INSTALLATION B-84194EN/04

4

5

O

1

7

0

95 99

SECTION A-A

断面 A-A

A A

°

6161

C

4-φ9 through

4-

O

9

J1-axis

J1軸回転中心

rotation center

󲆰󲎜

25

Front

正面

φ8 FG8 Depth10

O

8 FG8 深さ10

φ8 FG8 Depth10

O

8 FG8 深さ10

13

8

Fig. 1.2 (d) Dimensions of the robot base (CRX-10iA, CRX-10iA/L, CRX-20iA/L back side connector)

+0.024
+0.006

10

120

VIEW B

矢視 B

13

B

98.3

C

154198

13

+0.024

+0.006

8

50.2

7.6

8.1

50.7

10

Locating surface

突き当て面

OBLONG HOLE Depth10

長穴　深さ10

OBLONG HOLE Depth10

長穴 深さ10

8

O

SECTION C-C

断面 C-C

120

13

0.85

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

4

5

Front

正面

O

1

7

0

95 99

SECTION A-A

A A

25

149

断面 A-A

B

°

C

C

6161

4-φ9 through

4-

O

󲆰󲎜

9

J1-axis

J1軸回転中心

rotation center

8

O

SECTION C-C

断面 C-C

13

0.85

98.3

13

+0.024

7.6

1

.
8

+0.006

50.2

8

10

7

Locating surface

.

突き当て面

0
5

OBLONG HOLE Depth10

長穴　深さ10

OBLONG HOLE Depth10

長穴 深さ10

120

+0.024
+0.006

10

120

矢視 B

13

φ8 FG8 Depth10

O

8 FG8 深さ10

φ8 FG8 Depth10

O

8 FG8 深さ10

3
1

8

VIEW B

Fig. 1.2 (e) Dimensions of the robot base (CRX-10iA, CRX-10iA/L, CRX-20iA/L bottom connector)

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1. TRANSPORTATION AND INSTALLATION

B-84194EN/04

Fig. 1.2 (f) Dimensions of the robot base (CRX-25iA back side connector)

Fig. 1.2 (g), Table 1.2 (a) indicate the force and moment applied to the robot base.
Table 1.2 (b) indicate the stopping distance and time of the J1 through J3 axes until the robot stopped by
Power-Off stop or Smooth stop after input the stop signal.
Refer to the data below in considering the strength of the installation plane.

NOTE

Stopping times and distances in Table 1.2 (b) are reference values measured in

accordance with ISO 10218-1. Please measure and check the actual values,
since it varies depending on robot individual, load condition and operation
program.

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

M

V

F

F

H

Fig. 1.2 (g) Force and moment that acts on the robot base

Table 1.2 (a) Force and moment that acts on the robot base

Model Condition

During stillness 140 290 0 0

CRX-5iA

CRX-10iA,
CRX-10iA/L

CRX-20iA/L

CRX-25iA

CRX-25iA
(30kg payload
mode)

Table1.2 (b) Stopping time and distance until the robot stopping by Smooth stop after input of stop signal

Model Speed J1 J2 J3

CRX-5iA

CRX-10iA

CRX-10iA/L

During acceleration or deceleration 160 380 30 70
During Smooth stop 240 460 80 100
During stillness 310 490 0 0
During acceleration or deceleration 330 540 50 110
During Smooth stop 480 680 90 140
During stillness 470 600 0 0
During acceleration or deceleration 500 680 60 140
During Smooth stop 790 900 190 160
During stillness 1070 1570 0 0
During acceleration or deceleration 1320 1870 510 410
During Smooth stop 1770 2390 650 530
During stillness 1080 1620 0 0
During acceleration or deceleration 1400 1950 560 450
During Smooth stop 1930 2500 710 570

300mm/s

1000mm/s

250mm/s

300mm/s

1000mm/s

250mm/s

300mm/s

1000mm/s

Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
Stopping angle [deg] (rad)

Vertical

moment

[Nm]

M

V

- 11 -

V

M

H

Force in

vertical

direction

FV [N]

376 368 456

11.2(0.20) 8.8(0.15) 7.5(0.13)
392 416 496

31.5(0.55) 29.1(0.51) 24.9(0.43)
216 264 440

4.7(0.08) 3.9(0.07) 4.8(0.08)
232 280 480

6.0(0.10) 5.0(0.09) 6.2(0.11)
384 640 640

14.7(0.26) 24.7(0.43) 27.7(0.48)
240 432 440

4.8(0.08) 3.6(0.06) 4.8(0.08)
264 464 488

6.2(0.11) 4.6(0.08) 6.2(0.11)
424 640 640

14.7(0.26) 20.1(0.35) 27.7(0.48)

Horizontal

moment
MH [Nm]

Force in

horizontal

direction

FH [N]

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1. TRANSPORTATION AND INSTALLATION B-84194EN/04

Model Speed J1 J2 J3

250mm/s

CRX-20iA/L

CRX-25iA,
CRX-25iA
(30kg payload
mode)

CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-25iA
CRX-20iA/L

- Stopping time and distance until the robot stopping by contact stop after input of stop signal

When contact stop is performed, robot stops in stopping time/ stopping distance which is shorter than the
controlled stop. For the examination of the system, please use a value at the time of the controlled stop
mentioned above.

300mm/s

1000mm/s

250mm/s

280mm/s

1000mm/s

Model

Stopping time [ms] 304 552 584
Stopping angle [deg] (rad) 4.1 (0.07) 3.1 (0.05) 6.2 (0.11)
Stopping time [ms] 304 552 584
Stopping angle [deg] (rad) 4.9 (0.08) 3.7 (0.06) 7.5 (0.13)
Stopping time [ms] 448 880 928
Stopping angle [deg] (rad) 19 (0.33) 19.5 (0.34) 39.5 (0.69)
Stopping time [ms] 592 560 632
Stopping angle [deg] (rad) 6.8 (0.12) 4.7 (0.08) 5.3 (0.09)
Stopping time [ms] 592 560 640
Stopping angle [deg] (rad) 7.6 (0.13) 5.3 (0.09) 5.9 (0.10)
Stopping time [ms] 608 584 648
Stopping angle [deg] (rad) 25.1 (0.44) 18.9 (0.33) 21.1 (0.37)

Table 1.2 (c) MAX speed

Maximum speed in

collaborative mode (mm/s)

1000 2000
1000 1000

Maximum speed in

high speed mode (mm/s)

1.2.1 Angle of Mounting Surface Setting

For all robot mounts except floor mount, be sure to set the mounting angle referring to the procedure below.
The setting method differ depending on the software version. Refer to Section 3.1 for installation
specifications.

WARNING

Depends on the robot position, risk assessment has to be done.

Setting method for 7DF5/13 (V9. 40P/13) or before

1 Turn on the controller with [PREV] and [NEXT] key pressed.
2 Then select [3 Controlled start].
3 Press the [MENU] key and select [9 MAINTENANCE].
4 Select the robot for which you want to set the mount angle, and press the [ENTER] key.

ROBOT MAINTENANCE CTRL START MANU

5 Press the [F4] key.

Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-10iA 0

[TYPE]ORD NO AUTO MANUAL

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

6 Press the [ENTER] key until screen below is displayed.

*******Group 1 Initialization************
**************CRX-10iA********************

--- MOUNT ANGLE SETTING ---

0 [deg] : floor mount type
90 [deg] : wall mount type
180 [deg] : upside-down mount type

Set mount_angle (0-180[deg])->
Default value = 0

7 Input the mount angle referring to Fig.1.2.1 (a).

＋

Angle of

設置角度

mounting
surface

Fig. 1.2.1 (a) Mounting angle

8 Press the [ENTER] key until screen below is displayed again.

ROBOT MAINTENANCE CTRL START MANU

Setup Robot System Variables

9 Press the [FCTN] key and select [1 START (COLD)].

Group Robot Library/Option Ext Axes
1 CRX-10iA 0

[TYPE]ORD NO AUTO MANUAL

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1. TRANSPORTATION AND INSTALLATION B-84194EN/04

Setting method for from 7DF5/13 (V9. 40P/13) to 7DF5/24 (V9. 40P/24)

1 Turn on the controller with [PREV] and [NEXT] key pressed.
2 Then select [3 Controlled start].
3 Press the [MENU] key and select [9 MAINTENANCE].
4 Select the robot for which you want to set the mount angle, and press the [ENTER] key.

ROBOT MAINTENANCE CTRL START MANU

Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-10iA 0

[TYPE]ORD NO AUTO MANUAL

5 Press the [F4] key.
6 Press the [ENTER] key until screen below is displayed.

*******Group 1 Initialization************
*************CRX-10iA ******************

-------- MOUNT TYPE SETTING-------

1. Floor Mount Type

2. Angle Mount (Side)

3. Angle Mount (Front-Back)
Select mount type (1 - 3)->

Default value = 1

7 If the robot is installed tos side direction, input “2”. If the robot is installed to front-back, input “3”.
8 If the “ENTER” is pressed, the following screen will be displayed.

*******Group 1 Initialization************
*************CRX-10iA ******************

-------- MOUNT ANGLE SETTING-------

Set mount_angle (-180 - +180[deg])->

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

9 If angle mount is against side direction, refer to Fig. 1.2.1 (b), input the mount angle.

If angle mount is against front-back direction, refer to Fig. 1.2.1 (c), input the mount angle.

＋

Angle of

設置角度

mounting
surface

Fig. 1.2.1 (b) Mounting angle (side direction)

＋

設置角度

Fig. 1.2.1 (c) Mounting angle (front-back direction)

10 Press the [ENTER] key until screen below is displayed again.

11 Press the [FCTN] key and select [1 START (COLD)].

ROBOT MAINTENANCE CTRL START MANU

Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-10iA 0

[TYPE]ORD NO AUTO MANUAL

- 15 -

Angle of
mounting
surface

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1. TRANSPORTATION AND INSTALLATION B-84194EN/04

Setting method for 7DF5/25 (V9. 40P/25) or later

1 Turn on the controller with [PREV] and [NEXT] key pressed.
2 Then select [3 Controlled start].
3 Press the [MENU] key and select [9 MAINTENANCE].
4 Select the robot for which you want to set the mount angle, and press the [ENTER] key.

ROBOT MAINTENANCE CTRL START MANU

Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-10iA 0

[TYPE]ORD NO AUTO MANUAL

5 Press the [F4] key.
6 Press the [ENTER] key until screen below is displayed.

*******Group 1 Initialization************
*************CRX-10iA ******************

--- Angle of Mounting Surface---

--- to Floor Surface setting---

Enter angle(-180 - +180[deg])->

Default value = 0.000

7 According to Fig. 1.2.1 (d), input the angle of mounting surface 1.

Angle of mounting surface 1 = Rotation angle for front-back direction against the floor

設置角度 1=床面に対する前後方向の回転角度

Fig. 1.2.1 (d) Mounting angle

- 16 -

Mounting

設置面

surface

＋

Angle of mounting

設置角度 1

surface 1

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

8 If the “ENTER” is pressed, the following screen will be displayed.

*******Group 1 Initialization************
*************CRX-10iA ******************

--- Angle of Robot to ---

--- Mounting Surface setting --

0 [deg] : Front-Back (Default)
90 [deg] : Side
Enter angle (-180 - +180[deg])->

Default value = 0.000

9 According to Fig. 1.2.1 (e), input the angle of mounting surface 2.

Axis vertical to the

設置面に垂直な軸

mounting surface

Mounting

設置面

surface

＋

Angle of mounting

設置角度 2

surface 2

Angle of mounting surface 2 = Rotation angle for the axis which is vertical against the mounting surface

10 Press the [ENTER] key until screen below is displayed again.

11 Press the [FCTN] key and select [1 START (COLD)].

設置角度 2=設置面に垂直な軸回りの回転角度

Fig. 1.2.1 (e) Mounting angle

ROBOT MAINTENANCE CTRL START MANU

Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-10iA 0

[TYPE]ORD NO AUTO MANUAL

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1. TRANSPORTATION AND INSTALLATION B-84194EN/04

1.3 MAINTENANCE AREA

Fig. 1.3 (a) to (c) shows the maintenance area of the mechanical unit. Make sure to secure enough room for
mastering. Refer to Chapter 8 for the mastering.

(In case of bottom
connector plate)

Fig. 1.3 (a) Maintenance area (CRX-5iA)

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

500

400

500

500

(In case of bottom

(底面分線盤の場合)

connector plate)

500

Fig. 1.3 (b) Maintenance area (CRX-10iA, CRX-10iA/L, CRX-20iA/L)

810

500

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1. TRANSPORTATION AND INSTALLATION

B-84194EN/04

Fig. 1.3 (c) Maintenance area (CRX-25iA)

1.4

Refer to specification of Section 3.1 about installation conditions.

1.5

CRX-25iA is set to 100V specification or 200V specification by software at the time of factory-perform
according to the ordered power cable specification. Follow the procedure below to switch the input power
supply.
Note that the cycle time and the motion path may change between 100V and 200V. (The maximum speed
does not change.)

1 Turn on the controller with [PREV] and [NEXT] key pressed. Then select [3 Controlled start].
2 Press the [MENU] key and select [9 MAINTENANCE].
3 You will see a screen similar to the following.
Press arrow (↑,↓) keys and move the cursor to “CRX-25iA”. Then press F4, MANUAL.

INSTALLATION CONDITIONS

SWITCHING INPUT POWER SUPPLY 100V 200V (CRX-25iA)

ROBOT MAINTENANCE
1/10
Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-25iA 0

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B-84194EN/04 1. TRANSPORTATION AND INSTALLATION

4 Set to 100V specification or 200V specification on the following screen.

******** Group 1 Initialization ********

------- SELECT AC POWER SUPPLY -------

1. AC200V-240V single phase

2. AC100V-120V single phase

Select AC power supply (1 or 2)->

5 Press the [FCTN] key and select “1. START (COLD)”.

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2. CONNECTION WITH THE CONTROLLER B-84194EN/04

2 CONNECTION WITH THE CONTROLLER

The robot is connected with the controller via the power and signal cable, the earth line, the camera cable
or the force sensor cable. Connect these cables to the connectors on the back of the base. For details on
option cables, see refer to Chapter 5.

WARNING

Before turning on controller power, be sure to connect the robot and controller

with the earth line (ground). Otherwise, there is the risk of electrical shock.

CAUTION

1 Before connecting the cables, be sure to turn off the controller power.
2 Don’t use 10m or longer coiled cable without first untying it. The long coiled

cable could heat up and become damaged.

Robot

ロボット機構部

mechanical unit

Controller

制御装置

power, signal cable

動力、信号ケーブル

アース線

earth line

Earth terminal

アース端子

(M4 bolt)

(M4ボルト)

カメラケーブルコネクタ

Connector for camera cable

Fig. 2 (a) Cable connection (CRX-5iA back side connector)

Connector for camera cable

動力、信号線クランプ

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B-84194EN/04 2. CONNECTION WITH THE CONTROLLER

Robot

ロボット機構部

mechanical unit

Controller

制御装置

power, signal cable

動力、信号ケーブル

earth line

アース線

Earth terminal

アース端子

(M4 bolt)

(M4ボルト)

Fig. 2 (b) Cable connection (CRX-10iA, CRX-10iA/L, CRX-20iA/L back side connector)

Clamp for power

動力、信号線クランプ

and signal

Connector for

カメラケーブルコネクタ　もしくは

camera cable or force

力センサケーブルコネクタ

sensor cable

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2. CONNECTION WITH THE CONTROLLER B-84194EN/04

Robot

ロボット機構部

mechanical unit

Controller

制御装置

power, signal cable

動力、信号ケーブル

earth line

アース線

Clamp for power
and signal

動力、信号線クランプ

Fig. 2 (c) Cable connection (CRX-10iA, CRX-10iA/L, CRX-20iA/L bottom side connector)

Earth terminal is at the same place with the

アース端子は背面分線盤と同じ箇所

backside connector panel

Connector for

カメラケーブルコネクタ　もしくは

camera cable or force

力センサケーブルコネクタ

sensor cable

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B-84194EN/04 2. CONNECTION WITH THE CONTROLLER

Robot

ロボット機構部

mechanical unit

Controller

制御装置

power, signal cable

動力、信号ケーブル

earth line

アース線

Connector for additional

ユーザ用動力、信号線

power and signal

インタフェース

Connector for

カメラケーブル

camera cable

インタフェース

Earth terminal

アース端子

(M4 bolt)

(M4ボルト)

Fig. 2 (d) Cable connection (CRX-25iA back side connector)

Connector for power

動力、信号線コネクタ

and signal

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3. BASIC SPECIFICATIONS B-84194EN/04

3 BASIC SPECIFICATIONS

3.1 ROBOT CONFIGURATION

AC servo motor for J5-axis

J5軸用ACサーボモータ

AC servo motor

AC servo motor for J6-axis

J6軸用ACサーボモータ

End effector

エンドエフェクタ

mounting face

取り付け面

Wrist unit

手首ユニット

J3 arm

J3アーム

J4軸用ACサーボモータ

for J4-axis

AC servo motor

J3軸用ACサーボモータ

for J3-axis

J2 arm

J2アーム

AC servo motor for J2-axis

J2軸用ACサーボモータ

J2 base

J2ベース

J1 base

J1ベース

Fig. 3.1 (a) Mechanical unit configuration

J3

AC servo motor

J1軸用ACサーボモータ

for J1-axis

+

J4

-

X

J5

+

Y

J6

-

+

Z

-

+

J2

-

-

+

-

J1

Fig. 3.1 (b) Each axes coordinates and mechanical interface coordinates

NOTE

The end effector mounting face center is 0, 0, 0 of the mechanical interface

coordinates.

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B-84194EN/04 3. BASIC SPECIFICATIONS

Table 3.1 (a) Specifications (Note 1)

Item Specification

Model CRX-5iA CRX-10iA CRX-10iA/L CRX-20iA/L CRX-25iA

Type Articulated type

Controlled axes 6-axis(J1, J2, J3, J4, J5, J6)

Reach 994mm 1249 mm 1418 mm 1889mm

Installation Floor, Upside-down, Wall & Angle mount (Note 2)

J1-axis 400° (6.98 rad) 380° (6.63 rad) 360° (6.28 rad)
J2-axis 360° (6.28 rad)

Motion range

Maximum speed

Maximum load at wrist 5kg 10kg 20kg

Allowable

load moment

at wrist

Allowable

load inertia

at wrist

Repeatability (NOTE 6) ±0.03mm ±0.04mm ±0.05mm

Robot mass 25kg 40kg 40kg 41kg 135kg

Dust proof and drip

proof mechanism

Acoustic noise level Less than 70dB (NOTE 8)

Installation environment

J3-axis 635° (11.08 rad) 570° (9.95 rad) 540° (9.42 rad)
J4-axis 380° (6.63 rad)
J5-axis

J6-axis

1000mm/s (NOTE 4)

(NOTE 3)

J4-axis 19.0Nm 34.8Nm 70.0Nm

J5-axis 15.4Nm 26.0Nm 64.0Nm 85.0Nm
J6-axis 6.7Nm 11.0Nm 30.0Nm 32.0Nm
J4-axis 0.77kg.m
J5-axis 0.50kg.m2 0.90kg.m
J6-axis 0.10kg.m2 0.30kg.m

(NOTE 7)

Ambient temperature: Operating 0 to 45℃ (NOTE 9)
Storage,Transport -10 to 60℃
Ambient humidity: Normally 75%RH or less (No condensation allowed.)
Short time (Within 1 month) 95%RH or less (No condensation allowed.)
Permitted altitude: up to 1000 m above sea level
Free of corrosive gases (NOTE 10)
Vibration acceleration : 4.9m/s
Environment without fire

(high speed mode 2000mm/s (NOTE 5))

2

1.28kg.m2 4.00kg.m2 4.70kg.m2

2

(0.5G) or less (NOTE 11)

360° (6.28 rad)
450° (7.85 rad)

1000mm/s (NOTE4)

(high speed mode
000mm/s (NOTE5))

2

4.00kg.m2 4.00kg.m2

2

2.00kg.m2 2.00kg.m2

Conform to IP67

1000mm/s (NOTE4)

(high speed mode

2000mm/s (NOTE5))

25kg

(Max.30kg

NOTE 12)

100.0Nm

(Max.115.0Nm

NOTE13)

NOTE

1 Even if the robot is used according to the defined specifications, motion programs might shorten reducer life or cause the

robot to overheat. Use ROBOGUIDE for further evaluation before running production.

2 There is no limit of operating space for all the installation types. (CRX-5iA has restrictions. If you perform angle mount

installation, please contact your local FANUC representative.)
3 During short distance motions, the speed may not reach the maximum value stated.
4 It is necessary to set a motion speed according to risk assessment of system considering pinching with the surroundings.
5 If the area is monitored by a safety sensor (located separately).
6 Compliant with ISO9283.
7 Definition of IP code
Definition of IP 67

6 = Dust-tight: Complete protection against contact

7 = Protection from water immersion: Ingress of water in harmful quantity shall not be possible

when the enclosure is immersed in water under defined conditions of pressure and time.

8 This value is equivalent continuous A-weighted sound pressure level, which applied with ISO11201 (EN31201). This

value is measured with the following conditions.

- Maximum load and speed

- Operating mode is AUTO

9 When robot is used in low temperature environment that is near to 0ºC, or not operated for a long time in the environment

that is less than 0ºC in a holiday or the night, collision detection alarm (SRVO-050) etc. may occur since the resistance of

the drive mechanism could be high immediately after starting the operation.
10 Contact the service representative, if the robot is to be used in an environment or a place subjected to hot/cold

temperatures, severe vibrations, heavy dust, cutting oil splash and or other foreign substances.
11 Depending on the vibration of the floor or the hand, robot may stop due to the vibration in less than this value.
12 The operating space is restricted when 30kg payload mode is selected. Refer to Fig. 3.2 (e).
13 J4-axis allowable load moment when 30kg payload mode is selected.

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3. BASIC SPECIFICATIONS B-84194EN/04

Performance of resistant chemicals and resistant solvents

(1) The robot (including severe dust/liquid protection model) cannot be used with the following liquids.

Potentially these liquids will cause irreversible damage to the rubber parts (such as: gaskets, oil seals,
O-rings etc.). (As exception to this only liquids tested and approved by FANUC can be used with the
robot.)
(a) Organic solvents
(b) Cutting fluid or cleaning fluid including chlorine / gasoline
(c) Amine type cutting fluid or cleaning fluid
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, that will harm NBR or CR rubber

(2) When the robots work in the environment, using water or liquid, complete draining of J1 base must

be done. Incomplete draining of J1 base will make the robot break down.
(3) Don not use unconfirmed cutting fluid and cleaning fluid.
(4) Do not use the robot immersed in water, neither temporary nor permanent. Robot must not be wet

permanently.

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B-84194EN/04 3. BASIC SPECIFICATIONS

3.2 MECHANICAL UNIT EXTERNAL DIMENSIONS AND

OPERATING SPACE

Fig. 3.2 (a) to (d) show the robot operating space. When installing peripheral devices, be careful not to
interfere with the robot and its operating space.

Operating space of

J5-axis rotation center

Operating space of
end of flange
(J4=+90 DEG)

J5-axis rotation center

End of flange

Operating space of
J5-axis rotation center

Fig. 3.2 (a) Operating space (CRX-5iA)

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R

1

2

4

9

+190°

R

J5-axis rotation center

378

150

1

0

8

0

0 DEG

0°

Operating space of

J5-axis rotation center

J5軸回転中心

Operating space of
end of flange
(J4=+90 DEG)

End of flange

動作領域

フランジ先端
動作領域
(J4=+90°)

J5軸回転中心

フランジ先端

160 540

387

540245

+190 DEG

-190 DEG

-190°

433160

190

O

449

0

8

6

9

1

4

2

2

O

O

Fig. 3.2 (b) Operating space (CRX-10iA)

Operating space of

J5軸回転中心
動作領域

J5-axis rotation center

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0 DEG

0°

8

1

4

1

R

0

5

2

1

R

Operating space of
end of flange
(J4=+90 DEG)

J5-axis rotation center

378

150

End of flange

190O

Operating space of
J5-axis rotation center

J5軸回転中心

フランジ先端

J5軸回転中心
動作領域

フランジ先端
動作領域
(J4=+90°)

160 540

113 415

340

448

245 710

±180 DEG

±180°

6

3

8

2

O

0

0

5

2

O

Fig. 3.2 (c) Operating space (CRX-10iA/L, CRX-20iA/L)

Operating space of

J5軸回転中心

J5-axis rotation center

動作領域

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B-84194EN/04

Fig. 3.2 (d) Operating space (CRX-25iA)

0 DEG

6

5

7

1

R

0

0

7

1

R

OPERATING SPACE OF
J5-AXIS ROTATION CENTER

OPERATING SPACE OF

537

185

O

283

END OF FLANGE
(J4 = +90 DEG)

J5-AXIS ROTAION CENTER

END OF FLANGE

3778

O

0

0

4

3

O

Fig. 3.2 (e) Operating space (CRX-25iA (30kg payload mode))

750180

400

570176

1756 1756

950

370

450

u

180 DEG

OPERATING SPACE OF
J5-AXIS ROTATION CENTER

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B-84194EN/04 3. BASIC SPECIFICATIONS

3.3 ZERO POINT POSITION AND MOTION LIMIT

Zero point and motion range are provided for each controlled axis. Exceeding the software motion limit of
a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit for each
axis. The robot cannot exceed the motion range unless there is a loss of zero point position due to
abnormalities in servo system or system error.

Fig.3.3 (a) to (j) show the zero point, and motion limit of each axis.

* The motion range can be changed. For information on how to change the motion range, see Chapter

6, “AXIS LIMIT SETUP”.

Software restriction

+200º Stroke end (Upper limit)

Fig. 3.3 (a) J1-axis motion limit (CRX-5iA)

- 33 -

-200º Stroke end (Lower limit)

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Software restriction

-

1

9

0

°

+190º Stroke end (Upper limit)

+190°ストロークエンド（上限）

-190º Stroke end (Lower limit)

-190°ストロークエンド（下限）

190°+

Fig. 3.3 (b) J1-axis motion limit (CRX-10iA)

Software restriction

＋

1

8

0

°

+180º Stroke end (Upper limit)

+180°ストロークエンド（上限）

-180º Stroke end (Lower limit)

-180°ストロークエンド（下限）

180°-

Fig. 3.3 (c) J1-axis motion limit (CRX-10iA/L, CRX-20iA/L, CRX-25iA)

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Software restriction

ソフトウェアによる制限

-180º Stroke end (Lower limit)

-180°ストロークエンド（下限）

Fig. 3.3 (d) J2-axis motion limit (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L, CRX-25iA)

­1

8
0
°

(Note) Motion limit is restricted by the position of the J3-axis.

注)J3の位置によって動作範囲に制限を受けます。

ソフトウェアによる制限

Software restriction

+410°

°
0
8
1

+

+180º Stroke end (Upper limit)

+180°ストロークエンド（上限）

+410º

+410°ストロークエンド（上限）

Stroke end (Upper limit)

-225º

-225°ストロークエンド（下限）

Stroke end (Lower limit)

-225°

(Note) Motion limit is restricted by the position of the J2-axis.

注)　J2軸の位置によって動作範囲に制限を受けます。

Fig. 3.3 (e) J3-axis motion limit (CRX-5iA)

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Software restriction

ソフトウェアによる制限

+375°

+375º

+375°ストロークエンド（上限）

-195º

-195°ストロークエンド（下限）

Stroke end (Lower limit)

-195°

(Note) Motion limit is restricted by the position of the J2-axis.

注)　J2軸の位置によって動作範囲に制限を受けます。

Fig. 3.3 (f) J3-axis motion limit (CRX-10iA)

Software restriction

ソフトウェアによる制限

Stroke end (Upper limit)

-270º

-270°ストロークエンド（下限）

Stroke end (Lower limit)

0°+

27

­2

7

0

°

+270º

+270°ストロークエンド（上限）

Stroke end (Upper limit)

(Note) Motion limit is restricted by the position of the J2-axis.

Fig. 3.3 (g) J3-axis motion limit (CRX-10iA/L, CRX-20iA/L, CRX-25iA)

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ソフトウェアによる制限

Software restriction

0°

­1

9

0
°

°

0
9
1

+

-190º Stroke end
(Lower limit)

-190°ストロークエンド（下限）

Fig. 3.3 (h) J4-axis motion limit (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L, CRX-25iA)

ソフトウェアによる制限

Software restriction

180°+

+190º Stroke end
(Upper limit)

+190°ストロークエンド（上限）

+180º Stopper end

+180°ストロークエンド（上限）

(Upper limit)

-180º Stroke end
(Lower limit)

-180°ストロークエンド（下限）

Fig. 3.3 (i) J5-axis motion limit (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L, CRX-25iA)

180°-

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Software restriction

ソフトウェアによる制限

­2

2
5
°

+225º Stroke end

+190°ストロークエンド（上限）

(Upper limit)

Fig. 3.3 (j) J6-axis motion limit (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L, CRX-25iA)

°
5
2
2

+

-225º Stroke end

-190°ストロークエンド（下限）

(Lower limit)

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B-84194EN/04 3. BASIC SPECIFICATIONS

3.4 WRIST LOAD CONDITIONS

Fig. 3.4 (a) to (d) is diagrams showing the allowable load that can be applied to the wrist section.

• Apply a load within the region indicated in the graph.

• Please use it to meet the requirement of the allowable load moment and inertia at wrist. See the 3.1

about allowable load moment and inertia at wrist.

• See Section 4.1 about mounting of end effector.

Z[cm]

30

3kg

25

4kg

20

5kg

15

10

5

10

5

14.5cm

13cm

Fig. 3.4 (a) Wrist load diagram (CRX-5iA)

CAUTION

This diagram shows standard allowable wrist load values.

・

Use this information to make sure that your wrist load moment and inertia values

・

are allowed.

Be especially careful when determining your wrist load inertia because the

・

inertia will vary depending on the shape of the load.

15

20

30

25

X,Y[cm]

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Z(cm)

30

5kg

25

7kg

20

15

10kg

10

5

15

20

10

5

16cm

15cm

Fig. 3.4 (b) Wrist load diagram (CRX-10iA, CRX-10iA/L)

CAUTION

This diagram shows standard allowable wrist load values.

・

Use this information to make sure that your wrist load moment and inertia values

・

are allowed.

Be especially careful when determining your wrist load inertia because the

・

inertia will vary depending on the shape of the load.

X,Y(cm)

25

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Fig. 3.4 (c) Wrist load diagram (CRX-20iA/L)

CAUTION

This diagram shows standard allowable wrist load values.

・

Use this information to make sure that your wrist load moment and inertia values

・

are allowed.

Be especially careful when determining your wrist load inertia because the

・

inertia will vary depending on the shape of the load.

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3. BASIC SPECIFICATIONS B-84194EN/04

Z [cm]

80

70

60

50

40

30

20

10

5kg

10kg

15kg

20kg

25kg

70605040302010

X,Y [cm]

18cm

18.5cm

Fig. 3.4 (d) Wrist load diagram (CRX-25iA)

CAUTION

This diagram shows standard allowable wrist load values.

・

Use this information to make sure that your wrist load moment and inertia values

・

are allowed.

Be especially careful when determining your wrist load inertia because the

・

inertia will vary depending on the shape of the load.

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g

[cm]

Z

80

70

60

50

40

30

20

10

5kg

10kg

15kg

20kg

25kg

30kg

70605040302010

X,Y [cm]

18cm

18.5cm

Fig. 3.4 (d) Wrist load diagram (CRX-25iA (30kg payload mode))

CAUTION

This diagram shows standard allowable wrist load values.

・

Use this information to make sure that your wrist load moment and inertia values

・

are allowed.

Be especially careful when determining your wrist load inertia because the

・

inertia will vary depending on the shape of the load.

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4. EQUIPMENT INSTALLATION TO THE ROBOT B-84194EN/04

4 EQUIPMENT INSTALLATION TO THE

ROBOT

4.1 END EFFECTOR INSTALLATION TO WRIST

Fig. 4.1 (a) shows the figures for installing end effectors on the wrist. Select screws and positioning pins
of a length that matches the depth of the tapped holes and pin holes. See Appendix B “Bolt tightening
torque” for tightening torque specifications.

CAUTION

Notice the tooling coupling depth to wrist flange should be shorter than the

flange coupling length.

WARNING

When the robot mounted the end effector operates, the end effector may collide

with the robot, and if a part of body is pinched between the end effector and the
robot, it might cause heavy injury.

EE interface

6.5

6.5

25 ±0.05

0

5

O

4

5

°

Wrist interface

Fig. 4.1 (a) End effector interface (CRX-5iA, CRX-10iA, CRX-10iA/L, CRX-20iA/L, CRX-25iA)

5

4

°

31.5 H7

O

63 h7

O

O

7-M6 Depth10

Camera cable interface or
force sensor cable interface

6H7 Depth 6.5

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B-84194EN/04 4. EQUIPMENT INSTALLATION TO THE ROBOT

4.2 LOAD SETTING

WARNING

If the load setting is wrong, safety function may lost, and it may cause injury of

the personnel. If the load setting is changed, confirm the value and perform the
test again.

CAUTION

1 Perform load setting (payload, payload center and inertia) correctly. If load

setting is not correct, the sensitivity of the contact stop may getting worse. In
addition, collaborative robot always check the load is correct or not during
operations. If the robot detect the actual load does not match the load setting,
robot stops for safety. So if load setting is incorrect, you cannot operate the
robot.

2 Set the correct load condition parameter before the robot runs. Do not operate

the robot in over when its payload is exceeded or incorrect. Do not exceed the
allowable payload including connection cables and its swing. Operation in with
the robot over payload may result in troubles such as reducer life reduction.

Overview

Payload setting is a setting of the payload which is mounted on the robot. It consists of payload data such
as weight, center of gravity, etc. Setting appropriate payload data can bring the following effects:

● Improvement in motion performance (such as reduction of vibration and cycle time)

● More effective performance of functions related to dynamics (such as collision detection and gravity

compensation).
Wrong payload data can cause vibration, mis-detection of collision, and so on. For effective use of the robot,
set appropriate data of the load such as a hand, a workpiece, and an armload (equipment mounted on the
robot arm, not on the face plate).

You can set the payload data using “Motion Performance screens". In these screens, you can set up 10
schedules of payload setting. If you set up two or more payload schedules in advance, you can achieve
appropriate payload setting only by switching the schedule number according to changing of actual payload.
You can also change the schedule number using program instruction which you can place anywhere in TP
program. (Refer to the Subsection 4.10 PAYLOAD INSTRUCTION of the CONTROLLER
OPERATOR’S MANUAL (B-83284EN).)

As an option function, “Payload Identification” is available. This function enables the robot to calculate
load information automatically.

Motion Performance Screens (Payload setting screen)

You can set the payload data using “Motion Performance screens". Motion Performance screens consist of
list screen, payload setting screen and armload setting screen.

Table 4.3 (a) Motion Performance screen

Screen name Description

MOTION PERFORMANCE
(List screen)
MOTION / PAYLOAD SET A screen for detailed payload data for each schedule.

A screen to display the list of payload schedules (No. 1 ~ No. 10).
You can also check or switch the active schedule number in this screen.

You can display or modify the values of payload weight, gravity center position and
inertia in this screen.
This screen is provided for each individual payload setting number.

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4. EQUIPMENT INSTALLATION TO THE ROBOT B-84194EN/04

MOTION / ARMLOAD SET A screen for armload (equipments mounted on the robot arm, not on the face

plate).
You can set the weight of equipments mounted on such as J2 base and J3 arm.

The following description is a procedure to show Motion Performance screen, to input payload data and to
activate the payload schedule. You can also modify the setting values later.

NOTE

Depending on the combination of robot model and option, the payload data may

be set in advance.

Step

1 Press the [MENU] key to display the screen menu.
2 Press “0 NEXT”, then select “6 SYSTEM”.
3 Press F1 [TYPE] to display the screen switch menu.
4 Select “Motion”. The list screen (“MOTION PERFORMANCE” screen) appears. (If a screen other

than the list screen appears, press the [PREV] key several times until the list screen appears.) For a

multi-group system, if you want to go to the list screen of the other group, press F2, "GROUP" then

enter the group number you like.

MOTION PERFORMANCE JOINT 10%

Group1
No. PAYLOAD[kg] Comment

1 10.00 [ ]
2 0.00 [ ]
3 0.00 [ ]
4 0.00 [ ]
5 0.00 [ ]
6 0.00 [ ]
7 0.00 [ ]
8 0.00 [ ]
9 0.00 [ ]
10 0.00 [ ]

Active PAYLOAD number =0

[ TYPE] GROUP DETAIL ARMLOAD SETIND
IDENT >

NOTE

Up to 10 of payload data can be set as standard. The number of payload data

can be increased up to 256 by the following way. (up to 32 in R-30iB and R-30iB
Mate)

a. Turn on the controller with [PREV] and [NEXT] key pressed.

5 Move the cursor to the schedule number you want to set up, and press F3, "DETAIL" to display

PAYLOAD SET screen of the selected schedule number.

b. Select “3 Controlled start”.
c. Press the [MENU] key.
d. Select “4 Variables”
e. Set the number of payload data to the system variable $PLST_SCHNUM.
f. Restart (power off/on) the controller and "Control start" again.
g. Press the [FCTN] key.
h. Select “1 START (COLD)”.

>

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6 Enter the weight, gravity center position of the load, and inertia about its gravity center.
If required, you can enter the comment. The entered comment is displayed in list screen.

The X, Y, and Z directions displayed in the PAYLOAD SET screen correspond to those in the default

Center of robot

ロボットの

end effector mounting face

エンドエフェクタ取付面
中心

4. EQUIPMENT INSTALLATION TO THE ROBOT

MOTION PAYLOAD SET JOINT 100%

Group 1
Schedule No[ 1]:[Comment ]
1 PAYLOAD [kg] 10.00
2 PAYLOAD CENTER X [cm] -11.27
3 PAYLOAD CENTER Y [cm] 0.00
4 PAYLOAD CENTER Z [cm] 8.04
5 PAYLOAD INERTIA X [kgfcms^2] 0.25
6 PAYLOAD INERTIA Y [kgfcms^2] 0.29
7 PAYLOAD INERTIA Z [kgfcms^2] 0.24

[TYPE] GROUP NUMBER DEFAULT HELP

tool coordinate system (“default” means no Tool frame is set).

X

X

Z

x (cm)

g

m：Mass（kg）
xg：Center of gravity x direction (m)
yg：Center of gravity y direction (m)
zg：Center of gravity z direction (m)
Ix：Inertia at the center of the gravity (around the axis in the x direction through the center of gravity)（kgm^2）
Iy：Inertia at the center of the gravity (around the axis in the y direction through the center of gravity)（kgm^2）
Iz：Inertia at the center of the gravity (around the axis in the z direction through the center of gravity)（kgm^2）

Iy (kgf・cm・s )

Fig. 4.3 (a) Standard tool coordinate

z (cm)

g

2

Center of

重心

gravity

Mass m (kg)

質量m(kg)

Iz (kgf・cm・s )

2

Ix (kgf・cm・s )

y

Center of
gravity

重心

y (cm)

g

2

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4. EQUIPMENT INSTALLATION TO THE ROBOT B-84194EN/04

g

W：Mass (kg)

W：質量 (kg)

J：Inertia (kgm

J：イナーシャ (kgm^2)

a,b, l, r ：Length (m)

a, b, l, r ； 長さ (m)

Expressions for calculating inertia around the center

重心回りのイナーシャ計算式（形状イナーシャ）

of

ravity (geometric inertia)

2

)

r

l

JW

＝

i

12

2

l

JW

＝

i

2

r

2

22

＋

12

a

Fig. 4.3 (b) Calculating center of the gravity inertia

b

ab

JW

＝

i

r

2

JW

＝

i

2

r

5

NOTE

1 If a hand or workpiece has a complicated shape, divide it into simple shapes as

shown above. Calculate the geometric inertia and offset inertia of each shape,
then obtain their sum.

2 Confirm the input units in the payload setting screen. If necessary convert

values using the equation below.
1kgfcms^2 = 0.098kgm^2 (=980kgcm^2)

When you change the value, a confirmation message “Path and Cycle time will change. Set it?”

appears. Press F4, "YES" or F5, "NO".
Then, you may see a message “Load is OVER spec! Accept?”. This message indicates the load exceeds

the capacity of the robot. Reconfigure your system so that the load does not exceed the capacity.
In another case, you may see a message “Load is close to capacity! Accept?”. This message indicates

the load is close to capacity although it does not exceed the capacity.

CAUTION

Don’t install a load which exceeds the capacity of the robot because overload

can cause a life loss of the reducer.

7 If you want to go to the screen of the other schedule number, press F3, "NUMBER" then enter the

schedule number you like. For a multi-group system, if you want to go to the screen of the other group,

press F2, "GROUP" then enter the group number you like.
8 Activate payload schedule you are going to use. Press the [PREV] key to go back to the list screen,

press F5, "SETIND", and enter the index number of payload schedule you are going to use.

NOTE

The initial schedule number is 0. In order to activate the payload setting you

entered, you need to set the schedule number to 1-10. If the schedule number is
0, the system uses the default payload value which is shown in the screen
before you change the value.

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B-84194EN/04 4. EQUIPMENT INSTALLATION TO THE ROBOT

4.3 30kg PAYLOAD MODE (CRX-25iA)

30kg Payload Mode

Max. payload can be increased from 25kg to 30kg by changing payload mode. It is possible to operate with
a payload that exceeds the normal payload of 25 kg, but the motion range is limited. Payload mode is
changed by the following methods.

1 Turn on the controller with [PREV] key and the [NEXT] key pressed.

Then select “3. Controlled start”.
2 Press the [MENU] key and select “9. MAINTENANCE”.
3 You will see a screen similar to the following.

Press arrow (↑,↓) keys and move the cursor to “CRX-25iA”. Then press F4, MANUAL.

ROBOT MAINTENANCE
1/10
Setup Robot System Variables

Group Robot Library/Option Ext Axes
1 CRX-25iA 0

4 Set “25kg Payload Mode” or “30kg Payload Mode” on the PAYLOAD MODE SETTING screen.

******** Group 1 Initialization ********

------- PAYLOAD MODE SETTING -------

1. 25kg Payload Mode

2. 30kg Payload Mode
(Operating Space is Limited)

Select Payload Mode (1 or 2)->

5 Press the [FCTN] key and select “1. START (COLD)”.

Robot is set in 25kg payload mode when robot is shipped.

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TS TECH USA CORPORATION*

HICKES

TS TECH USA CORPORATION*

HICKES

TS TECH USA CORPORATION*

HICKES

TS TECH USA CORPORATION*

HICKES

5. PIPING AND WIRING TO THE END EFFECTOR B-84194EN/04

5 PIPING AND WIRING TO THE END

EFFECTOR

WARNING

Only use appropriately-specified mechanical unit cables.

•

Do not add user cables or hoses inside of the mechanical unit.

•

Please do not obstruct the movement of the mechanical unit cable when cables

•

are added to outside of mechanical unit.

Please do not perform remodeling (adding a protective cover, or secure an

•

additional outside cable) that obstructs the behavior of the outcrop of the cable.

When external equipment is installed in the robot, make sure that it does not

•

interfere with other parts of the robot.

Cut and discard any unnecessary length of wire strand of the end effector (hand)

•

cable. Insulate the cable with seal tape. (See Fig. 5 (a))

If you have end effector wiring and a process that develops static electricity,

•

keep the end effector wiring as far away from the process as possible. If the
end effector and process must remain close, be sure to insulate the cable.

Be sure to seal the connectors of the user cable and terminal parts of all cables

•

to prevent water from entering the mechanical unit. Also, attach the cover to the
unused connector.

Frequently check that connectors are tight and cable jackets are not damaged.

•

When precautions are not followed, damage to cables might occur. Cable failure

•

may result in incorrect function of end effector, robot faults, or damage to robot
electrical hardware. In addition, electric shock could occur when touching the
power cables.

End effector (hand) cable

Cut unnecessary length of unused wire strand

Fig. 5 (a) Treatment method of end effector (hand) cable

Insulation processing

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