Mitsubishi Electric CR800-05VD User manual

Mitsubishi Electric Industrial Robot
CR800-05VD Controller Instruction Manual
Controller Setup and Maintenance
BFP-A3731-B

■Basic precautions and important points when using collaborative robots
Collaborative robots have a variety of safety functions, so unlike conventional industrial robots,
they can work in the same space as humans without being separated by a machine guard.
Even though collaborative robots are equipped with safety functions, it does not guarantee that
they will not cause injury. To prevent injury, customers who use robots, machine manufacturers who
construct robot systems, and system builders such as system integrators must select and use
functions correctly. Peripherals must be designed, manufactured, set, programmed, maintained, and
inspected appropriately. Before working with collaborative robots, conduct risk assessments, check
that no risk is present, and ensure all required documentation is in order.
It is vitally important that all the points mentioned above are fully understood in order to work with
collaborative robots safely and without incident. When using collaborative robots, always keep in
mind that they may move unexpectedly.
Always read the following precautions and the separate
"Collaborative Robot Safety Manual" before starting use of the
robot to learn the required measures to be taken.
Safety Precautions

*CR800-05VD controller
Notes of the basic component are shown.
Please install the earth leakage breaker in the primary side power supply of the
controller because of leakage protection.
1) Prepare the following items.
2) Confirm that the primary power matches the specifications.
3) Confirm that the primary power is OFF and that the earth leakage breaker power switch is OFF.
4) Connect the ACIN cable to the breaker.
Connect the power terminals of the ACIN cable to the secondary side terminals of the earth leakage breaker.
Also, ground the FG terminal of the cable.
5) Connect the ACIN cable to the ACIN connector on the rear of the controller.
<1> Face the main key on the ACIN cable plug upwards. (Refer to the "ACIN cable connection" illustration.)
<2> Align the main key of the ACIN cable plug with the grooves on the ACIN connector. Push the plug into the
connector as far as it will go.
The plug may be damaged if it is not correctly aligned with the connector.
<3> Tighten the coupling on the ACIN cable, turning it to the right until it locks.
6) Connect one end of the grounding cable to the PE (protective earth) terminal on the controller and ground the
other end (2-point grounding) in order to comply with the requirements of EN 61800-5-1 for the touch cur-
rent of 3.5 mA AC or more.
7) Connect the primary power cable to the primary side terminal of the earth leakage breaker.
Part name Specifications Remarks
Earth leakage breaker Recommended product: Single phase NV30FAU-2P-
10A-AC100-240V-30mA (manufactured by Mitsubishi
Electric).
Make sure to attach the TCS-05FA2 terminal cover
(manufactured by Mitsubishi Electric).
Prepared by customer.
Recommended specifications:
・ Rated current: 10A
・ Rated sensed current: 30mA
・ Rated breaking capacity: 2.5kA
Cable for primary power supply AWG14 (2mm2) or above Prepared by customer.
Tightening torque for terminal
fixing screw is 2 ～ 3Nm.
Grounding cable AWG14 (2mm2) or above Prepared by customer.
Tightening torque for terminal
fixing screw is 2 ～ 3Nm.
ACIN cable Terminal: M5, cable length: 3m Supplied with the product.
CAUTION
Note 1) Always use the terminal cover for the earth leakage breaker.
LN
Controller rear
ACIN cable
(attachment)
PE terminal
PE terminal
Primary side
Secondry
side
Single phase
AC100V/200V
ACIN connector
PE (protective earth) terminal
M4 screw
Grounding cable
Note 1)
Earth
leakage
breaker
(NV)
<3>
<1> <2>
ACIN cable connection
ACIN cable
(male)
ACIN connector
(female)
Main key (wide)
Top
Top
Coupling
Groove for main
key (wide)

Revision history
Date of print Specifications No. Details of revisions
2020-04-10 BFP-A3731 ・ First print
2020-10-09 BFP-A3731-A ・ Revised information on the parts included in the Easy-setup kit.
2020-12-25 BFP-A3731-B ・ Added an example of a protective circuit. (Fig. 2-5)
・ Added precautions for vertical installation of the robot controller.

■ Introduction
Thank you for purchasing the Mitsubishi industrial robot.
This manual explains the unpacking, installation, maintenance, and inspection methods of the controller.
Always read through this manual before starting use to ensure correct usage of the robot.
The optional equipments and power supply voltage are different according to connecting robot type.
Refer to separate "Standard Specifications Manual" for detail.
The information contained in this document has been written to be accurate as much as possible. Please
interpret that items not described in this document "cannot be performed."
This manual is for the CR800-05VD controller.
Installation of the emergency stop switch
To be able to stop the robot immediately at the time of the abnormalities because of safety, please
install the emergency stop switch in the position which is certainly easy to operate it, and connect with
the controller. Refer to the Page 10, "2.3.3 Connecting the external emergency stop and mode selector
switch" for the connection method.
And, the connection method of the door switch or the mode selector switch is also indicated here.
Please use it together with the emergency stop switch.
・ No part of this manual may be reproduced by any means or in any form, without prior consent from
Mitsubishi.
・ The details of this manual are subject to change without notice.
・ The information contained in this document has been written to be accurate as much as possible.
Please interpret that items not described in this document "cannot be performed." or "alarm
may occur".
Please contact your nearest dealer if you find any doubtful, wrong or skipped point.
・ This is the original document.
・ Company names and production names in this document are the trademarks or registered trade-
marks of their respective owners.
・ Illustrations in this Instruction Manual may differ from the actual products.
Copyright(C) 2020 MITSUBISHI ELECTRIC CORPORATION
Notice
*ONLY QUALIFIED SERVICE PERSONNEL MAY INSTALL OR SERVICE THE ROBOT SYSTEM.
*ANY PERSON WHO PROGRAM, TEACHES, OPERATE, MAINTENANCE OR REPAIRS THE ROBOT
SYSTEM IS TRAINED AND DEMONSTRATES COMPETENCE TO SAFELY PERFORM THE
ASSIGNED TASK.
*ENSURE COMPLIANCE WITH ALL LOCAL AND NATIONAL SAFETY AND ELECTRICAL CODES
FOR THE INSTALLATION AND OPERATION OF THE ROBOT SYSTEM.

For users who operate the robot using external signals
Operation of robot programs such as start-up and shutdown are carried out using external signals
(exclusive input/output signals). This instruction manual is based on key operations on the teaching
pendant and operation in the operation screen of the teaching pendant. Using the parameter set-
tings, please assign exclusive input/output signals that correspond with each operation to general
purpose input/output signals, and operate the robot using signal operations.
The following table details exclusive input/output signals that correspond with the key operations of
the operation panel explained in this manual. Please use this as a reference to assign signals and
operate the robot.
For further details regarding parameters please see the separate instruction manual "Detailed expla-
nations of functions and operations".
Table: Dedicated I/O signals corresponding to the teaching pendant (T/B) operations
T/B operation Parameter
name Class Function Default
setting
Start
In operation
START Input Starts a program. 3,0
Output Indicates that a program is being executed.
[STOP] key
Standby
STOP Input Stops a program. 0,-1
Output Indicates that the program is paused.
[RESET] key
ERROR lamp
Program reset
ERRRESET Input Releases the error state. 2,2
Output Indicates that an error has occurred.
SLOTINIT Input Cancels the paused status of the program and brings the exe-
cuting line to the top. Executing a program reset makes it possi-
ble to select a program.
-1,-1
Output Outputs that in the program selection enabled state.
Program selection
[OVRD ↑] key
[OVRD ↓] key
Step display
PRGSEL Input Selects the value inputted into the signal assigned to the numer-
ical input as a program number.
-1,
Output -
PRGOUT Input Outputs the program number selected to the signal assigned to
the numerical output.
-1,-1
Output Indicates outputting the program number to the numerical out-
put.
OVRDSEL Input Sets the value inputted into the signal assigned to the numerical
input as a override.
-1,
Output -
OVRDOUT Input Outputs the override value to the signal assigned to the numeri-
cal output.
-1,-1
Output Indicates outputting the override value to the numerical output.
LINEOUT Input Outputs the current line number to the signal assigned to the
numerical output.
-1,-1
Output Indicates outputting the current line number to the numerical
output.
ERROUT Input Outputs the error number to the signal assigned to the numerical
output.
-1,-1
Output Indicates outputting the error number to the numerical output.
IODATA Input Reads the program number and the override value as a binary
value.
-1,-1,
-1,-1
Output Outputs the program number, line number and override value as
a binary value.
Continuous
Cycle
CYCLE Input Starts the cycle stop. -1,-1
Output Outputs that the cycle stop is operating.
[SERVO] key
SERVO lamp
SRVON Input Turns ON the servo power supply. 4,1
Output Indicates the servo power supply is ON.
[SERVO] key
SERVO lamp
SRVOFF Input Turns OFF the servo power supply. 1,-1
Output This output indicates a status where the servo power supply
cannot be turned ON. (Echo back)

Contents
i
Page
1 Before starting use .......................................................................................................................... 1-1
1.1 Using the instruction manuals ................................................................................................... 1-1
1.1.1 The details of each instruction manuals ............................................................................... 1-1
1.1.2 Symbols used in this manual ............................................................................................... 1-2
2 Unpacking to installation .............................................................................................................................................................. 2-3
2.1 Confirming the products ....................................................................................................................................................... 2-3
2.2 Installation .................................................................................................................................................................................. 2-4
2.2.1 Unpacking procedures ................................................................................................................................................... 2-4
2.2.2 Transportation procedures .......................................................................................................................................... 2-4
2.2.3 Installation procedures .................................................................................................................................................. 2-5
(1) CR800-05VD controller ............................................................................................................................................ 2-5
(2) Safety extension unit ................................................................................................................................................. 2-7
2.3 Connection ................................................................................................................................................................................. 2-8
2.3.1 Connecting the power cable and the grounding cable ..................................................................................... 2-8
2.3.2 Emergency stop input and output etc. ................................................................................................................... 2-9
2.3.3 Connecting the external emergency stop and mode selector switch ..................................................... 2-10
2.3.4 Examples of safety measures ................................................................................................................................... 2-16
(1) External emergency stop connection [supplementary explanation] .................................................... 2-23
2.3.5 Connecting to the robot arm .................................................................................................................................... 2-24
(1) Connecting a machine cable ................................................................................................................................. 2-24
(2) Removing a machine cable .................................................................................................................................... 2-24
2.3.6 Connecting the safety extension unit to the controller ................................................................................ 2-25
(1) Equipment supplied by customer ........................................................................................................................ 2-25
(2) Connection method .................................................................................................................................................. 2-25
(3) Connectors and pin assignment .......................................................................................................................... 2-26
(4) Electrical specifications .......................................................................................................................................... 2-29
(5) Station number ........................................................................................................................................................... 2-34
3 Installing the option devices ..................................................................................................................................................... 3-35
3.1 Installing/removing the Option Card ............................................................................................................................. 3-35
3.1.1 Installing the Option Card .......................................................................................................................................... 3-35
3.1.2 Removing the Option Card ........................................................................................................................................ 3-36
3.2 Installing and connecting the Easy-setup kit ............................................................................................................ 3-37
3.2.1 Installing the Easy-setup kit ..................................................................................................................................... 3-37
(1) Installing the Earth leakage breaker / safety extension unit power supply box ............................. 3-37
(2) Installing the EMG / Mode selector switch box ........................................................................................... 3-37
(3) Installing the safety extension unit .................................................................................................................... 3-38
3.2.2 Connecting the Easy-setup kit ................................................................................................................................ 3-38
(1) Connecting the power supply and grounding wire to the safety extension unit ............................ 3-38
(2) Connecting the robot controller and the Earth leakage breaker / safety extension unit power supply
box ........................................................................................................................................................................................................... 3-39
(3) Connecting SDIO cables to the safety extension unit .............................................................................. 3-40
(4) Connecting the safety extension unit to the robot controller ............................................................... 3-41
(5) Connecting the EMG / Mode selector switch box to the robot controller ...................................... 3-42
4 Basic operations ............................................................................................................................................................................ 4-43
4.1 Handling the controller ........................................................................................................................................................ 4-44
4.1.1 Names of each parts .................................................................................................................................................... 4-44
4.1.2 CR800-05VD controller .............................................................................................................................................. 4-44
4.1.3 Safety extension unit ................................................................................................................................................... 4-46
4.2 Handling the T/B ................................................................................................................................................................... 4-47
4.2.1 Installing and removing the T/B .............................................................................................................................. 4-47
(1) Installing the T/B ...................................................................................................................................................... 4-47
(2) Removing the T/B .................................................................................................................................................... 4-47
4.2.2 Functions of each key ................................................................................................................................................. 4-48
4.3 Turning the power ON and OFF ...................................................................................................................................... 4-49

Contents
ii
Page
4.3.1 Turning the control power ON ................................................................................................................................. 4-49
4.3.2 Input the serial number ............................................................................................................................................... 4-50
(1) Setting the serial number using RT VisualBox ............................................................................................. 4-50
(2) Setting the serial number using the teaching pendant .............................................................................. 4-54
4.3.3 Shutting OFF the control power ............................................................................................................................. 4-55
4.4 Changing the power supply voltage settings ............................................................................................................. 4-56
5 Maintenance and Inspection ..................................................................................................................................................... 5-57
5.1 Maintenance and inspection interval ............................................................................................................................. 5-57
5.2 Inspection items ..................................................................................................................................................................... 5-58
5.2.1 Daily inspection items .................................................................................................................................................. 5-58
5.2.2 Periodic inspections ..................................................................................................................................................... 5-58
5.3 Maintenance and inspection procedures ..................................................................................................................... 5-59
5.3.1 The check of the filter, cleaning, exchange. ....................................................................................................... 5-59
5.4 Maintenance parts ................................................................................................................................................................. 5-60

1-1 Using the instruction manuals
1Before starting use
1 Before starting use
This chapter explains how to use this manual. It also contains information on safety and the basic symbols
used in this manual. Moreover, handling and operation of a teaching pendant (T/B) are described based on
R32TB in instruction manuals. If using other T/B, such as R56TB, refer to a supplied instruction manual of
the T/B.
1.1 Using the instruction manuals
1.1.1 The details of each instruction manuals
The contents and purposes of the documents enclosed with this product are shown below. Use these doc-
uments according to the application.
Manual name Description Manual No.
Collaborative Robot
Safety Manual
Describes the common precautions and safety measures to be taken for robot handling,
system design and manufacture to ensure safety of the operators involved with the robot.
Read this manual first.
BFP-A3733
Hello ASSISTA Quick
Set-up Guide
Describes procedures including unpacking, installation, programming using RT VisualBox,
and operation of the robot.
BFP-A3715
Standard Specifications
Manual
Describes the standard specifications, option configuration, and maintenance parts of the
product. This also describes safety and technical precautions when incorporating the
robot.
BFP-A3727
Robot Arm Setup and
Maintenance
Describes the procedures (unpacking, transport, installation, and operation check),
maintenance, and inspection to use the robot arm.
BFP-A3729
Controller Setup and
Maintenance (This
manual)
Describes the procedures (unpacking, transport, and installation), maintenance, and
inspection to use the robot controller.
BFP-A3731
Collaborative Robot:
Detailed explanations of
functions and
operations
Describes functions specific to the collaborative robot. BFP-A3735
Detailed explanations of
functions and
operations Note1)
Note1) Instances where the CR800-D controller is mentioned also refer to the CR800-05VD.
Describes details on functions and operation including information of how to use functions,
MELFA-BASIC VI commands used in programs, how to connect external input/output
devices, and parameters. The information of functions and operation refers to the FR
series. For unsupported functions, refer to the Collaborative Robot: Detailed explanations
of functions and operations.
BFP-A3478
Troubleshooting Note1) Describes a cause and solution corresponding to an error number. BFP-A3480
Tracking Function Note1) Describes the specifications, functions, and usage of the conveyor tracking. BFP-A3520
GOT Direct Connection
Extended Function
Note1)
Describes the data configuration of the memory between the GOT and the robot,
monitoring, and operating procedures.
BFP-A3546
Ethernet Function Note1) Describes how to enable the communications with a personal computer on Ethernet by
using the TCP/IP protocol.
BFP-A3379

1Before starting use
Using the instruction manuals 1-2
1.1.2 Symbols used in this manual
Symbols used in this manual are explained in Table 1-1.
Learn the meaning of these symbols before reading this instruction manual.
Table 1-1:Symbols in instruction manual
Terminology Symbol Meaning
Symbol
Precaution indicating cases where there is a risk of operator fatality or
serious injury if handling is mistaken. Always observe these precau-
tions to safely use the robot.
Precaution indicating cases where the operator could be subject to
fatalities or serious injuries if handling is mistaken. Always observe
these precautions to safely use the robot.
Precaution indicating cases where operator could be subject to injury
or physical damage could occur if handling is mistaken. Always
observe these precautions to safely use the robot.
[JOG] Square brackets ([ ]) are used to represent operation keys.
[RESET] + [EXE]
(A) (B)
This indicates to press the (B) key while holding down the (A) key.
In this example, the [RESET] key is pressed while holding down the
[EXE] key.
T/B This indicates the teaching pendant.
Descriptions in this manual are based on R32TB.
DANGER
WARNING
CAUTION

2-3 Confirming the products
2Unpacking to installation
2 Unpacking to installation
2.1 Confirming the products
Confirm that the parts shown in the standard configuration of the controller shown in Table 2-1 are enclosed
with the purchased product.
Users who have purchased optional products should refer to the separate volume, "Standard Specifications
Manual".
Table 2-1 ： Standard configuration
No. Part name Type Qty. Remarks
CR800-05VD controller
1 Controller CR800-05VD 1 unit Stand alone type
2 CD-ROM (Instruction manual) 5F-BQ00-C00 1 pc. A digital copy of the RV-5AS-D Series Instruction
Manual.
The Hello ASSISTA Quick Set-up Guide and RV-
5AS-D Series Instruction Manuals are on this CD.
3ACIN cable BKO-FA1006H53 1 pc. Accessory cable for single phase. The cable is 3m
in length.
4 CNUSR11 connector DFMC-1.5-16-ST-
3.5-LR
1 pc. Manufactured by PHOENIX CONTACT
5 CNUSR12 connector DFMC-1.5-9-ST-
3.5-LR
1 pc. Manufactured by PHOENIX CONTACT
6 1.6A fuse (reserves) LM16 1 pc. -
7 EU DECLARATION OF CONFORMITY BFP-A5735-49 1 copy -
8 Safety extension unit 4F-SFUNIT 1 unit
9 RIO cable 2F-SFRIOCBL 1 pc.
10 DCIN connector set 2F-SFDCINCON 1 This set consists of the following (both
manufactured by TE Connectivity).
Housing: 2-178288-3 × 1
Contact: 1-175218-5 × 3
11 SDI connector set 2F-SFSDICON 1 This set consists of the following (both
manufactured by TE Connectivity).
Housing: 175363-1 × 8
Contact: 175218-2 × 32
12 SDO connector set 2F-SFSDOCON 1 This set consists of the following (both
manufactured by TE Connectivity).
Housing: 178289-4 × 2
Contact: 175218-2 × 16
13 Terminator cap 2F-SFTM 1 pc.
14 CD-ROM (Instruction manual) BFP-A3543 1 pc. Robot Safety Option Instruction Manual
15 Machine cable 1F-05UCBL-41 1 pc. Fixed type. Cable length: 5m

2Unpacking to installation
Installation 2-4
2.2 Installation
2.2.1 Unpacking procedures
The controller is shipped from the factory packaged in cardboard.Open the cardboard package and take out the
controller.
Slowly pull the controller box straight up. Be careful not to let the controller slip out of
the box.
2.2.2 Transportation procedures
This section explains how to transport the controller and the safety extension unit.
Fig. 2-1 ： Transporting controller
1) Slightly tilt the controller and put your hands underneath. Providing steady support with both hands, lift it up
and transport.
Be careful not to trap fingers when transporting the controller.
CAUTION
Controller
Mass: Approx. 12.5kg
Safety extension unit
Mass: Approx. 0.8kg

2-5 Installation
2Unpacking to installation
2.2.3 Installation procedures
(1) CR800-05VD controller
The installed size is shown as follows.
When installing the controller horizontally, only one controller can be stacked on top of another controller.
Fig.2-2 ： Installation dimensions
When installing the controller vertically, ensure that the air intake is at the
bottom as illustrated in Fig. 2-2.
㻴㼛㼞㼕㼦㼛㼚㼠㼍㼘㻌㼕㼚㼟㼠㼍㼘㼘㼍㼠㼕㼛㼚
㼂㼑㼞㼠㼕㼏㼍㼘㻌㼕㼚㼟㼠㼍㼘㼘㼍㼠㼕㼛㼚
㻝㻠㻡㼙㼙
㻭㼕㼞㻌㼕㼚㼠㼍㼗㼑
㻭㼕㼞㻌㼕㼚㼠㼍㼗㼑
㻝㻣㻜㼙㼙 㻝㻡㻜㼙㼙
㻞㻜㼙㼙
㻡㻜㼙㼙
㻝㻡㻜㼙㼙
㻝㻠㻡㼙㼙
㻝㻡㻜㼙㼙
CAUTION

2Unpacking to installation
Installation 2-6
Fixing installation section sure for prevention from the fall, when using the controller
placing vertically. The reference figure of the metal plate for fixing is shown in Fig. 2-3.
You should install the metal plate for fixation to the controller with M4 x 8 or the shorter
screw. The screw projection length inside the controller (side board thickness is 1.2 mm)
surely makes 6.8 mm or less.
When storing the controller in a cabinet, etc., take special care to the heat radiating
properties and ventilation properties so that the ambient temperature remains within the
specification values. And, don't install the controller in the position where direct rays or
the heat of lighting hits. The skin temperature of the controller may rise, and the error
may occur.
Fig.2-3 ： Metal plate for fixation to placing vertically
CAUTION
CAUTION
㻔㻝㻠㻕㻝㻞㻜
㻝㻞㻜 㻝㻞㻜
㻟㻢㻜
㻠㻜㻜
㻠㻞㻜
㻝㻞㻜 㻞㻝㻚㻣
㻝㻞㻚㻝
㻡㻝
㻢㻚㻡
㻠㻞 㻢㻠
㻢㻤㻠㻜 㻔㻠㻜㻕
㻝㻠㻤
㻠㻙䃥㻝㻜㻌㼔㼛㼘㼑
㻠㻙䃥㻢㻚㻡㻌㼔㼛㼘㼑
㻠㻙䃥㻠㻚㻡㻌㼔㼛㼘㼑
㻠㻙㻯㻟
㻝㻜
㻞㻜
㻔㼠㻞㻕
㻝㻜
㻝㻠
㻔㻝㻜㻕

2-7 Installation
2Unpacking to installation
(2) Safety extension unit
To fix the safety extension unit in place, use the holes indicated by "*1" in the figure below or a DIN rail. Fix the
unit in a place where it will not be subject to vibration.
Fig.2-4 ： Safety extension unit external dimensions
3-M5 screw hole (*1)
100 115
6
6156
88
168

2Unpacking to installation
Installation and connectionInstallation 2-8
2.3 Connection
2.3.1 Connecting the power cable and the grounding cable
The following shows how to connect the power cables and grounding cables.
Please install the earth leakage breaker in the primary side power supply of the
controller because of leakage protection.
1) Prepare the following items.
2) Confirm that the primary power matches the specifications.
3) Confirm that the primary power is OFF and that the earth leakage breaker power switch is OFF.
4) Connect the ACIN cable to the breaker.
Connect the power terminals of the ACIN cable to the secondary side terminals of the earth leakage breaker. Also,
ground the FG terminal of the cable.
5) Connect the ACIN cable to the ACIN connector on the rear of the controller.
<1> Face the main key on the ACIN cable plug upwards. (Refer to the "ACIN cable connection" illustration.)
<2> Align the main key of the ACIN cable plug with the grooves on the ACIN connector. Push the plug into the connec-
tor as far as it will go.
The plug may be damaged if it is not correctly aligned with the connector.
<3> Tighten the coupling on the ACIN cable, turning it to the right until it locks.
6) Connect one end of the grounding cable to the PE (protective earth) terminal on the controller and ground the other end
(2-point grounding) in order to comply with the requirements of EN 61800-5-1 for the touch current of 3.5 mA AC or
more.
7) Connect the primary power cable to the primary side terminal of the earth leakage breaker.
Part name Specifications Remarks
Earth leakage breaker Recommended product: Single phase NV30FAU-2P-
10A-AC100-240V-30mA (manufactured by Mitsubishi
Electric).
Make sure to attach the TCS-05FA2 terminal cover
(manufactured by Mitsubishi Electric).
Prepared by customer.
Recommended specifications:
・ Rated current: 10A
・ Rated sensed current: 30mA
・ Rated breaking capacity: 2.5kA
Cable for primary power supply AWG14 (2mm2) or above Prepared by customer.
Tightening torque for terminal
fixing screw is 2 ～ 3Nm.
Grounding cable AWG14 (2mm2) or above Prepared by customer.
Tightening torque for terminal
fixing screw is 2 ～ 3Nm.
ACIN cable Terminal: M5, cable length: 3m Supplied with the product.
CAUTION
Note 1) Always use the terminal cover for the earth leakage breaker.
LN
Controller rear
ACIN cable
(attachment)
PE terminal
PE terminal
Primary side
Secondry
side
Single phase
AC100V/200V
ACIN connector
PE (protective earth) terminal
M4 screw
Grounding cable
Note 1)
Earth
leakage
breaker
(NV)
<3>
<1> <2>
ACIN cable connection
ACIN cable
(male)
ACIN connector
(female)
Main key (wide)
Top
Top
Coupling
Groove for main
key (wide)

2-9 Installation and connectionInstallation
2Unpacking to installation
2.3.2 Emergency stop input and output etc.
Do wiring of the external emergency stop, the special stop input, the door switch, and the mode selector switch
from the "special input/output" terminal connector.
Connection of the external emergency stop is explained in "2.3.3 Connecting the external emergency stop and
mode selector switch". And about wiring of the others, refer to separate "Standard Specifications Manual".
Table 2-2: Special input/output terminal
*At the time of the power supply OFF, the output point of contact is always open.
[Note] The contact capacity of each input/output terminal is DC24V/100mA. Don't connect the equipment
except for this range. Noise or other effects that overload contact capacities will lead to failure. An
example of noise prevention is shown in Fig. 2-5.
In the customer's system, do not ground the + side of 24V power supply prepared by customer for connect
to the controller. (related with emergency stop and parallel input/output) If it connects with the controller
under the condition that the + side is grounded, it will lead to failure of controller.
Fig. 2-5 ： Protection circuit example
Item Name Function
Input Emergency stop Applies the emergency stop. Dual emergency line.
Input Special stop input Applies the stop.
(Refer to "Special stop input (SKIP)" in separate "Standard Specifications Manual".)
Input Door switch Servo-off. Dual line, normal close.
(Refer to "Door switch function" in separate "Standard Specifications Manual".)
Input Mode selector switch Changes the mode (MANUAL/AUTOMATIC) of the controller. Dual line.
(Refer to "Enabling device function" in separate "Standard Specifications Manual".)
Output Robot error output Contactor is opening during error occurrence.
Output Emergency stop output The point of contact opens under occurrence of emergency stop of external input signal, emergency
stop of OP, emergency stop of T/B.
Output Mode output MANUAL mode: contactor is opening, AUTOMATIC mode: contactor is closing.
Robot controller 100mA
Customer device
Supplied by customer
Contact
*1) Contact capacity:
24 V DC Varistor
An example of connecting devices such as relays
Use noise prevention methods
that are specific to the devices
being used and the environment
they are being used in.
Use noise prevention methods that are specific to the devices
being used and the environment they are being used in.
Robot controller 100mA Customer device
Supplied by customer
Contact
*1) Contact capacity:
24 V DC Varistor
An example of connecting devices such as PLCs
Diode
*1) The actual internal robot controller circuit differs from the internal robot controller circuit in the figure.
Recommended varistor
Model Manufacturer Varistor voltage Max. permissible circuit voltage
ERZV10D390 Panasonic 39V 31V
72210S0250K101 TDK 39V 31V

2Unpacking to installation
Installation and connectionInstallation 2-10
[Note] If a stop signal or servo OFF signal is input simultaneously with a door switch open/emergency stop input,
the error, H056n “Servo sys. error (A/D)” may occur.
When a door switch open/emergency stop is input, the robot turns off the servo after it stops. It is
unnecessary to input a stop signal or servo OFF signal. To input a stop signal or servo OFF signal with a
door switch open/emergency stop input, wait for 100ms or more after a door switch open/emergency stop
input.
2.3.3 Connecting the external emergency stop and mode selector switch
The following shows how to connect the external emergency stop.
For external emergency stop, connect to the connector of the controller (see Fig. 2-6).
The input terminals for the external emergency stop, door switch, and mode selector switch are arranged as
shown in Fig. 2-7. Customers should be sure to prepare the external emergency stop, door switch, and mode
selector switch, etc. and use the robot while these are connected. Connection procedures are shown below.
In addition, refer to Page 16, "2.3.4 Examples of safety measures" for the information on the emergency stop
connection and cautions.
[Caution] The emergency stop circuit is duplicated inside the controller. The emergency stop switch uses a
double contact-type switch, so please be sure to fix both of the contacts to the connector pins as
shown below in order to ensure the wiring is duplicated. An error will continue to occur in the event that
only one of the pins is connected.
1) Please prepare the emergency stop switch, door switch, and mode selector switch.
2) Connect the contacts of each switch to the contacts as shown below:
a) External emergency switch
CNUSR11 connector "between 7 and 23" and "between 14 and 30".
b) Door switch
CNUSR11 connector "between 6 and 22" and "between 13 and 29".
c) Mode selector switch
CNUSR11 connector "between 5 and 21" and "between 12 and 28".
[Caution] Be sure to use a shield cable for the emergency stop wiring cable. And when operating in an
environment that is easily affected by noise, be sure to install the ferrite core (recommended model
name: E04SR301334, manufacturer: Seiwa Electric Mfg. Co., Ltd.). Be sure to place the ferrite core in
300mm or less from the connecting terminal section.
Make sure there are no mistakes in the wiring. Connecting differently to the way
specified in the manual can result in failures, such as the emergency stop not being
released. In order to prevent from occurring, please be sure to check that all functions
(such as the teaching box emergency stop, customer emergency stop, and door switch)
are working properly after the wiring setup is completed.
You should always connect doubly connection of the emergency stop, the door switch,
and the mode selector switch. In connection of only one side, if the relay of customer
use should break down, it may not function correctly.
The robot output contacts (error output, emergency stop output, mode output) are
redundant (wired in series). As with emergency stop switches and door switches,
ensure that devices connected to these contacts support redundancy.
When using several emergency stop switches, perform wiring carefully to make sure
that each emergency stop switch functions independently. Check and make sure that
the emergency stop does not function under an AND condition (when multiple
emergency stop switches are ON at the same time).
CAUTION
CAUTION
CAUTION

2-11 Installation and connectionInstallation
2Unpacking to installation
Fig. 2-6 ： Emergency stop cable and mode selector switch connection
Refer to the following for details on the example of external emergency stop connection, arrangement of
connectors for exclusive input/output signals, and pin assignment.
Item Reference
Example of external emergency stop connection Fig. 2-7
Arrangement of connectors for exclusive input/output
signals
Fig. 2-8
Pin assignment CNUSR11 connector: Table 2-3
CNUSR12 connector: Table 2-4
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