dr external axis controller (1l4805a-e-3)

7/18/2019 DR External Axis Controller (1L4805A-E-3)

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GENERAL CONTENTS

IMPORTANT

TRAINING COURSES

LIMITED WARRANTY

SAFETY WARNING

1. FUNDAMENTAL SPECIFICATIONS

1.1 What is External Axes Controller?......................................................................................................... 1-1

1.2 Specifications of External Axes Controller ............................................................................................1-1

1.3 External Dimensions of External Axes Controller ................................................................................. 1-3

2. FOUNDATION WORK AND INSTALLATION

2.1 Foundation Work for Installation of Robot Controller with External Axes Controller ......................2-2

2.2 Transport Method of Robot Controller with External Axes Controller ............................................. 2-4

2.3 Installation of Robot Controller with External Axes Controller ........................................................2-6

2.3.1 Installation Dimensions of Robot Controller with External Axes Controller .............................2-6

2.3.2 Installation of Robot Controller with External Axes Controller ................................................. 2-7

2.3.3 Installation of External Axes Controller onto Robot Controller. ............................................... 2-8



3. CONNECTING ROBOT PERIPHERAL JIGS

3.1 Types of Robot Peripheral Jigs ....................................................................................................... 3-2

3.2 Connecting Peripheral Jigs to External Axes Controller .................................................................3-3

3.2.1 System Configuration ............................................................................................................... 3-3

3.2.2 External Axes Cables for Peripheral Jigs................................................................................. 3-4

3.3 Internal Jumper Pin Settings of External Axes Controller ...............................................................3-5

3.4 Connecting External Axes Controller to Robot Controller ...............................................................3-7

3.4.1 Fixing Method of Servo I/F Board ............................................................................................3-7

3.4.2 Connecting External Axes Controller to Robot Controller........................................................ 3-8

3.5 Connecting External Axis/Axes Cable 1 & 2 ................................................................................. 3-18

3.5.1 Where to connect External Axis/Axes Cable 1 & 2 ................................................................3-18

3.5.2 Adding One External Axis ......................................................................................................3-23

3.5.3 Adding Two External Axes .....................................................................................................3-27

3.5.3.1 Adding One 2-axis Peripheral Jig ..............................................................................................3-27

3.5.3.2 Adding Two 1-axis Peripheral Jigs ............................................................................................3-30

3.5.4 Adding Three External Axes

(When adding a standard 1-axis slider and a standard 2-axes positioner.)..................... 3-38

3.5.5 Adding Four External Axes (When adding two standard 2-axis positioners.) ......................3-47

3.5.6 Adding One Manipulator.........................................................................................................3-57

3.5.7 Adding one 4.5 kW Motor .......................................................................................................3-613.5.8 Adding one 4.5 kW Motor and one 1.5 kW Motor ..................................................................3-65

4. PARTS LIST

4.1 External Axis Controller (L5380) ..................................................................................................... 4-2

4.2 External Axes Controller (L5381) .................................................................................................... 4-4



4.5 External Axes (Axis) Controller (L5561) ........................................................................................4-10

4.6 External Axes Controller (L5562) ..................................................................................................4-12



4.9 Large-capacity External Axes Controller (L5930 ~ L5932) ...........................................................4-18

5. MAINTENANCE (EXTERNAL AXES CONTROLLER)



5.1 Servo I/F Board L4805C................................................................................................................5-10

5.1.1 Functions of Servo I/F Board.................................................................................................. 5-10

5.1.2 Connectors of Servo I/F Board...............................................................................................5-10

5.1.3 Jumper Pin Settings of Servo I/F board ................................................................................. 5-10

5.2 External Axes Board L4805D ........................................................................................................5-11

5.2.1 Functions of External Axes Board ..........................................................................................5-11

5.2.2 Operating State Indicators of External Axes Board ...............................................................5-12

5.2.3 Relays on External Axes Board..............................................................................................5-12

5.2.4 Fuses on External Axes Board...............................................................................................5-12

5.2.5 Connectors of External Axes Board .......................................................................................5-13

5.2.6 Test Pins on External Axes Board .........................................................................................5-13

5.2.7 Jumper Pin Settings of External Axes Board ......................................................................... 5-14

5.3 Servo Unit ......................................................................................................................................5-15

5.3.1 Functions of Servo Unit .......................................................................................................... 5-155.3.2 Control Module W-L00958 .....................................................................................................5-17

5.4 Power Unit L4800P........................................................................................................................5-19

5.4.1 Functions of the Power Unit ...................................................................................................5-19

5.4.2 Connectors of the Power Unit ................................................................................................5-20

5.5 Charging Unit L4797P ...................................................................................................................5-21

5.5.1 Functions of the Charging Unit...............................................................................................5-21

5.5.2 Connectors of the Charging Unit ............................................................................................5-21

5.6 Charging Battery L6390N00 .......................................................................................................... 5-22

5.6.1 Functions of the Charging Battery..........................................................................................5-22

5.6.2 Specifications of the Charging Battery ...................................................................................5-22

5.6.3 Replacing the Charging Battery .............................................................................................5-22

5.7 Cooling Fans..................................................................................................................................5-25

6. ELECTRICAL CONNECTION DIAGRAM

6.1 Electrical Connection Diagram for External Axes Controller ..............................................................6-1

6.2 Electrical Connection Diagram for External Axes Controller for 4.5 kW Motor ..................................6-7

6.3 Electrical Connection Diagram for External Axes Cable...................................................................6-11



1

Fundamental Specif ications

C O N T E N T S

1.1 What is External Axes Controller?......................................................................................................... 1-1

1.2 Specifications of External Axes Controller ............................................................................................1-1

1.3 External Dimensions of External Axes Controller ................................................................................. 1-3



FUNDAMENTAL SPECIFICATIONS 1-1

1 FUNDAMENTAL SPECIFICATIONS

1.1 What is External Axes Controller?

When combining a manipulator with robot peripheral jigs such as a positioner and/or a slider, anoptional controller to control jigs needs to be added to the standard robot controller.This controller is called "External Axes Controller", and it is capable of connecting up to 6 axes of

peripheral jigs. (“1.2 Specifications of External Axes Controller”: Note 3)The standard robot controller can control a single mechanism (one manipulator: 6 axes) only.

1.2 Specifications of External Axes Controller

Item Specifications

Name External Axes Controller

Driving system AC servo

In case of connecting robot peripheral jigs

(Controlling the External Axes Controller without a combinationof motors of 800 W or below and those of 1500 W)

Combination of

corresponding motorsModel

Combination of

corresponding motorsModel

800 W or below x 1 axis L5380 1500 W x 1 axis L5561

800 W or below x 2 axes L5381 1500 W x 2 axes L5562

800 W or below x 3 axes L5382 1500 W x 3 axes L5563

800 W or below x 4 axes L5562

800 W or below x 5 axes

800 W or below x 6 axesL5563

In the case of connecting robot peripheral jigs

(Controlling the External Axes Controller with acombination of motors of 800 W or below and those of

1500 W)

Combination of corresponding motors Model

1500 W x 1 axis + 800 W or below x 1 axis

1500 W x 1 axis + 800 W or below x 2 axesL5562

1500 W x 2 axes + 800 W or below x 1 axis

1500 W x 1 axis + 800 W or below x 3 axes

1500 W x 2 axes + 800 W or below x 2 axes

1500 W x 1 axis + 800 W or below x 4 axes

L5563

4500 W x 1 axis + 1500 W x 1 axis L5930

4500 W x 2 axes + 1500 W x 1 axis

4500 W x 1 axis + 1500 W x 2 axesL5931

4500 W x 2 axes + 1500 W x 3 axes

4500 W x 3 axes + 1500 W x 1 axisL5932

In the case of connecting a manipulator made by DAIHEN Corporation

Manipulator Model

DR-3200/4200/600/500 series L5554

Number of axes / model(Note 1, 2, 3)

DR-4200L/4300/4400 L5564



1-2 FUNDAMENTAL SPECIFICATIONS

DR-4800, DR-4900 L5009

Item Specifications

Automatic Operation Speed

During positioningRefer to the corresponding specification for each

peripheral jig

During welding10 cm600 cm / min.Settable every 1 cm / min

Origin Return Origin return is not required because of the absolute positiondetecting function of battery back-up. (Note 4,5)

Cooling System Indirect cooling methoda sealed type controller

Ambient Temperature Range 045

Ambient Humidity Range 2080 %RhNo dew condensation

3-phase AC 200 V +10 % -15% 50 / 60 Hz

Model Rated value Model Rated value

L5380 1 kVA L5561 2 kVA

L5381 2 kVA L5562 4 kVA

L5382 L5563 6 kVAL5554

3 kVAL5564 7 kVA

L8220 6 kVA

L8221 9 kVA

L8222

Input power (note 6)

L500912 kVA

GroundingPeripheral jigs should be grounded independently, and the resistanceshould be less than 100 ohm.

External dimensions of

External Axes Controller

358 (W) 515 (D) 525 (H) (mm)

358 (W) 785 (D) 1188 (H) (mm)(External Axes Controller for 4.5kW motors)

Mass Approx. 35 kg (for L5563)

Approx. 110kg (for L8222)

Painting color Basesky gray / front panelblue

Note (1) Since the model of External Axes Controller differs according to a robot peripheral jig, select a

corresponding model when ordering one(2) For a combination of motors other than specified above, contact your nearest distributor.(3) By adding another External Axes Controller, a maximum of 12 external axes can be added (18 in

total). The number of axes that can be added depends on the system. Contact your nearest

distributor for more details.(4) Position data are backed up by absolute encoders. The period of the battery backup while the

primary power is OFF is approximately 10 days. The duration of battery backup may be shorter

due to an ambient temperature, service conditions and so on. After the backup, absolute offsetadjustment work and recharging of the battery must be done due to a loss of position data

(5) If External Axes Cable is plugged off either from External Axes Controller or peripheral jigs intimes of reinstallment, absolute encoder data will be lost. Once the External Axes Cable isdisconnected, “absolute offset setting” must be performed after the reinstallement.

(6) The rated values of the primary-side power source here (in this table) are only for External Axes

Controller. Be aware that the rated values for a robot system are the sum of the rated values forExternal Axes Controller and those for Robot Controller. For the rated value of a controller,refer to “Installation: 3.3.1 Connecting the Primary Power Cable” in "INSTALLATION &

MAINTENANCE" for model DR series.



FUNDAMENTAL SPECIFICATIONS 1-3

698

358

300

4 16

525

518

438

748

466

300

498

515

External Axis Cable 1


Eyebolt

Door Key

A


Robot Controller

Unitmm



1.3 External Dimensions of External Axes Controller

Fig. 1.3.0.1 External Dimensions of External Axes Controller



1-4 FUNDAMENTAL SPECIFICATIONS

Fig. 1.3.0.2 External Dimansions of External Axes Controller (for 4.5kW motors)

Left Side Front Right Side

"A"

"A"

1138

1188

View A

358

5 2 5

Door key

498515

External AxesController

(for 4.5kW motors)



FOUNDATION WORK AND INSTALLATION 2-1

2 FOUNDATION WORK AND INSTALLATION

Installing External Axes Controller properly is very important for maintaining the proper function ofperipheral jigs and for safely. Correct installation not only keeps safety of workers around the peripheral jigs

but also extends life of the External Axes Controller.This chapter describes how to install the External Axes Controller. See "Installation: Chapter 2" in

"INSTALLATION and MAINTENANCE" for DR series.

WARNING

1. Disconnect the power before installing arobot and connecting cables. Touchinglive electrical parts will cause anelectrical shock or a burn that may

results in a loss of life.

WARNING

Do not touch live electrical

ELECTRIC SHOCKcan kill.

parts.

Disconnect all power

Multiple sources of voltage

may exist inside this

enclosure.

before installing or servicing.

NC8051

2. Install the External Axes Controller

outside the working range of the robot.If anyone approaches the moving robot,an accident that results in a loss of lifemay occur.

Keep out of robot area whenmain power is on.Do not locate this device

in robot work area.Read instruction manual.

WARNING

NC8050

3. When the External Axes Controller,

welding power source, etc., are to beinstalled at such an elevated position(over 2 m high) as on a frame, provide aworking floor shown in Fig. 2.0.0.1 to

allow adjustment, maintenance andinspection.

4. Be sure to fix Robot Controller with

External Axis Controller to a proper place

for installment. Do not lean against thecontroller. If the controller falls down, notonly the controller may break down butalso a fatal accident may occur.

min.0.6m

(Rear)

Robotcontrol unit

(Front)

min.1m

Fig. 2.0.0.1 Installing an External Axes Controller

at an Elevated Position

CAUTION

1. Provide at least 20-cm-wide spacebetween the External Axes Controller unitand a wall. TO AVOID DAMAGE TO THE ROBOTCONTROL

UNIT, KEEP THE AIR INLET AND EXHAUST

CLEAR. (AT LEAST0.2M FROM WALL.)

CAUTION

NC8054

2. Upon completion of the installation, make absolute offset adjustments until the robot peripheral jigagrees with the position coordinate data stored in the robot control unit. For the adjustingprocedure, see “Installation: Section 4.2 Absolute Offset Adjustment” in “Installation and

Maintenance” for DR series.



2

Foundation Work and Installation

C O N T E N T S

2.1 Foundation Work for Installation of Robot Controller with External Axes Controller .......................2-2

2.2 Transport Method of Robot Controller with External Axes Controller ..............................................2-4

2.3 Installation of Robot Controller with External Axes Controller .........................................................2-6

2.3.1 Installation Dimensions of Robot Controller with External Axes Controller ..............................2-6

2.3.2 Installation of Robot Controller with External Axes Controller ..................................................2-7

2.3.3 Installation of External Axes Controller onto Robot Controller. ................................................2-8



2-2 FOUNDATION WORK AND INSTALLATION

518

300

438

4 16

466

A

View A

Make holes with

a concrete drill.

Hole diameter and

depth vary depending

on the type of an

anchor bolt.

Insert an anchor

bolt.

50

130

50

220

50

150

150

50

438

300

Drive the bolt

fully into a hole

by a hammer.

"B" "B"

View "B"-"B"

J-type Bolt(M12-250L)

2.1 Foundation Work for Installation of Robot Controllerwith External Axes Controller

WARNING

A robot controller does not have any mobile parts as a manipulator does, however it should befixed when installed so that it will not fall down from the elevated position or on the floor.

When installing a controller directly on the floor, use M12 concrete anchor to fix it as shown in Fig.2.1.0.1.If the strength of the floor is insufficient, embed J-shaped foundation bolt as shown in Fig. 2.1.0.3.

Fig. 2.1.0.1 Installation Dimensions of Robot Controller with External Axes Controller

Fig. 2.1.0.2 Installation of Concrete Anchor

Fig. 2.1.0.3 Foundation Drawing

for Installation by enbedding

Anchor Bolt. (Unitmm)




Fig. 2.1.0.4 Installation Method of External Axes Controller for 4.5kW Motors with External Axes Controller

Fig. 2.1.0.5 Foundation Drawing for Installation by enbedding Anchor Bolt(for External Axes Controller for 4.5kW Motors with External Axes Controller)

518

5 0 0

438

4 16

7 2 0

A

View A

50

130

5 0

2 2 0

50

1 5 0

150

5 0

438

5 0 0

J type Bolt




Transport Method of Robot Controller with External Axes Controller

(1) Robot Controller with External Axes Controller should be transported to the place for installation

with a crane, a forklift, or a hand lifter .When transporting it with a crane, use two eyebolts as shown in Fig. 2.2.0.1. When transportingit with a forklift or hand lifter, be careful not to let the robot controller fall down.

CAUTION

External axes controller and robot controller are equipped with printed circuit boards and other

precision parts. Thus, do not give a shock to the controllers while transporting them.

(2) The mass of the robot controller with the external axes controller is approximately 80 kg . Wearhelmet, safety shoes and other protectives, and work in an appropriate working clothes.

Fig. 2.2.0.1 Transport Method for Robot Controller with External Axes Controller

Wooden Protector

Fix wire ropes tightto eyebolts usingshackles.

Wire Rope

Fixing Rope

Forklift

Prepare shackleswhose maximumload-carrying capacityis 0.4 t or more.




(3) Robot Controller for 4.5kW motors with External Axes Controller should not be suspended

together when transported.Load it on a pallet and transport it with a forklift as shown in Fig. 2.2.0.2. When suspend it whiletransporting, separate Robot Controller and External Axes Controller and suspend each unit.

CAUTION

External axes controller and robot controller are equipped with printed circuit boards and otherprecision parts. Thus, do not give a shock to the controllers while transporting them.

(4) The mass of the robot controller for 4.5kW motors with the external axes controller isapproximately 145 kg . Wear helmet, safety shoes and other protectives, and work in anappropriate working clothes.

Fig. 2.2.0.2 Transport Method for Robot Controller for 4.5kW Motors with External Axes Controller

Fixing Rope

Forklift

Wooden Protector

Wire Rope

Fix wire ropes tightto eyebolts usingshackles.

Prepare shackles that meetthe following requirements.

Model SC- 10Withstand Load0.4 tJIS B2801

Withstand Loadmin. 1400 kgLength min. 1.5 m

Wire Rope

Prepare shackles that meet thefollowing requirements.

Model SC- 14Withstand Load1.2 tJIS B2801

Withstand Loadmin. 270 kgLength min. 1.5m

For External Axes Controller For Large- capacity External Axes Controller




518

5 0 0

438

4 16

7 2 0

A

View A

2.2 Installation of Robot Controller with External Axes Controller

2.3.1 Installation Dimensions of Robot Controller with External Axes Controller

Fig. 2.3.1.1 Installation Dimensions of Robot Controller with External Axes Controller

Fig. 2.3.1.2 Installation Dimensions of External Axes Controller for 4.5kW Motors

518

300

438

4 16

466

A

View A




2.3.2 Installation of Robot Controller with External Axes Controller

When installing Robot Controller with External Axes Controller on the floor, fix the support channelattached to the bottom of robot controller to the foundation bolt (M12) with 4 lock nuts (M12) as shown

in Fig. 2.3.2.1. (Clamping Torque : 42.2 Nm)

WARNING

Robot Controller does not have any mobile parts as a manipulator does, however it should be fixedwhen installed so that it will not fall down from the elevated position or on the floor.

Fig. 2.3.2.1 Installation of Robot Controller with External Axes Controller

Support Channel

Robot Controller

Anchor Bolt

Lock Nut (M12)(Clamping Torque : 42.2Nm)

Spring Washer

Flat Washer

Foundation


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2.3.3 Installation of External Axes Controller onto Robot Controller.

Refer to the following method to install the External Axes Controller on Robot Controller.

1 Do the foundation work for the installation of Robot Controller with External Axes Controller

according to the section 2.3.2.

2 Remove the lock nuts that are fixing Robot Controller.

3 Hang the robot controller 60 mm upward from the earth with a crane, forklift or hand lifter.

4 Remove the support channels fixed at the lower part of each side of the Robot Controller and then

fix support channels (Parts No. : L4805B04) that are the accessories of External Axes Controlleras shown in Fig. 2.3.3.1.

5 Install the Robot Controller to the installation place and then fix the support channels as shown in

Fig. 2.3.3.1.

6 Remove two eyebolts with spring washers and flat washers fixed on the top of the Robot

Controller and then drive them into the two M10 tapped holes on the top of the External AxesController.

7 Put the External Axes Controller on the top of the Robot Controller with a crane.

8 Fix the lower part of the External Axes Controller and the upper part of the Robot Controller

together at both sides with a plate (Parts No. : L4794B03A) and four M6 screws that are

accessories of the External Axes Controller (clamping torque : 11.5 Nm (117 kgf cm)). (Refer to

Fig. 2.3.3.2.) Apply LOCKTITE after the clamping.

9 Use grounding cable to connect grounding studs of the Robot Controller and the External Axes

Controller as shown in Fig. 2.3.3.3.

Fig. 2.3.3.1 Fixing Support Channels for the External Axes Controller to the Robot Controller

Remove it.

Remove it.

Support Channel(Type : L4805B04)

Robot Controller

Screw (M6)

Screw (M6)

Support Channel(Type : L4805B04)


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Fig. 2.3.3.2

Installation of External Axes Controller to Robot Controller

Fig. 2.3.3.3

Installation of External Axes Controller for 4.5kW motors to External Axes Controller

4 M616


Robot Controller

(Type : L4794B03B)

Fixing Plate (accessory of External Axes Controller)

Screw

4 M616Screw

Eyebolt (removed from the Robot Controller

Fixing Plate (accessory of External Axes Controller)

(Type : L4794B03B)

Put a toothed lock washer betweenthe fixing plate and a screw sothat the notched side of the washer may dig into the fixing plate.

Toothed Lock Washer

4 M616


External Axes Controller for 4.5kW Motors

L4794B03B

Screw

L4794B03B

4 M616

Toothed Lock Washer

Put a toothed lock washer betweenthe fixing plate and a screw so thatthe notched side of the washer maydig into the fixing plate.

Fixing Plate(accesory of External Axes Controller)

Fixing Plate(accesory of External Axes Controller)

Screw


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Fig. 2.3.2.4 Connecting between Robot Controller

and External Axes Controller for 4.5kW Motors with Grounding Cable

FC3

CN4

Front

PCB2Main Board

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

CN301 CN302

SW301

Robot Controller

External AxisController

Right (inside)

View "A" "A""A"

"A"

CN203

CN201

Grounding Stud

Grounding Cableor




3 Connecting Robot Peripheral Jigs

C O N T E N T S













3.5.3.1 Adding One 2-axis Peripheral Jig ................................................................................... 3-27

3.5.3.2 Adding Two 1-axis Peripheral Jigs..................................................................................3-30

3.5.4 Adding Three External Axes(When adding a standard 1-axis slider and a standard 2-axes positioner.)..................... 3-38

3.5.5 Adding Four External Axes..................................................................................................... 3-47

3.5.6 Adding One Manipulator.........................................................................................................3-57

3.5.7 Adding one 4.5 kW Motor .......................................................................................................3-61

3.5.8 Adding one 4.5 kW Motor and one 1.5 kW Motor ..................................................................3-65



CONNECTING ROBOT PERIPHERAL JIG

3-1

3 CONNECTING ROBOT PERIPHERAL JIGS

This chapter provides information on the connections of Jig Control cables, and on the settings of variousswitches in Robot Controller and External Axes Controller that are necessary to connect a robot peripheral

jig, such as positioners and sliders. See each instruction manual for installation of robot peripheral jigs.

WARNING

1. Disconnect the power before installing a

robot and connecting cables. Touchinglive electrical parts will cause anelectrical shock or a burn that may

results in a loss of life.

WARNING

Do not touch live electrical

ELECTRIC SHOCKcan kill.

parts.

Disconnect all power

Multiple sources of voltage

may exist inside this

enclosure.

before installing or servicing.

NC8051

2. Install the External Axes Controlleroutside the working range of the robot.

Approaching approaches the movingrobot may lead to an accident that results

in a loss of life.

Keep out of robot area whenmain power is on.Do not locate this device

in robot work area.Read instruction manual.

WARNING

NC8050

CAUTION

Upon completion of the installation, make absolute offset adjustments until the robot peripheral jigagrees with the position coordinate data stored in the robot control unit. For the adjusting procedure,see “Installation: 4.2 Absolute Offset Adjustment” in “INSTALLATION & MAINTENANCE” for model DR

series.



3-2


3.1 Types of Robot Peripheral Jigs

DAIHEN provides the products listed in Table 3.1.0.1 as peripheral jigs that can be combined with robots

Table 3.1.0.1 Robot Peripheral Jigs

Item Type Specification

RPH-200N Maximum payload 200kg

RPH-500N Maximum payload 500kgPositioner head stock

RPH-1000N Maximum payload 1000kg

RP1S-200N Maximum payload 200kg

RP1S-500N Maximum payload 500kg1-axis side positioner

RP1S-1000N Maximum payload 1000kg

RP1D-200N Maximum payload 200kg

RP1D-500N Maximum payload 500kg1-axis double support positioner

RP1D-1000N Maximum payload 1000kg

RP2E-150N Maximum payload 150kg2-axis double support positioner

RP2E-300N Maximum payload 300kg

RP2T-500N Maximum payload 500kg2-axis tilt positioner

RP2T-1000N Maximum payload 1000kg

RP1T-500N Maximum payload 500kgTurntable

RP1T-1000N Maximum payload 1000kg

RSB-1000N Traverse stroke 1.0mPortable slider

RSB-2000N Traverse stroke 2.0m

RSR-2900N Traverse stroke 2.9m




Standard slider


RSR-1900NP Traverse stroke 1.9m




Slider with a connecting wagon




CONNECTING ROBOT PERIPHERAL JIG 3-3

3.2 Connecting Peripheral Jigs to External Axes Controller

3.2.1 System Configuration

A max. of 3 axes of peripheral jigs can be connected to a External Axes Controller. Some typicalexamples of the system configuration are presented in Table 3.2.1.1.

Table 3.2.1.1 Examples of System Configuration

Peripheral Jig

Examples of ConfigurationNo. ofaxes Jig 1 Jig 2

Type of External Axis (Axes) Cable Q'ty

1-axis positioner 1 axis

1-axis slider External Axis Cable for 1 axis 1 set

2-axis positioner External Axes Cable for 2 axes 1 set2 axes

1-axis slider 1-axis positioner External Axis Cable for 1 axis 2 set

3 axes 1-axis slider 2-axis positioner

External Axis Cable for 1 axis

External Axes Cable for 2 axes

1 set

each

4 axes 2-axis positioner 2-axis positioner External Axes Cable for 2 axes 2 set



3-4


3.2.2 External Axes Cables for Peripheral Jigs

A peripheral jig is connected to the External Axes Controller with External Axes Cables listed in Table3.2.2.1. To connect a peripheral jig, a set of 2 external axes cables - one motor cable (External AxesCable 1) and one encoder cable (External Axes Cable 2) - is required.

Table 3.2.2.1

External Axes Cables for Peripheral Jigs

Component

Type Item Part No. Q'ty Cable length Remarks

External Axis Cable 1 L5372B00 1L5372

External Axis Cable 2 L5372C00 13m




External Axis Cable 2 5374C00 110m



For 1-axisperipheral jig

External Axes Cable 1 L5376B00 1L5376

External Axes Cable 2 L5376C00 13m

















(for 4.5 kW motor)




3-5

3.3 Internal Jumper Pin Settings of External Axes Controller

In order to connect a robot peripheral jig such as a positioner or a slider to External Axes Controller, it is

necessary to change the settings of jumper pins on each printed circuit board in the External AxesController. Jumper pins that need change in their settings are listed in Table 3.3.0.1.

Table 3.3.0.1

Jumper pin settings of each printed circuit board in External Axes Controller

Printed circuit board Jumper pin

Ref. No. Name No. Name On Off Default

JP201 CN271 overrun Open Short-circuit Short-circuited







JP211 CN7A shock sensor Open Short-circuit Short-circuited

JP212 CN39 shock sensor Open Short-circuit Short-circuited

JP221 1-2: short-circuited


PCB103External Axes

board


PCB102 Servo I/F board JP1

Never change

these settings.

Open

CAUTION

1. Open jumper pins JP105 & JP106 on the mother board in the Robot Controller when connecting

the External Axes Controller. If they are short-circuited, overrun limit switches and shocksensors do not operate. (Refer to “Maintenance: 5.2.7 Jumper Pin Settings of Mother Board” in"INSTALLATION and MAINTENANCE" for model DR series.)

2. After setting jumper pins JP201 to 207, 211 or 212, be sure to check the operation of thecorresponding overrun limit switches or shock sensors.



3-6


Fig 3.3.0.1

Jumper Pin Settings that Require Special Attention

CN81

JP222JP221

CN80A

CN67A

TP13ATP12ATP15ATP14A

CR3FCR3ECR3DF7

F6

TP3A

TP4A

JP212 JP207

CN39CN40

F5

JP211

JP223

JP201

JP202

JP203

JP204

JP205

JP206

CR4ACR1A

CN29A

CN271

CN272

CN273

CN274

CN275

C

N276

CN7A CN1A

CN41ACN149LED100A

LED105A

LED107A

CN81

JP222JP221

JP223

CN41A

13 1 3

1 3

<PCB103 External Axes Board>

(Shaded areas show the jumper points of JP221, 222 and 223)




3.4 Connecting External Axes Controller to Robot Controller

3.4.1 Fixing Method of Servo I/F Board

In order to connect the External Axes Controller to the Robot Controller, it is necessary to connect

Servo I/F board to the main board of the Robot Controller. When connecting the External AxesController to the External Axes Controller for 4.5kW motors, it is necessary to connect Servo I/F boardto the main board of the External Axes Controller for 4.5kW motors.

(1) Follow the instructions in “Maintenance: 5.1.5 Precautions for Replacing Main Board” of"INSTALLATION & MAINTENANCE" for model DR series to remove the main board from theRobot Controller or the External Axes Controller for 4.5kW motors.

(2) Connect CN50 of the main board to the corresponding connector CN50 of the Servo I/F board asshown in Fig. 3.4.1.1.

(3) Sandwich and fix an insulating support between the main board and Servo I/F board on both

sides with four screws (M36) as shown in Fig. 3.4.1.1.

(4) Follow the instructions in “Maintenance: 5.1.5 Precausions for Replacing Main Board” of

“INSTALLATION & MAINTENANCE” for model DR series to transfer the teaching data andsystem parameters after installing the main board with the Servo I/F board into the RobotController or the External Axes Controller for 4.5kW motors.

Fig. 3.4.1.1 Fixing Method of Servo I/F Board

Inslating Support

ScrewsM36

ScrewsM36

M a i n B o a r d

P C B 2

PCB102

Servo I/F Board

CN50

CN50

FC10IC138

FC27

FC23FC24

CN16

CN44

CN1 CN7

CN111

CN19

CN18

CN41

CN30

CN73

CN38

CN40

CN37

CN150

CN80

CN67

TB1

CN250

CN251

FC10

Front

PCB3Mother Board

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

CN302

CN50

JP1

CN151

PCB102

Servo I/F Board

CN203

CN201

CN301 CN302

SW301

Robot Controller

FC10IC138

FC27

FC23FC24

CN16

CN44

CN1 CN7

CN111

CN19

CN18

CN41

CN30

CN73

CN38

CN40

CN37

CN150

CN80

CN67

TB1

FC10

PCB3Mother Board

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

CN302

CN50

JP1

CN151

PCB102

Servo I/F Board

CN203

CN201

CN301 CN302

SW301


CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN14A

CN149



Front



3-8


3.4.2 Connecting External Axes Controller to Robot Controller

(1) Connecting signal cables

<When connecting the Robot Controller and External Axes Controller>

Robot Controller External Axes Controller

Connector CN40 PCB3 Mother board Connector CN40 PCB103 External Axes board

Connector CN80 PCB3 Mother board Connector CN81 PCB103

External Axes board

Connector CN302 PCB102 Servo I/F board Connector CN301 PCB152 Control Module

(a) Follow the instructions in “2.3.2 Installation of Robot Controller with External Axes Controller” to

install the External Axes Controller on the Robot Controller.

(b) Connect one end of connector CN40 of the cable attached to the External Axes Controller with

connector CN40 of the mother board, and connect the other end with connector CN40 of theExternal Axes board.

CAUTION

1. Open jumper pins JP105 & JP106 on the mother board in the Robot Controller when connecting

External Axes Controller. If they are short-circuited, overrun limit switches and shock sensorsdo not operate. (Refer to “Maintenance: 5.2.7 Jumper Pin Settings of Mother Board” in"INSTALLATION & MAINTENANCE" for model DR series.)

(c) Connect CN80 and CN81 of the cable attached to the External Axes Controller with connectorCN81 of the mother board and connector CN81 of the External Axes board.

Connect CN302 and CN301 of the cable attached to the External Axes Controller with connector CN302

of the Servo I/F board in the Robot Controller and connector CN301 of the control module in the externalaxes respectively.




3-9

< When connecting the External Axes Controller for 4.5kW motors and External Axes Controller >

External Axes Controller for 4.5kW motors External Axes Controller

Connector CN81A External Axes Controller for 4.5kWmotors

Connector CN81 PCB103

External Axes board

Connector CN302 PCB102 Servo I/F board Connector CN301 PCB152

Control Module

< When using L5930 ~ L5932 for External Axes Controller for 4.5kW motors >

Connector CN39 PCB003 Mother Board Connector CN40 PCB103 External Axes board

< When using L5003 for External Axes Controller for 4.5kW motors>

Connector CN40 PCB3 Mother Board Connector CN40 PCB103 Control Module

(a) Follow the instructions in “2.3.2 Installation of Robot Controller with External Axes Controller” toinstall the External Axes Controller on the Robot Controller.

(b) Connect one end of connector CN39 of the cable attached to the cable L8203C00 withconnector CN40 of the External Axes Board for the External Axes Controller for 4.5kW motors,

and connect the other end with connector CN40 of the External Axes board for the External Axes Controller.

CAUTION

1. Open jumper pins JP105 & JP106 on the mother board in the Robot Controller when connectingExternal Axes Controller. If they are short-circuited, overrun limit switches and shock sensors

do not operate. (Refer to “Maintenance: 5.2.7 Jumper Pin Settings of Mother Board” in"INSTALLATION & MAINTENANCE" for model DR series.)

(c) Connect CN81A and CN81 of the cable attached to the External Axes Controller with connector

CN81A of the External Axes Controller for 4.5kW motors and connector CN81 of the External Axes Board respectively.

(d) Connect CN302 and CN301 of the cable attached to the External Axes Controller withconnector CN302 of the Servo I/F Board and connector CN301 of the Control module in the

External Axes Board respectively.



3-10


CN40

CN80

TB1

CN250

CN251

Front

PCB3Mother board

CN81

CN40

CN205

CN302

CN50

JP1

CN151

PCB102

Servo I/F Board

PCB103

External Axes Board

CN203

CN201

CN301 CN302

SW301

PCB152

Control Module

Robot Controller


Cable Assembly

L4805N00

L4805T00

L4805U00

PCB2Main board

Cable Assembly

Cable Assembly

CAUTION

1. Do not bind these cables with the primary-side power cable.

2. Arrange the cable assembly (L4805N00) as far apart as possible from the cable assemblies(L4805T00 and L4805U00).

Fig. 3.4.2.1 Connecting External Axes Controller to Robot Controller




3-11

Fig. 3.4.2.2 External Axes Controller for 4.5kW Motors

FC10IC138

FC27

FC23FC24

CN16

CN44

CN1 CN7

CN111

CN19

CN18

CN41

CN30

CN73

CN38

CN40

CN37

CN150

CN80

CN67

TB1

FC10

Front

PCB3Mother Board

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN149

CN205

CN302

CN50

JP1

CN151

PCB102

Servo I/F Board

PCB103

External Axes Board

CN203

CN201CN301 CN302

SW301

PCB152

Control Module



Cable Assy.

L4805N00

Cable Assy.

L8203C00

Cable Assy.

L4805V00

PCB2Main Board

CN41A

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN149

CN81A

Auxiliary Transformer T1



3-12


Fig. 3.4.2.3 Connecting Robot Controller for 4.5kW Motors (L5003) and External Axes Controller

FC10IC138

FC27

FC23FC24

CN16

CN44

CN1 CN7

CN111

CN19

CN18

CN41

CN30

CN73

CN38

CN40

CN37

CN150

CN80

CN67

TB1

FC10

Front

PCB3Mother Board

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN149

CN205

CN302

CN50

JP1

CN151

PCB102

Servo I/F Board

PCB103

External Axes Board

CN203

CN201CN301 CN302

SW301

PCB152

Control Module

Robot Controller for 4.5kW Motors


Cable Assy.

L4805N00

Cable Assy.

L8203C00

Cable Assy.

L4805V00

PCB2Main Board

CN41A

CN81A

Auxiliary Transformer T1




3-13

(2) Connecting a power cable

(a) When the power source for the Robot Controller is 3-phase, AC 200V( +10%, -15%)

Robot Controller External Axes Controller

Secondary side of the breaker NFB1 Connector CN101A PCB101 Power unit

WARNING

1. Be sure to turn OFF the power source before connecting a power cable in order to avoid electric

shock.

2. Be sure that the primary-side power supply of Robot Controller is 3 AC200 V (10 %, -15 %). If

valtage other than the rated value is applied by mistake, Robot Controller and External Axes

Controlelr will be damaged.

3. Use Step-down Transformer (optional) when using voltage that is not rated. See section (c) for

its connection.

CAUTION

Do not bind this cable with signal cables.

(a)-1 Connect No.4 to 6 terminals of the power cable that is connected to the power unit inside

the External Axes Controller to the secondary-side terminals of the breaker in the RobotController from the left in order.



3-14


Fig. 3.4.2.2

Connecting External Axes Controller to Robot Controller

or External Axes Controller for 4.5kW Motors (2)(When the power source for the robot controller is 3-phase, AC 200V (+10%, -15%))

CN250

CN251

FC10

NFB1

4 6

1 2 3

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272CN273

CN274

CN275

CN276CN7A

CN1A

CN41A

CN149

CN205

CN302

CN50

JP1

CN151

PCB102

PCB103

B 3

A 3

C N 1 0 1

3 A C 2 0 0 V I N

F A N

F A N

F A N

F A N

1

3

1

2

1

2

1

2

1

2

P I L O T

L A M P

S E R V O P O W E R

T R A N S F O R M E R

P C B 1 2

P O W E R R E L A Y

E X

. P O W E R R E L A Y

1

3

1

3

1

B 1

A 1

B 3

A 3

C N 1 0 5

C N 1 0 9

C N 1 0 8

C N 1 1 0

C N 1 0 6

C N 3 0 6

C N 1 1 2

C N 1 1 3

C N 1 1 4

C N 1 1 5

C N 1 0 7

C N 1 1 6

4

1

4

1

I N P U T V O L T A G E

A C 2 0 0 V

A C 2 2 0 V

A C 2 3 0 V

C O N N E C T

1 P I N

2 P I N

1 P I N

3 P I N

1 P I N

4 P I N

1 3

C N 1 0 4

P S 1 , P S 2

T O U C H S E N S O R

5

B

CN101A CN301 CN302

SW301

PCB152

CN203

CN201

Power Cable

No FuseBreaker

Right Side (inside)

Primary-side Power Cable

Grounding Stud [M4]PE


1 023M DIB1 0231 023

PCB2

Front

External Axes Board

Control Module

Servo I/F Board

Main Board


Connected to theupper- side of thisconnector.

PCB101 Power Unit

View B

Robot Controller or


View "A"--"A"

"A"

"A"




3-15

(b) When the power source for the Robot Controller is other than 3 , AC200V (+10%, -15%)

Secondary-side of the breaker NFB1 Terminal U, V, W(Robot Controller) The primary-side of Aux. Transformer TF10

(Step-down Transformer)

Connector CN101 PCB1 Power unit Terminal R, S, T(Robot Controller) The secondary-side of Aux. Transformer TF10

(Step-down Transformer)

Connector CN101 PCB1 Power unit Connector CN101A

PCB101 Power unit

(Robot Controller) (External Axes Controller)

WARNING

1. Be sure to turn OFF the power source before connecting a power cable in order to avoid electric

shock.

2. For selecting the voltage of Step-down Transformer, refer to “Maintenance: 5.16.4 Voltage

Selector Mounting Position” in "INSTALLATION & MAINTENANCE" for model DR series.

3. Applying a voltage that exceeds its allowance will damage the robot controller. Prior to turning

on the robot controller, make sure that the jumper wires of Step-down Transformer are properlyconnected and suitable for the power supply voltage that are actually supplied.

CAUTION

Do not bind this cable with signal cables.

(b)-1 Remove the side cover of the Robot Controller on the right.

(b)-2 Lead CN101 of cable assembly (L4794D00) attached to Step-down Transformer into theboard through the bottom of the panel of the Robot Controller, and connect it to the rightcolumn, viewed from the back of the panel, of CN101 of the power unit.

(b)-3 Connect No.4 to 6 terminals of the cable assembly (L4794D00) with the secondary-side

terminals of the breaker in the Robot Controller from left in order.

(b)-4 Lead the remaining connector of the cable assembly (L4794D00) to the Step-downTransformer through the inlet on the base of the Robot Controller, and then fix the cableflange to the Robot Controller. After that, connect the terninals U, V, W, R, S and T of thecable to the corresponding terminals U, V, W, R, S and T of Aux. Transformer TF10,respectively.

(b)-5 Connect CN101 of the cable assembly (L4794F00) of the Step-down Transformer with theleft column of CN101, viewed from the back of the panel, of the power unit inside the RobotController.

(b)-6 Connect CN101A of the cable assembly (L4794F00) to the upper row of CN101A of thepower unit in the External Axes Controller.

(b)-7 Put the side cover of the Robot Controller back in place.



3-16


Fig. 3.4.2.5

Connecting External Axes Controller to Robot Controller (3)(When the power source for the Robot Controller is other than 3 , AC200V (+10%, -15%))

CN250

CN251

Right Side (inside)

FC10

Front

PCB2

Main Board

PCB3Mother Board

NFB1

1 2 3

Grounding Stud [M4]

PE

"A"

View "A" "A"


Inlet for Primary-side Power Cable

R S T Sh

4 5 6

CN101

Power Unit

"A"

U V W

L4794D00

Cable Assembly

Aux. Transformer

TF10

PCB1

Step-down Transformer

L4794

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN41A

CN149

CN205

B

CN301 CN302

SW301

CN203

CN201

B3

A3

CN101

3 AC200VIN

F AN

F AN

F AN

F AN

1

3

1

2

1

2

1

2

1

2

PIL

OT

L AMP

SERVOPOWER

TR

ANSFORMER

PCB12

POWERREL

AY

EX.P

OWERREL

AY

1

3

1

3

1

B1

A1

B3

A3

CN105

CN109

CN108

CN110

CN106

CN306

CN112

CN113

CN114

CN115

CN107 CN116

4

1

4

1

INPUTVOLT

AGE

AC200V

AC220V

AC230V

CONNECT

1PIN2PIN

1PIN3PIN

1PIN4PIN

1 3

CN104

PS1,PS2

TOUCHSENSOR

View B

CN101A

PCB101 Power Unit

Connected to the upper-sideof this connector.


PCB103

External Axes Board

PCB152

Control Module

No FuseBreaker

PCB102

Servo I/F Board

CN302

CN50

JP1

CN151

Connector

B3

A3

CN101

3

AC200VIN

FAN

FAN

FAN

FAN

1

3

12

12

12

12

PILOTLAMP

SERVO POWER

TRANSFORMER

PCB12

POWER RELAY

EX.POWER RELAY

1

31

31

B1

A1

B3

A3

CN105

CN109

CN108

CN110

CN106

CN306

CN112

CN113

CN114

CN115

CN107

CN116

41

41

INPUT VOLTAGE

AC200V AC220V AC230V

CONNECT1PIN 2PIN

1PIN 3PIN1PIN 4PIN

1

3

CN104

PS1,PS2

TOUCHSENSOR

(from the back of panel)

To the secondary-side of Aux.transformer TF10

To the upper-side of the connector CN101A on power unit in the External

Axes Controller

Robot Controller

L4794F00Cable Assembly

Panel




3-17

Fig. 3.4.2.6 Connecting External Axes Controller to External Axes for 4.5kW Motor

FC10

Front

PCB2

Main Board

PCB3Mother Board

NFB1

1 2 3

Grounding Stud [M4]PE

"A"


4 5 6

CN101

Power Unit

"A"

PCB1

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN149

CN205

B

CN301 CN302

SW301

CN203

CN201


PCB103

External Axes Board

PCB152

Control Module

No FuseBreaker

PCB102

Servo I/F Board

CN302

CN50

JP1

CN151


PCB003External Axes Board

CN41A

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN14A

CN149

NFB

U V W

TSR

Primary-sidePower Cable

Step-down Transformer

7kVAW-L00557 or 12kVAW-L00558

Connected to theright- side of thisconnector.

B 3

A 3

C N 1 0 1

3

A C 2 0 0 V I N

FAN

FAN

FAN

FAN

1

3

12

12

12

12

PILOTLAMP

SERVO POWER

TRANSFORMER

PCB12

POWER RELAY

EX.POWER RELAY

1

31

31

B1

A1

B3

A3

CN105

CN109

CN108

CN110

CN106

CN306

CN112

CN113

CN114

CN115

CN107

C N 1 1 6

41

41

INPUTVOLTAGE

AC200V AC220V AC230V

CONNECT1PIN 2PIN

1PIN 3PIN1PIN 4PIN

1

3

C N 1 0 4

P S 1 , P

S 2


View C

CN101A

PCB1 Power Unit

Connector

B 3

A 3

C N 1 0 1

3 A C 2 0 0 V I N

F A N

F A N

F A N

F A N

1

3

1

2

1

2

1

2

1

2

P I L O T

L A M P

S E R V O P O W E R

T R A N S F O R M E R

P C B 1 2

P O W E R R E L A Y

E X . P

O W E R R E L A Y

1

3

1

3

1

B 1

A 1

B 3

A 3

C N 1 0 5

C N 1 0 9

C N 1 0 8

C N 1 1 0

C N 1 0 6

C N 3 0 6

C N 1 1 2

C N 1 1 3

C N 1 1 4

C N 1 1 5

C N 1 0 7

C N 1 1 6

4

1

4

1

I N P U T V O L T A G E

A C 2 0 0 V

A C 2 2 0 V

A C 2 3 0 V

C O N N E C T

1 P I N 2 P I N

1 P I N 3 P I N

1 P I N 4 P I N

1 3

C N 1 0 4

P S 1 , P S 2


View B

CN101A

PCB101 Power Unit

Connected to the upper-sideof this connector.

Connector



3-18 CONNECTING ROBOT PERIPHERAL JIG

CN205

CN203

CN201

For Encoder Cable(s)of External Axis/Axes Cable 2


Front

B1 B2 B3 B4 B5 B6

CN205

CN203

CN201

8 7

10 9

12 11

7

8

9

10

11

12

CN67A

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

712Driver Nos.

712Driver Nos.

For Brake Cable(s)of External Axis/Axes Cable 1

For Motor Cable(s)of External Axis/Axes Cable 1

3.5 Connecting External Axis/Axes Cable 1 & 2

This section provides the method of connecting External Axis/Axes Cable 1 & 2 and some examples

of the system configuration to show the method in detail.

3.5.1 Where to connect External Axis/Axes Cable 1 & 2

Where to connect External Axis/Axes Cable 1 & 2 depends on “motor axis Nos.” and “driver Nos.”described below.

(1) Axis Nos. of motors

Axis Nos. 1 -6 of External Axes Motor are basically defined from 1 in order according to the

priority described in Fig. 3.5.1.1. The bigger the capacity of a motor is, the smaller the axis numberof the motor is. Moreover, the axis number of a slider is smaller than positioners’ when thecapacity of their motors are the same.

Fig. 3.5.1.1 Priority of Axis No.

(2) Driver Nos. of motors

Connectors for connecting External Axes of External Axes Controller and of External Axes Controllerfor 4.5kW Motors are shown in Fig. 3.5.1.2 and Fig. 3.5.1.3 respectively.Nos. 7 – 12 on CN201, 203, 205 (for External Axes Controller) are called “DRIVER Nos.”.

Fig. 3.5.1.2 Connectors for External Axis/Axes Cables

Small

Large

Axis No.

1500 W Motor

Slider (800 W)

Tilt axis of 2-axis positioner (800 W)

Table axis of 2-axis positioner (800 W)

1-axis positioner (800 W)




3-19

Fig. 3.5.1.3 Connectors for External Axes Controller for 4.5kW Motors


Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN149

FC10IC138

FC27

FC23FC24

CN16

CN44

CN1 CN7

CN111

CN19

CN18

CN41

CN30

CN73

CN38

CN40

CN37

CN150

CN80

CN67

TB1PCB3Mother Board

Encoder Cable for External Axes(External Axes 2)

7

8

910

11

12

CN271

CN272

CN273CN274

CN275

CN276

E7

CN7A

712Driver Nos.

Follow the driver No. in the table below when connecting brake cable.

(Connector for the brake cable)

Odd Axes

Even Axes

Inverter Driver No. Where to connect on CN67

Driver No. 7

Odd Axes

Odd Axes

Even Axes

Even Axes

Driver No. 9

Driver No. 11

Driver No. 8

Driver No. 10

Driver No. 12




See Table 3.5.1.1 for driver Nos. (7 – 12) that correspond to “axis Nos.” (1 -6 ) and “the combination

of motors”. After that, connect the motor cable(s) (External Axis/Axes Cable 1) and the encoder cable(s) (External Axis/Axes Cable 2) as shown in Fig. 3.5.1.2.

Fig. 3.5.1.1 Driver Nos. that Correspond to “the Number of Axes” and “the Combination of Motors”

The combination of motors(pieces)

Axis No. of External Axes Motor(External Axis 1-6 Motor)

The number

of axes

External Axis/Axes

Controller 1500 W 800 W or below 1 2 3 4 5 6

Remarks

L4805 0 1 81 axis

L5521 1 0 8

L4806 0 2 8 10

2 0 8 102 axesL5522

1 1 8 10

L4807 0 3 8 10 12

L5522 1 2 8 9 10

2 1 8 10 123 axes

L55233 0 8 10 12

L5522 0 4 7 8 9 101 3 8 9 10 124 axesL5523

2 2 8 10 11 12

0 5 7 8 9 10 125 axes L5523

1 4 8 9 10 11 12

L5523 0 6 7 8 9 10 11 12

L4808 DR-3200/4200/600/503S 12 10 8 11 9 76 axes

L5524 DR-4200L/4300/4400 12 10 8 11 9 7(Note 1)

Note 1) In these cases, connect encoder cables to CN7A.

2) 1 -6 are axis Nos. of motors. Ex.) 3 implies External Axis 3.

3) 1500 W motors are connected to inverter modules that correspond to driver Nos. in shadedrectangles.

Ex.) External axes: 1500 W motor + RP2E-300N (2-axis double support positioner)

Combination of motors: 1500 W motor x 1 + 800 W x 2

The axis Nos. for these motors obtained from Fig 3.5.1.0. are as follows.

Since the External Axes Controller to be used is L5522 for 3 External Axes Specifications, driver Nos.obtained from Table 3.5.1.1 are as follows.

CAUTION

In case of connecting a peripheral jig, the axis No. of the motion axis of the unit is defined by thedata settings of System Parameter. Therefore, connect the motion axis of the unit properly as

defined by System Parameter.

Wrong settings cause not only the malfunction of the unit but also the movement of the unit in wrongdirections or breakage of the unit itself, creating a very dagerous situation.

1500 W motor

RP2E-300N tilt axis

RP2E-300N table axis

1

2

3

1500 W motor

RP2E-300N tilt axis

RP2E-300N table axis

8

9

10




Fig. 3.5.1.2 Driver Nos. that Corresponds to “the Number of Axes” and “the Combination of Motors”(for External Axes Controller for 4.5kW Motors)

The combination of motors(pieces)

Axis No. of External Axes Motor(External Axis 1-6 Motor)

The numberof axes

Controllerfor 4.5kW, etc.

4.5kW 1.5kW or below 1 2 3 4 5 6

1 axis L5930 1 0 8

L5930 1 1 8 72 axes

L5931 2 0 8 10

1 2 8 7 9L5931

2 1 8 10 73 axes

L5932 3 0 8 10 12

L5932 1 3 8 7 9 11

L5931 2 2 8 10 7 94 axes

L5932 3 1 8 10 12 7

1 4 8 7 9 10 11

2 3 8 10 7 9 115 axes L5932

3 2 8 10 12 7 9

1 5 8 7 9 10 11 122 4 8 10 7 9 11 12L5932

3 3 8 10 12 7 9 116 axes

L5003 3 3 12 10 8 11 9 7

Note 1) 1 -6 are axis Nos. of motors. Ex.) 3 implies External Axis 3.

2) The crosshatched sections show that 4.5kW motor is connected.3) The axes Nos. are smaller as the motor capacity is larger and the axes Nos. of the slider are

smaller when the motor capacity is the same.




(3) Where to connect brake cable(s) (External Axis/Axes Cable 1)Basically, connect brake cable(s) (External Axis/Axes Cable 1) according to the number of

external axes and axis Nos. (1 -6 ) as shown in Table 3.5.1.3.

Table 3.5.1.3 Where to Connect Brake Cables

The number

of externalaxes

Which column(s) of CN67A

to connect brake cable(s)

1 B1

2 B1, B3

3 B1, B3, B5

4 B1 – B4

5 B1 – B5

6 B1 – B6

Examples of connecting External Axes Cables are shown on the next page onwards.

Table 3.5.1.4 Examples of System Configuration

Robot peripheral jigs

ConfigurationThe number of axes

Jig 1 Jig 2

Referencepage

1-axis positioner 1 axis

1-axis slider pp. 3-23

2-axis positioner pp. 3-272 axes

1-axis positioner 1-axis positioner pp. 3-32

3 axes 1-axis slider 2-axis positioner pp. 3-40

4 axes 2-axis positioner 2-axis positioner pp. 3-49

6 axes Manipulator pp. 3-60

1 axes (4.5kW motor) 4.5kW motor pp. 3-64

2 axes (4.5kW motor) 4.5kW motor + 1.5kW motor pp. 3-68

1

1

2

1

2

3

1

2

3

4

1

2

3

4

5

1

2

3

4

5

6




3-23

3.5.2 Adding One External Axis

The driver No. that corresonds to the External Axis Motor is “8” according to Table 3.5.1.1.Therefore, connect the motor cable, the encoder cable and the brake cable to CN201-8, CN272 and

CN67A-B1, respectively.

Fig. 3.5.2.1 Where to Connect External Axis Cables

(1) Connecting External Axis Cable 1

Jig 1

Cannon plug CN1 Connector CN201-8

Connector CN67A-B1

Grounding cable

External Axis Controller

PCB103 External Axes board


(a) Connect CN1 of the External Axis Cable 1 to the corresponding connector CN1 of jig 1.

(b) Lead connectors CN201, CN67 and the grounding cable into the External Axis Controllerthrough the shaded area on the right side of the External Axis Controller as shown in Fig.

3.5.2.2, and then fix the cable flange in place without leaving any clearance with that of theExternal Axis Cable 2.

(c) Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to theright side of the External Axis Controller.

(d) Connect CN67 to the corresponding connector CN67A-B1 of the External Axes board.

(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axis Controller. (Be sure to fix the grounding cable to this stud.)

CN205

CN203

CN201

7

10 9

12 11

8

7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

For Motor Cableof External Axis Cable 1

B1 B2 B3 B4 B5 B6

CN67A

External Axes Board

Shaded rectanagles: indicate whereto connect respective cables.

For Brake Cableof External Axis Cable 1

For Encoder Cableof External Axis Cable 2



3-24


Fig. 3.5.2.2

Connecting External Axis Cable 1 when Adding 1 External Axis

CAUTION

1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and thewelding cable.

2. Arrange External Axis Cable 1 as far apart as possible from External Axis Cable 2 inside theExternal Axis Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. When using it in such moving sections, please contact us forconsultation.

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN41A

CN149

CN205

PCB103

CN301 CN302

SW301

PCB152

CN203

CN201

CN67A

CN201

PCB2

External Axes Board


Connect here

Clamp this grounding cable withthat of External Axis Cable 2.

ControlModule

Connect here



Right Side (inside)

View "A" "A"

Front

Robot Controller Main Board

"A"

"A"




3-25


Jig 1

Cannon plug CN2 Connector CN272

Grounding cable

PCB103

External Axes board


(a) Connect CN2 of the External Axis Cable 2 to the corresponding connector CN2 of jig 1.

(b) Lead connector CN272 and the grounding cable into the External Axis Controller through the

shaded area on the right side of the External Axis Controller as shown in Fig. 3.5.2.3, and thenfix the cable flange in place without leaving any clearance with that of the External Axis Cable 1.

(c) Connect CN272 to the corresponding connector CN272 of the External Axes board.

(d) If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with anoverrun limit switch, open the corresponding jumper pin JP202 by reinserting only one side of

the pin. (Refer to Table 3.3.0.1.)

CAUTION

If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with an overrun

limit switch, open the corresponding jumper pin JP202 by reinserting only one side of the pin.If it is short-circuited, the overrun limit switch connected to CN272 does not operate.

(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axis Controller. (Be sure to fix the grounding cable to this stud.)

CAUTION

After changing the setting of the jumper pin JP202, be sure to check the operation of the

corresponding overrun limit switch in Teach mode.



3-26


Fig. 3.5.2.3

Connecting External Axis Cable 2 when Adding 1 External Axis

CAUTION

1. Arrange External Axis Cable 2 as far apart as possible from the primary power cable and the

welding cable.

2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 in theExternal Axis Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving/bending sections of a slider cableveyor, etc. When using it in such moving sections, please

contact us for consultation.

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

PCB103

CN301 CN302

SW301

PCB152

"A"

CN203

CN201

PCB2

External Axes Board


ControlModule



Front Right Side (inside)

View "A" "A"

Main Board

"A"


Robot Controller




CN205

CN203

CN201

7

10 9

12 11

8

7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

B1 B2 B3 B4 B5 B6

CN67A

External Axes Board

Shaded rectangles: indicate whereto connect respective wires.

For Motor Cablesof External Axes Cable 1

For Brake Cablesof External Axes Cable 1

For Encoder Cablesof External Axes Cable 2

3.5.3 Adding Two External Axes

3.5.3.1 .. Adding One 2-axis Peripheral Jig

Driver No. are “8” for External Axis Motor 1 and “10” for External Axis Motor 2 according to Table

3.5.1.1. Therefore, where to connect the External Axes Cable 1 & 2 are shown in Table 3.5.3.1.

Table 3.5.3.1 Where to connect External Axes Cables

Cable name Constituents Axis No.Where to connect

External Axes CableExternal Axis 1 CN201-8

Motor cableExternal Axis 2 CN203-10External Axes Cable 1

Brake cable External Axis 1/2 CN67A-B1

External Axis 1 CN272External Axes Cable 2 Encoder cable

External Axis 2 CN274

Fig 3.5.3.1 Where to connect External Axes Cables


Jig 1 Cannon plug CN1 Connector CN201-8

Connector CN203-10

Connector CN67A-B1

Grounding cable





(a) Connect CN1 of External Axes Cable 1 to the corresponding connector CN1 of jig 1.

(b) Lead connectors CN201, CN203, CN67 (2) and the grounding cable into the External Axes

Controller through the shaded area on the right side of the External Axes Controller as shown in

Fig. 3.5.3.2, and then fix the cable flange in place without leaving any clearance with that ofExternal Axes Cable 2.

(c) Connect CN201 and CN203 with the corresponding connectors CN201-8 and CN203-10 of the junction cables fixed to the right side of the External Axes Controller, respectively, as shown inFig. 3.5.3.1.

(d) As well, connect CN67 to CN67A-B1 on the External Axes board as shown in Fig 3.5.3.1.

(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of

the External Axes Controller. (Be sure to fix the grounding cable to this stud.)



3-28


Fig. 3.5.3.2 Connecting External Axes Cable 1 when Adding One 2-Axis Peripheral Jig

CAUTION

1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and thewelding cable.

2. Arrange External Axes Cable 1 as far apart as possible from External Axes Cable 2 in the

External Axes Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving

/bending sections of a slider cableveyor, etc. When using it in such moving sections, pleasecontact us for consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

PCB103

External AxesBoard

CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


View "A" "A"

"A"

"A"

CN203

CN201

Clamp this grounding cable withthat of External Axes Cable 2.

Connect here

External Axes Cable 1


CN67A

Connect here

Right Side (inside)

PCB2Main Board




3-29

(2) Connecting External Axes Cable 2

Jig 1

Cannon plug CN2 Connector CN272

Connector CN274

Grounding cable




(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector CN2 of jig 1.

(b) Lead connectors CN272, CN274 and the grounding cable into the External Axes Controller

through the shaded area on the right side of the External Axes Controller as shown in Fig.3.5.3.3, and then fix the cable flange in place without leaving any clearance with that of External

Axes Cable 1.

(c) Connect CN272 and CN274 to the corresponding connectors CN272 and CN274 of theExternal Axes board, respectively.

(d) If a peripheral jig such as a positioner or a slider connected to CN272 and CN274 is equippedwith an overrun limit switch(es), open the corresponding jumper pin JP202 and/or JP204 by

reinserting only one side of the pin(s).

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN272 and CN274, isequipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP202

and/or JP204 by reinserting only one side of the pin(s).If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN272 and CN274does(do) not operate.



CAUTION

After setting jumper pin JP202 and/or JP204, be sure to check the operation of the correspondingoverrun limit switch(es) of the peripheral jig, which is connected to CN272 and CN274, in Teachmode.



3-30


Fig. 3.5.3.3

Connecting External Axes Cable 2 when Adding One 2-Axis Jig

CAUTION


2. Arrange External Axes Cable 2 as far apart as possible from External Axes Cable 1 in the External

Axes Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. When using it in such moving sections, please contact us forconsultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN14A

CN149

CN205


CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


Right Side (inside)

View "A" "A""A"

"A"

CN203

CN201




PCB2Main Board



3

Connecting Robot Peripheral Jigs

C O N T E N T S













3.5.3.1 Adding One 2-axis Peripheral Jig ................................................................................... 3-27




3-31

CN205

CN203

CN201

7

10 9

12 11

8

7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

B1 B2 B3 B4 B5 B6

CN67A

External Axes Board

Shaded rectanagles: indicate whereto connect respective cables.

For Motor Cablesof External Axis Cable 1

For Brake Cablesof External Axis Cable 1

For Encoder Cablesof External Axis Cable 2

3.5.3.2 Adding Two 1-axis Peripheral Jigs

Driver Nos. are “8” for External Axis Motor 1 and “10” for External Axis Motor 2 according to Table

3.5.1.1. Therefore, where to connect External Axis Cables is shown in Table 3.5.3.2.

Table 3.5.3.2 Where to connect External Axis Cables

Cable name ConstituentsWhere to Connect

CablesMotor cable CN201-8External Axis Cable 1

for External Axis 1 Brake cable CN67A-B1


for External Axis 1Encoder cable CN272

Motor cable CN203-10External Axis Cable 1

for External Axis 2 Brake cable CN67A-B3



Fig 3.5.3.4 Where to Connect External Axis Cables

(1) Connecting External Axes Cable 1 for External Axis 1 (Jig 1)

Jig 1 Cannon plug CN1(External Axis 1)

Connector CN201-8

Connector CN67A-B1

Grounding cable


PCB103

External Axes board


(a) Connect CN1 of External Axis Cable 1 for External Axis 1 to the corresponding connector CN1

of jig 1.

(b) Lead connectors CN201, CN67 and the grounding cable into the External Axes Controller

through the shaded area on the right side of the External Axes Controller as shown in Fig.3.5.3.5, and then fix the cable flange in place without leaving any clearance with that of External

Axis Cable 2 for External Axis 1.

(c) Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to the rightside of the External Axes Controller.

(d) Connect CN67A to the corresponding connector CN67A-B1 on the External Axes board.




3-32






3-33

Fig. 3.5.3.5

Connecting External Axis Cable 1 for External Axis 1 when Connecting Two 1-Axis Jigs

CAUTION


2. Arrange External Axis Cable 1 as far apart as possible from External Axis Cable 2 in the External

Axes Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. When using it in such moving sections, please contact us for

consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

PCB103

External Axes Board

CN301 CN302

SW301

PCB152ControlModule

Robot Controller


Right Side (inside)

View "A" "A"

"A"

"A"

CN203

CN201


External Axis Cable 2for External Axis 2

CN67A


Connect here

CN201

PCB2

Main Board



Connect here



3-34


(2) Connecting the External Axis Cable 2 for External Axis 1 (Jig 1)

Jig 1

Cannon plug CN2(External Axis 1)

Connector CN272

Grounding cable

PCB103

External Axes board


(a) Connect CN2 of the External Axis Cable 2 for External Axis 1 to the corresponding connector

CN2 of jig 1.

(b) Lead connector CN272 and the grounding cable into the External Axes Controller through theshaded area of the right side of the External Axes Controller as shown in Fig. 3.5.3.6, and then

fix the cable flange in position without leaving any clearance with that of External Axis Cable 1.


(d) If a peripheral jig such as a positioner or a slider connected to CN272, is equipped with anoverrun limit switch, open the corresponding jumper pin JP202 by reinserting only one side ofthe pin.

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin.

If it is short-circuited, the overrun limit switch connected to CN272 does not operate.

(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)

CAUTION

After changing the setting of the jumper pin JP202, be sure to check the operation of thecorresponding overrun limit switch.




3-35

Fig. 3.5.3.6

Connecting External Axis Cable 2 for External Axis 1 When Adding Two 1-axis Jigs

CAUTION


2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 in theExternal Axes Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. If it is to be used in such moving sections, please contact us for

consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276

CN7A

CN1A

CN14A

CN149

CN205


CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


Right Side (inside)

View "A" "A"

"A"

"A"

CN203

CN201




for External Axis 2


for External Axis 1


PCB2Main Board



3-36


(3) Connecting External Axis Cable 1 for External Axis 2 (Jig 2)

Jig 2


Connector CN203-10

Connector CN67A-B3

Grounding cable




(a) Connect CN1 of the External Axis Cable 1 for External Axis 2 to the corresponding connectorCN1 of jig 2.

(b) Lead connectors CN203, CN67 and the grounding cable into the External Axes Controllerthrough the shaded area on the right side of the External Axes Controller as shown in Fig.3.5.3.7, and then fix the cable flange in place without leaving any clearance with the cableflange of the External Axis Cable 2 for External Axis 2.

(c) Connect CN203 to the corresponding connector CN203-10 of the junction cable fixed to theright side of the External Axes Controller.

(d) Connect CN67 to CN67A-B3 on the External Axes board.





3-37

Fig. 3.5.3.7 Connecting External Axis Cable 1 for External Axis 2 when Adding Three 1-Axis Jigs

CAUTION


2. Arrange External Axis Cable 1 as far apart as possible from the External Axis Cable 2 in theExternal Axes Controller. (Do not bind them together.)

3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider , etc. If it is to be used in such moving sections, please contact us forconsultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN14A

CN149

CN205


CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


Right Side (inside)

View "A" "A"

"A"

"A"

CN203

CN201

Clamp this groundning cable withthat of External Axis Cable 2.



for External Axis 2

CN67A


for External Axis 1


Connect here

CN203

PCB2Main Board

Connect here



3-38


(4) Connecting External Axis Cable 2 for External Axis 2 (Jig 2)

Jig 2


Connector CN274

Grounding cable



(a) Connect CN2 of the External Axis Cable 2 for External Axis 2 to the corresponding connector

CN2 of jig 2.

(b) Lead connector CN274 and the grounding cable into the External Axes Controller through theshaded area on the right side of the External Axes Controller as shown in Fig. 3.5.3.8, and thenfix the cable flange in place without leaving any clearance with that of the External Axis Cable 1.


(d) If a peripheral jig such as a positioner or a slider connected to CN274 is equipped with anoverrun limit switch, open the corresponding jumper pin JP204 by reinserting only one side of

the pin .

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN274, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP204 by reinserting only oneside of the pin .If it is short-circuited, the overrun limit switch connected to CN274 does not operate.

(e) Fix the grounding cable to the grounding stud provided at the upper left to the inlet of theExternal Axis Cable 2 for External Axis 2. (Be sure to fix the grounding cable to this stud.)

CAUTION

After changing the setting of the jumper pin JP204, be sure to check the operation of thecorresponding overrun limit switch.




3-39

Fig. 3.5.3.8

Connecting External Axis Cable 2 for External Axis 2 when Adding Two 1-axis Jigs

CAUTION

1 Arrange External Axis Cable 2 as far apart as possible from the primary power cable and thewelding cable.

2 Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 in theExternal Axes Controller. (Do not bind them together.)

3 Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /

bending sections of a slider, etc. If it is to be used in such moving sections, please contact us forconsultation.

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276

CN7A

CN1A

CN14A

CN149

CN205

CN301 CN302

SW301

PCB152

"A"

"A"

CN203

CN201

PCB2



for External Axis 2





Robot Controller

Main Board

ControlModule

Front Right side (inside)

View "A" "A"

Grounding Stud




3.5.4 Adding Three External Axes(When adding a standard 1-axis slider and a standard 2-axes positioner.)

This section illustrates the method of connecting External Axis/Axes Cables with the case that

standard 1-axis slider (slider henceforth) and a standard 2-axis positioner are added.The rated value of the motors used for a standard slider and a standard positioner are 800 W.Therefore, the axis Nos. of the motors in this particular case, which can be obtained from Fig. 3.5.1.1,

are listed in Table 3.5.4.1.

Table 3.5.4.1 Axis Nos of Motors.

Axis Name Axis No. Rated value of motor

Slider 1

Tilt axis of 2-axis positioner 2

Table axis of 2-axis positioner 3

800 W

According to Table 3.5.1.1, driver Nos. are “8” for a slider, “10” for the tilt axis of 2-axis positioner and

“12” for the table axis of 2-axis positioner.Thus, where to connect External Axis/Axes Cables is shown in Table 3.5.4.2.

Table 3.5.4.2 Where to connect External Axis/Axes Cables

Cable Name Constituents Cable nameWhere to ConnectExternal Axis/Axes

Cable

Motor Cable CN201-8External Axis Cable 1

for Slider Brake Cable CN67A-B1


for SliderEncoder Cable

Slider axis

CN272

Tilt axis

for 2-axis positioner

CN203-10

Motor CableTable axis

for 2-axis positionerCN205-12

External Axes Cable1 for Positioner

Brake Cable 2-axis positioner CN67A-B3

Tilt axis

for 2-axis positionerCN274

External Axes Cable

2 for PositionerEncoder Cable

Table axisfor 2-axis positioner

CN276




3-41

CN205

CN203

CN201

7

10 9

12 11

8

7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

B1 B2 B3 B4 B5 B6

CN67A

External Axes Board

Shaded rectangles: indicate whereto connect respective cables.

For Motor Cablesof External Axis/Axes Cable 1

For Brake Cablesof External Axis/Axes Cable 1

For Encoder Cablesof External Axis/Axes Cable 2

Fig. 3.5.4.1 Where to connect External Axis/Axes Cables

(1) Connecting External Axis Cable 1 for a slider

Slider


Connector CN201

Connector CN67A-B1

Grounding cable




(a) Connect CN2 of the External Axis Cable 1 for a slider to the corresponding connector CN1 of aslider.

(b) Lead connectors CN201, CN67 and the grounding cable into the External Axes Controllerthrough the shaded area (inlet) on the right side of the External Axes Controller as shown in Fig.3.5.4.2, and then fix the cable flange in place without leaving any clearance with the cableflange of the External Axis Cable 2 for a slider.

(c) Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to the sideof the External Axes Controller.

(d) Connect CN67 to the corresponding connector CN67A-B1 on the External Axes board.




3-42


Fig. 3.5.4.2 Connecting External Axis Cable 1 for Slider (External Axis 1)When Adding Both Slider and 2-axis Positioner

CAUTION


2. Arrange External Axis Cable 1 as far apart as possible from the External Axis Cable 2 inside theExternal Axes Controller. (Do not bind them together.)

3. Since External Axis Cable 1 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

PCB103

External Axes Board

CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


Right Side (inside)

View "A" "A"

"A"

"A"

CN203

CN201

Clamp this gounding cable withthat of External Axis Cable 2.


for 2-axis Positioner

CN67A

External Axes Cable 1for 2-axis Positioner

Connect here

CN201

PCB2

Main Board

External Axis Cable 1for Slider


for Slider

Connect here




3-43

(2) Connecting External Axis Cable 2 for a slider

Slider


Connector CN272

Grounding cable

PCB103

External Axes Board


(a) Connect CN2 of the External Axis Cable 2 for a slider to the corresponding connector CN2 of a

slider.

(b) Lead connector CN272 and the grounding cable into the External Axes Controller through theshaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.4.3, andthen fix the cable flange in place without leaving any clearance with the cable flange of the

External Axis Cable 1 for a slider.


(d) If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin.

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin.

If it is short-circuited, the overrun limit switch connected to CN272 does not operate.

(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)

CAUTION

After changing the setting of jumper pin JP202, be sure to check the operation of the

corresponding overrun limit switch of the the peripheral jig, which is connected to CN272, in Teachmode.



3-44


Fig. 3.5.4.3 Connecting External Axis Cable 2 for Slider (External Axis 1)When Adding Both Slider and 2-axis Positioner

CAUTION

1. Arrange External Axis Cable 2 as far apart as possible from the primary power cable and the

welding cable.

2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 inside theExternal Axes Controller. (Do not bind them together.)

3. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please


Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276

CN7A

CN1A

CN41A

CN149

CN205


CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


Right Side (inside)

View "A" "A"

"A"

"A"

CN203

CN201




for 2-axis Positioner


for Slider

External Axes Cable 1for 2-axis Positioner

PCB2Main Board




3-45

(3) Connecting External Axes Cable 1 for 2-axis Positioner

2-axis Positioner

Cannon plug CN1(External Axis 2 & 3)

Connector CN203

Connector CN205

Connector CN67A-B3

Grounding cable





(a) Connect CN1 of the External Axes Cable 1 for 2-axis positioner to the corresponding connectorCN1 of 2-axis positioner.

(b) Lead connectors CN203, CN205, CN67 x 2 and the grounding cable into the External Axes

Controller through the shaded area (inlet) on the right side of the External Axes Controller asshown in Fig. 3.5.4.4, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2 for 2-axis positioner.

(c) Connect CN203 and CN205 to the corresponding connectors CN203-10 and CN205-12 of the junction cable fixed to the side of the External Axes Controller.

(d) Connect CN67 to the corresponding connector CN67A-B3 on the External Axes board.





3-46


Fig. 3.5.4.4 Connecting External Axes Cable 1 for 2-axis Positioner (External Axis 2 & 3)When Adding Both Slider and 2-axis Positioner

CAUTION


2. Arrange External Axes Cable 1 as far apart as possible from the External Axes Cable 2 inside theExternal Axes Controller. (Do not bind them together.)

3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN41A

CN149

CN205

CN301 CN302

SW301

PCB152

"A"

"A"

CN203

CN201

CN67A

PCB2

Connect here

PCB103

External Axes Board


Robot Controller

Main Board


Connect here

ControlModule


View "A" "A"

External Axes Cable 2for Positioner







3-47

(4) Connecting External Axes Cable 2 for 2-axis Positioner

2-axis Positioner


Connector CN274

Connector CN276

Grounding cable




(a) Connect CN2 of the External Axes Cable 2 for 2-axis positioner to the corresponding connector

CN2 of a slider.

(b) Lead CN274, CN276 and the grounding cable into the External Axes Controller through the

shaded area (inlet) on the right side of the External Axis Controller as shown in Fig. 3.5.4.5, andthen fix the cable flange in place without leaving any clearance with the cable flange of theExternal Axes Cable 1 for 2-axis positioner.

(c) Connect CN274 and CN276 to the corresponding connectors CN274 and CN276 of the External Axes board.

(d) If a peripheral jig such as a positioner or a slider, which is connected to CN274 and CN276, is

equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP204and/or JP206 by reinserting only one side of the pin(s). (Refer to Table 3.3.0.1.)

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN274 and CN276, isequipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP204and/or JP206 by reinserting only one side of the pin(s).If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN274 and CN276does(do) not operate.


CAUTION

After changing the setting of jumper pin JP204 and/or JP206, be sure to check the operation of thecorresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN274 andCN276, in Teach mode.



3-48


Fig. 3.5.4.5 Connecting External Axes Cable 2 for 2-axis PositionerWhen Adding Both Slider and 2-axis Positioner

CAUTION




CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN1A

CN41A

CN149

CN205

CN301 CN302

SW301

PCB152

"A"

"A"

CN203

CN201

PCB2



Robot Controller

Main Board

ControlModule External Axes Cable 2for Positioner





View "A" "A"

Grounding stud



3

Connecting Robot Peripheral Jigs

C O N T E N T S

3.5.3.2 Adding Two 1-axis Peripheral Jigs ................................................................................. 3-31

3.5.4 Adding Three External Axes

(When adding a standard 1-axis slider and a standard 2-axes positioner.)..................... 3-39




3.5.5 Adding Four External Axes(When adding two standard 2-axis positioners.)

This section illustrates the method of connecting External Axes Cables with the case that twostandard 2-axis positioners are added.

The rated value of the motor used for a standard 2-axis positioner is 800 W.The axis Nos. of the motors in this particular case, which can be obtained from Fig. 3.5.1.1, are listedin Table 3.5.5.1.

The Nos. of positioners, whether Positioner 1 or 2, have been set beforehand.

Table 3.5.5.1 Axis Nos. of Motors

Axis Name Axis No. Rated value of motor

Tilt axis of Positioner 1 1

Table axis of Positioner 1 2



800 W

Therefore, the corresponding driver Nos. obtained from Table 3.5.1.1 are listed in Table 3.5.5.2.

Table 3.5.5.2 Driver Nos. of Motors

Axis Name Drver No.








3-49

Where to connect External Axes Cables is shown in Table 3.5.5.3.

Table 3.5.5.3 Where to connect External Axes Cables

Cable name Constituents Axis NameWhere to Connect

Cables

Tilt axis for Positioner 1 CN201-7Motor cable

Table axis for Positioner 1 CN201-8External Axes Cable 1

for Positioner 1Brake cable Positioner 1 CN67A-B1

Tilt axis for Positioner 1 CN271External Axes Cable 2for Positioner 1

Encoder cableTable axis for Positioner 1 CN272

Tilt axis for Positioner 2 CN203-9Motor cable

Table axis for Positioner 2 CN203-10External Axes Cable 1

for Positioner 2Brake cable Positioner 2 CN67A-B3

Tilt axis for Positioner 2 CN273External Axes Cable 2for Positioner 2

Encoder cableTable axis for Positioner 2 CN274

Fig. 3.5.5.1 Where to Connect External Axes Cables

CN205

CN203

CN201

7

10 9

12 11

8

7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

B1 B2 B3 B4 B5 B6

CN67A

External Axes Board

Shaded rectangles: indicate whereto connect respective cables.

For Motor Cablesof External Axes Cable 1

For Brake Cablesof External Axes Cable 1

For Encoder Cablesof External Axes Cable 2



3-50


(1) Connecting External Axes Cable 1 for Positioner 1 (External Axis 1 & 2)

Positioner 1


Connector CN201-7

Connector CN201-8

Connector CN67A-B1

Grounding cable





(a) Connect CN1 of the External Axes Cable 1 for Positioner 1 to the corresponding connector CN1of Positioner 1

(b) Lead connectors CN201-7, CN201-8, CN67 x 2 and the grounding cable into the External Axes

Controller through the shaded area (inlet) on the right side of the External Axes Controller asshown in Fig. 3.5.5.2, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2 for Positioner 1.

(c) Connect CN201-7 and CN201-8 to the corresponding connectors CN201-7 and CN201-8 of the junction cable fixed to the right side of the External Axes Controller.

(d) As well, connect CN67 to the corresponding connector CN67A-B1 on the External Axes Board.






3-51

Fig. 3.5.5.2 Connecting External Axes Cable 1 for Positioner 1 (External Axis 1 & 2)When Adding 2 Standard 2-axis Positioners

CAUTION




CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN41A

CN149

CN205


CN301 CN302

SW301

PCB152ControlModule

Robot Controller


"A"

"A"

CN203

CN201

Connect here

CN67A

PCB2Main Board


View "A" "A"

External Axes Cable 2for Positioner 2



External Axes Cable 2for Positioner 1Clamp this grounding cable withthat of External Axes Cable 2.




3-53


CAUTION




CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN7A

CN1A

CN41A

CN149

CN205

PCB103

External Axes Board

CN301 CN302

SW301

PCB152

"A"

"A"

CN203

CN201

PCB2

CN276





Right Side (inside)

View "A" "A"

Front


Robot Controller

Control

Module

Main Board




3-54



Positioner 2


Connector CN203-9

Connector CN203-10

Connector CN67A-B3

Grounding cable





(a) Connect CN1 of the External Axes Cable 1 for Positioner 2 to the corresponding connector CN1of Positioner 2.

(b) Lead connectors CN203-9, CN203-10, CN67 x 2 and the grounding cable into the External Axes

Controller through the shaded area (inlet) on the right side of the External Axes Controller asshown in Fig. 3.5.5.4, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2 for Positioner 2.

(c) Connect CN203-9 and CN203-10 to the corresponding connectors CN203-9 and CN203-10 ofthe junction cable fixed to the right side of the External Axes Controller.


(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of the

External Axes Controller. (Be sure to fix the grounding cable to this stud.)




3-55


CAUTION


2. Arrange External Axes Cable 1 as far apart as possible from the External Axes Cable 2 inside the

External Axes Controller. (Do not bind them together.)

3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it in

the moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN41A

CN149

CN205


CN301 CN302

SW301

PCB152ControlModule

Robot Controller


"A" "A"

"A"

"A"

CN203

CN201


Connect here

CN67A


PCB2Main Board






3-56



Positioner 2


Connector CN273

Connector CN274

Grounding cable




(a) Connect CN2 of the External Axes Cable 2 for Positioner 2 to the corresponding connector CN2

of Positioner 2.

(b) Lead CN273, CN274 and the grounding cable into the External Axes Controller through the

shaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.5.5,and then fix the cable flange in place without leaving any clearance with the cable flange of theExternal Axes Cable 1 for Positioner 2.

(c) Connect CN273 and CN274 to the corresponding connectors CN273 and CN274 of theExternal Axes board.

(d) If a peripheral jig such as a positioner or a slider, which is connected to CN273 and CN274, is

equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP203and/or JP204 by reinserting only one side of the pin(s). (Refer to Table 3.3.0.1.)

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN273 and CN273, isequipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP203and/or JP203 by reinserting only one side of the pin(s).If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN273 and/or CN273does(do) not operate.


CAUTION

After changing the setting of jumper pin JP203 and/or JP204, be sure to check the operation of thecorresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN273

and/or CN274, in Teach mode.



3-58


3.5.6 Adding One Manipulator

This section describes the method of connecting External Axes Cables when a manipulator is used asan external axis.

(1) Connecting External Axes Cable 1 for a manipulator

Manipulator Cannon plug CN1 Connector CN250

Connector CN251

Connector CN67A

Grounding cable x 2





(a) Connect CN1 of the External Axes Cable 1 to the corresponding connector CN1 of themanipulator.

(b) Lead connectors CN250, CN251, CN67 and the grounding cable into the External AxesController through the shaded area (inlet) on the right side of the External Axes Controller as

shown in Fig. 3.5.6.1, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2.

(c) Connect CN250 and CN251 to the corresponding connectors CN250 and CN251 of the junctioncable fixed to the right side of the External Axes Controller.

(d) As well, connect CN67 to the corresponding connector CN67A-B1 on the External Axes board.

(e) Fix the grounding cables (x 2) to the grounding stud provided at the lower-right corner of thebase of the External Axes Controller. (Be sure to fix the grounding cable to this stud.)




3-59

Fig. 3.5.6.1 Connecting External Axes Cable 1 when Adding One Manipulator

CAUTION



3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it in

the moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.

External Axes Cable 2for Manipulator


CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN41A

CN149

CN251

PCB103

CN301 CN302

SW301

PCB152

"A"

"A"

CN250

Connect here

CN67A

PCB2


View "A" "A"


Robot Controller

External Axes Board

ControlModule


Main Board



3-60


(2) Connecting External Axes Cable 2 for a manipulator

Manipulator Cannon plug CN2 Connector CN7A

Grounding cable



(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector CN2 of the

manipulator.

(b) Lead CN7A and the grounding cable into the External Axes Controller through the shaded area

(inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.6.2, and then fix thecable flange in place without leaving any clearance with the cable flange of the External AxesCable 1.

(c) Connect CN7A to the corresponding connector CN7A on the External Axes board.

(d) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)

(e) In order to operate the overrun limit switch of Axis 1 of the manipulator, open JP201 by

reinserting only one side of the pin except when DR-500s is in use.Since DR-500s is not equipped with an overrun limit switch, DO NOT open JP201.

CAUTION

If Axis 1 of a manipulator (except for DR-500s) is equipped with an overrun limit switch, be sure to

open the corresponding jumper pin JP201 by reinserting only one side of the pin.If it is short-circuited, the overrun limit switch mounted on the manipulator does not operate and themanipulator may be damaged.

CAUTION

After changing the setting of jumper pin JP201, be sure to check the operation of thecorresponding overrun limit switch of the manipulator in Teach mode.

(f) When using a torch with a shock sensor, open JP211 by reinserting only one side of the pin inorder to operate the shock sensor. (See Table 3.3.0.1.)

CAUTION

When using a torch with a shock sensor, be sure to open JP211 by reinserting only one side of the

pin.

If it is short-circuited, the shock sensor does not operate and the torch or a peripheral jig may bedamaged.




3-61

Fig. 3.5.6.2 Connecting External Axes Cable 2 when Adding One Manipulator

CAUTION



3. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please


Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN7A

CN1A

CN41A

CN149

PCB103

External Axes Board

CN301 CN302

SW301

PCB152

ControlModule

Robot Controller


Right Side (Inside)

View "A"--"A""A"

"A"



PCB2Main Board

CN276

CN251

CN250




3-62


Encoder Cable for External Axes


7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

External Axes Board

3.5.7 Adding 1-axis 4.5 kW Motor

As is shown in Table 3.5.1.2, the driver No. for 4.5kW motor is “8.”Therefore, connect motor cable, encoder cable, and brake cable to CN257, Cn272, and to CN67-B2

respectively.

Fig. 3.5.7.1 Where to Connect External Axes Cables


Connector CN257 External Axes Controllerfor 4.5kW Motor

Connector CN67-B2External Axes Controller

for 4.5kW Motor

4.5kW Motor

Cannon plug CN1(for motor)

Grounding cable External Axes Controllerfor 4.5kW Motor

(a) Connect Connector of the External Axes Cable 1to the corresponding Cannon plug CN1(for motor) of 4.5kW motor

(b) Lead the rest of connectors CN257, CN67, and the grounding cable into the External Axes

Controller through the shaded area (inlet) on the right side of the External Axes Controller as shownin Fig. 3.5.7.2, and then fix the cable flange in place without leaving any clearance with the cableflange of the External Axes Cable 2.

(c) Connect CN201 to the corresponding connector CN257 of the junction cable fixed to the right sideof the External Axes Controller.







3-63

3.5.7.2 Connecting External Axes Cable 1 when adding 4.5kW Motor

CAUTION


2. Since External Cable 1 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please contactus for consultation.



3-64



4.5kW Motor Cannon plug CN2

(for Encoder)

Connector CN272

Grounding cable


External Axes Controllerfor 4.5kW Motor

(a) Connect CN2 of the External Axes Cable 2 to the corresponding Cannon plug CN2 of 4.5kW motor.

(b) Lead the rest of CN272 and the grounding cable into the External Axes Controller through theshaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.7.3, andthen fix the cable flange in place without leaving any clearance with the cable flange.

(c) Connect CN272 to the corresponding connector CN272 on the External Axes board.

(d) If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting onlyone side of the pin. (See Table 3.3.0.1).

CAUTION

If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin. If it is short-circuited, the overrun limit switch connected to CN202 does not

operate.



CAUTION

After changing the setting of jumper pin JP202, be sure to check the operation of thecorresponding overrun limit switch of the manipulator in Teach mode.




3-65

Fig. 3.5.7.3 Connecting External Axes Cable 2 when adding 4.5kW Motor

CAUTION

1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and the

welding cable.

2. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please contactus for consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN14A

CN149

PCB003

External Axes Board


Right Sideinside

View "A" "A""A"

"A"




3-66


Encoder Cable for External Axes(External Axes Cable 2)

7

8

9

10

11

12

CN271

CN272

CN273

CN274

CN275

CN276

E7

CN7A

External Axes Board

3.5.8 Adding 1-axis 4.5 kW Motor and 1-axis1.5 kW Motor

Driver Nos. are “8” for External Axes Motor 1 (4.5kW motor) and “7” for External Axes Motor 2(1.5kW motor) according to Table 3.5.1.2,.

Therefore, where to connect External Axes Cable 1 & 2 is shown in Table 3.5.8.1

Table 3.5.8.1 Where to Connect External Axes Cables

Cable name ConstituentsWhere to

Connect Cables Motor cable CN257External Axes Cable 1

for External Axis 1 Brake cable CN67-B2



Motor cable CN256External Axes Cable 2for External Axis 1 Brake cable CN67-B1

External Axes Cable 2for External Axis 2

Encoder cable CN271

Fig. 3.5.8.1 Where to Connector for External Axes Cable

(1) Connecting External Axes Cable 1 for External Axiz 1 (4.5 kW motor)

Connector CN257 External Axes Controllerfor 4.5kW Motor

Connector CN67-B2 External Axes Controller

for 4.5kW Motor

External Axis 1

Cannon plug CN1(4.5kW Motor) (for motor)

Grounding cable External Axes Controller

(a) Connect Connector of the External Axes Cable 1 to the corresponding Cannon plug CN1(for motor) of 4.5kW motor

(b) Lead the rest of connectors CN257, CN67, and the grounding cable into the External AxesController through the shaded area (inlet) on the right side of the External Axes Controller as shownin Fig. 3.5.8.1, and then fix the cable flange in place without leaving any clearance with the cable

flange of the External Axes Cable 1.







3-67

3.5.8.2 Connecting External Axes Cable 1 when adding 4.5kW Motor

CAUTION


2. Since External Cable 1 is intended for use in non-moving sections of a jig, do not use it in the

moving / bending sections of a slider, etc. If it is to be used in such moving sections, please contactus for consultation.



3-68


(2) Connecting External Axes Cable 2 for External Axis 1 (4.5kW motor)

External Axes 1 Cannon plug CN2

(4.5kW Motor ) (for Encoder)

Connector CN272

Grounding cable



(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector of a peripheral jig of

External Axes 1.



(d) If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting onlyone side of the pin. (See Table 3.3.0.1).

CAUTION

If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only one

side of the pin. If it is short-circuited, the overrun limit switch connected to CN202 does notoperate.


CAUTION

After changing the setting of jumper pin JP202, be sure to check the operation of thecorresponding overrun limit switch of the peripheral jig, which is connected to CN271, in Teachmode.




3-69

Fig. 3.5.8.3 Connecting External Axes Cable 2 for External Axes 1 when adding 4.5kW motor

CAUTION


2. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please contact

us for consultation.

Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN14A

CN149

PCB003

External Axes Board


Right Sideinside

View "A" "A""A"

"A"




3-70


(3) Connecting External Axes Cable 1 for External Axes 2 (1.5kW motor)

Connector CN256External Axes Controller

for 4.5kW Motor

Connector CN67-B1 PCB 003 External Axes Board

External Axis 2

Cannon plug CN1(for 1.5kW Motor) (for motor)

Grounding cable External Axes Controllerfor 4.5kW Motor

(a) Connect Connector of the External Axes Cable 2 to the corresponding connector of a peripheral jigof External Axes 2.

(b) Lead the rest of connectors CN256, CN67, and the grounding cable into the External AxesController through the shaded area (inlet) on the right side of the External Axes Controller as shownin Fig. 3.5.8.4, and then fix the cable flange in place.







3-71

3.5.8.4 Connecting External Axes Cable 1 for External Axes 2 when adding 1.5kW motor

CAUTION

1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and the

welding cable.





3-72


(4) Connecting External Axes Cable 2 for External Axes 2 (for 1.5kW motor)

External Axes 2 Cannon plug CN2

(for 1.5kW motor) (for Encoder)

Connector CN271

Grounding cable



(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector of a peripheral jig of

External Axes 2.



CAUTION

If a peripheral jig, such as a positioner or a slider connedcted to CN271, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP201 by reinserting only oneside of the pin. If it is short-circuited, the overrun limit switch connected to CN271 does notoperate.

(d) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)

CAUTION

After changing the setting of jumper pin JP201, be sure to check the operation of the

corresponding overrun limit switch of the manipulator in Teach mode.




3-73

3.5.8.5 Connecting External Axes Cable 2 for External Axes 2 when adding 1.5kW motor

CAUTION




Front

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274CN275

CN276CN7A

CN14A

CN149

PCB003

External Axes Board

External Axes Controller for 4.5kW Motor

Right Side (inside)

View "A" "A""A"

"A"




PARTS LIST 4-1

4 PARTS LIST

This chapter provides instructions on major parts and components of the External Axes Controller.

For a robot controller, a wire feed unit, welding expendables and robot peripheral jigs, see the respectiveinstruction manuals. A robot system based on special specifications may have different parts numbers fromthose of a standard robot system. Therefore, when you place an order for replacement parts, be sure to

check the actual parts No. of each specific item and advise us of the model No. stamped each on themanipulator and the robot control unit, together with the parts No. information.

For the delivery time and prices of maintenance parts, please contact our local distributor or salesrepresentatives in your country.



4-20 PARTS LIST

4

Parts List

C O N T E N T S

4.1 External Axis Controller (L5380) ..................................................................................................... 4-2




4.5 External Axes (Axis) Controller (L5561) ........................................................................................ 4-10




4.9 Large-capacity External Axes Controller (L5930 ~ L5932) ........................................................... 4-18



4-2 PARTS LIST

4.1 External Axis Controller (L5380)

Ref. No. Item DWG. No. & Model Q'ty Parts No.

(1) Power Relay G7J-4A-B(DC24V) 1 4341-134

(2) Cooling Fan 4715PS-22T-B30-B18 4 4805-033

(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204

(3)-2 Control Module W-L00958 (1) 5096-240

(3)-3 Inverter Module W-L00956 (1) 5096-224

(3)-4 SWR Module W-L01170 (1) 5096-338

(3)-5 Capacitor Module W-L00954 (1) 5096-208

(3)-6 Power Supply Module W-L00955 (1) 5096-209

(4) Resistor Assy. L4798U00 1 L4798U00

(5) P.C.B. (Power Unit) L4800P00 1 L4800P00

(6) P.C.B. (Servo I/F Board) L4805C00 1 L4805C00

(7) P.C.B. (External Axes Board) L4805D00 1 L4805D00

(7)-1 Glass Tube Fuse 2A, AC250V (3) 4610-009

(8) Charging Unit L4797P00 1 L4797P00

(9) Charging Battery L6390N00 1 L6390N00

(10) Protective Cover L4805F01 1 L4805F01

(11) Door Key Handle A-120-1 2 4739-273

Note 1. Increasing the number of protective axes by one requires an increase of both an invertermodule and software, both optional, by one.

2. Servo I/F board (Ref. No. (6)) is not installed in the External Axes Controller but is installed onthe main board in the Robot Controller.



PARTS LIST 4-3

Fig. 4.1.0.1 External Axes Controller (L5380)

1

2

2

3

-1

3

-6

3

-5

3

-4

3

-3

3

-2

4

5

6

7

8

10

2

9

11



4-4 PARTS LIST

4.2 External Axes Controller (L5381)




(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338











(11) Door Key Handle A-120-1 2 4739-273


2. Servo I/F board (Ref. No. (6)) is not installed on the External Axes Controller but is installed onthe main board in the Robot Controller.



PARTS LIST 4-5


1

2

2

3

-1

3

-6

3

-5

3

-4

3

-3

3

-2

4

5

6

7

8

10

2

9

11



4-6 PARTS LIST





(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338











(11) Door Key Handle A-120-1 2 4739-273

Note: Servo I/F board (Ref. No. (6)) is not installed in the External Axes Controller but is installed onthe main board in the Robot Controller.



4-8 PARTS LIST





(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338









(9) Door Key Handle A-120-1 2 4739-273




PARTS LIST 4-9


1

2

2

3

-1

3

-6

3

-5

3

-4

3

-3

3

-2

4

5

6

7

8

2

9



4-10 PARTS LIST

4.5 External Axes (Axis) Controller (L5561)




(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338











(11) Door Key Handle A-120-1 2 4739-273





PARTS LIST 4-11


1

2

2

3

-1

3

-6

3

-5

3

-4

3

-3

3

-2

4

5

6

7

8

10

2

9

11



4-12 PARTS LIST





(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338











(11) Door Key Handle A-120-1 2 4739-273





PARTS LIST 4-13


1

2

2

3

-1

3

-6

3

-5

3

-4

3

-3

3

-2

4

5

6

7

8

10

2

9

11



4-14 PARTS LIST





(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338











(11) Door Key Handle A-120-1 2 4739-273




4-16 PARTS LIST





(3) Servo Unit 1

(3)-1 P.C.B. (Backplane) W-L00950 (1) 5096-204



(3)-4 SWR Module W-L01170 (1) 5096-338









(9) Door Key Handle A-120-1 2 4739-273




4-18 PARTS LIST

4.9 Large-capacity External Axes Controller (L5930 ~ L5932)


(1) Auxiliary Transformer W-L00699 1 4810-278

(2) Power Unit L4800P00 1 L4800P00

(3) Electromagnetic Contactor SC-3N (AC100V) 1 4340-083

(4) Surge Killer CR-20151 1 4516-011

(5) Constant Voltage Power Supply (5V) ZWS50-5/J 1 4814-033

(6) Constant Voltage Power Supply (10V) ZWS50-24/J 1 4814-034

(7) Relay (Servo ON) G4W-11123A-US-TB8 1 4340-616


(9) Pilot Lamp NPA10-2H-WS 1 4600-341

(10) AC Outlet Assy. L4798R00 1 L4798R00

(11) Servo Unit L5003J 1 L5003J00


(11)-2 Small Signal Backplane Board W-L01179 (1) 5096-352

(11)-3 Inverter Module W-L01177see

below

Large-capacity External Axes Controller (L5930) (1)



5096-353

(11)-4 SW Regulator Module W-L01237 (or W-L01170) (1) 5096-354


(11)-6 Large Current Backplane Board W-L01180 (1) 5096-356


(13) P.C.B (Main Board) L5000C00 1 L5000C00

(13)-1 CPU Cooler W-L01066 (3) 4805-047

(14) P.C.B (Mother Board) L5000C00 1 L5000F00



(15) P.C.B (External Axes Board) L4805D00 1 L4805D00

(16) Memory Battery L3391V00 1 5096-095

(17) Auto-breaker SA103B-40A (3) 1 4614-071

(18) Operation Handle BZ-N35B 1 4739-329

(19) Door Key Handle A-120-1 2 4739-273

(20) Eyebolt M12-ZMC 2 3364-005

(21) Relay (Brake) G7L-2A-TUB 1 4340-617

(22) Charging Unit L4797P00 1 L4797-P00




PARTS LIST 4-19

Fig. 4.9.0.1 Large-capacity External Axes Controller (L5930 ~ L5932)

FC10

FC3

Left side Front Right side

- 5

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN14A

CN149

- 4

- 1

-2,6

- 3

21

15

23

22



5 Maintenance (External Axes Controller)

C O N T E N T S

5.1 Servo I/F Board L4805C................................................................................................................ 5-10

5.1.1 Functions of Servo I/F Board ................................................................................................. 5-10

5.1.2 Connectors of Servo I/F Board............................................................................................... 5-10



5.2.1 Functions of External Axes Board.......................................................................................... 5-11

5.2.2 Operating State Indicators of External Axes Board ............................................................... 5-12

5.2.3 Relays on External Axes Board ............................................................................................. 5-125.2.4 Fuses on External Axes Board............................................................................................... 5-12

5.2.5 Connectors of External Axes Board ....................................................................................... 5-13

5.2.6 Test Pins on External Axes Board ......................................................................................... 5-13


5.3 Servo Unit ...................................................................................................................................... 5-15

5.3.1 Functions of Servo Unit .......................................................................................................... 5-15

5.3.2 Control Module W-L00958 .....................................................................................................5-17

5.4 Power Unit L4800P........................................................................................................................ 5-19

5.4.1 Functions of the Power Unit ...................................................................................................5-19

5.4.2 Connectors of the Power Unit ................................................................................................ 5-20

5.5 Charging Unit L4797P ................................................................................................................... 5-21

5.5.1 Functions of the Charging Unit............................................................................................... 5-21

5.5.2 Connectors of the Charging Unit............................................................................................ 5-21

5.6 Charging Battery L6390N00 .......................................................................................................... 5-22

5.6.1 Functions of the Charging Battery ......................................................................................... 5-22

5.6.2 Specifications of the Charging Battery ................................................................................... 5-225.6.3 Replacing the Charging Battery ............................................................................................. 5-22

5.7 Cooling Fans.................................................................................................................................. 5-25



5 Maintenance (External Axes Controller)

C O N T E N T S

5.1 Servo I/F Board L4805C................................................................................................................5-10

5.1.1 Functions of Servo I/F Board.................................................................................................. 5-10

5.1.2 Connectors of Servo I/F Board...............................................................................................5-10



5.2.1 Functions of External Axes Board ..........................................................................................5-11

5.2.2 Operating State Indicators of External Axes Board ...............................................................5-12

5.2.3 Relays on External Axes Board..............................................................................................5-12

5.2.4 Fuses on External Axes Board...............................................................................................5-12

5.2.5 Connectors of External Axes Board .......................................................................................5-13

5.2.6 Test Pins on External Axes Board .........................................................................................5-13




MAINTENANCE (EXTERNAL AXES CONTROLLER) 5-1

5 MAINTENANCE (EXTERNAL AXES CONTROLLER)

This chapter provides information on the following components of the External Axes Controller with respectto their functions, displays of operating states, switch settings and so on.

Components of External Axes Controller

(1) Servo I/F Board L4805C(2) External Axes Board L4805D(3) Servo Unit (4) Power Unit L4800P

(5) Charging Unit L4797P(6) Charging Battery L6390N(7) Cooling Fan

Figs. 5.0.0.1 and 5.0.0.2 show the parts arrangement plan and the block diagram of the External AxesController, respectively.

Components of External Axes Controller for 4.5 kW Motor

(1) Main Board L5000C

(2) Mother Board L5000F(3) Servo Driver(4) Brake Unit L5573G(5) Power Unit L4800P(6) Memory Battery L3391V(7) Auxiliary Transformer W-L00699

(8) Cooling Fans(9) Constant Voltage Power Supply(10) External Axes Board L4805D

(11) Charging Unit L4797P(12) Charging Battery L6390N(13) Relay Unit (optional)

For these components’ functions, displays of operating states, and switch settings, see the correspondingsection of MAINTENANCE in the Instruction Manual.

Table 5.0.0.1 Where to refer in “INSTALLATION & MAINTENANCE” for model DR series

ItemWhere to refer in “INSTALLATION & MAINTENANCE”

for model DR seriesMain Board “5.1 Main Board L5000C”Mother Board “5.2 Mother Board L5000F”Power Unit “5.3 Power Unit L4800P”Servo UnitControl ModuleSWR Module

“5.4 Servo Unit”

Servo UnitSmall Signal Backplane BoardInverter ModulePower Supply ModuleLarge Current Backplane Board

Additional Edition of BV80/120“7.1 Servo Unit”

Memory Battery “5.6 Memory Battery L3391V”Relay Unit (optional) “5.8 Relay Unit L5550”

Figs. 5.0.0.3 and 5.0.0.4 show the parts arrangement plan and the block diagram of the External Axes

Controller for 4.5 kW Motor, respectively.



5-2 MAINTENANCE (EXTERNAL AXES CONTROLLER)

Fig. 5.0.0.1

Parts Arrangement Plan of the External Axes Controller

CN81

CN80A

CN67A

CN39 CN40

CN29A

CN271

CN272

CN273

CN274

CN275

CN276CN7A

CN1A

CN14A

CN149

CN205

CN301 CN302

SW301

CN203

CN201

FC10IC138

FC27

FC23FC24

CN16

CN44

CN1 CN7

CN111

CN19

CN18

CN41

CN30

CN73

CN38

CN40

CN37

CN150

CN80

CN67

TB1

CN250

CN251

FC10

FC3

CN4

PCB2

Main board

PCB3Mother Board

SWR Module #1

PCB156

Capacitor Module #1

PCB158

(Remove side cover)

Left side Front

External Axes oard #1PCB103

Charging BatteryBT2

Charging Unit #1

PCB114

Servo I/F Board #1

PCB102

Control Module #1

PCB152

Power Supply Module #1

PCB159

Inverter Module 1 #1


Robot Controller

PCB153

CN302

CN50

JP1

CN151


PCB154


PCB155



MAINTENANCE (EXTERNAL AXES CONTROLLER)

5-3

Fig. 5.0.0.2

Block Diagram of External Axes Controller (L4807/L5523: 3 External Axes)

M a n i p u l a t o r

C N 2

C N 1

( S i g n a l L i n e )

( P o w e r L i n e )

C N 2 5 1

C N 2 5 0

C N 2 0 5 C N 2 0 3 C N 2 0 1

C N 2 0 9

C N 2 1 0

C N 2 2 7

C N 2 1 5

R e g e n e r a t i v e R e s i s t o r

J 2

A

F C 2

B a c k p l a n e # 0

P C B 5 1

P o w e r R e l a y

M S 1

M A C B_

# 0

C o n t r o l M o d u l e

P C B 5 2

C N 1

C N 5

P S 1

D C 5 V

P S 2

D C 2 4 V

A u x i l i a r y

T r a n s f o r m e r

T F 1

C N 1 0 6 C N 1 0 5

C N 3 0 6

C N 1 0 4

C N 1 1 0

C N 1 0 9

C N 1 0 1

P o w e r U n i t

P C B 1

C o o l i n g F a n C o o l i n g

U n i t

C N 1 5 0

C N 8 0

C N 7

C N 6 7

C N 4 0

C N 1

C N 3 8

C N 4 1

F C 1 0

M o t h e r B o a r d

P C B 3

F C 1 0

C N 3 0 2

T B P 1

A C 1 0 0 V

( M A X 0 . 5 A )

E x t e r n a l F l o p p y

D i s k D r i v e C

N 9 4

A

A C 2 0 0 V

3

B r e a k e r

N F B 1

< R o b o t C o n t r o l l e r >

M a i n B o a r d

P C B 2

S e r v o

I / F B o a r d

P C B 1 0 2

C N 4

B T 1

C N 5 0

C N 1 0 7

W N L 1

G R

P E

P C B 5 3 I n v e r t e r M o d u l e 1

S e r

v o U n i t # 0



P C B 5 6 S W R M o d u l e

P C B 5 8 C a p a c i t o r M o d u l e

P C B 5 9 P o w e r S u p p l y M o d u l e

C N 1 0 6 C N 1 0 5

C N 3 0 6

C N 1 0 4

C N 1 1 0

C N 1 0 9

C N 1 0 1

P o w e r U n i t # 1

P C B 1 0 1

M A C B_

# 1


P C B 1 5 2

C N 1

C N 5

< E x t e r n a l A x e s C o n t r o l l e r >

C o o l i n g F a n C o o l i n g U n i t

E x t e r n a l A x e s

B o a r d # 1

P C B 1 0 3

C N 4 0

C N 3 9

C N 1 A

C N 8 0 A

C N 8 1

C N 4 1 A

C

N 7 A

C N

2 9 A

C N 6 7 A

C N 2 7 1

C N 2 7 2

C N 2 7 3

C N 2 7 4

C N 2 7 5

C N 2 7 6

C

h a r g i n g B a t t e r y # 1

C N 3 2

P C B 1 0 4

C

N 3 0

C N 3 1

B T 1 0 2

P o w e r

R e l a y # 1

M S 1 0 1

G R

C N 2 0 9

C N 2 1 0

C N 2 0 5

C N 2 0 3

C N 2 0 1

C N 2 2 7

C N 2 1 5


P C B 1 5 1

P C B 1 5 3 I n v e r t e r M o d u l e 1

S e r v o U n i t # 1



P C B 1 5 6 S W R M o d u l e

P C B 1 5 8 C a p a c i t o r M o d u l e

P C B 1 5 9 P o w e r S u p p l y M o d u l e

A R C N E T C a r d # 1

P C B 1 6 0

C N 3 0 1

C N 3 0 2

R e g e n e r a t i v e

R e s i s t o r # 1

C N 2 0 5 /

C N 2 0 6

C N

2 0 3 /

C N

2 0 4

C N 2 0 1 /

C N 2 0 2

E x . A x - 3

E x . A

x - 2

E x . A x - 1

E x . A x - 3

E x . A x - 2

E x . A x - 1

E x . B K - 1

E x t e r n a l A

x e s E n c o d e r

( S i g n a l L i n

e )

E x t e r n a l A x e s M o t o r ( P

o w e r L i n e )

R e f 1 )

C h a r g i n g U n i t # 1

: I n s t a l l e d o n t h e r o b o t c o n t r o l l e r

R 5 1

E x . B K - 2

E x . B K - 3

E x t e r n a l A x e s B r a k e s

C N 1 0 7

C N 1

C N 1

C N 2

C N 2




Fig. 5.0.0.3

Block Diagram of External Axes Controller (L5523: 6 External Axes)

C N 1 0 6 C N 1 0 5

C N 3 0 6

C N 1 0 4

C N 1 1 0

C N 1 0 9

C N 1 0 1

P C B 1 0 1

E

M A C B_

# 1 P

C B 1 5 2

C N 1

C N 5

P C B 1 0 3

C N 4 0 C N 3 9

C N

1 A

C N 8 0 A

C N 8 1

C N 4 1 A

C N 7 A

C N 2 9 A

C N 6 7 A

C N 2 7 1

C N 2 7 2

C N 2 7 3

C N 2 7 4

C N 2 7 5

C N 2 7 6

C N 3 2

P C B 1 0 4

C N 3 0 C

N 3 1

B T 1 0 2

G R

C N 2 0 9

C N 2 1 0

C N 2 0 5

C N 2 0 3

C N

2 0 1

C N 2 2 7

C N 2 1 5

P C B 1 5 1

P C B 1 6 0

C N 3 0 1

C N 3 0 2

C N 2 0 5 /

C N 2 0 6

C N 2 0 3 /

C N 2 0 4

C N 2 0 1 /

C N 2 0 2

E x . A x - 3 E

x . A x - 2 E x . A x - 1

E x . A x - 6

E x . A x - 4

E x . A x - 2

E x B K - 5

E x . A x - 5

E x . A x - 3

E x . A x - 1

E x . A x - 6 E x . A x - 5 E

x . A x - 4

C N 2

C N 1

C N 2 5 1

C N 2 5 0

C N 2 0 5 C N 2 0 3 C N 2 0 1

C N 2 0 9

C N 2 1 0

C N 2 2 7

C N 2 1 5

J 2

A

F C 2

P C B 5 1

M S 1

M A C B_ #

0 P C B 5 2

C N 1

C N 5

P S 1

D C 5 V

P S 2

D C 2 4 V

T F 1

C N 1 0 6 C N 1 0 5

C N 3 0 6

C N 1 0 4

C N 1 1 0

C N 1 0 9

C N 1 0 1

P C B 1

C N 1 5 0

C N 8 0

C N 7

C N 6 7

C N 4 0

C N 1

C N 3 8

C N 4 1

F C 1 0

P C B 3

F C 1 0

C N 3 0 2

T B P 1

A C 1 0 0 V

( M A X 0 . 5 A )

C N 9 4

A

A C 2 0 0 V

3

P C B 2

C N 4

B T 1

C N 5 0

C N 1 0 7

W N L 1

G R

R 5 1

E x B K - 4 E x B K - 3

E x B K - 2 E x B K - 1

E x B K - 6

P E

C N 1

C N 1

C N 2

C N 2

C N 1 0 7

C h a r g i n g B a t t e r y # 1

< E x t e r n a l A x e s C o n t r o l l e r >


R e f . 1 )




B

a c k p l a n e # 0

P o w e r R e l a y

A u x i l i a r y


P o w e r U n i t



B r e a k e r

N F B 1

M a i n B o a r d

S e r v o

I / F B o a r d

P C B 1 0 2






P C B 5 8 C a p a c i t o r M o d u l e

P C B 5 9 P o w e r S u p p l y M o d u l e








P C B 1 5 6 S

W R M o d u l e

P C B 1 5 8 C

a p a c i t o r M o d u l e

P C B 1 5 9 P

o w e r S u p p l y M o d u l e


R e g e n e r a t i v e R e s i s t o r # 1

E x t e r n a l A x e s M o t o r ( P o w e r L i n e )

C h a r g i n g U n i t # 1


E x t e r n a l A x e s E n c o d e r ( S i g n a l L i n e )


P o w e r

R e l a y # 1

M S 1 0 1

E x t e r n a l A

x e s

B o a r d #

1


D i s k D r i v e


R

e g e n e r a t i v e R e s i s t o r

: I n s t a l l e d i n t h e r o b o t c o n t r o l l e r




5-5

Fig. 5.0.0.4

Block Diagram of External Axes Controller (L4808/L5524: Manipulator Extended)

C N 2 5 0

C N 2

C N 1

C N 2 0 5 C N 2 0 3 C N 2 0 1

C N 2 0 9

C N 2 1 0

C N 2 2 7

C N 2 1 5

J 2

A

F C 2


P C B 5 1

M S 1

M A C B_

# 0 P

C B 5 2

C

N 1

C N 5

P S 1

D C 5 V

P S 2

D C 2 4 V

T F 1

C N 1 0 6 C N 1 0 5

C N 3 0 6

C N 1 0 4

C N 1 1 0

C N 1 0 9

C N 1 0 1

P C B 1

C N 1 5 0

C N 8 0

C N 7

C N 6 7

C N 4 0

C N 1

C N 3 8

C N 4 1

F C 1 0

F C 1 0

C N 3 0 2

T B P 1

A C 1 0 0 V

( M A X 0 . 5 A )

C N 9 4

A

A C 2 0 0 V

3

C N 4

B T 1

C N 5 0

C N 1 0 7

W N L 1

G R

C N 1 0 6 C N 1 0 5

C N 3 0 6

C N 1 0 4

C N 1 1 0

C N 1 0 9

C N 1 0 1

P C B 1 0 1

E

M A C B_

# 1 P

C B 1 5 2

C N 1

C N 5

P C B 1

0 3

C N 4 0 C

N 3 9

C

N 1 A

C N

8 0 A

C

N 8 1

C N 4 1 A

C N 7 A

C N 2 9 A

C N 6 7 A

C N 2 7 1

C N 2 7 2

C N 2 7 3

C N 2 7 4

C N 2 7 5

C N 2 7 6

G R

C N 2 0 9

C N 2 1 0

C N 2 0 5

C N 2 0 3

C N 2 0 1

C N 2 2 7

C N 2 1 5

P C B 1 5 1

P C B 1 6 0

C N 3 0 1

C N 3 0 2

E x . A x - 1 t o 6

E x . A x : 1 - 6

R 5 1

C N 2 5 1

C N 2 5 0

C N 2 5 1

C N 1

C N 1

C N 2

C N 2

P E

C N 1 0 7

P C B 3

P C B 2

< E x t e r n a l

A x e s C o n t r o l l e r >


R e f . 1 )

P o w e r R e l a y

A u x i l i a r y


P o w e r U n i t


B r e a k e r

N F B 1

M a i n B o a r d


S e r v o U n

i t # 0




P C B 5 8 C a p

a c i t o r M o d u l e

P C B 5 9 P o w

e r S u p p l y M o d u l e



S e r v o u n i t # 1



P C B 1 5 6 S W R M o d u l e

P C B 1 5 8 C a p a c i t o r M o d u l e

P C B 1 5 9 P o w e r S u p p l y M o d u l e

E x t e r n a l A x e s M o t o r ( P o w e r L i n e )


E x t e r n a l A x e s E n c o d e r ( S i g n a l L i n e )


E x t e r n a l

A x e s

B o a r d

# 1


D i s k D r i v e


: I n s t a l l e d i n t h e r o b o t c o n t r o l l e r

E x t e n d e d M a n i p u l a t o r



R e g e n e r a t i v e R e s i s t o r # 1


P o w e r

R e l a y # 1

M S 1 0 1





R e g e n e r a t i v e R e s i s t o r

S e r v o

I / F B o a r d

P C B 1 0 2




5-7

Fig. 5.0.0.6 Block Diagram of External Axes Controller for 4.5kW Motor (L5930 ~ L5932)




For inspection, maintenance, adjustments, repairs or other similar work on the robot system, entering

into the robot working range or working with the primary-side power or servo power turned on may benecessary. In any case, be sure to take the following precautions for inspection, maintenance,adjustments and repairs.

WARNING • NEVER enter the robot working range when the power is ON.

• Approaching an operating robot may result in a fatal injury.

WARNING • NEVER touch any charged parts.

• Touching any charged part may result in a fatal electric shock hazard or burn.

WARNING

• NEVER put your hand, finger, hair, clothes or the like close to any rotatingsection.

• Putting your hand, finger, hair or clothes close to the wire feed roll of the wirefeed unit may cause you to get caught, resulting in a serious injury.

• Similarly, putting your hand, finger, hair or clothes close to the rotating section

of a cooling fan may cause you to get caught and hurt.

(1) Prior to carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a

helmet, safety shoes, gloves and other protective means that may be deemed necessary, asspecified by law. To be more specific, wear clothes that are suited to each specific work.

(2) Prior to initiating work, press the EMERGENCY Stop button or the Stop button to check if the

robot system stops instantly. Furthermore, if a safety plug, a dead man switch and/or other

protective devices are added to the robot system, they must be checked for their proper operation.Should any fault be detected, stop the inspection work, turn off the main power immediately, checkfor causes and take necessary countermeasures accordingly.

(3) Ensure that no one, except those who are involved in robot-related work, approach the safety

fence of the robot system.

(4) Prior to starting work, put up a sign “Under

Inspection” at a visible place to inform those

around the robot system that inspection isnow being carried out.

Under Inspection

(5) Do not use any devices that may generate electromagnetic noise, in and around the area whereinspection is being performed.

(6) At least two workers should involve in the inspection or maintenance work, one to perform actual

work and the other to serve as a watcher.

(7) Personnel to be involved for robot inspection, maintenance, adjustment and/or repairs shouldreceive instructions and training on robot functions, operation and maintenance. In addition, if

special devices or facilities are provided in the robot system, their entire mechanism must also befully understood.

(8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who arequalified by receiving special training. Moreover, even if they have received such special training,they are not allowed to perform inspection, maintenance, adjustment or repairs of machinery other

than those they are fully familiar with.

(9) Any sign that may be given to workers, watchers and/or operators of related machines must be in

conformity with the Customer’s safety management standards.

(10) The watcher must observe the following. He shall:

(a) stand at a place that commands a view of the entire robot working range, and devote himself

to the duty of watching the work.




5-9

(b) always hold the EMERGENCY Stop button to be able to press it immediately whenever any

abnormality occurs.

(c) make sure that no one except those who are involved in inspection, and so on come close to

the robot working range.

(11) Workers to be involved in inspection or other work must observe the following.

(a) If work can be carried out OUTSIDE the robot working range, specify the work details before

starting the work and make sure to carry out the work OUTSIDE the robot working range in any

case.(b) In principle, perform inspection and the like while a robot is stopped. In case inspection or

other work needs to be performed while the robot is operating, be sure to report that to a safetymanager who is responsible. With permission obtained, the operator may perform the workduring the operation OUTSIDE the robot working range.

(c) If a robot is required to be in an operable condition during inspection or the like, specify the

work procedure in detail beforehand to be able to perform work safely and efficiently. If not,carry out the work while the robot control unit, the welding power supply and other input-sidepower supplies are all turned off. Except in special occasions, be sure to turn off the

input-side power supplies for jigs and peripheral devices or make them inactive.

(d) When working in the robot working range, make sure to be ready to press the EMERGENCYStop button immediately whenever a robot malfunctions.

(e) Check your footing carefully before starting the work. Make sure to avoid an unstable scaffoldor a scaffold provided at an elevated position (more than 2 meters high).

(f) When working in the robot working range, do not work with your back facing the manipulator.

(g) When replacing PCBs provided in Robot Controller or Teach Pendant, take countermeasuresagainst static electricity such as applying protective sheets.

(12) If any abnormality occurs during work, follow the following procedure carefully.

(a) If any malfunction is observed in the robot system, press the EMERGENCY Stop button

immediately.

(b) Report that to the watcher immediately, turn

off the control power of the Robot Controller,

and then put up a sign “Do Not Switch ON”.Do Not Switch ON

(c) Make sure that all the related machines are stopped.

(d) When one has to go inside the safety fence, be sure that the one who is going to enter pullsout the safety plug oneself, carries it along and proceeds with the work concerned.

(e) Even when the robot has automatically stopped due to a fault in supply voltage to the robotsystem, hydraulic pressure or air pressure of related devices, make sure to stop the robotcompletely before investigating causes and taking necessary countermeasures.

(f) If the EMERGENCY Stop button or other safety devices have failed to operate, turn off the

main power immediately, investigate causes and take necessary countermeasures.

(g) When restarting the robot after stopping it by pressing the EMERGENCY Stop button,

investigate causes, take necessary countermeasures, replace the safety plug, and then restartit from outside the safety fence.

(13) Make sure that all the necessary connectors, covers, panels, etc. have been mounted and wiredcorrectly when finishing the work.




5.1 Servo I/F Board L4805C

5.1.1 Functions of Servo I/F Board

This PCB, which is equipped on the main board of the Robot Controller, communicates with the

control module of the External Axes Controller.

Fig. 5.1.1.1 External View of Servo I/F Board

5.1.2 Connectors of Servo I/F Board

The Servo I/F board is provided with connectors listed in Table 5.1.2.1.

Table 5.1.2.1 Connectors on Servo I/F Board

Connector Devices to be connected to

CN50 Main board (inside the robot control unit)

CN151 (Optional)

CN302 Control module of the first External Axes Controller (inside the External Axes Controller)

5.1.3 Jumper Pin Settings of Servo I/F board

Jumper pins listed in Table 5.1.3.1 are provided on the Servo I/F board

Table 5.1.3.1 Servo I/F Board Jumper Pin Setting

Jumper Pin Standard Setting Remarks

JP1 1-2 Open Never change the

standard setting.

95

95

CN302

CN50

JP1

CN151




5-11

5.2 External Axes Board L4805D

5.2.1 Functions of External Axes Board

This PCB controls various I/O signals, both internal and external, of the External Axes Controller andhas the following functions.This PCB has the following functions with respect to its control over various I/O signals both inside

and outside (, both internal and external,) the External Axes Contorller.

(1) Function to control the sequence circuits for high voltage and 24 V systems of the External AxesController

(2) Function to relay signals from peripheral devices, which are connected to the External AxesController, to the SERVO unit.

(3) Function to send and receive I/O signals to and from the External Axes Controller and peripheral

jigs.(4) Function to control the brakes of peripheral jigs.(5) Function to supply power to the charging unit for absolute encoder data backup while the

primary-side power is ON.

Fig. 5.2.1.1 External View of External Axes Board

125

185

CN81

JP222JP221

CN80A

CN67A

TP13A

TP12ATP15ATP14A

F7

F6

TP3A

TP4A

JP212 JP207

CN39

CN40

F5

JP211

JP223

J

P201

JP202

JP203

JP204

JP205

JP206

CR4ACR1A

CN29A

CN271

CN272

CN273

CN274

CN275

CN276

CN7A CN1A

CN14ACN149

LED

100A

LED

105A

LED

107A

3 1 3 1

31




5.2.2 Operating State Indicators of External Axes Board

LEDs listed in Table 5.2.2.1 are provided on the External Axes Board to indicate the operating state of

the sequence circuit, etc. inside the External Axes Controller. For each LED location, see Fig.5.2.1.1.

Table 5.2.2.1 Operating State Indicators of External Axes Board

LED No. Function Status

LED100A (green) Break Release ON when brake relay is turned.

LED105A (green) OVERRUN Detection Input OFF when peripheral jigs overrun.

LED107A (green) Shock Sensor OFF when shock sensor operates.

5.2.3 Relays on External Axes Board

Relays listed in Table 5.2.3.1 are provided on the external axes board to indicate the operating stateof the sequence circuit, etc. inside the robot controller. For each relay location, see Fig. 5.2.1.1.

Table 5.2.3.1 Relays on External Axes BoardRelay No. Function Status Related LED

CR 1A OVERRUN Contact opens when peripheral jigs overrun. LED105A OFF

CR 3D BRAKE D Contact closes when brake D is released.

CR 3E BRAKE A Contact closes when brake A is released.

CR 3F BRAKE F Contact closes when brake F is released.

LED100A ON

CR 4A Shock Sensor Contact opens when shock sensor operates. LED107A OFF

5.2.4 Fuses on External Axes Board

Fuses listed in Table 5.2.4.1 below are provided on the External Axes board to protect the robot

system. When replacing blown fuses, be sure to eliminate all the causes of the fusing and replacewith those of the same rating.

Table 5.2.4.1 Fuses on External Axes Board

Fuse No. Rating Application Parts No.

F5 250 V, 2A, glass tube type24 V power supply inside External

Axes Controller4610-009

F6 250 V, 2A, glass tube type AC 12 V power supply for External Axes Controller charging unit

4610-009

F7 250 V, 2A, glass tube typePower to release the unit brake ofperipheral jigs

4610-009




5-13

5.2.5 Connectors of External Axes Board

Connectors listed in Table 5.2.5.1 below are provided on the External Axes board to connectperipheral devices.

Table 5.2.5.1 Connectors of External Axes Board

Connector No. Peripheral devices to be connected to

CN1A Servo unit (inside External Axes Controller)

CN7A Manipulator-type peripheral jigs (External Axes Cable 2)

CN29A Charging unit (inside External Axes Controller)

CN39 (Optional)

CN40 Mother board (inside Robot Controller)

CN41A Power unit (inside External Axes Controller)

CN67A Peripheral jigs (power supply for brake)

CN80A Brake unit (optional) (inside Robot Controller)

CN81 Mother board (inside Robot Controller)

CN149 (Optional)

CN271 Peripheral jigs (External Axes Cable 2)






5.2.6 Test Pins on External Axes Board

Test pins listed in Table 5.2.6.1 below are provided on the External Axes board.

Table 5.2.6.1 Test Pins on External Axes Board

Test pin No. Signal Name Function

TP3A 24 V DC24 V

TP4A 0 V GND for DC24 V Power Supply

TP12A BK_COM Brake Release Output Common (DC90 V)

TP13A BK_D Brake Release Output D

TP14A BK_E Brake Release Output E

TP15A BK_F Brake Release Output F




5.2.7 Jumper Pin Settings of External Axes Board

Jumper pins listed in Table 5.2.7.1 below are provided on the external axes board. Performnecessary jumper pin setting in accordance with the specific robot system.

Table 5.2.7.1 Jumper Pin Setting of External Axes Board

Jumper Pin Function Standard Setting

JP201 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN7A or CN271.When overrun sensor is provided in a peripheral device (such as a

slider or a positioner) that is connected to CN7A or CN271, set this jumper pin at "ON" (OPEN).

1-2 Short : OFF

JP202 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN272.When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN272, set this jumper pin

at "ON" (OPEN).

1-2 Short : OFF

JP203 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN273.

When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN273, set this jumper pinat "ON" (OPEN).

1-2 Short : OFF

JP204 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN274.When overrun sensor is provided in a peripheral device (such as a

slider or a positioner) which is connected to CN274, set this jumper pinat "ON" (OPEN).

1-2 Short : OFF

JP205 ON-OFF selection of OVERRUN signal of a peripheral device which is

connected to CN275.When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN275, set this jumper pinat "ON" (OPEN).

1-2 Short : OFF

JP206 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN276.

When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN276, set this jumper pinat "ON" (OPEN).

1-2 Short : OFF

JP207 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN39.When an optional device is connected to CN39, set this jumper pin at

"ON" (OPEN).

1-2 Short : OFF

JP211 ON-OFF selection of shock sensor which is connected to CN7A.When shock sensor is provided in a peripheral device (such as a slider

or a positioner) which is connected to CN7A, set this jumper pin "ON"

(OPEN).

1-2 Short : OFF

JP212 ON-OFF selection of shock sensor which is connected to CN39.

When an optional device is connected to CN39, set this jumper pin at"ON" (OPEN).

1-2 Short : OFF

JP221 1-2 Short : OFF

JP222 1-2 Short : OFF

JP222

(For optional devices)

Do not change the standard setting.

1-2 Short : OFF

WARNING

When replacing the External Axes board with a new one, make sure that the jumper pin settings areproper. Wrong settings may result in the failure of peripheral jigs to perform OVERRUN or in

malfunction of the detecting circuit, creating a dangerous situation.




5.3 Servo Unit

5.3.1 Functions of Servo Unit

The servo unit controls servo system of up to six axes and supplies power to servo motors inaccordance with a specific control signal, and it consists of the following modules.The only difference between this unit and the servo unit L4800J of Robot Controller is in control

module.

Table 5.3.1.1 Configuration of Servo Unit for External Axes Controller L5380L5382, L5554

Module name DWG No. Q’ty

Parts No. Remarks

Backplane W-L00950 1

5096-204 1

Control module W-L00958

1 5096-225

Inverter module W-L00956

4 5096-224 1

SW Regulator module W-L00953

1 5096-207 1

Capacitor module W-L00954 1 5096-208 1

Power supply module W-L01146

1 5096-321 1

Table 5.3.1.2 Configuration of Servo Unit for External Axes Controller L5561L5564

Module name DWG No. Q’ty Parts No. Remarks

Backplane W-L00950 1

5096-204 1

Control module W-L00958

1 5096-225

Inverter module W-L00960

4

5096-305 3

SW Regulator module W-L01170

1 5096-338

3

Capacitor module W-L00954

1 5096-208 1

Power supply module W-L01146

1 5096-321 1

1 Used commonly for Robot Controller IRBC-602/621/631.

2 Used commonly for Robot Controller IRBC-602/621.

3 Used commonly for Robot Controller IRBC-631.

4 The quantity differs according to the number of extended axes.




This section explains only about control module.

For other modules, see “Maintenance 5.4: Servo Unit” in “INSTALLATION & MAINTENANCE” formodel DR series.

Fig. 5.3.1.1 External View of Servo Unit L4805G

310

CAUTION

30

3

78

SWR ModuleCapacitor Module

Power Supply Module

Inverter Module 1Control Module

Backplane

98

90

CN227

CN210

CN211

CN201 CN205CN203

CN208

CN209

CN207

CN216

PWR PWR

AC SERVO SYSTEM AC SERVO SYSTEM AC SERVO SYSTEM

W L00955 W L00954 W L00953

CAUTION CAUTION

PWR

65

4321

CAUTION

AC SERVO SYSTEM

W L00951

Enlarged viewof servo unit

Left-side View

Remove Side Cover

Inverter Module 3Inverter Module 2




5.3.2 Control Module W-L00958

(1) Functions of Control Module

This module controls the servo system of up to six axes, and has the following functions. Function to receive commands from the main board and generate signals for driving an inverter

module

Function to perform high-speed arithmetic operations required for servo control.

Function to detect a servo-related alarm signal sent from an absolute encoder and to send thisalarm to the control module.

Function to receive absolute offset data from an absolute encoder. Function to detect various alarms related to the servo system.

Fig. 5.3.2.1 External View of the Control Module

(2) Operating State Indicators of Control Module

Seven LEDs, one small-signal power supply LED (LED PWR: green) and six alarm LEDs (LEDs 1-6:red), are provided on the control module panel.

If any faulty occurs in the servo unit, the corresponding LED will be lit up.

The operating state information given by these LEDs can be checked on Teach Pendant, thus it isnot necessary to monitor those LEDs on the control module panel.

CAUTIONMay cause electric shock.Don't touch this systemduring power ON or 5 min.

135

12220

184

56

Backplane

PWR

6

5

4

3

2

1

AC SERVO SYSTEM

W L00958

Front View

Left-side View Rear View

Bottom View

CN1 CN2

CN215

CN

220

CN215

CN220

CN301 CN302

CN301 CN302




Backplane

Power Supply Module

Capacitor Module

SWR Module

Inverter Module

Control Module

Servo Frame

External Axes Board

Screw(16-M4x8)

(3) Precautions to be taken for replacing control module with a new one.

When replacing the control module, proceed as follows.

(a) Disconnect the cable from connector CN301 provided at the bottom of the control module.

CAUTION

Prior to removing the control module to be replaced, be sure to disconnect this cable.

(b) Remove the side cover on the left from the External Axes Controller.

(c) Remove the upper and lower screws (2 pcs. each) that are fixing the control module to theservo frame.

(d) Remove the control module to be replaced.

(e) Insert a replacement control module in place (at the rightmost on the lower level of a servo

frame), and connect it to connectors CN215 & CN220 on the backplane.

(f) Check, by viewing from the front, that the above two connectors are fully inserted to their

respective ends.

CAUTION

If those connectors of the control module are not fully inserted to their respective ends, they maysuffer a

contact failure, resulting in malfunction of the robot system. Therefore, make sure that theyare fully inserted and firmly connected.

(g) Fix the control module to the servo frame , using the above upper and lower screws (2 pcs.

each).

CAUTION

Vibrations or shocks may cause a contact failure of connectors and that could lead to a malfunction ofthe robot system. Therefore, be sure to fix the control module to the servo frame with screws.

Fig. 5.3.2.2 Fixing the Control Module to the Servo Frame




5.4 Power Unit L4800P

5.4.1 Functions of the Power Unit

This PCB has the function to supply AC200 V power to each unit (such as cooling fans, power relay

units and a servo unit) inside the robot control unit after eliminating noise that comes into the robotcontrol unit from the primary-side power.

Fig. 5.4.1.1 External View of the Power Unit

96

190

B3

A3

CN

101

3

AC200VI

N

FAN

FAN

FAN

FAN

1

3

12

12

12

12

PILOTLAMP

SERVO POWER

TRANSFORMER

PCB12

POWER RELAY

EX.POWER RELAY

1

31

31

B1

A1

B3

A3

CN105

CN109

CN108

CN110

CN106

CN306

CN112

CN113

CN114

CN115

CN107

CN116

41

41

INPUT VOLTAGE

AC200V

AC220V

AC230V

CONNECT

1PIN 2PIN

1PIN 4PIN

1PIN 3PIN

PART NO. L4800PL4800P02

1

3

CN104

PS1,PS2

TOUCHSENSOR




5.4.2 Connectors of the Power Unit

The power unit is provided with connectors as listed in Table 5.4.2.1 below, to supply power to eachinner unit.

Table 5.4.2.1 Connectors of Power Unit


CN101 3 AC200 V power supply input (inside the robot control unit)

CN104 (Reserved) (inside the robot control unit)

CN105 Power relay MS1servo unit (inside the External Axes Controller)

CN106 Power relay MS1 (inside the External Axes Controller)

CN107 Pilot lamp (PL1) (inside the Robot Controller)

CN108 (Reserved) (inside the External Axes Controller)

CN109 (Reserved) ( inside the External Axes Controller)

CN110 External Axes board (inside the External Axes Controller)

CN112 Cooling fan FM14 (inside the External Axes Controller)

CN113 Cooling fan FM 11 (inside the External Axes Controller)





WARNING

Since some connector pins of the power unit are applied with a high voltage, touching themaccidentally during maintenance or other work may result in an electric shock hazard. Therefore,DO NOT touch live electrical parts.

CAUTION

Never use the reserved connectors in Table 5.4.2.1 for purposes other than specified.




5.5 Charging Unit L4797P

5.5.1 Functions of the Charging Unit

This charging unit is used to supply power to absolute encoders and has the following functions

(1) Charges the charging battery while the control power is ON.(2) Detects overdischarge of the charging battery to thereby disconnect the load.

(3) Backs up the data of each absolute encoder using the charging battery when the control poweris OFF.

Fig. 5.5.1.1 External View of the Charging Unit

5.5.2 Connectors of the Charging Unit

This charging unit is equipped with connectors in Table 5.5.2.1 to back up data of the absoluteencoders.

Table 5.5.2.1 Connectors of the Charging Unit


CN30 AC200 V power supply input (inside the robot controller)

CN31 Backup power supply output to each encoder (inside peripheral devices)

CN32 Charging battery

WARNING

1. When the power is ON, never touch any parts of the robot control unit except the charging batterybecause that may result in an electric shock hazard.

2. Disconnecting CN32 while the control power is turned off results in a loss of absolute-encoderdata.

3. Power of the charging battery is supplied to an absolute encoder of each axis via the charging unitconnector CN31 and External Axes Cable. Therefore, disconnecting the connector or the

External Axes Cable irrespective of whether the control power is ON or OFF results in a loss of

absolute-encoder data. When either of them is disconnected for maintenance or inspection, besure to make absolute offset adjustments for each peripheral jig.

For the absolute offset adjustments, see “Installation: 4.2 Absolute Offset Adjustments” in“INSTALLATION & MAINTENANCE” for DR series.

TP1

TP2

TP3

VR1

CR1

CN30

C

N32

CN31

1

3

2

8

1

1

L4797P




5.6 Charging Battery L6390N00

5.6.1 Functions of the Charging Battery

A charging battery is provided in the External Axes Controller to back up data of each absolute

encoder with which peripheral jigs are equipped. It is charged while the control power is ON, andsupplies power to the absolute encoder for data backup purposes when the control power is OFF.Therefore, when the robot system is not used for an extended period of time, the residual battery

capacity will decrease, eventually failing to supply power to the absolute encoder.

In that case, priorto initiating automatic operation, be sure to make absolute offset adjustments for each manipulator.

WARNING

Removing External Axes Cable while the control power is off results in a loss of absolute encoderdata. In such a case, be sure to make absolute offset adjustments for each peripheral jig.

For the absolute offset adjustments, see “Installation: 4.2 Absolute Offset Adjustments” in“INSTALLATION & MAINTENANCE” for model DR series.

CAUTION

1. The data backup period of the absolute encoder while the control power is OFF is approximately10 days. After the period, absolute offset adjustments need to be carried out

2. The data backup period of the absolute encoder may be shorter depending on environmentalconditions, operating conditions and other factors.

5.6.2 Specifications of the Charging Battery

Nominal Voltage

Discharge VoltageThe Lowest Possible Voltage for Recharging

: 4.0 V (5.0 Ah)

: 3.8 V 4.2 V: 3.7 V

The above specifications are applicable when absolute encoder, charging unit and other loads are

connected.

5.6.3 Replacing the Charging Battery

The charging battery characteristics gradually deteriorate with repeated charge-discharge cycles.Therefore, it is necessary to replace the charging battery with a new one at the 3-year periodicinspection in accordance with the procedure described below.

WARNING

Because of a possible fire or electric shock hazard, NEVER attempt to short terminals (+) and (-)with a wire or other similar conductive materials when replacing the charging battery with a new oneor conveying it.

(1) Perform block operation in accordance with the origin position check program <such as P999>

and make sure that the origin position is in alignment with a matchmark <>. If not, mark that

position.

(2) With the control power of the robot controller ON, remove the two bolts (M58) that are fixing

the charging battery to the External Axes Controller in order to remove the battery.

(3) Remove the tab-on terminals of the connecting cable from the charging battery.




WARNING

(1) Disconnecting the charging battery with the control power OFF results in a loss of absolute-encoder data. Be sure to turn on the control power when replacing the charging battery.

(2) When the power is ON, NEVER touch any parts of the robot control unit except the chargingbattery because that may result in an electric shock hazard.

(4) Connect a connecting cable to the new charging battery <namely, the wire identification mark[+] (white wire) to the plus terminal of the charging battery, and the mark [-] (blue wire)to the minus terminal, respectively>.

(5) Fix the charging battery in position using the two bolts (M58) that were removed in procedure

(3).




Fig. 5.6.3.1 Replacing the Charging Battery

CN205

CN203

CN201

Front

Charging BatteryBT2


Robot Controller

Breaker Handle

Cooling UnitPower Unit

Power Relay

Charging Battery

"C""C"

View "C" "C"

M48Screw

Replace thecharging batterywhile the controlpower is ON.




Rear View Left-side View

Air flowdirection

(Cooling Unit)(Cooling Unit) Air flowdirection

"C" "C"

View "C" "C"

FM111

FM112

Side Cover

FM114

FM113

Front

Rear

FM114

Air flowdirection

Air flowdirection

Panel Internal View

5.7 Cooling Fans

The External Axes Controller is of an enclosed type and is internally air-cooled by four cooling fans as

shown in Fig. 5.7.0.1.

Cooling fans FM111 and FM112 are mounted on the air cooling unit.

Cooling fan FM113 is mounted on the left-side cover of the robot control unit.

Cooling fan FM114 is mounted on the bottom of the servo frame.

Fig. 5.7.0.1 Cooling Fans

WARNING

NEVER put your hand, finger, hair or clothes close to a rotating fan becauseyou may be caught and injured.

WARNING

When you are performing maintenance or checking on the servo unit or other

devices, NEVER attempt to remove the side cover while the power is ONbecause you may get your hand, finger, hair or clothes caught by a rotating fanand be injured.

CAUTION

Dust accumulation on the radiation fins of the cooling unit causes a decline in cooling capability, thusclean the fins periodically.




6-1

6 ELECTRICAL CONNECTION DIAGRAM

6.1 Electrical Connection Diagram of External Axes Controller



6

Electrical Connection Diagram

C O N T E N T S

6.1 Electrical Connection Diagram of External Axes Controller ............................................................6-1

6.2 Electrical Connection Diagram for External Axes Controller for 4.5 kW Motor............................... 6-7

6.3 Electrical Connection Diagram for External Axes Cable ...............................................................6-11



G en

er al E l e

c t r i c al

C on

n e c t i onDi a

gr am of E x

t er n

al A x

e

s C on

t r ol l er

( L 4

8 0 7

/ L

5 5 2

3 :

3 E

x t er n

al A x

e s ) ( 1 / 1 )

Manipulator

CN2 CN1(Signal Line) (Power Line)

CN251 CN250

CN205 CN203 CN201

CN209 CN210

CN227

CN215

Regenerative Resistor

J2

A FC2

Backplane #0PCB51

Power RelayMS1

MACB_#0

Control Module

PCB52

CN1 CN5PS1

DC5V

PS2

DC24V

AuxiliaryTransformer

TF1

CN106 CN105 CN306

CN104

CN110

CN109

CN101

Power UnitPCB1

Cooling FanCooling Unit

CN150

CN80

CN7

CN67

CN40

CN1

CN38

CN41FC10

Mother Board

PCB3

FC10

CN302

TBP1 AC100V

(MAX0.5A)

External FloppyDisk Drive

CN94

A

AC200V 3

Breaker NFB1

<Robot Controller>

Main BoardPCB2

ServoI/F Board

PCB102

CN4

BT1

CN50

CN107

W

NL1

GR

PE

PCB53 Inverter Module 1Servo Unit #0

PCB54 Inverter Module 2PCB55 Inverter Module 3

PCB56 SWR Module

PCB58 Capacitor ModulePCB59 Power Supply Module

External AxesBoard #1

PCB103

CN40 CN39

CN1A

CN80A

CN81

CN41A

CN7A

CN29A

CN67A

CN271CN272CN273CN274CN275CN276

Charging Battery #1

CN32

PCBCN30 CN31

BT102

C

Ex.Ax-3 Ex.Ax-2 Ex.Ax-1

External Axes Encoder (Signal Line)

Ref 1)

Cha

: Installed on the robot controller

R51

Ex

CN1

CN1

CN2

CN2



M

A I NT E NA N

C E

( E X T E RNA L A X

E S C ONT R

OL L E R

)

6 - 3

G en

er al E l e

c

t r i c al

C onn

e c t i onDi a

gr am of E x

t er n al A x

e s C on

t r ol l er

( L 5 5 2

3 :

6

E x t er n

al A x

e s ) ( 1 / 1 )

PCB103

CN40 CN39

CN1A

CN80A

CN81

CN41A

CN7A

CN29A

CN67A


CN32

PCB104CN30 CN31

BT102

GRCN209

PCB151

Ex.Ax-3Ex.Ax-2

Ex.Ax-1 ExBK-5Ex.Ax-6 Ex.Ax-5

Ex.Ax-4

CN2 CN1

CN251 CN250

CN205 CN203 CN201

CN209 CN210

CN227

CN215

J2

A FC2 PCB51

MS1

MACB_#0

PCB52

CN1 CN5PS1

DC5VPS2

DC24V

TF1

CN106 CN105 CN306

CN104

CN110

CN109

CN101

PCB1

CN150

CN80

CN7

CN67

CN40

CN1

CN38

CN41FC10

PCB3

FC10

CN302

TBP1 AC100V

(MAX0.5A)CN94

A

AC200V 3

PCB2

CN4

BT1

CN50

CN107

W

NL1

GR

R51

ExBK-4

ExBK

ExBK-6

PE

CN1

CN1

CN2

CN2

Charging Battery #1

<Robot Controller>

Ref.1)

Manipulator

(Signal Line) (Power Line)

Backplane #0

Power Relay


Power Unit


Mother Board

Breaker NFB1

Main Board

ServoI/F Board

PCB102

PCB53 Inverter Module 1Servo Unit #0


PCB56 SWR ModulePCB58 Capacitor Module

PCB59 Power Supply Module

Backplane

Charging Unit

External Axes




Control Module


: Installed in the robot controller



G

en er al E l e c t r i c al C onn e c t i onDi a

gr am of E x t er n al A x e s C on t r ol l e

r

( L 4 8 0 8 / L 5 5 2 4 : M ani p

ul a t or E x t en d e d ) ( 1 / 1 )

CN2 CN1

CN205 CN203 CN201

CN209 CN210

CN227

CN215

J2

A FC2Backplane #0

PCB51

MS1

MACB_#0

PCB52

CN1 CN5PS1

DC5V

PS2

DC24V

TF1

CN106 CN105 CN306

CN104

CN110

CN109

CN101

PCB1

CN150

CN80

CN7

CN67

CN40

CN1

CN38

CN41FC10

FC10

CN302

TBP1 AC100V

(MAX0.5A)CN94

A

AC200V 3

CN4

BT1

CN50

CN107

W

NL1

GR

PCB103

CN40 CN39

CN1A

CN80A

CN81

CN41A

CN7A

CN29A

CN67A


CN209

P

Ex.Ax-1 to 6

R51CN251 CN250

CN1

CN1

CN2

CN2

PE

PCB3

PCB2

<Robot Controller>

Ref.1)

Power Relay


Power UnitMother Board

Breaker NFB1

Main Board PCB53 Inverter Module 1Servo Unit #0


PCB56 SWR ModulePCB58 Capacitor Module

PCB59 Power Supply Module

Back

Ext




Control Module

: Installed in the robot controller

Extended


Manipulator

(Signal Line) (Power Line)


ServoI/F Board

PCB102



M

A I NT E NA N C E

( E X T E RNA L A X

E S C ONT R OL L E R )

6 - 5

E l e c t r i c al C onn e c t i onDi a gr am of E x t er n al A x e s C on t r ol l er ( 1 / 2 )

B T 102

1

B A T -

2

A T +

NF B 1

F M F M

CN114

CN

115 CN112

CN106

CN 306

1

3

3

1

1

3

2

CN109

3

1

2

CN108

1

2

5

CN104

6

3

1

CN110

A 3

A 1

CN105

A 2

B 2

B 3

B 1

CN107

2

1

5

6

7

8

2

3

1 2 1 2 1 2 1 2

3 A C 200 V

I NP UT

34

24

14

33

23

13

R S T

A 1

B 1 B 2

A 2

B 3

3

M S 101

1

DR1

DR2

P C B 101

CN101

4

Z R1

Z R2

Z R 3

Z R4 Z R 5

Z R 6

C 1

C 2

C 3

C 4

C 5

C 6

C 7

C 8

C 9

L1

1

2

3

4

5

6

4

3

7

4

1 2 CN116

4 5 6

7

8

9

CN113

7 7 7 7

7

8

9 26

70

9 9 9 9

1

3

4

2

2

NC

2 NC

102 F M

P C B 114

N. C .

A C 12 V

A C 12 V

CN 30 A

CN 32 A

CN 31 A

GND

BA T

2

101

M S

F M

104 103

101

C har gi ng B a tt er y

C har gi ng Uni t

B r ak er

P ow er Uni t



MA I NT E NA N

C E

( E X T E RNA L A X E S

C ONT R

OL L E R

)

6 - 9

E l e

c

t r i c al

C onn

e c t i onDi a

gr am

of E x

t er n al A x

e s C on

t r ol l er f or 4 . 5 k W

M o t or

( 1 / 3 )

ConstantVoltagePower Supply

ConstantVoltagePower Supply

FM11

INPUT3 AC200V

No Fuse Breaker NFB1

R S T

CN101

ZR4 ZR5

ZR6 ZR1

ZR2

ZR3C2

C1

C31 3 5

2 4 6

L1

C4

C5

C6

C7

C9

C8

7

8

9MS1 26

70NC

CN106

1

2

3

DR1

MS2

NC

CN306

DR2

1

2

3

CN109

7

9

13

14

1

2

3

4

CN108

4

3

2

1

W2 AC220V

W1 AC200V

W

CN104

NC

NC

NC

CN110

7

8

7

8

3

1

5

4

2

67

1

2

3

NC

CN105

7

9

A1

A2

A3

B1

B2

B3

CN107

2

1

8

7

7 9 7 9 7 9 7 9

CN113

CN114

CN115

CN112

FM1 FM2 FM3 FM4 WNL1

NC

NC

1

5

3

1

4

2

5

NC

NC

1

3

42

220V 200V 0V

0V 100V 0V 8.5V

NC

12V

TF1

20

21

10

11

3

4

1

2

CN38

AC

AC

32

27

26

25

26

70

CN41

1

2

3

4

5

6

MS1

MS1

+5V

GND

+24V

0V

32

27

Cooling Fan4

Touch Sensor

CN116

Power Indicator

PS1

(DC5V)

PS2

(DC24V)

Po

(S


Power Unit

PCB1

A1 A2 A3 A3

4 5 6

B1 B2 B3

1 2 1 2 1 2 1 2 1 2

5

3

2

1

MainBoard

PCB2

4

CN11

FM6

FM5FM7

Cooling Fan3

A4

CN203

Ro

To

M

PCB61

Backplane

Small Signal

1

2

3

Ro

To

NC

TB282

FM14

FM13

FM12

Cooling Fan4

MS1

1

5

2

4

6

3

3

1

3

B4



M

A I NT E NA N C E ( E X T E RNA L A X

E S C ONT R OL L E R )

6 -1 1

E l e c

t r i c al C onn e c t i onDi a gr am of E x

t er n al A x e s C on t r ol l er f or 4 . 5 k W

M o t or ( 3 / 3 )



6.3 Electrical Connection Diagram for External Axes Cable

(1) External axes cable 1 for 1-axis peripheral jig

Note: Connectors on the left-hand side in this figure are the destinations when one 1-axis peripheral

jig is used. When using the peripheral jig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.


Note: Connectors on the left-hand side in this figure are the destinations when one 1-axis peripheral jig is used. When using the peripheral jig for other combinations, see “3.5 Connecting External

Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.

B

E

H

C

J

F

External Axes Controller Positioner CN2

+SD

GND

VCC

CN272

G

A

E

I GND

D

-SD

RESET(+)

BAT

OVRN LS-1

OVRN LS-COM

RESET(-)

SHIELD

AC12V A

ABSRST

2

E0V

8

6

3

1

OVRUN

9

E5V

BAT

10

+SD

OVCOM

-SD

5

7

4

AC12V B

W

E

E

B2

B

A

B3

B1

F


U

CN1

GND

GND

CN201

CN67

B

C

D

V

A

Positioner

Brake (-)

Brake (+)




6-13


Note: Connectors on the left-hand side in this figure are the destinations when one 2-axis peripheral

jig is used. When using the peripheral j ig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.


Note: Connectors on the left-hand side in this figure are the destinations when one 2-axis peripheral jig is used. When using the peripheral j ig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.

P RESET(-)

S RESET(-)

E SHIELD

E0V

-SD2

+SD2

OVRUN2

OVCOM2

AC12VA

AC12VB

+SD

J -SD

G GNDT RESET(+)

F VCC

RESET(+)

K

OVRN LS-COM

N.C.

H1

2

3

6

7

8

CN274

BAT

5

4

9

10

E5V2

ABSRST2

10

C4

5

VCC

BAT

-SD

CN272

E

AC12VA

8

7

6

3

2

1

N

D

B

M

L

R

CN2

-SD1

OVRN LS-1

E5V1

E0V

+SD1

ABSRST1

BAT

A

GND

+SD

AC12VB

OVRUN1

OVCOM1

9

External Axes Controller Positioner

GND

GND

W

G

B2

2

1

B3

B2

B1

B3

B1

F

E

J

I

H

External Axes Controller Positioner

U

W

CN1

CN67

U

V

GND

GND

CN201

CN203

B

C

D

V

A

Brake (-)

Brake (+)



(5) External axes cable 1 for 1-axis 4.5 kW motor

Note: Connections on the left-hand side in this figure are the destinations when one 4.5 kW motor axisis used. When using the peripheral jig for other combinations, see “3.5 Connecting External Axis

Cable 1&2” and check where to connect the above-mentioned connectors. For External axes cable2 for1-axis 4.5 kW motor, use external axes cable 2 for 1-axis peripheral jig.



6 Electrical Connection Diagram

C O N T E N T S

6.1 Electrical Connection Diagram of External Axes Controller ............................................................6-1

6.2 Electrical Connection Diagram for External Axes Controller for 4.5 kW Motor............................... 6-8

6.3 Electrical Connection Diagram for External Axes Cable ...............................................................6-12

dr external axis controller (1l4805a-e-3)

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