Mitsubishi Electric CR800 Series User manual

Mitsubishi Electric Industrial Robot
CR800 Series Controller
INSTRUCTION MANUAL
Controller setup, basic operation, and maintenance
CR800-D
CR800-R
CR800-Q
BFP-A3476-H

All teaching work must be carried out by an operator who has received special
training. (This also applies to maintenance work with the power source turned
ON.)
Enforcement of safety training
For teaching work, prepare a work plan related to the methods and procedures
of operating the robot, and to the measures to be taken when an error occurs
or when restarting. Carry out work following this plan. (This also applies to
maintenance work with the power source turned ON.)
Preparation of work plan
Prepare a device that allows operation to be stopped immediately during
teaching work. (This also applies to maintenance work with the power source
turned ON.)
Setting of emergency stop switch
During teaching work, place a sign indicating that teaching work is in progress
on the start switch, etc. (This also applies to maintenance work with the power
source turned ON.)
Indication of teaching work in progress
Provide a fence or enclosure during operation to prevent contact of the
operator and robot.
Installation of safety fence
Establish a set signaling method to the related operators for starting work, and
follow this method.
Signaling of operation start
As a principle turn the power OFF during maintenance work. Place a sign
indicating that maintenance work is in progress on the start switch, etc.
Indication of maintenance work in progress
Before starting work, inspect the robot, emergency stop switch and other
related devices, etc., and confirm that there are no errors.
Inspection before starting work
Always read the following precautions and the separate "Safety
Manual" before starting use of the robot to learn the required
measures to be taken.
Safety Precautions
CAUTION
CAUTION
WARNING
CAUTION
DANGER
CAUTION
CAUTION
CAUTION

The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.
When automatic operation of the robot is performed using multiple control
devices (GOT, programmable controller, push-button switch), the interlocking of
operation rights of the devices, etc. must be designed by the customer.
Use the robot within the environment given in the specifications. Failure to do
so could lead to a drop or reliability or faults. (Temperature, humidity,
atmosphere, noise environment, etc.)
Transport the robot with the designated transportation posture. Transporting
the robot in a non-designated posture could lead to personal injuries or faults
from dropping.
Always use the robot installed on a secure table. Use in an instable posture
could lead to positional deviation and vibration.
Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
Do not apply excessive force on the connector or excessively bend the cable.
Failure to observe this could lead to contact defects or wire breakage.
Make sure that the workpiece weight, including the hand, does not exceed the
rated load or tolerable torque. Exceeding these values could lead to alarms or
faults.
Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or
flies off during operation.
Securely ground the robot and controller. Failure to observe this could lead to
malfunctioning by noise or to electric shock accidents.
Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
When carrying out teaching work in the robot's movement range, always secure
the priority right for the robot control. Failure to observe this could lead to
personal injuries or damage if the robot is started with external commands.
Keep the jog speed as low as possible, and always watch the robot. Failure to do
so could lead to interference with the workpiece or peripheral devices.
After editing the program, always confirm the operation with step operation
before starting automatic operation. Failure to do so could lead to interference
with peripheral devices because of programming mistakes, etc.
Make sure that if the safety fence entrance door is opened during automatic
operation, the door is locked or that the robot will automatically stop. Failure to
do so could lead to personal injuries.
Never carry out modifications based on personal judgments, or use non-
designated maintenance parts.
Failure to observe this could lead to faults or failures.
DANGER
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
WARNING
CAUTION
WARNING
CAUTION
CAUTION
CAUTION
CAUTION

When the robot arm has to be moved by hand from an external area, do not
place hands or fingers in the openings. Failure to observe this could lead to
hands or fingers catching depending on the posture.
Do not stop the robot or apply emergency stop by turning the robot controller's
main power OFF. If the robot controller main power is turned OFF during
automatic operation, the robot accuracy could be adversely affected. Moreover,
it may interfere with the peripheral device by drop or move by inertia of the arm.
Do not turn off the main power to the robot controller while rewriting the
internal information of the robot controller such as the program or parameters.
If the main power to the robot controller is turned off while in automatic
operation or rewriting the program or parameters, the internal information of the
robot controller may be damaged.
Do not connect the Handy GOT when using the GOT direct connection function
of this product. Failure to observe this may result in property damage or bodily
injury because the Handy GOT can automatically operate the robot regardless
of whether the operation rights are enabled or not.
Do not connect the Handy GOT to a programmable controller when using an iQ
Platform compatible product with the CR800-R/CR800-Q controller. Failure to
observe this may result in property damage or bodily injury because the Handy
GOT can automatically operate the robot regardless of whether the operation
rights are enabled or not.
Do not remove the SSCNET III cable while power is supplied to the multiple
CPU system or the servo amplifier. Do not look directly at light emitted from
the tip of SSCNET III connectors or SSCNET III cables of the Motion CPU or
the servo amplifier. Eye discomfort may be felt if exposed to the light.
(Reference: SSCNET III employs a Class 1 or equivalent light source as
specified in JIS C 6802 and IEC60825-1 (domestic standards in Japan).)
Do not remove the SSCNET III cable while power is supplied to the controller.
Do not look directly at light emitted from the tip of SSCNET III connectors or
SSCNET III cables. Eye discomfort may be felt if exposed to the light.
(Reference: SSCNET III employs a Class 1 or equivalent light source as
specified in JIS C 6802 and IEC60825-1 (domestic standards in Japan).)
Attach the cap to the SSCNET III connector after disconnecting the SSCNET
III cable. If the cap is not attached, dirt or dust may adhere to the connector
pins, resulting in deterioration connector properties, and leading to malfunction.
Make sure there are no mistakes in the wiring. Connecting differently to the way
specified in the manual can result in errors, such as the emergency stop not
being released. In order to prevent errors occurring, please be sure to check
that all functions (such as the teaching box emergency stop, customer emer-
gency stop, and door switch) are working properly after the wiring setup is com-
pleted.
WARNING
CAUTION
CAUTION
DANGER
DANGER
DANGER
DANGER
DANGER
CAUTION

Use the network equipments (personal computer, USB hub, LAN hub, etc)
confirmed by manufacturer. The thing unsuitable for the FA environment
(related with conformity, temperature or noise) exists in the equipments
connected to USB. When using network equipment, measures against the noise,
such as measures against EMI and the addition of the ferrite core, may be
necessary. Please fully confirm the operation by customer. Guarantee and
maintenance of the equipment on the market (usual office automation
equipment) cannot be performed.
To maintain the security (confidentiality, integrity, and availability) of the robot
and the system against unauthorized access, DoS*1 attacks, computer viruses,
and other cyberattacks from unreliable networks and devices via network, take
appropriate measures such as firewalls, virtual private networks (VPNs), and
antivirus solutions.
Mitsubishi Electric shall have no responsibility or liability for any problems
involving robot trouble and system trouble by unauthorized access, DoS
attacks, computer viruses, and other cyberattacks.
*1 DoS: A denial-of-service (DoS) attack disrupts services by overloading sys-
tems or exploiting vulnerabilities, resulting in a denial-of-service (DoS) state.
CAUTION
CAUTION

*CR800 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 The following is recommended product. Prepared by customer.
Single phase: NV30FAU-2P-10A-AC100-240V-30mA
(Terminal cover: TCS-05FA2)
Three phase: NV30FAU-3P-10A-AC100-240V-30mA
(Terminal cover: TCS-05FA3)
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.
L1 L2 L3 L N
Controller rear
ACIN cable
(attachment)
PE terminal
PE terminal
PE terminal
Primary side
Secondry side
Single phase
AC200V
Three phase
AC200V
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
2017-04-25 BFP-A3476 ・ First print
2017-09-25 BFP-A3476-A ・ ”4.3.2 Input the serial number” was added.
2017-11-01 BFP-A3476-B ・ Description of countermeasures against unauthorized access was added.
・ Descriptions of CR800-R controller in “4.1.1 Names of each parts” were
supplemented.
2018-03-01 BFP-A3476-C ・ Descriptions of CR800-Q controller were added.
2018-09-01 BFP-A3476-D ・ ”3.1 Installing/removing the Option Card” was modified.
2018-12-25 BFP-A3476-E ・ Added further explanation of the ACIN cable.
・ ”2.3.8 Magnet contactor control connector output (AXMC) for addition axes” was
modified.
2019-04-19 BFP-A3476-F ・ Description of connectors (EXT1, OPT1, OPT2) was corrected.
2019-07-18 BFP-A3476-G ・ Correction of figures. (Fig. 2-8, 14)
2020-10-30 BFP-A3476-H ・ Amended the precautions regarding the prevention of unauthorized access.
・ Added an example of a protective circuit. (Fig. 2-7)
・ Added precautions for vertical installation of the robot controller.
・ Revised the steps for replacing the battery.
・ Corrected other mistakes and changed some sections.

■ Introduction
Thank you for purchasing the Mitsubishi industrial robot.
This instruction manual explains the unpacking methods, installation, basic operation, maintenance and
inspection 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 document explains for CR800 series 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 25, "2.3.6 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.
Synchronous connection of the addition axis servo power supply
It is building the circuit so that the output point of contact (additional axis synchronization output:
AXMC) installed in the controller may be used in use of the addition axis function and the power supply
of the servo amplifier for addition axes may be shut down by opening of this output,The servo ON/OFF
state of the addition axis can be synchronized with the servo ON/OFF state of the robot arm. With
reference to Page 36, "2.3.8 Additional axis synchronization output", I ask you to have synchronous
connection made.
・ 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) 2017-2020 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 operating robots that have not been mounted with an operation panel:
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)