DR External Axis Controller (1L4805A-E-3)

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 2.3.2 2.3.3

Installation Dimensions of Robot Controller with External Axes Controller ............................. 2-6 Installation of Robot Controller with External Axes Controller ................................................. 2-7 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 3.2.2

System Configuration ............................................................................................................... 3-3 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 3.4.2

3.5

Fixing Method of Servo I/F Board ............................................................................................ 3-7 Connecting External Axes Controller to Robot Controller........................................................ 3-8

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....................................................................................................... 3-61 3.5.8 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

4.3


4.4


4.5

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

4.6

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

4.7


4.8


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 5.1.2 5.1.3

5.2

External Axes Board L4805D ........................................................................................................ 5-11 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7

5.3

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

Charging Battery L6390N00 .......................................................................................................... 5-22 5.6.1 5.6.2 5.6.3

5.7

Functions of the Power Unit ................................................................................................... 5-19 Connectors of the Power Unit ................................................................................................ 5-20

Charging Unit L4797P ................................................................................................................... 5-21 5.5.1 5.5.2

5.6

Functions of Servo Unit .......................................................................................................... 5-15 Control Module W-L00958 ..................................................................................................... 5-17

Power Unit L4800P........................................................................................................................ 5-19 5.4.1 5.4.2

5.5

Functions of External Axes Board .......................................................................................... 5-11 Operating State Indicators of External Axes Board ............................................................... 5-12 Relays on External Axes Board.............................................................................................. 5-12 Fuses on External Axes Board............................................................................................... 5-12 Connectors of External Axes Board ....................................................................................... 5-13 Test Pins on External Axes Board ......................................................................................... 5-13 Jumper Pin Settings of External Axes Board ......................................................................... 5-14

Servo Unit ...................................................................................................................................... 5-15 5.3.1 5.3.2

5.4

Functions of Servo I/F Board.................................................................................................. 5-10 Connectors of Servo I/F Board............................................................................................... 5-10 Jumper Pin Settings of Servo I/F board ................................................................................. 5-10

Functions of the Charging Battery.......................................................................................... 5-22 Specifications of the Charging Battery ................................................................................... 5-22 Replacing the Charging Battery ............................................................................................. 5-22

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 Specifications CONTENTS

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

1


1.1 What is External Axes Controller? When combining a manipulator with robot peripheral jigs such as a positioner and/or a slider, an optional 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

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

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

Model

Combination of corresponding motors

Model

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


L5382

1500 W x 3 axes

L5563


L5562

800 W or below x 5 axes 800 W or below x 6 axes

L5563

In the case of connecting robot peripheral jigs (Controlling the External Axes Controller with a combination 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

L5562

1500 W x 1 axis + 800 W or below x 2 axes 1500 W x 2 axes + 800 W or below x 1 axis 1500 W x 1 axis + 800 W or below x 3 axes

L5563

1500 W x 2 axes + 800 W or below x 2 axes 1500 W x 1 axis + 800 W or below x 4 axes 4500 W x 1 axis + 1500 W x 1 axis

L5930

4500 W x 2 axes + 1500 W x 1 axis

L5931

4500 W x 1 axis + 1500 W x 2 axes 4500 W x 2 axes + 1500 W x 3 axes

L5932

4500 W x 3 axes + 1500 W x 1 axis

In the case of connecting a manipulator made by DAIHEN Corporation Manipulator

Model

DR-3200/4200/600/500 series

L5554

DR-4200L/4300/4400

L5564 FUNDAMENTAL SPECIFICATIONS

1-1

DR-4800, DR-4900 Item

L5009

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 position detecting 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%

Input power (note 6)

Model

Rated value

Model

Rated value

L5380

1 kVA

L5561

2 kVA

L5381

2 kVA

L5562

4 kVA

L5563

6 kVA

L5564

7 kVA

L5382

3 kVA

L5554 L8220

6 kVA

L8221

9 kVA

L8222

12 kVA

L5009 Grounding External dimensions of External Axes Controller Mass Painting color

50 / 60 Hz

Peripheral jigs should be grounded independently, and the resistance should be less than 100 ohm. 358 (W) 515 (D) 525 (H)

(mm)

358 (W) 785 (D) 1188 (H) (mm) (External Axes Controller for 4.5kW motors) Approx. 35 kg (for L5563) Approx. 110kg (for L8222) 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 offset adjustment 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 in times of reinstallment, absolute encoder data will be lost. Once the External Axes Cable is disconnected, “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 for External 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.

1-2


1.3

External Dimensions of External Axes Controller

Unitmm Eyebolt


358

515 498 External Axis Cable 1 External Axis Cable 2

Door Key

5 2 5

External Axis Cable 2 External Axis Cable 1

8 4 7

8 9 6

300

438 518

Robot Controller

A 4 16

0 0 3

Fig. 1.3.0.1

6 6 4

External Dimensions of External Axes Controller


1-3

Left Side

Right Side

Front

"A"

358

515 498

525

Door key

8 8 1 1

"A"


8 3 1 1

(for 4.5kW motors)

View A

Fig. 1.3.0.2

1-4

External Dimansions of External Axes Controller (for 4.5kW motors)


2 FOUNDATION WORK AND INSTALLATION Installing External Axes Controller properly is very important for maintaining the proper function of peripheral 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 a robot and connecting cables. Touching live electrical parts will cause an electrical shock or a burn that may results in a loss of life.

WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Disconnect all power before installing or servicing. Multiple sources of voltage may exist inside this enclosure. 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 life may occur.

WARNING Keep out of robot area when main power is on. Do not locate this device in robot work area. Read instruction manual. NC8050

3. When the External Axes Controller, welding power source, etc., are to be installed at such an elevated position (over 2 m high) as on a frame, provide a working floor shown in Fig. 2.0.0.1 to allow adjustment, maintenance and inspection.

m 6. 0 n.i m

(Rear)

Robot control unit

4. Be sure to fix Robot Controller with External Axis Controller to a proper place for installment. Do not lean against the controller. If the controller falls down, not only the controller may break down but also a fatal accident may occur.

(Front)

m 1 n.i m

Fig. 2.0.0.1

Installing an External Axes Controller at an Elevated Position

CAUTION 1. Provide at least 20-cm-wide space between the External Axes Controller unit and a wall.

CAUTION TO AVOID DAMAGE TO THE ROBOT CONTROL UNIT, KEEP THE AIR INLET AND EXHAUST CLEAR. (AT LEAST 0.2M FROM WALL.) NC8054

2. Upon completion of the installation, make absolute offset adjustments until the robot peripheral jig agrees with the position coordinate data stored in the robot control unit. For the adjusting procedure, see “Installation: Section 4.2 Absolute Offset Adjustment” in “Installation and Maintenance” for DR series.

FOUNDATION WORK AND INSTALLATION

2-1

2 Foundation Work and Installation CONTENTS

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 2.3.2 2.3.3

Installation Dimensions of Robot Controller with External Axes Controller ..............................2-6 Installation of Robot Controller with External Axes Controller ..................................................2-7 Installation of External Axes Controller onto Robot Controller. ................................................2-8

2.1

Foundation Work for Installation of Robot Controller with External Axes Controller

WARNING A robot controller does not have any mobile parts as a manipulator does, however it should be fixed 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.

4 16

0 0 3

6 6 4

438 518

View A

A

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

Fig. 2.1.0.2

Insert an anchor Make holes with bolt. a concrete drill. Hole diameter and depth vary depending on the type of an anchor bolt.

Installation of Concrete Anchor

Drive the bolt fully into a hole by a hammer.

0 5

J-type Bolt (M12-250L)

0 5 1

50 150

Fig. 2.1.0.3 Foundation Drawing for Installation by enbedding Anchor Bolt. (Unitmm)

"B"

0 0 3

"B"

50


0 5

130 438

2-2

0 2 2

View "B"-"B"

500

720

4 16

438 518

View A

A

Installation Method of External Axes Controller for 4.5kW Motors with External Axes Controller

J type Bolt

150

50 50 150

220

50

50

500

Fig. 2.1.0.4

130 438

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)


2-3

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 transporting it 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 . Wear helmet, safety shoes and other protectives, and work in an appropriate working clothes. Wooden Protector

Fixing Rope

Forklift

Wire Rope

Fix wire ropes tight to eyebolts using shackles. Prepare shackles whose maximum load-carrying capacity is 0.4 t or more.

Fig. 2.2.0.1 2-4

Transport Method for Robot Controller with External Axes Controller


(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 while transporting, 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 other precision 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 is approximately 145 kg . Wear helmet, safety shoes and other protectives, and work in an appropriate working clothes. Wooden Protector

Fixing Rope

Forklift

Wire Rope Prepare shackles that meet the following requirements. SC- 10 Model Withstand Load0.4 t JIS B2801 Wire Rope Withstand Loadmin. 270 kg min. 1.5m Length

Withstand Loadmin. 1400 kg min. 1.5 m Length Prepare shackles that meet the following requirements. SC- 14 Model Withstand Load1.2 t JIS B2801

Fix wire ropes tight to eyebolts using shackles.

For External Axes Controller

Fig. 2.2.0.2

For Large- capacity External Axes Controller

Transport Method for Robot Controller for 4.5kW Motors with External Axes Controller


2-5

2.2 2.3.1

Installation of Robot Controller with External Axes Controller Installation Dimensions of Robot Controller with External Axes Controller

4 16

0 0 3

6 6 4

438 518

View A

A

Fig. 2.3.1.1

Installation Dimensions of Robot Controller with External Axes Controller

720

500

4 16

438 518

View A

A

Fig. 2.3.1.2

2-6

Installation Dimensions of External Axes Controller for 4.5kW Motors


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 channel attached 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 fixed when installed so that it will not fall down from the elevated position or on the floor.

Robot Controller Support Channel Anchor Bolt Lock Nut (M12) (Clamping Torque : 42.2Nm) Spring Washer

Flat Washer Foundation

Fig. 2.3.2.1 Installation of Robot Controller with External Axes Controller


2-7

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 Controller as 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 Axes Controller. 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 kgfcm)). (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.

Robot Controller

Remove it. Remove it. Screw (M6)

Support Channel (Type : L4805B04)

Support Channel (Type : L4805B04)

Screw (M6)

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

2-8


Eyebolt (removed from the Robot Controller Fixing Plate (accessory of External Axes Controller) (Type : L4794B03B)

Screw 4 M616


Fixing Plate (accessory of External Axes Controller) (Type : L4794B03B)

Screw 4 M616 Toothed Lock Washer Put a toothed lock washer between the fixing plate and a screw so that the notched side of the washer may dig into the fixing plate. Robot Controller

Fig. 2.3.3.2 Installation of External Axes Controller to Robot Controller Fixing Plate (accesory of External Axes Controller) L4794B03B

Screw 4 M616


Fixing Plate (accesory of External Axes Controller) L4794B03B

Screw 4 M616 Toothed Lock Washer Put a toothed lock washer between the fixing plate and a screw so that the notched side of the washer may dig into the fixing plate.

External Axes Controller for 4.5kW Motors

Fig. 2.3.3.3

Installation of External Axes Controller for 4.5kW motors to External Axes Controller FOUNDATION WORK AND INSTALLATION

2-9

Right (inside)

Front

View "A" "A"

"A"

CN80A CN67A

CN81

CN39 CN40

External Axis Controller

CN14A CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A CN29A CN276

CN203

CN205

Grounding Stud

CN4

Robot Controller or External Axes Controller for 4.5kW Motors

Grounding Cable

FC3

PCB2 Main Board

"A"

Fig. 2.3.2.4 Connecting between Robot Controller and External Axes Controller for 4.5kW Motors with Grounding Cable

2-10


3 Connecting Robot Peripheral Jigs CONTENTS

3.1


3.2



3.3


3.4


3.5


Connecting External Axis/Axes Cable 1 & 2 ................................................................................. 3-18 3.5.1 3.5.2 3.5.3

Where to connect External Axis/Axes Cable 1 & 2 ................................................................ 3-18 Adding One External Axis ...................................................................................................... 3-23 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..................................................................................................... 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

3 CONNECTING ROBOT PERIPHERAL JIGS This chapter provides information on the connections of Jig Control cables, and on the settings of various switches 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. Touching live electrical parts will cause an electrical shock or a burn that may results in a loss of life.

WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Disconnect all power before installing or servicing. Multiple sources of voltage may exist inside this enclosure. NC8051

2. Install the External Axes Controller outside the working range of the robot. Approaching approaches the moving robot may lead to an accident that results in a loss of life.

WARNING Keep out of robot area when main power is on. Do not locate this device in robot work area. Read instruction manual. NC8050

CAUTION

Upon completion of the installation, make absolute offset adjustments until the robot peripheral jig agrees 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.

CONNECTING ROBOT PERIPHERAL JIG 3-1

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

Positioner head stock

1-axis side positioner

1-axis double support positioner

Type

Specification

RPH-200N

Maximum payload

200kg

RPH-500N

Maximum payload

500kg

RPH-1000N

Maximum payload 1000kg

RP1S-200N

Maximum payload

200kg

RP1S-500N

Maximum payload

500kg

RP1S-1000N


RP1D-200N

Maximum payload

200kg

RP1D-500N

Maximum payload

500kg

RP1D-1000N


RP2E-150N

Maximum payload

150kg

RP2E-300N

Maximum payload

300kg

RP2T-500N

Maximum payload

500kg

RP2T-1000N


RP1T-500N

Maximum payload

RP1T-1000N


RSB-1000N

Traverse stroke 1.0m

RSB-2000N


RSR-2900N


RSR-3900N


RSR-4900N


RSR-5900N


RSR-6900N


RSR-1900NP


RSR-2900NP


RSR-3900NP


RSR-4900NP


RSR-5900NP


2-axis double support positioner

2-axis tilt positioner 500kg

Turntable

Portable slider

Standard slider

Slider with a connecting wagon

3-2 CONNECTING ROBOT PERIPHERAL JIG

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. examples of the system configuration are presented in Table 3.2.1.1.

Some typical

Table 3.2.1.1 Examples of System Configuration Peripheral Jig No. of axes

Examples of Configuration Jig 1

2 axes

Jig 2

1-axis positioner

1-axis slider

2-axis positioner

1 axis

Type of External Axis (Axes) Cable Q'ty

External Axis Cable for 1 axis

1 set

External Axes Cable for 2 axes

1 set

1-axis slider

1-axis positioner

External Axis Cable for 1 axis

2 set

1-axis slider

2-axis positioner

External Axis Cable for 1 axis External Axes Cable for 2 axes

1 set

3 axes 4 axes

2-axis positioner

2-axis positioner

External Axes Cable for 2 axes

2 set

each


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 Table 3.2.2.1. To connect a peripheral jig, a set of 2 external axes cables - one motor cable (External Axes Cable 1) and one encoder cable (External Axes Cable 2) - is required. Table 3.2.2.1 External Axes Cables for Peripheral Jigs Component

Type

L5372

L5373

L5374

L5375

L5376

L5377

L5378

Cable length

Item

Part No.

External Axis Cable 1

L5372B00

1


L5372C00

1


L5373B00

1


L5373C00

1


L5374B00

1


5374C00

1


L5375B00

1


L5375C00

1

External Axes Cable 1

L5376B00

1


L5376C00

1


L5377B00

1


L5377C00

1


L5378B00

1


L5378C00

1


L5379B00

1


L5379C00

1


L5919B00

1


L5372C00

1


L5920B00

1


L5373C00

1


L5921B00

1


L5374C00

1


L5922B00

1


L5375C00

1

L5379

L5919

L5920

L5921

L5922

Remarks

Q'ty 3m

5m For 1-axis peripheral jig 10m

15m

3m

5m For 2-axis peripheral jig 10m

15m


3m

5m

10m

15m

For 1-axis peripheral jig (for 4.5 kW motor)

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 Axes Controller. 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 Ref. No.

Name

No.

Name

Jumper pin On

Off

Default

JP201

CN271 overrun

Open

Short-circuit

Short-circuited

JP202

CN272 overrun

Open

Short-circuit

Short-circuited

JP203

CN273 overrun

Open

Short-circuit

Short-circuited

JP204

CN274 overrun

Open

Short-circuit

Short-circuited

JP205

CN275 overrun

Open

Short-circuit

Short-circuited

External Axes

JP206

CN276 overrun

Open

Short-circuit

Short-circuited

board

JP207

CN39 overrun

Open

Short-circuit

Short-circuited

JP211

CN7A shock sensor

Open

Short-circuit

Short-circuited

JP212

CN39 shock sensor

Open

Short-circuit

Short-circuited

PCB103

JP221

PCB102

Servo I/F board

1-2: short-circuited

JP222

Never change


JP223

these settings.


JP1

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 shock sensors 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 the corresponding overrun limit switches or shock sensors.


CN67A CN80A CN81

TP13A TP14A TP15A JP221

TP12A

JP222

CN81 F7

CR3D

CR3E

CR3F

F6

TP3A

CN39

3 CN40

LED 100A

3

1 1 JP221

CN41A

CN149

JP222

JP223 F5 JP211

JP212 JP207 TP4A

CR1A LED 105A

CR4A LED 107A

CN29A

1 0 2 P J 2 0 2 P J 3 0 2 P J 4 0 2 P J 5 0 2 P J 6 0 2 P J

1 7 2 N C 2 7 2 N C 3 7 2 N C 4 7 2 N C 5 7 2 N C 6 7 2 N C

CN41A

3

1 JP223

CN7A

CN1A

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

Fig 3.3.0.1 Jumper Pin Settings that Require Special Attention


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 Axes Controller to the External Axes Controller for 4.5kW motors, it is necessary to connect Servo I/F board to 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 the Robot 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 as shown 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 and system parameters after installing the main board with the Servo I/F board into the Robot Controller or the External Axes Controller for 4.5kW motors.

ScrewsM36

Front

Front

P Ma CB2 in Bo ard


CN80A CN67A

CN81

CN39 CN40

CN14A CN149 SW301


CN271 CN272 CN273 CN274 CN275

CN1A CN201 CN302

CN301

CN276

CN29A

CN7A

CN203

CN80A

PCB102 Servo I/F Board

CN205

CN67A

CN81

CN39 CN40

CN14A CN149 SW301

CN271 CN272 CN273 CN274 CN275

ScrewsM36

CN1A CN201 CN302

CN301

CN7A CN29A

CN203

CN276

CN205

CN50

Inslating Support


CN151

CN50

JP1 FC10

CN50

CN302

PCB102 Servo I/F Board CN1 CN7 IC138

CN151

CN250

FC10

TB1

CN18

CN302 CN251


CN111

FC27

JP1

Robot Controller

FC10

PCB3 Mother Board

CN50

CN19

CN67

CN80

CN73

FC24 FC23

CN40

CN41

CN150

CN1 CN7 IC138

CN16

FC10

CN30 CN38

CN37

CN44

PCB3 Mother Board

CN111

TB1

FC27 CN80A CN18

CN67A

CN81 CN19

CN67 CN39 CN40

CN40

CN41 CN16

CN30 CN38

CN44

CN37

CN150

CN14A CN149

CN80

CN73

FC24 FC23

CN271 CN272 CN273 CN274 CN275

CN1A

CN7A CN29A

CN276

Fig. 3.4.1.1 Fixing Method of Servo I/F Board CONNECTING ROBOT PERIPHERAL JIG 3-7

3.4.2 Connecting External Axes Controller to Robot Controller (1) Connecting signal cables Robot Controller


Connector CN40

PCB3

Mother board

Connector CN40

PCB103 External Axes board

Connector CN80

PCB3

Mother board

Connector CN81


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 the External 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 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 CN80 and CN81 of the cable attached to the External Axes Controller with connector CN81 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 external axes respectively.


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


Connector CN81A

External Axes Controller for 4.5kW motors

Connector CN81

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


Connector CN40


< When using L5003 for External Axes Controller for 4.5kW motors> Connector CN40

PCB3

Mother Board

(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 CN39 of the cable attached to the cable L8203C00 with connector 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 connecting External 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 with connector CN302 of the Servo I/F Board and connector CN301 of the Control module in the External Axes Board respectively.


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). Front PCB103 External Axes Board PCB152 Control Module

CN81

CN40


Cable Assembly

SW301

L4805U00 CN201 CN302

CN301

Cable Assembly

CN203

L4805T00 CN205

Cable Assembly

L4805N00

PCB2 Main board

CN151

Robot Controller

CN50 CN250 JP1 CN302 CN251


PCB3 Mother board

TB1

CN80 CN40

Fig. 3.4.2.1 Connecting External Axes Controller to Robot Controller 3-10 CONNECTING ROBOT PERIPHERAL JIG

Front

PCB103 External Axes Board PCB152 Control Module

CN80A CN67A

CN81

CN39 CN40

Cable Assy.

L4805V00 Cable Assy.

CN41A


CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN1A CN201 CN301

CN302

CN7A CN29A

CN203

CN276

L8203C00 CN205

Cable Assy.

L4805N00

CN81A

PCB2 Main Board

CN151


CN50

JP1 FC10

CN302

PCB102 Servo I/F Board IC138

CN1 CN7

FC10

PCB3 Mother Board

CN111

TB1

FC27 CN18 CN19

CN67

CN80

CN73

FC24 FC23

CN40

CN41

CN150

CN30

CN16 CN44

CN38

CN37

CN80A CN67A

CN81

CN39 CN40 CN149 CN271 CN272 CN273 CN274 CN275

CN1A

Auxiliary Transformer T1 CN7A

CN29A

Fig. 3.4.2.2

CN276



Front

PCB103 External Axes Board PCB152 Control Module

CN80A CN67A

CN81

CN39 CN40

Cable Assy.

L4805V00 Cable Assy.

CN41A


CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN1A CN201 CN301

CN302

CN7A CN29A

CN203

CN276

L8203C00 CN205

Cable Assy.

L4805N00

CN81A

PCB2 Main Board

CN151

Robot Controller for 4.5kW Motors

CN50

JP1 FC10

CN302

PCB102 Servo I/F Board IC138

CN1 CN7

FC10

PCB3 Mother Board

CN111

TB1

FC27 CN18 CN19

CN67

CN80

CN73

FC24 FC23

CN40

CN41 CN16

CN150

CN30

CN44

CN38

CN37

Auxiliary Transformer T1

Fig. 3.4.2.3

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


(2) Connecting a power cable

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

External Axes Controller 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. its connection.

CAUTION

See section (c) for

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 Robot Controller from the left in order.


Right Side (inside)

Front "A"

View "A"-- "A" PCB103 External Axes Board


CN80A


CN67A

CN81

CN39 CN40

CN41A CN149 SW301

CN271

CN302

CN301

CN29A

CN203

CN276

CN205

B

Power Cable

3 CN306

3

CN106

CN201 CN1A CN7A

Primary- side Power Cable

1

PCB12

POWER RELAY

1

PS1,PS2 CN104

1

EX.POWER RELAY

3 CN110

CN101A Connected to the upper- side of this connector.

CN272 CN273 CN274 CN275

4

CN108 1

TRANSFORMER

4

A3

1

1 CN107

B3

CN105

SERVO POWER

1

1 A1

CN115

1

CN114

2

1

CN113

Grounding Stud [M4] PE

PILOT LAMP 2

B1

B3

2

FAN

A3

CN101 3 AC200V IN

2

3 2 1 0

CN116

CN112

CN109

1

FAN

B I MD

TOUCH SENSOR

FAN

3 2 1 0

3

FAN

INPUT VOLTAGE CONNECT 1PIN 2PIN AC200V 1PIN 4PIN AC220V 1PIN 3PIN AC230V

PCB101

3 2 1 0

Power Unit

View B

1

2

3

NFB1 PCB2


No Fuse Breaker

Main Board 4 CN151

5

6

CN50 CN250 JP1

FC10

CN302 CN251

Robot Controller or External Axes Controller for 4.5kW Motors


"A"

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%))


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

NFB1

Terminal U, V, W The primary-side of Aux. Transformer TF10 (Step-down Transformer)

Connector CN101 PCB1 Power unit (Robot Controller)

Terminal R, S, T The secondary-side of Aux. Transformer TF10 (Step-down Transformer)

Connector CN101 PCB1 Power unit (Robot Controller)

Connector CN101A PCB101 Power unit (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 properly connected 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 the board through the bottom of the panel of the Robot Controller, and connect it to the right column, 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-down Transformer through the inlet on the base of the Robot Controller, and then fix the cable flange to the Robot Controller. After that, connect the terninals U, V, W, R, S and T of the cable 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 the left column of CN101, viewed from the back of the panel, of the power unit inside the Robot Controller.

(b)-6

Connect CN101A of the cable assembly (L4794F00) to the upper row of CN101A of the power unit in the External Axes Controller.

(b)-7

Put the side cover of the Robot Controller back in place.


Front

Right Side (inside) "A"

View "A" "A"

External Axes Controller CN80A

Connector CN101A Connected to the upper-side of this connector.

0 1 1 N 3 C

2SP,1SP

6 0 1 N 3 C Y A L E R R E W O P

2 1 B C P

401 NC

1

Y A L E R R E W O P X. E

CN39 CN40

CN41A CN149 SW301

CN271 CN272 CN273 CN274 CN275

6 0 3 N 3 C

1

CN67A

CN81

CN201 CN1A CN7A

CN29A

External Axes Board PCB103

CN302

CN301

CN203

CN276

1

3 B

5 0 1 N C

4 3 A

4 R E M R O F S N A R T

R E W O P O V R E S

3A

3B N I V 002C A 3 101 NC

1 B

1

N A F

CN205

Control Module PCB152

B

1

1 1 4 1 1 N C

2 N A F

T N N CN I I P I P E P N 2 4 3 N N ON N I I P I P C P 1 1 1 E G A T L V V V O 0 0 3 0 V 0 2 2 2 T 2 C C U C P A A A N I

1

1 3 1 1 N C

8 0 1 N C

RO S NES HC UO T

1 A

1 2 1 1 N C

9 0 1 N C

2 N A F

3 1

5 1 1 N C 2 N A F

7 0 1 N C

611 NC

TP 2 OM L A PI L

PCB101 Power Unit View B Primary-side Power Cable Robot Controller Grounding Stud [M4] PE Cable Assembly L4794F00

PCB2 Main Board

1

2

3

Inlet for Primaryside Power Cable

NFB1 No Fuse Breaker CN50 CN151

CN250

4

JP1

FC10

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

3 B

6

CN251

Servo I/F Board PCB102 Power Unit PCB1

3 A

NI V 0 0 2 1 C 0 A 1 N C 3

PCB3 Mother Board

5

CN302

Cable Assembly L4794D00 CN101

2 S P, 1 S P

4 0 1 N C

FAN 1 CN112 FAN 2

1 CN113

B1

PCB12

B3

FAN

CN105 2

1

A1

1

3 CN110

To the secondaryside of Aux. transformer TF10

Panel

A3

CN114 SERVO POWER

FAN 2

POWER RELAY

CN109

1

1

CN115 PILOT LAMP 2

1 1

R O 1 S N E S H C U O T

6 1 1 N C

3 CN106

4 TRANSFORMER

1 CN107

CN108

EX.POWER RELAY 4

1

3 CN306

INPUT VOLTAGE CONNECT 1PIN 2PIN AC200V 1PIN 4PIN AC220V 1PIN 3PIN AC230V

3

(from the back of panel)

U

Aux. Transformer TF10

W

V

Step-down Transformer L4794 R

S

T

Sh

"A"

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%))


Front "A" External Axes Controller CN80A

Connector CN101A Connected to the upper- side of this connector.

CN67A

CN81

CN39 CN40

CN41A CN149 SW301

3 CN306

3

4

B3

1 CN107 PILOT LAMP 2

B1

A1

1

1

1

CN115

CN114 FAN

2

CN113

2

CN116

3 AC200V IN

1

1

CN101

CN112


3

A3

1

TOUCH SENSOR

2

CN205

B

1

CN109

CN108

TRANSFORMER

4

A3

B3

CN105

FAN

CN203

CN276

1

CN106

FAN


CN302

CN301

CN7A CN29A

FAN

CN201 CN1A

INPUT VOLTAGE CONNECT 1PIN 2PIN AC200V AC220V 1PIN 4PIN AC230V 1PIN 3PIN

3 CN110 PCB12

CN104

1

1

POWER RELAY

EX.POWER RELAY

PS1,PS2

SERVO POWER

CN271 CN272 CN273 CN274 CN275

PCB101 Power Unit View B Primary- side Power Cable External Axes Controller for 4.5kW Motors Grounding Stud [M4] PE

PCB2 Main Board

1

2

3

NFB1 No Fuse Breaker CN50 CN151

FC10

5

4

JP1

6

CN302

Servo I/F Board PCB102 CN101

Power Unit PCB1

PCB3 Mother Board

Connector Connected to the CN101A right- side of this connector.


A3

3 AC200V IN

CN101

B3

NFB


CN80A

CN104

FAN

CN39 CN40

CN14A

PS1,PS2

CN67A

CN81

1

U

V

W

R

S

T

CN112

CN149

FAN 2

1 CN113

CN271 CN272 CN273 CN274 CN275

CN1A

PCB12

B3 CN105

2

1

A1

1

3 CN110

A3

CN114 SERVO POWER

FAN 2

1 1

3 CN106

4

1

PILOT LAMP 2

TRANSFORMER

1 TOUCH SENSOR

CN276

POWER RELAY

CN109

1 CN115

CN7A

CN107

CN108 1

EX.POWER RELAY 4

1

INPUT VOLTAGE CONNECT AC200V 1PIN 2PIN 1PIN 4PIN AC220V 1PIN 3PIN AC230V

3

CN116

CN29A

B1

FAN

3 CN306

PCB1 Power Unit View C

"A"

Fig. 3.4.2.6

Step- down Transformer 7kVAW- L00557 or 12kVAW- L00558

Connecting External Axes Controller to External Axes for 4.5kW Motor


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 1 - 6 of External Axes Motor are basically defined from 1 in order according to the Axis Nos. priority described in Fig. 3.5.1.1. The bigger the capacity of a motor is, the smaller the axis number of the motor is. Moreover, the axis number of a slider is smaller than positioners’ when the capacity of their motors are the same.

1500 W Motor

Small

Slider (800 W) Axis No.

Large

Tilt axis of 2-axis positioner (800 W) Table axis of 2-axis positioner (800 W) 1-axis positioner (800 W)

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 Controller for 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.”.

Front CN67A External Axes Controller

B1 B2 B3 B4 B5 B6

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

CN201 For Encoder Cable(s) of External Axis/Axes Cable 2

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

8

7

CN203 CN201

E7 CN203

10 9

712 Driver Nos.

CN205

CN7A

CN205

712 Driver Nos.

12 11

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

Fig. 3.5.1.2

Connectors for External Axis/Axes Cables


Front External Axes Controller for 4.5kW Motors CN1 CN7

FC10

IC138

PCB3 Mother Board

CN111

TB1

FC27 CN18 CN19

CN67

CN80

CN73

FC24 FC23

CN40

CN41

CN150

CN30

CN16 CN44

CN38

CN37

CN80A CN67A

CN81

CN39 CN40

Driver No. 7 CN149

CN271 CN272 CN273 CN274 CN275

Driver No. 9

CN1A

Driver No. 8

Driver No. 11 CN7A

CN29A

Driver No. 10

CN276

Driver No. 12

Encoder Cable for External Axes (External Axes 2)

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

Follow the driver No. in the table below when connecting brake cable. (Connector for the brake cable) E7

Inverter

CN7A 712 Driver Nos.

Fig. 3.5.1.3

Odd Axes Even Axes Odd Axes Even Axes Odd Axes Even Axes

Driver No.

Where to connect on CN67

Connectors for External Axes Controller for 4.5kW Motors


1 - 6 ) and “the combination See Table 3.5.1.1 for driver Nos. (7 – 12) that correspond to “axis Nos.” ( 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 The number of axes 1 axis 2 axes

3 axes

Driver Nos. that Correspond to “the Number of Axes” and “the Combination of Motors” External Axis/Axes Controller

The combination of motors (pieces) 1500 W 800 W or below

L4805 L5521 L4806

0 1 1 0 0 2 2 0 1 1 0 3 1 2 2 1 3 0 0 4 1 3 2 2 0 5 1 4 0 6 DR-3200/4200/600/503S DR-4200L/4300/4400

L5522 L4807 L5522 L5523 L5522

4 axes

L5523

5 axes

L5523

6 axes

L5523 L4808 L5524

Axis No. of External Axes Motor (External Axis 1-6 Motor) 1 2 3 4 5 6 8 8 8 8 8 8 8 8 8 7 8 8 7 8 7 12 12

10 10 10 10 9 10 10 8 9 10 8 9 8 10 10

12 10 12 12 9 10 11 9 10 9 8 8

10 12 12 10 11 10 11 11

12 12 11 9 9

12 7 7

Remarks

(Note 1)

Note 1) In these cases, connect encoder cables to CN7A. 1 - 6 are axis Nos. of motors. 3 implies External Axis 3. 2) Ex.) 3) 1500 W motors are connected to inverter modules that correspond to driver Nos. in shaded rectangles. 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. 1500 W motor RP2E-300N tilt axis RP2E-300N table axis

1

2

3

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. 1500 W motor RP2E-300N tilt axis RP2E-300N table axis

CAUTION

8

9

10

In case of connecting a peripheral jig, the axis No. of the motion axis of the unit is defined by the data 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 wrong directions or breakage of the unit itself, creating a very dagerous situation.


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 number of axes

Controller for 4.5kW, etc.

1 axis

L5930 L5930 L5931

2 axes 3 axes

4 axes

5 axes

6 axes

L5931 L5932 L5932 L5931 L5932 L5932

L5932 L5003

The combination of motors (pieces) 4.5kW 1.5kW or below 1 0 1 1 2 0 1 2 2 1 3 0 1 3 2 2 3 1 1 4 2 3 3 2 1 5 2 4 3 3 3 3

Axis No. of External Axes Motor (External Axis 1-6 Motor) 1 2 3 4 5 6 8 8 7 8 10 8 7 9 8 10 7 8 10 12 8 7 9 11 8 10 7 9 8 10 12 7 8 7 9 10 11 8 10 7 9 11 8 10 12 7 9 8 7 9 10 11 12 8 10 7 9 11 12 8 10 12 7 9 11 12 10 8 11 9 7

1 - 6 are axis Nos. of motors. 3 implies External Axis 3. Ex.) Note 1) 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 1 - 6 )as shown in Table 3.5.1.3. external axes and axis Nos. ( Table 3.5.1.3 The number of external axes

Where to Connect Brake Cables Which column(s) of CN67A to connect brake cable(s)

1

1

B1

2

1 2

B1, B3

3

1 2 3

B1, B3, B5

4

1 2 3 4

B1 – B4

5

1 2 3 4 5

B1 – B5

6

1 2 3 4 5 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 Reference page

Configuration The number of axes Jig 1

Jig 2

1-axis positioner

1-axis slider

2-axis positioner

pp. 3-27

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

pp. 3-64

1 axis

pp. 3-23

2 axes

1 axes (4.5kW motor) 4.5kW motor 2 axes (4.5kW motor) 4.5kW motor + 1.5kW motor


pp. 3-68

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. CN67A CN201 B1 B2 B3 B4 B5 B6 8

7

For Brake Cable of External Axis Cable 1 For Encoder Cable of External Axis Cable 2 CN271 7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

CN203 10 9

E7

Shaded rectanagles: indicate where to connect respective cables.

CN205 12 11

CN7A

External Axes Board For Motor Cable of External Axis Cable 1

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


(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 Controller through 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 the External Axis Cable 2.

(c)

Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to the right 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 of the External Axis Controller. (Be sure to fix the grounding cable to this stud.)


Right Side (inside)

Front

Connect here

View "A" "A"

CN67A "A" PCB103 External Axes Board

Connect here

CN80A CN67A

CN81

CN39 CN40

CN201


CN41A CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN7A


CN302

CN203

CN29A CN276

External Axis Cable 1 CN205

Clamp this grounding cable with that of External Axis Cable 2.

Robot Controller

PCB2 Main Board

"A"

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 the welding cable. 2. Arrange External Axis Cable 1 as far apart as possible from External Axis Cable 2 inside the External 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 for consultation.



CN2

Connector CN272


Grounding cable


(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 then fix 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 an overrun 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 of the 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.


Right Side (inside)

Front "A" PCB103 External Axes Board

View "A" "A"

CN80A CN67A

CN81

CN39 CN40


CN14A CN149

SW301


CN271 CN272 CN273

CN201 CN1A

CN274 CN275

CN301

CN7A


CN302

CN203

CN29A CN276

External Axis Cable 1 CN205

Clamp this grounding cable with that of External Axis Cable 1.

PCB2

Main Board

Robot Controller

"A"

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 the External 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.


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 Cable name


Where to connect External Axes Cables Where to connect Constituents Axis No. External Axes Cable External Axis 1 CN201-8 Motor cable External Axis 2 CN203-10

Brake cable External Axes Cable 2

Encoder cable

External Axis 1/2

CN67A-B1

External Axis 1

CN272

External Axis 2

CN274

CN67A CN201 B1 B2 B3 B4 B5 B6 8 For Brake Cables of External Axes Cable 1

For Encoder Cables of External Axes Cable 2

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

7

CN203 10 9

E7

Shaded rectangles: indicate where to connect respective wires.

CN205 12 11

CN7A

External Axes Board For Motor Cables of External Axes Cable 1

Fig 3.5.3.1

Where to connect External Axes Cables


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 of External 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 in Fig. 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.)


Front

Connect here

Right Side (inside) View "A" "A" "A"

CN67A

Connect here

PCB103 External Axes Board

CN80A CN67A

CN81

CN39 CN40



CN14A CN149

SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN7A CN29A CN276


CN302

CN203

External Axes Cable 1 CN205

Clamp this grounding cable with that of External Axes Cable 2.

PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.3.2

CAUTION

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

1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and the welding 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, please contact us for consultation.


(2) Connecting External Axes Cable 2 Jig 1 Cannon plug

CN2

Connector CN272

PCB103

External Axes board

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 the External Axes board, respectively. (d) If a peripheral jig such as a positioner or a slider connected to CN272 and CN274 is equipped with 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, is equipped 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 CN274 does(do) not operate. (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.) CAUTION

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


Right Side (inside)


CN80A CN67A

CN81

CN39 CN40


View "A" "A"


CN14A CN149

SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN7A CN29A CN276


CN302

CN203

External Axes Cable 1 CN205


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.3.3 Connecting External Axes Cable 2 when Adding One 2-Axis Jig

CAUTION

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


3 Connecting Robot Peripheral Jigs CONTENTS

3.1


3.2



3.3


3.4


3.5


Connecting External Axis/Axes Cable 1 & 2 ................................................................................. 3-18 3.5.1 3.5.2 3.5.3

Where to connect External Axis/Axes Cable 1 & 2 ................................................................ 3-18 Adding One External Axis ...................................................................................................... 3-23 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

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

Where to Connect Cables

Constituents


Motor cable

CN201-8

for External Axis 1

Brake cable

CN67A-B1

Encoder cable

CN272


Motor cable

CN203-10

for External Axis 2

Brake cable

CN67A-B3

Encoder cable

CN274

External Axis Cable 2 for External Axis 1

External Axis Cable 2 for External Axis 2 CN67A

CN201 B1 B2 B3 B4 B5 B6 8

7

For Brake Cables of External Axis Cable 1 For Encoder Cables of External Axis Cable 2 CN271 7

CN272

CN203 10 9

8

CN273

9

CN274

10

CN275

11

CN276

12

E7

Shaded rectanagles: indicate where to connect respective cables.

CN205 12 11

CN7A

External Axes Board For Motor Cables of External Axis Cable 1

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 (External Axis 1)

CN1

Connector CN201-8


Connector CN67A-B1


Grounding cable


(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 right side of the External Axes Controller. (d) Connect CN67A to the corresponding connector CN67A-B1 on the External Axes board. (e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of CONNECTING ROBOT PERIPHERAL JIG 3-31

the External Axes Controller.

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


Right Side (inside)

Front

Connect here

View "A" "A" "A"

CN67A

Connect here


CN67A

CN39 CN40


CN201

CN80A CN81


CN14A

External Axis Cable 2 for External Axis 2 External Axis Cable 1 for External Axis 2

CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A CN29A CN276

CN203

CN205

External Axis Cable 1 for External Axis 1 Clamp this grounding cable with that of External Axis Cable 2.


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.3.5 Connecting External Axis Cable 1 for External Axis 1 when Connecting Two 1-Axis Jigs CAUTION

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


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

CN2

Connector CN272


Grounding cable


(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 the shaded 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. (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 an overrun limit switch, open the corresponding jumper pin JP202 by reinserting only one side of the pin.

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN272, is equipped with an overrun 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 CN272 does not operate.

(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.)

CAUTION

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


Right Side (inside)

Front

View "A" "A" "A" PCB103 External Axes Board

CN80A CN67A

CN81

CN39 CN40



CN14A


CN149 SW301

CN271 CN272 CN273

CN201 CN1A

CN274 CN275

CN301

CN302

CN7A CN29A CN276

CN203

CN205

External Axis Cable 1 for External Axis 1 Clamp this grounding cable with that of External Axis Cable 1.


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.3.6 Connecting External Axis Cable 2 for External Axis 1 When Adding Two 1-axis Jigs 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 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. If it is to be used in such moving sections, please contact us for consultation.


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

CN1

Connector CN203-10


Connector CN67A-B3


Grounding cable


(a) Connect CN1 of the External Axis Cable 1 for External Axis 2 to the corresponding connector CN1 of jig 2. (b) Lead connectors CN203, 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. 3.5.3.7, and then fix the cable flange in place without leaving any clearance with the cable flange 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 the right side of the External Axes Controller. (d) Connect CN67 to CN67A-B3 on the External Axes board. (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.)


Right Side (inside)

Front

Connect here

View "A" "A" "A"

CN67A

Connect here


CN67A

CN39 CN40


CN203

CN80A CN81


CN14A


CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A CN29A CN276

CN203

CN205

External Axis Cable 1 for External Axis 1 Clamp this groundning cable with that of External Axis Cable 2.


PCB2 Main Board

Robot Controller "A"

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

1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and the welding cable. 2. Arrange External Axis Cable 1 as far apart as possible from the 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. If it is to be used in such moving sections, please contact us for consultation.


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

CN2

Connector CN274

PCB103

External Axes board

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 the shaded area on the right side of the External Axes Controller as shown in Fig. 3.5.3.8, and then fix the cable flange in place without leaving any clearance with that of the External Axis Cable 1. (c) Connect CN274 to the corresponding connector CN274 of the External Axes board. (d) If a peripheral jig such as a positioner or a slider connected to CN274 is equipped with an overrun 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 an overrun limit switch, be sure to open the corresponding jumper pin JP204 by reinserting only one side 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 the External 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 the corresponding overrun limit switch.


Right side (inside)

Front


Grounding Stud CN80A CN67A

CN81

CN39 CN40



CN14A


CN149 SW301

CN271 CN272 CN273

CN201 CN1A

CN274 CN275

CN301

CN7A CN29A CN276

CN302

CN203

CN205



PCB2 Main Board

Robot Controller

"A"

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 the welding cable. 2 Arrange External Axis Cable 2 as far apart as possible from the External Axis 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. If it is to be used in such moving sections, please contact us for consultation.


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.

Slider

1

Tilt axis of 2-axis positioner

2

Table axis of 2-axis positioner

3

Rated value of motor 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

External Axis Cable 1 for Slider

Motor Cable


External Axes Cable 1 for Positioner

Brake Cable

Motor Cable

Encoder Cable


Where to Connect External Axis/Axes Cable CN201-8

Slider axis

Encoder Cable

Brake Cable External Axes Cable 2 for Positioner

Cable name

CN67A-B1 CN272

Tilt axis for 2-axis positioner Table axis for 2-axis positioner 2-axis positioner

CN203-10 CN205-12 CN67A-B3

Tilt axis for 2-axis positioner

CN274

Table axis for 2-axis positioner

CN276

CN67A CN201 B1 B2 B3 B4 B5 B6 8

7

For Brake Cables of External Axis/Axes Cable 1 For Encoder Cables of External Axis/Axes Cable 2

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

CN203 10 9

E7

Shaded rectangles: indicate where to connect respective cables.

CN205 12 11

CN7A

External Axes Board For Motor Cables of External Axis/Axes Cable 1

Fig. 3.5.4.1

Where to connect External Axis/Axes Cables

(1) Connecting External Axis Cable 1 for a slider Slider Cannon plug (External Axis 1)

CN1

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 a slider. (b) Lead connectors CN201, 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 shown in Fig. 3.5.4.2, and then fix the cable flange in place without leaving any clearance with the cable flange 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 side of the External Axes Controller. (d) Connect CN67 to the corresponding connector CN67A-B1 on the External Axes board. (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.)


Right Side (inside)

Front

Connect here

View "A" "A" "A"

CN67A

Connect here


CN67A

CN39 CN40


CN201

CN80A CN81


CN14A

External Axes Cable 2 for 2-axis Positioner External Axes Cable 1 for 2-axis Positioner

CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A CN29A CN276

CN203

CN205

External Axis Cable 1 for Slider Clamp this gounding cable with that of External Axis Cable 2.


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.4.2

CAUTION

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

1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and the welding cable. 2. Arrange External Axis Cable 1 as far apart as possible from the External Axis Cable 2 inside the External 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 in the moving / bending sections of a slider, etc. If it is to be used in such moving sections, please contact us for consultation.


(2) Connecting External Axis Cable 2 for a slider Slider Cannon plug (External Axis 1)

CN2

Connector CN272


Grounding cable


(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 the shaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.4.3, and then fix the cable flange in place without leaving any clearance with the cable flange of the External Axis Cable 1 for a slider. (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 an overrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only one side of the pin.

CAUTION

If a peripheral jig such as a positioner or a slider, which is connected to CN272, is equipped with an overrun 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 CN272 does not operate.

(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.) 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 Teach mode.


Right Side (inside)

Front


CN80A CN67A

CN81

CN39 CN40



CN41A

External Axes Cable 2 for 2-axis Positioner External Axes Cable 1 for 2-axis Positioner

CN149 SW301

CN271 CN272 CN273

CN201 CN1A

CN274 CN275

CN301

CN302

CN7A CN29A CN276

CN203

CN205

External Axis Cable 1 for Slider Clamp this grounding cable with that of External Axis Cable 1.


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.4.3

CAUTION

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

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


(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 connector CN1 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 as shown in Fig. 3.5.4.4, and then fix the cable flange in place without leaving any clearance with the 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. (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.)


Right Side (inside)

Front

View "A" "A" Connect here


CN80A CN67A

CN81

CN39 CN40


Connect here

"A"

CN67A


CN41A

External Axes Cable 2 for Positioner External Axes Cable 1 for Positioner

CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A CN29A CN276

CN203

CN205

External Axis Cable 1 for Slider Clamp this grounding cable with that of External Axis Cable 2.


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.4.4

CAUTION

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

1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and the welding cable. 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, please contact us for consultation.


(4) Connecting External Axes Cable 2 for 2-axis Positioner 2-axis Positioner Cannon plug CN2 (External Axis 2 & 3)

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, and then fix the cable flange in place without leaving any clearance with the cable flange of the External 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 JP204 and/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, is equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP204 and/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 CN276 does(do) not operate.


CAUTION

After changing the setting of jumper pin JP204 and/or JP206, be sure to check the operation of the corresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN274 and CN276, in Teach mode.


Right Side (inside)

Front


CN80A CN67A

CN81

CN39 CN40


Grounding stud


CN41A


CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN7A CN29A CN276

CN302

CN203

CN205

External Axis Cable 1 for Slider External Axis Cable 2 for Slider

PCB2 Main Board


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

CAUTION



3 Connecting Robot Peripheral Jigs CONTENTS 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 two standard 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 listed in 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.

Tilt axis of Positioner 1

1

Table axis of Positioner 1

2


3


4

Rated value of motor

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 Axis Name

Driver Nos. of Motors Drver No.


7


8


9


10


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

Where to connect External Axes Cables

Constituents

External Axes Cable 1 for Positioner 1

Motor cable

Tilt axis for Positioner 1

CN201-7

Table axis for Positioner 1

CN201-8

Positioner 1

Brake cable External Axes Cable 2 for Positioner 1 External Axes Cable 1 for Positioner 2

Encoder cable Motor cable

Encoder cable

CN67A-B1


CN271


CN272


CN203-9


CN203-10

Positioner 2

CN67A-B3

Brake cable External Axes Cable 2 for Positioner 2

Where to Connect Cables

Axis Name


CN273


CN274

CN67A CN201 B1 B2 B3 B4 B5 B6 8

For Encoder Cables of External Axes Cable 2

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

7

For Brake Cables of External Axes Cable 1

CN203 10 9

E7

Shaded rectangles: indicate where to connect respective cables.

CN205 12 11

CN7A

External Axes Board For Motor Cables of External Axes Cable 1

Fig. 3.5.5.1

Where to Connect External Axes Cables


(1) Connecting External Axes Cable 1 for Positioner 1 (External Axis 1 & 2) Positioner 1 Cannon plug CN1 (External Axis 1 & 2)

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 CN1 of 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 as shown in Fig. 3.5.5.2, and then fix the cable flange in place without leaving any clearance with the 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. (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.)


Right Side (inside)

Front

Connect here

View "A" "A" "A"

CN67A PCB103 External Axes Board

CN80A CN67A

CN81

CN39 CN40


CN41A

External Axes Cable 2 for Positioner 2 External Axes Cable 1 for Positioner 2

CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A

CN203

CN29A CN276

CN205

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


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.5.2

CAUTION

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




Connector CN271


Connector CN272


Grounding cable


(a) Connect CN2 of the External Axes Cable 2 for Positioner 2 to the corresponding connector CN2 of Positioner 1. (b) Lead CN271, CN272 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. 3.5.5.3, and then fix the cable flange in place without leaving any clearance with the cable flange of the External Axes Cable 1 for Positioner 1. (c) Connect CN271 and CN272 to the corresponding connectors CN271 and CN272 on the External Axes board. (d) If a peripheral jig such as a positioner or a slider, which is connected to CN271 and CN272, is equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP201 and/or JP202 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 CN271 and CN272, is equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP201 and/or JP202 by reinserting only one side of the pin(s). If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN271 and CN272 does(do) not operate.


CAUTION

After changing the setting of jumper pin JP201 and/or JP202, be sure to check the operation of the corresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN271 and CN272, in Teach mode.


Right Side (inside)


CN80A CN67A

CN81

CN39 CN40


CN41A CN149


View "A" "A"


SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A

CN203

CN29A CN276

CN205



PCB2 Main Board


Fig. 3.5.5.3

CAUTION





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 CN1 of 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 as shown in Fig. 3.5.5.4, and then fix the cable flange in place without leaving any clearance with the 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 of the junction cable fixed to the right side of the External Axes Controller. (d) As well, connect CN67 to the corresponding connector CN67A-B3 on the External Axes Board. (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.)


Front

Connect here

"A" "A" "A"


CN67A CN80A CN81

CN39 CN40


CN41A


CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN302

CN7A

CN203

CN29A CN276

CN205

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


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.5.4

CAUTION





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 the External Axes Cable 1 for Positioner 2. (c) Connect CN273 and CN274 to the corresponding connectors CN273 and CN274 of the External 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 JP203 and/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, is equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP203 and/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 CN273 does(do) not operate.


CAUTION

After changing the setting of jumper pin JP203 and/or JP204, be sure to check the operation of the corresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN273 and/or CN274, in Teach mode.


Right Side (inside)

Front

View "A" "A"

"A" PCB103 External Axes Board

Grounding Stud

CN80A CN67A

CN81

CN39 CN40


CN41A


CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN1A CN301

CN7A CN29A CN276

CN302

CN203

CN205


PCB2 Main Board


Fig. 3.5.5.5

CAUTION




3.5.6

Adding One Manipulator

This section describes the method of connecting External Axes Cables when a manipulator is used as an 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 the manipulator. (b) Lead connectors CN250, CN251, 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 shown in Fig. 3.5.6.1, and then fix the cable flange in place without leaving any clearance with the cable flange of the External Axes Cable 2. (c) Connect CN250 and CN251 to the corresponding connectors CN250 and CN251 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. (e) Fix the grounding cables (x 2) 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.)


Front

Connect here

Right Side (inside) View "A" "A" "A"


CN80A CN67A

CN81

CN39 CN40


CN41A CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN250 CN1A CN301

CN302

CN7A CN29A CN276 CN251

External Axes Cable 2 for Manipulator External Axes Cable 1 for Manipulator


PCB2 Main Board

Robot Controller

"A"

Fig. 3.5.6.1

CAUTION

Connecting External Axes Cable 1 when Adding One Manipulator



(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 the cable flange in place without leaving any clearance with the cable flange of the External Axes Cable 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 of the 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 the manipulator may be damaged.

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. (f)

When using a torch with a shock sensor, open JP211 by reinserting only one side of the pin in order 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 be damaged.


Right Side (Inside)


View "A"--"A"

CN80A CN67A

CN81

CN39 CN40


CN41A CN149


SW301

CN271 CN272 CN273 CN274 CN275

CN250

CN1A CN301

External Axes Cable 2 for Manipulator

CN302

External Axes Cable 1 for Manipulator

CN7A CN29A CN276 CN251


PCB2 Main Board


Fig. 3.5.6.2

Connecting External Axes Cable 2 when Adding One Manipulator

CAUTION

1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and the welding cable. 2. Arrange External Axes Cable 2 as far apart as possible from the External Axes Cable 1 inside the External 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 the moving / bending sections of a slider, etc. If it is to be used in such moving sections, please contact us for consultation.


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.

External Axes Board

Encoder Cable for External Axes External Axes Cable 2

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

E7

CN7A

Fig. 3.5.7.1

Where to Connect External Axes Cables

(1) Connecting External Axes Cable 1 4.5kW Motor Cannon plug CN1 (for motor)

Connector CN257 Connector CN67-B2 Grounding cable

External Axes Controller for 4.5kW Motor External Axes Controller for 4.5kW Motor External Axes Controller for 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 shown in Fig. 3.5.7.2, and then fix the cable flange in place without leaving any clearance with the cable flange of the External Axes Cable 2. (c) Connect CN201 to the corresponding connector CN257 of the junction cable fixed to the right side of the External Axes Controller. (d) As well, connect CN67 to the corresponding connector CN67A-B2 on the External Axes Board. (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.)


3.5.7.2

CAUTION

Connecting External Axes Cable 1 when adding 4.5kW Motor

1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and the welding cable. 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 contact us for consultation.


(2) Connecting External Axes Cable 2 4.5kW Motor

Cannon plug CN2 (for Encoder)

Connector CN272


Grounding cable

External Axes Controller for 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 the shaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.7.3, and then 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 an overrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only one 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 an overrun 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 not operate.

(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.) CAUTION

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


Right Sideinside


View "A" "A"

CN80A CN67A

CN81

CN39 CN40

CN14A CN149


CN271 CN272 CN273


CN274 CN275 CN7A CN29A CN276

"A"

Fig. 3.5.7.3

CAUTION




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 Where to Cable name Constituents Connect Cables External Axes Cable 1 Motor cable CN257 for External Axis 1 Brake cable CN67-B2 External Axes Cable 1 Encoder cable CN272 for External Axis 2 External Axes Cable 2 Motor cable CN256 for External Axis 1 Brake cable CN67-B1 External Axes Cable 2 Encoder cable CN271 for External Axis 2

External Axes Board

Encoder Cable for External Axes (External Axes Cable 2)

CN271

7

CN272

8

CN273

9

CN274

10

CN275

11

CN276

12

E7

CN7A

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) External Axis 1 Cannon plug CN1 (4.5kW Motor) (for motor)

Connector CN257 Connector CN67-B2 Grounding cable

External Axes Controller for 4.5kW Motor External Axes Controller for 4.5kW Motor 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 Axes Controller through the shaded area (inlet) on the right side of the External Axes Controller as shown in 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. (c) Connect CN257 to the corresponding connector CN257 of the junction cable fixed to the right side of the External Axes Controller. (d) As well, connect CN67 to the corresponding connector CN67A-B2 on the External Axes Board. (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.) 3-66 CONNECTING ROBOT PERIPHERAL JIG

3.5.8.2


CAUTION



(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. (b) Lead the rest of CN272 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. 3.5.8.3, and then 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 an overrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only one side of the pin. (See Table 3.3.0.1).

CAUTION



CAUTION

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


Right Sideinside


View "A" "A"

CN80A CN67A

CN81

CN39 CN40

CN14A CN149


CN271 CN272 CN273



"A"

Fig. 3.5.8.3

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

CAUTION



(3) Connecting External Axes Cable 1 for External Axes 2 (1.5kW motor) External Axis 2 Cannon plug CN1 (for 1.5kW Motor) (for motor)

Connector CN256


Connector CN67-B1

PCB 003 External Axes Board

Grounding cable


(a) Connect Connector of the External Axes Cable 2 to the corresponding connector of a peripheral jig of External Axes 2. (b) Lead the rest of connectors CN256, 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 shown in Fig. 3.5.8.4, and then fix the cable flange in place. (c) Connect CN256 to the corresponding connector CN256 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. (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.)


3.5.8.4

CAUTION




(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. (b) Lead the rest of CN271 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. 3.5.8.5, and then fix the cable flange in place without leaving any clearance with the cable flange. (c) Connect CN271 to the corresponding connector CN271 on the External Axes board.

CAUTION


(d) 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.)

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.


Right Side (inside)


View "A" "A"

CN80A CN67A

CN81

CN39 CN40

CN14A CN149


CN271 CN272 CN273



"A"

3.5.8.5


CAUTION



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 respective instruction manuals. A robot system based on special specifications may have different parts numbers from those 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 the manipulator 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 sales representatives in your country.

PARTS LIST

4-1

4 Parts List CONTENTS

4.1

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

4.2


4.3


4.4


4.5

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

4.6


4.7


4.8


4.9

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

4-20

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

(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

1

Note 1. Increasing the number of protective axes by one requires an increase of both an inverter module and software, both optional, by one. 2.

4-2

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

PARTS LIST

2

2

6

1 1

13

5

1

4

9

0 1

2

7

8 43 23

53 63

Fig. 4.1.0.1

33

External Axes Controller (L5380)

PARTS LIST

4-3

4.2


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

(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

(2)

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)


L4805C00

1

L4805C00

(7)


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

1. Increasing the number of protective axes by one requires an increase of both an inverter module and software, both optional, by one. 2. Servo I/F board (Ref. No. (6)) is not installed on the External Axes Controller but is installed on the main board in the Robot Controller.

4-4

PARTS LIST

2

2

6

1 1

13

5

1

9

4

0 1

2

7

8 43

23

53

33

63

Fig. 4.2.0.1


PARTS LIST

4-5

4.3

External Axes Controller (L5382) Item

Ref. No.

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

(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

(3)

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)


L4805C00

1

L4805C00

(7)


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:

4-6

1


PARTS LIST

2

2

6

1 1

13

5 4

1

9

0 1

2

7

8 43 53

23

63

33

Fig. 4.3.0.1


PARTS LIST

4-7

4.4


Ref. No.

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

(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

(3)

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)


L4805C00

1

L4805C00

(7)


L4805D00

1

L4805D00

(7)-1

Glass Tube Fuse

2A, AC250V

(3)

4610-009

(8)

Protective Cover

L4805F01

1

L4805F01

(9)

Door Key Handle

A-120-1

2

4739-273

Note:

4-8

1


PARTS LIST

2

2

6

13

5

9

1

4

8

2

7

43 53

23

63

33

Fig. 4.4.0.1


PARTS LIST

4-9

4.5

External Axes (Axis) Controller (L5561) Item

Ref. No.

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

(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-L00960

(1)

5096-305

(3)-4

SWR Module

W-L01170

(1)

5096-338

(3)-5

Capacitor Module

W-L00954

(1)

5096-208

(3)-6

Power Supply Module

W-L01146

(1)

5096-321

(4)

Resistor Assy.

L5002U00

1

L5002U00

(5)

P.C.B. (Power Unit)

L4800P00

1

L4800P00

(6)


L4805C00

1

L4805C00

(7)


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

1

Note 1. Increasing the number of protective axes by one requires an increase of both an inverter module 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 on the main board in the Robot Controller.

4-10

PARTS LIST

2

2

6

1 1

13

5

1

4

9

0 1

2

7

8 43 23

53 63

Fig. 4.5.0.1

33


PARTS LIST

4-11

4.6


Ref. No.

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

(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-L00960

(2)

5096-305

(3)-4

SWR Module

W-L01170

(1)

5096-338

(3)-5

Capacitor Module

W-L00954

(1)

5096-208

(3)-6

Power Supply Module

W-L01146

(1)

5096-321

(4)

Resistor Assy.

L5002U00

1

L5002U00

(5)

P.C.B. (Power Unit)

L4800P00

1

L4800P00

(6)


L4805C00

1

L4805C00

(7)


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

1

Note 1. Increasing the number of protective axes by one requires an increase of both an inverter module 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 on the main board in the Robot Controller.

4-12

PARTS LIST

2

2

6

1 1

13

5

1

9

4

0 1

2

7

8 43

23

53

33

63

Fig. 4.6.0.1

External Axes Controller (L5562) PARTS LIST

4-13

4.7


Ref. No.

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

(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-L00960

(3)

5096-305

(3)-4

SWR Module

W-L01170

(1)

5096-338

(3)-5

Capacitor Module

W-L00954

(1)

5096-208

(3)-6

Power Supply Module

W-L01146

(1)

5096-321

(4)

Resistor Assy.

L5002U00

1

L5002U00

(5)

P.C.B. (Power Unit)

L4800P00

1

L4800P00

(6)


L4805C00

1

L4805C00

(7)


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:

4-14

1


PARTS LIST

2

2

6

1 1

13

5 4

1

9

0 1

2

7

8 43 53

23

63

33

Fig. 4.7.0.1


PARTS LIST

4-15

4.8


Ref. No.

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

(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-L00960

(3)

5096-305

(3)-4

SWR Module

W-L01170

(1)

5096-338

(3)-5

Capacitor Module

W-L00954

(1)

5096-208

(3)-6

Power Supply Module

W-L01146

(1)

5096-321

(4)

Resistor Assy.

L5002U00

1

L5002U00

(5)

P.C.B. (Power Unit)

L4800P00

1

L4800P00

(6)


L4805C00

1

L4805C00

(7)


L4805D00

1

L4805D00

(7)-1

Glass Tube Fuse

2A, AC250V

(3)

4610-009

(8)

Protective Cover

L4805F01

1

L4805F01

(9)

Door Key Handle

A-120-1

2

4739-273

Note:

4-16

1


PARTS LIST

2

2

6

13

5

9

1

4

8

2

7

43 53

23

63

33

Fig. 4.8.0.1


PARTS LIST

4-17

4.9

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

Ref. No.

DWG. No. & Model

Q'ty

Parts No.

(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

(8)

Cooling Fan

4715PS-22T-B30-B18

11

4805-033

(9)

Pilot Lamp

NPA10-2H-WS

1

4600-341

(10)

AC Outlet Assy.

L4798R00

1

L4798R00

(11)

Servo Unit

L5003J

1

L5003J00

(11)-1

Control Module

W-L00957

(1)

5096-245

(11)-2

Small Signal Backplane Board

W-L01179

(1)

5096-352

(11)-3

Inverter Module

W-L01177

see below

5096-353

Large-capacity External Axes Controller (L5930)

(1)


(2)


(3)

(11)-4

SW Regulator Module

W-L01237 (or W-L01170)

(1)

5096-354

(11)-5

Power Supply Module

W-L01178

(1)

5096-355

(11)-6

Large Current Backplane Board

W-L01180

(1)

5096-356

(12)

Resistor Assy.

L5573U00

1

L5573U00

(13)

P.C.B (Main Board)

L5000C00

1

L5000C00

CPU Cooler

W-L01066

(3)

4805-047

P.C.B (Mother Board)

L5000C00

1

L5000F00

(14)-1

Glass Tube Fuse

1A, AC250V

(1)

4610-008

(14)-2

Glass Tube Fuse

2A, AC250V

(3)

4610-009

(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

(23)

Charging Battery

L6390N00

1

L6390N00

(13)-1 (14)

4-18

PARTS LIST

Front

Left side

- 5

- 2,6

- 4

Right side

FC3

- 1

FC10

- 3

15 21

22

CN80A CN67A

CN81

CN39 CN40

CN14A

23

CN149

CN271 CN272 CN273 CN274 CN275 CN7A CN29A

CN276

Fig. 4.9.0.1

Large-capacity External Axes Controller (L5930 ~ L5932)

PARTS LIST

4-19

5 Maintenance (External Axes Controller) CONTENTS

5.1

Servo I/F Board L4805C................................................................................................................ 5-10 5.1.1 5.1.2 5.1.3

5.2


5.3

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

Charging Battery L6390N00 .......................................................................................................... 5-22 5.6.1 5.6.2 5.6.3

5.7

Functions of the Power Unit ................................................................................................... 5-19 Connectors of the Power Unit ................................................................................................ 5-20

Charging Unit L4797P ................................................................................................................... 5-21 5.5.1 5.5.2

5.6

Functions of Servo Unit .......................................................................................................... 5-15 Control Module W-L00958 ..................................................................................................... 5-17

Power Unit L4800P........................................................................................................................ 5-19 5.4.1 5.4.2

5.5

Functions of External Axes Board.......................................................................................... 5-11 Operating State Indicators of External Axes Board ............................................................... 5-12 Relays on External Axes Board ............................................................................................. 5-12 Fuses on External Axes Board............................................................................................... 5-12 Connectors of External Axes Board ....................................................................................... 5-13 Test Pins on External Axes Board ......................................................................................... 5-13 Jumper Pin Settings of External Axes Board ......................................................................... 5-14

Servo Unit ...................................................................................................................................... 5-15 5.3.1 5.3.2

5.4

Functions of Servo I/F Board ................................................................................................. 5-10 Connectors of Servo I/F Board............................................................................................... 5-10 Jumper Pin Settings of Servo I/F board ................................................................................. 5-10

Functions of the Charging Battery ......................................................................................... 5-22 Specifications of the Charging Battery ................................................................................... 5-22 Replacing the Charging Battery ............................................................................................. 5-22

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

5 Maintenance (External Axes Controller) CONTENTS 5.1

Servo I/F Board L4805C................................................................................................................ 5-10 5.1.1 5.1.2 5.1.3

5.2

Functions of Servo I/F Board.................................................................................................. 5-10 Connectors of Servo I/F Board............................................................................................... 5-10 Jumper Pin Settings of Servo I/F board ................................................................................. 5-10


Functions of External Axes Board .......................................................................................... 5-11 Operating State Indicators of External Axes Board ............................................................... 5-12 Relays on External Axes Board.............................................................................................. 5-12 Fuses on External Axes Board............................................................................................... 5-12 Connectors of External Axes Board ....................................................................................... 5-13 Test Pins on External Axes Board ......................................................................................... 5-13 Jumper Pin Settings of External Axes Board ......................................................................... 5-14

5 MAINTENANCE (EXTERNAL AXES CONTROLLER) This chapter provides information on the following components of the External Axes Controller with respect to their functions, displays of operating states, switch settings and so on. Components of External Axes Controller (1) (2) (3) (4) (5) (6) (7)

Servo I/F Board External Axes Board Servo Unit Power Unit Charging Unit Charging Battery Cooling Fan

L4805C L4805D L4800P L4797P L6390N

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

Components of External Axes Controller for 4.5 kW Motor

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Main Board Mother Board Servo Driver Brake Unit Power Unit Memory Battery Auxiliary Transformer Cooling Fans Constant Voltage Power Supply External Axes Board Charging Unit Charging Battery Relay Unit (optional)

L5000C L5000F L5573G L4800P L3391V W-L00699

L4805D L4797P L6390N

For these components’ functions, displays of operating states, and switch settings, see the corresponding section of MAINTENANCE in the Instruction Manual. Table 5.0.0.1

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

Item Main Board Mother Board Power Unit Servo Unit Control Module SWR Module Servo Unit Small Signal Backplane Board Inverter Module Power Supply Module Large Current Backplane Board Memory Battery Relay Unit (optional)

Where to refer in “INSTALLATION & MAINTENANCE” for model DR series “5.1 Main Board L5000C” “5.2 Mother Board L5000F” “5.3 Power Unit L4800P” “5.4 Servo Unit”

Additional Edition of BV80/120 “7.1 Servo Unit” “5.6 Memory Battery L3391V” “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.

MAINTENANCE (EXTERNAL AXES CONTROLLER) 5-1

Left side

Front

(Remove side cover) Power Supply Module #1 PCB159

Capacitor Module #1 PCB158


SWR Module #1 PCB156

External Axes oard #1 PCB103 CN80A CN67A

CN81

CN39 CN40

Charging Unit #1 PCB114

CN14A CN149 SW301

CN271 CN272 CN273 CN274 CN275

CN201 CN302

CN301

CN7A CN29A

CN276

CN203 CN1A

Charging Battery BT2

CN205

CN4

Inverter Module 1 #1

PCB153

Control Module #1 PCB152

FC3

Inverter Module 2 #1

PCB2 Main board

PCB154 Inverter Module 3 #1

PCB155

Servo I/F Board #1 PCB102

CN151

CN50

CN250

JP1 FC10

CN302 CN251

CN1

FC10

IC138

CN7

PCB3 Mother Board

Robot Controller

CN111

TB1

FC27 CN18 CN19

CN67

CN80

CN73

FC24

CN40

FC23 CN41 CN16

CN30 CN38

CN44

Fig. 5.0.0.1 Parts Arrangement Plan of the External Axes Controller

5-2


CN37

CN150

Fig. 5.0.0.2 Block Diagram of External Axes Controller (L4807/L5523: 3 External Axes)


Ref 1)

: Installed on the robot controller

TBP1 AC100V (MAX0.5A)

A

J2

CN94

CN306

CN107

Power Unit PCB1

AC200V 3

Regenerative Resistor R51

PE

CN1

NL1 W

CN5


MACB_#0

CN215

CN227 Servo Unit #0 PCB56 SWR Module PCB58 Capacitor Module PCB59 Power Supply Module

Cooling Fan Cooling Unit

CN101

CN109

CN110

Breaker NFB1

CN1

CN106 CN105 CN104

Power Relay MS1

CN210

CN205 CN203 CN201 PCB53 Inverter Module 1 PCB54 Inverter Module 2 PCB55 Inverter Module 3

CN1

Auxiliary Transformer TF1

PS2 CN2 DC24V

PS1 CN2 DC5V

CN209 GR

Backplane #0 PCB51

External Floppy Disk Drive

CN40

CN80

CN38

CN41

CN1

CN150

Mother Board PCB3

Main Board PCB2

CN7

CN67

FC10

FC10

CN50

CN4

FC2

CN302

Servo I/F Board PCB102

BT1

A

CN251 CN250

CN1 (Power Line)

Manipulator CN2 (Signal Line)

CN209 GR

Charging Unit #1

CN80A

External Axes Board #1 PCB103

CN40 CN39

CN271 CN272 CN273 CN274 CN275 CN1A CN276

CN7A

CN41A CN67A CN81

CN29A

CN30 CN31 PCB104

CN32

Backplane #1 PCB151

CN203

CN201

CN201/ CN202

Ex.Ax- 1

CN203/ CN204

Ex.Ax- 2

CN205/ CN206

CN205

Ex.Ax- 3

External Axes Motor (Power Line)

CN227

Regenerative Resistor #1

Cooling Unit

CN107

CN1

CN301

CN302

ARCNET Card #1 PCB160

CN5


MACB_#1

CN215

Cooling Fan

CN101

CN109

CN106 CN105 CN306 CN104 Power Unit #1 PCB101 CN110

Power Relay #1 MS101

CN210

Servo Unit #1 PCB156 SWR Module PCB153 Inverter Module 1 PCB158 Capacitor Module PCB154 Inverter Module 2 PCB155 Inverter Module 3 PCB159 Power Supply Module

Ex. Ex. Ex. BK- 3 BK- 2 BK- 1

External Axes Brakes

Charging Battery #1 BT102

Ex.Ax- 3 Ex.Ax- 2 Ex.Ax- 1

External Axes Encoder (Signal Line)

Fig. 5.0.0.3 Block Diagram of External Axes Controller (L5523: 6 External Axes)

5-4


CN40

Ref.1)

: Installed in the robot controller

J2

CN94 AC200V 3

Cooling Fan

CN101

CN109

CN110

CN306

PE

Cooling Unit

CN107

CN1

NL1 W

CN5


MACB_#0

CN215

CN227


PCB56 SWR Module PCB58 Capacitor Module PCB59 Power Supply Module

Power Unit PCB1

CN106 CN105 CN104

Breaker NFB1

CN1

CN1

Power Relay MS1

CN210

PCB53 Inverter Module 1 PCB54 Inverter Module 2 PCB55 Inverter Module 3

CN205 CN203 CN201 Servo Unit #0

CN251 CN250

CN1 (Power Line)


A


PS2 CN2 DC24V

PS1 CN2 DC5V

CN209 GR

Backplane #0 PCB51


CN150

CN80

CN38

CN41

CN1

Mother Board PCB3

PCB2

Main Board

CN7

CN67

FC10

FC10

CN50

CN4

FC2

CN302


BT1

A

CN2 (Signal Line)

Manipulator


Charging Unit #1

CN80A


CN40 CN39


CN7A

CN41A CN67A CN81

CN29A

CN30 CN31 PCB104

CN32


CN209 GR

Backplane #1 PCB151

Cooling Fan

E CN101

CN109

CN201

CN227

Regenerative Resistor #1 CN201/ CN202

Ex.Ax- 1

CN1

CN5

CN301

CN302


PCB152

Control Module

MACB_#1

CN215

Cooling Unit

CN107



CN210

CN203

CN203/ CN204

Ex.Ax- 3


CN205

CN205/ CN206

Ex.Ax- 5

Ex Ex Ex External Axes Motor (Power Line) BK- 6 BK- 4 BK- 2 Ex.Ax- 4 Ex Ex Ex Ex.Ax- 2 Ex.Ax- 4 Ex.Ax- 2 BK- 5 BK- 3 BK- 1 Ex.Ax- 6 Ex.Ax- 6 Ex.Ax- 5 Ex.Ax- 3 Ex.Ax- 1 External Axes Encoder (Signal Line)

Fig. 5.0.0.4 Block Diagram of External Axes Controller (L4808/L5524: Manipulator Extended)


CN40

Ref.1)


J2

CN94 AC200V 3

Cooling Fan

CN101

CN109

Breaker NFB1

CN1


PE

Cooling Unit

CN107

CN1

NL1 W

CN5


MACB_#0

CN215


CN106 CN105 CN306 CN104 Power Unit CN110 PCB1

Power Relay MS1

CN210

PCB53 Inverter Module 1 PCB54 Inverter Module 2 PCB55 Inverter Module 3

CN205 CN203 CN201

CN251 CN250

CN1 (Power Line)

CN1


A


CN2 DC24V

PS2

PS1 CN2 DC5V

CN209 GR

Backplane #0 PCB51


CN150

CN80

CN38

CN41

CN1

Mother Board PCB3

Main Board PCB2

CN7

CN67

FC10

FC10

CN50

CN4

FC2

CN302


BT1

A

CN2 (Signal Line)

Manipulator

CN80A


CN40 CN39


CN7A

CN41A CN67A CN81

CN29A

Ex.Ax- 1 to 6

Backplane #1 PCB151

CN203

Cooling Fan

E CN101

CN109

CN201

CN227


CN1

CN301

CN302


CN5


MACB_#1

CN215

Cooling Unit

CN107



CN210

CN205

CN250

Servo unit #1 PCB156 SWR Module PCB153 Inverter Module 1 PCB154 Inverter Module 2 PCB158 Capacitor Module PCB155 Inverter Module 3 PCB159 Power Supply Module

CN251

Ex.Ax:1- 6

External Axes Motor (Power Line) External Axes Brakes

CN209 GR


Extended Manipulator

Front

Left- side Power Supply Module PCB59

Right- side

SW Regulator Module PCB56

FC3

Control Module

PCB2 Main Board

PCB52 (Cooling Unit)

FC10

Inverter Module 1 (for 6,3 Drive Axes ) PCB53 PCB3

Inverter Module 2 (for 5,2 Drive Axes) PCB54

Mother Board

Power Unit PCB1

Constant Voltage Power Supply PS1 Constant Voltage Power Supply

Inverter Module 3

PS2

(for 4,1 Drive Axes) PCB55

External Board #1 PCB103 RelayBrake

Charging Unit #1 PCB114

CN80A CN67A

CN81

CN39 CN40

CN14A CN149

Magnet Switch MS1

CN271 CN272 CN273 CN274 CN275


CN7A CN29A

CN276


DoorInside

Left- sideInside

Floppy Disk Memory Unit Connecting Cable Mounting hole

PCB5 Additional Relay Unit (optional)

PCB4 Relay Unit (Optional

PCB8

Additional I/F Board (Optional)

Touch Sensor PCB10 (Optional)

Fig. 5.0.0.5

5-6

Parts Arrangement Diagram of External Axes Controller for 4.5kW Motors (L5930 ~ L5932)


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 be necessary. 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 rotating section. • Putting your hand, finger, hair or clothes close to the wire feed roll of the wire feed 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, as specified 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, check for 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 is now being carried out.

Under Inspection

(5) Do not use any devices that may generate electromagnetic noise, in and around the area where inspection 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 should receive 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 be fully understood. (8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who are qualified 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. 5-8


(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 safety manager who is responsible. With permission obtained, the operator may perform the work during 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-side power 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 EMERGENCY Stop button immediately whenever a robot malfunctions. (e) Check your footing carefully before starting the work. Make sure to avoid an unstable scaffold or 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 countermeasures against 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 pulls out 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 robot system, hydraulic pressure or air pressure of related devices, make sure to stop the robot completely 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 restart it from outside the safety fence. (13) Make sure that all the necessary connectors, covers, panels, etc. have been mounted and wired correctly 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.

CN151

5 9

JP1 CN50

CN302 95

Fig. 5.1.1.1

5.1.2

External View of Servo I/F Board

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 Connector

Connectors on Servo I/F Board 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

5-10

Servo I/F Board Jumper Pin Setting

Jumper Pin

Standard Setting

Remarks

JP1

1-2 Open

Never change the standard setting.


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 and has 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 Axes Controller (2) Function to relay signals from peripheral devices, which are connected to the External Axes Controller, 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.

CN67A CN80A CN81

3

1

3

TP13A

1

TP14A TP15A JP221

TP12A

JP222 F7

F6 LED 100A

CN40 CN39

CN14A

CN149

1

TP3A

3

JP223

5 8 1

F5 JP211

JP212 JP207 TP4A

CR1A LED 105A

CR4A LED 107A

CN29A

1 7 2 N C 2 7 2 N C 3 7 2 N C 4 7 2 N C 5 7 2 N C 6 7 2 N C

1 0 2 P J 2 0 2 P J 3 0 2 P J 4 0 2 P J 5 0 2 P J 6 0 2 P J

CN7A

CN1A

125

Fig. 5.2.1.1 External View of External Axes Board MAINTENANCE (EXTERNAL AXES CONTROLLER) 5-11

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 state of 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 Board Relay No.

5.2.4

Function

Status Contact opens when peripheral jigs overrun.

CR

1A

OVERRUN

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.

CR

4A

Shock Sensor

Contact opens when shock sensor operates.

Related LED LED105A OFF

LED100A ON

LED107A OFF

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 replace with those of the same rating. Table 5.2.4.1

5-12

Fuses on External Axes Board

Fuse No.

Rating

F5

250 V, 2A, glass tube type

24 V power supply inside External Axes Controller

4610-009

F6


AC 12 V power supply for External Axes Controller charging unit

4610-009

F7


Power to release the unit brake of peripheral jigs

4610-009

Application


Parts No.

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 connect peripheral devices. Table 5.2.5.1

Connectors of External Axes Board

Connector No.

5.2.6

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)

CN272


CN273


CN274


CN275


CN276


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 pin No.

Test Pins on External Axes Board

Signal Name

Function

TP3A

24 V

DC24 V

TP4A

0V

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. necessary jumper pin setting in accordance with the specific robot system. Table 5.2.7.1 Jumper Pin JP201

JP202

JP203

JP204

JP205

JP206

JP207

JP211

JP212

JP221 JP222 JP222

Perform

Jumper Pin Setting of External Axes Board Function

ON-OFF selection of OVERRUN signal of a peripheral device which is connected 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). ON-OFF selection of OVERRUN signal of a peripheral device which is connected to CN272. When overrun sensor is provided in a peripheral device (such as a slider or a positioner) which is connected to CN272, set this jumper pin at "ON" (OPEN). ON-OFF selection of OVERRUN signal of a peripheral device which is connected to CN273. When overrun sensor is provided in a peripheral device (such as a slider or a positioner) which is connected to CN273, set this jumper pin at "ON" (OPEN). ON-OFF selection of OVERRUN signal of a peripheral device which is connected 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 pin at "ON" (OPEN). 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 a slider or a positioner) which is connected to CN275, set this jumper pin at "ON" (OPEN). ON-OFF selection of OVERRUN signal of a peripheral device which is connected to CN276. When overrun sensor is provided in a peripheral device (such as a slider or a positioner) which is connected to CN276, set this jumper pin at "ON" (OPEN). ON-OFF selection of OVERRUN signal of a peripheral device which is connected to CN39. When an optional device is connected to CN39, set this jumper pin at "ON" (OPEN). 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). 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). (For optional devices) Do not change the standard setting.

Standard Setting 1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF

1-2 Short : OFF 1-2 Short : OFF 1-2 Short : OFF

WARNING

When replacing the External Axes board with a new one, make sure that the jumper pin settings are proper. Wrong settings may result in the failure of peripheral jigs to perform OVERRUN or in malfunction of the detecting circuit, creating a dangerous situation.

5-14


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 in accordance 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 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

Module name

Table 5.3.1.2 Configuration of Servo Unit for External Axes Controller L5561L5564 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

Module name

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.


5-15

This section explains only about control module. For other modules, see “Maintenance 5.4: Servo Unit” in “INSTALLATION & MAINTENANCE” for model DR series.

Capacitor Module

SWR Module 30

Power Supply Module

Backplane

CN227

AC SERVO SYSTEM PWR

W L00955

AC SERVO SYSTEM PWR

Enlarged view of servo unit

AC SERVO SYSTEM

W L00954

W L00953

CN210

0 8 9 9 CAUTION

CAUTION

CAUTION

CN211

8 7 3 AC SERVO SYSTEM PWR

W L00951

6 5 4 3 2 1

CN216

CAUTION

CN201

CN203

CN209

CN205

CN207 CN208

310

Inverter Module 1

Control Module

Inverter Module 2

Inverter Module 3

Fig. 5.3.1.1

5-16

External View of Servo Unit L4805G


Left-side View Remove Side Cover

5.3.2 (1)

Control Module W-L00958 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 this alarm to the control module. Function to receive absolute offset data from an absolute encoder. Function to detect various alarms related to the servo system. 135 122

20

Backplane

0 2 2 N C

0 2 2 N C

5 1 2 N C

5 1 2 N C

AC SERVO SYSTEM PWR

W L00958

6 5 4 3 2 1

4 8 1

CAUTION May cause electric shock. Don't touch this system during power ON or 5 min. !

CN301

56

CN302

Left-side View

Rear View

Front View

CN301

CN302

CN1

CN2

Bottom View

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 is not necessary to monitor those LEDs on the control module panel. MAINTENANCE (EXTERNAL AXES CONTROLLER)

5-17

(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 the servo 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 may suffer a contact failure, resulting in malfunction of the robot system. Therefore, make sure that they are 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 of the robot system. Therefore, be sure to fix the control module to the servo frame with screws. Servo Frame Backplane

SWR Module Capacitor Module Power Supply Module

Screw (16-M4x8)

Inverter Module

External Axes Board

Control Module

Fig. 5.3.2.2

5-18

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 robot control unit from the primary-side power. 96

PART NO. L4800P L4800P02 3 A

3 B

NI V 0 0 2 C A 3

1 0 1 N C

0 9 1

2 S P, 1 S P

4 0 1 N C

FAN 1 CN112 FAN 2

1 CN113

B1

PCB12

B3

FAN

CN105 2

1

A1

1

3 CN110

A3

CN114 SERVO POWER

FAN 2

1

CN115 PILOT LAMP 2

POWER RELAY

CN109

1 1 1

1

4 TRANSFORMER R O 1 S N E S H C U O T

CN107 6 1 1 N C

3 CN106

CN108

EX.POWER RELAY 4

1

3 CN306

INPUT VOLTAGE AC200V AC220V AC230V

CONNECT 1PIN 2PIN 1PIN 3PIN 1PIN 4PIN

3

Fig. 5.4.1.1

External View of the Power Unit


5-19

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 each inner unit. Table 5.4.2.1 Connector No.

Connectors of Power Unit Peripheral devices to be connected to

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)

CN114


CN115


CN116


CN306


WARNING Since some connector pins of the power unit are applied with a high voltage, touching them accidentally 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.

5-20


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 power is OFF.

L4797P 1

3 1

2

CR1

0 3 N C

TP1 2 3 N C

VR1 TP2

1

TP3

1 3 N C 8

Fig. 5.5.1.1

5.5.2

External View of the Charging Unit

Connectors of the Charging Unit

This charging unit is equipped with connectors in Table 5.5.2.1 to back up data of the absolute encoders. Table 5.5.2.1

Connectors of the Charging Unit

Connector No.

Peripheral devices to be connected to

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 battery because that may result in an electric shock hazard. 2. Disconnecting CN32 while the control power is turned off results in a loss of absolute-encoder data. 3. Power of the charging battery is supplied to an absolute encoder of each axis via the charging unit connector 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, 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 DR series. MAINTENANCE (EXTERNAL AXES CONTROLLER)

5-21

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, and supplies 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, prior to 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 encoder data. 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 approximately 10 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 environmental conditions, operating conditions and other factors.

5.6.2

Specifications of the Charging Battery

Nominal Voltage Discharge Voltage The 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 periodic inspection 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 one or conveying it.

5-22

(1)

Perform block operation in accordance with the origin position check program 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 absoluteencoder 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 charging battery because that may result in an electric shock hazard.

(4)

(5)

Connect a connecting cable to the new charging battery . Fix the charging battery in position using the two bolts (M58) that were removed in procedure (3).


5-23

Front External Axes Controller


CN201

CN203

CN205

"C"

"C" Breaker Handle Replace the charging battery while the control power is ON.

Robot Controller

Cooling Unit

Power Unit

Power Relay

Screw M48

Charging Battery

View "C" "C"

Fig. 5.6.3.1 5-24

Replacing the Charging Battery


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.

Side Cover

FM111

Air flow direction

FM113 (Cooling Unit)

(Cooling Unit)

Air flow direction

FM112 FM114 Air flow direction Air flow direction

Panel Internal View "C"

Left-side View

Rear View "C"

Rear

FM114

Fig. 5.7.0.1

Cooling Fans

Front

View "C" "C"

WARNING NEVER put your hand, finger, hair or clothes close to a rotating fan because you 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 ON because you may get your hand, finger, hair or clothes caught by a rotating fan and be injured.

CAUTION Dust accumulation on the radiation fins of the cooling unit causes a decline in cooling capability, thus clean the fins periodically.


5-25

6 ELECTRICAL CONNECTION DIAGRAM 6.1

Electrical Connection Diagram of External Axes Controller


6 Electrical Connection Diagram

CONTENTS

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

General Electrical Connection Diagram of External Axes Controller (L4807 / L5523: 3 External Axes) (1/1)

Manipulator CN2 (Signal Line)


CN1 (Power Line)

Ex.Ax- 3 Ex.Ax- 2 Ex.Ax- 1

External Axes Brakes Ex. Ex. Ex. BK- 3 BK- 2 BK- 1

External Axes Motor (Power Line) Ex.Ax- 2

Ex.Ax- 3

Ex.Ax- 1

Regenerative Resistor R51 CN205/ CN206

CN251 CN250

A

FC2

Backplane #0 PCB51

Main Board PCB2

BT1 Servo I/F Board PCB102


J2

CN210

CN209 GR

CN4

Backplane #1 PCB151


CN209 GR

CN215

MACB_#0 Control Module PCB52

Power Relay MS1


CN205

CN203/ CN204

CN203

CN201/ CN202


CN227

CN201


CN210

CN215

MACB_#1 Power Relay #1 MS101


CN50 FC10

PS1 CN2 DC5V

CN302

FC10

PS2 CN2 DC24V

CN41 Mother Board PCB3

CN5

CN1

CN1

CN106 CN105 CN104 CN1

CN306

Power Unit PCB1

CN29A

CN41A CN67A CN81

CN67 Auxiliary Transformer TF1

CN109

CN107

CN80A CN271 CN272 CN273 CN274 CN275 CN1A CN276

CN40

CN80


Cooling Fan Cooling Unit

A

Breaker NFB1

: Installed on the robot controller

ARCNET Card #1 PCB160 CN301

CN302

CN107

CN109 CN101

CN94 External Floppy Disk Drive

Cooling Fan

Cooling Unit

NL1 W

AC200V 3 Ref 1)


CN40 CN39

CN150


CN5

CN7A CN101

CN1

CN7

CN1 Charging Unit #1

CN30 CN31 PCB104

CN110 CN38

CN32

PE


General Electrical Connection Diagram of External Axes Controller (L5523: 6 External Axes) (1/1)

External Axes Brakes Manipulator CN2

Ex Ex Ex External Axes Motor (Power Line) BK- 6 BK- 4 BK- 2 Ex.Ax- 4 Ex Ex Ex Ex.Ax- 2 Ex.Ax- 4 Ex.Ax- 2 BK- 5 BK- 3 BK- 1 Ex.Ax- 6 Ex.Ax- 3 Ex.Ax- 6 Ex.Ax- 5 Ex.Ax- 1 External Axes Encoder (Signal Line)

CN1 (Power Line)

(Signal Line)

Ex.Ax- 5

Ex.Ax- 3

Ex.Ax- 1

Regenerative Resistor R51 CN205/ CN206

CN251 CN250

A

FC2

J2

PCB2


Backplane #0 PCB51

Main Board

CN210

CN209 GR

CN4

Backplane #1 PCB151

CN227

CN205 CN203 CN201 Servo Unit #0 PCB53 Inverter Module 1 PCB54 Inverter Module 2 PCB55 Inverter Module 3

PCB56 SWR Module PCB58 Capacitor Module PCB59 Power Supply Module

CN209 GR

CN215

MACB_#0 Control Module PCB52

Power Relay MS1


CN205

CN203/ CN204

CN203

Regenerative Resistor #1 CN201/ CN202

CN227

CN201


CN210

CN215

MACB_#1 Control Module


PCB152

CN50 FC10

PS1 CN2 DC5V

CN302

FC10


PS2 CN2 DC24V

CN5

CN1

CN106 CN105 CN104 CN1 CN110

CN306

Power Unit PCB1

CN29A

CN41A CN67A CN81


CN109

CN107

CN7A CN80A

CN101


CN1

CN7

CN40

CN80

Cooling Fan

A



Cooling Unit

Breaker NFB1

CN106 CN105 CN306 CN104 Power Unit #1 PCB101 CN110 CN109


CN302

CN107

E CN101

Cooling Fan

Cooling Unit

NL1 W

CN94 AC200V 3

Ref.1)

CN5

CN40 CN39

CN150


CN1

Charging Unit #1

CN30 CN31 PCB104

CN67 CN38

CN32

CN1


PE

Extended Manipulator Manipulator CN2 (Signal Line)

External Axes Motor (Power Line)


CN1 (Power Line)

Ex.Ax- 1 to 6


Ex.Ax:1- 6



CN251 CN250

General Electrical Connection Diagram of External Axes Controller (L4808 / L5524: Manipulator Extended) (1/1)

A

FC2


Backplane #0 PCB51

Main Board PCB2


J2

Backplane #1 PCB151


CN210

CN209 GR

CN4

CN251

CN209 GR

CN215

CN205

CN250

CN203

CN210

CN215

MACB_#0

MACB_#1 Power Relay #1 MS101


Power Relay MS1

CN227

CN201

Servo unit #1 PCB156 SWR Module PCB153 Inverter Module 1 PCB154 Inverter Module 2 PCB158 Capacitor Module PCB155 Inverter Module 3 PCB159 Power Supply Module


CN50 FC10

CN1

PS1 CN2 DC5V

CN302

PS2 FC10


CN2 DC24V

CN1

CN106 CN105 CN306 CN104 Power Unit CN110 PCB1

CN29A

CN41A CN67A CN81

CN67 CN38

CN7

CN80


CN109

CN107

CN7A CN80A

CN101


CN1

CN40

Cooling Fan

A

Ref.1)

CN5

CN106 CN105 CN306 CN104 Power Unit #1 PCB101 CN110 CN109


CN302

CN107

E CN101

CN40 CN39

CN150


CN1

CN5

CN1


Cooling Unit

Breaker NFB1

Cooling Fan

Cooling Unit

NL1 W

CN94 AC200V 3



PE

V 0 0 2 C A 3

1 er B k a F Br N

T U P NI

5

6

S 4

T

R

y ert at B g n gi ar h C

3 2 A 1 A

9 0 1 N C

1 0 1 N C 3 B 2 B 1 B

2 0 1 T B

1

5 R Z

4 R Z

2

1 R Z

6 R Z

3 4

2 R Z

3 R Z

8 0 1 N C

2 C

A 2 3 N C

1 C

4

A 9 2 N C

1 2

1

3

5

3

A 0 3 N C

3 C

T D A N B G

d ar o B s e x A al n ert x E

3

T A B

1

V 2 1 C A 2

3

4

1

2

A 1 3 N C

1

4 0 1 N C

V 2 1 C A

6 C

. C . N

5 C

8 C 7 C

V 2 1 C A

1

2

4

6

4 C

-TAB

+TA

2

1 L

A 1 4 N C

2

3

9 C

3 0 1 B C P

V 4 2 V 0 5

A B _ _ 1 1 S S M M

. C . N 4

. C . N 3 0 7

6

2

7

D N G

6 2

1

3

8

6

7

5

4 1 1 B C P

2

1 R D

2

0 7

t ni U g n gi ar h C

4

9

1

C N

6

4

8

5

3

1

7

6 0 1 N C

1 S0 M1

6 2

0 1 1 N C

6 0 3 N C

1

1

2

C N

2 R D

2

3

3

ort s si e R e vi at er n e g e R 1 5 1 R

7 2 2 N C

0 1 2 N C S

9 1

3 A

T

C N 3 A

2 A

0 1 9 9 1 2 A A

R

8 1

3 1

1 A 7 1

3 2

A

4 1

3 3

A

1 0 1 S 4 4 M 3 2

A

5 0 1 7 8 9 N C 1 2 3

9

0

T 4 B

0 C 0 N 6 1 2 B B

0

R 4 A 7

t ni U er w o P

3 B

1 B

1 0 1 B C P

e n a pl ck a B

2 B

9 0 2 N C

)t ni U o v er S(

3 B

3

T U O V 5 + 4

N VI 3 3. + 5

C N

1 5 1 B C P

1

D N G

1

2

2

N VI 5 +

7 0 1 N C

Electrical Connection Diagram of External Axes Controller (1/2)

2 1

2 1

2 1

2 1

2 1

6 1 1 N C

2 N1 C1

5 N1 C1

4 N1 C1

3 N1 C1

9 7 9 7 9 7 9 7

4 M0 F1

3 M0 F1

2 M0 F1

1 M0 F1


1 N C

1 N C

3 5 1 B C P

)t ni 2 U 5 B o C v er P S (

8 1 N C

e ul d o M orl nt o C

1 e ) ul nti d oU Mo v ert er er S v ( nI

2 1 2 N C

). C . P (

3 1 2 N C

1 N C

1 N C

5 1 2 N C 0 2 2 N C e n a pl k c a B 1 5 B C P


d ar o B er h ot M

)t ni U o v er S (

4 1 2 N C

2 5 1 B C P

3 B C P

6 1 2 N C

0 1 C F

0 1 C F

4 N C

1 1 1 N C

6 5 1 B C P

1 T B

d ar 2 o B B C P

1

ni a M

2 2

el ) u t d ni oU M o R vr e WS S (

4 2 2 N C

3 C F

0 5 C F


7 2

F)/ I W S D (

2

e ul d o M ort ci a p a C

9 4 1 N C

)t ni U o v er S (

2 2 2 N C

1 K B V S

A 7 6 N C

3

2 0 3 N C

4

1 0 3 N C

y ) pl p ti u n 9 S U 5 1 e B er ul o vr C wd P o oe P MS (

2

d ar o B 2 0 1 F/ B I C o P v er S

1 # 3 0 1 B C P

8 5 1 B C P

1 2 2 N C

9 3 N C 4 B

5 B 1

2

3

4

T)I N U E K A R B (

3 B

A 0 8 N C

2 B B V 0 9 C D

1 B A V 0 9 C D

8

6 D S +

5 A K B V S

3 3

V E

4 A V 4 2

4 3

6 V 5 E

3 A V 0

2

T A B

2 A K B V S

1

T A B

9

0 1 B V 2 1 C A

1 A . C . N

4 2

2() V 2 1 C A

8 A V 2 1 C A

B V 2 1 C A

V 4 2

7 _ M O C V O

3 2

1() V 2 1 C A

7 1 M O C V O

0 1

P M A L

8 2

V 0

6 1 N U R V O

A V 2 1 C A

2 _ M O C 2 K H S

7 2

P M A L

5 T A B

9

N 0V S

8 2

1 M O C K H S

4 1 T S R S B A

8

2 M O C V O

7 N U R V O

6 2

N _I K C O H S

3 1 V 5 E

7

2 N U R V O

2 K C O H S

3 1

1 M O C V O

2 V E

6

T A B

4 7 2 N C

3 7 2 N C

5 2

1 1 D S -

5

2 T S R S B A

er n oi t si o P s xi A 1-

0 8 N C

1 8 N C

4

3 A

K B

2 A 1 8 B V 2 1 C A

3

1 A B V 0 9 C D

+ K B

A V 0 9 C D V 0 0 1 C A

A

1 B V 0 0 1 C A

B

2 B 1 8 A V 2 1 C A

3 B

0 1

V 2 D E S +

0 4 N C

0 4 N C

A V 2 1 C A

9

0 1

B V 2 1 C A

0 1 B V 2 1 C A

2 D S 5 1

8

A V 2 1 C A

4

1 2

2 V 5 E

7 3 M O C V O

9

4 D S 7 1

6 3 N U R V O

8

4 M O C V O

6

5 T A B

7

4 N U R V O

4 D S +

4 3 T S R S B A

6

T A B

9 2

3 V 5 E

5

4 T S R S B A

V E

3

4 V 5 E

0 3

2 V E

4

4 V 5 E

1 3 D S -

3

V E

6 D S 9 1

3 D S +

2

4 D S -

3 A

N U R V 0 X E 4 A

N 0 V S 2 B

M O C _ K S X E 3 B

O C _ V 0 X E 4 B

1 K C O L 5 B

K B V S 6 B

V 0

d ar o B er h ot M

1 B

0 4 B _ V 2 1 C A M

6 A

V 4 2

4 B 5 B V 0

6 B

P M A L 5 A

2 A

K C O H S X E

3 B

1 B

2 B

6 A

3 A

5 A

2 A K B V S

4 A

1 A 1 K C O L

0 4 B _ V 2 1 C A M O C _ V 0 X E

V 4 2

M O C _ K S X E

P M A L

N U R V 0 X E N 0 V S

K C O H S X E

3

0 1 B V 2 1 C A

0 4 A _ V 2 1 C A

9

B V 2 1 C A

1 D S 4 1

8 A V 2 1 C A

0 1

9

7 5 M O C V O

9

A V 2 1 C A

V 1 D E S +

3 D S 6 1

6 5 N U R V O

8

6 M O C V O

0 2

5

3 D S +

5 T A B

7

6 N U R V O

1 V 5 E

1 1

V E

4 5 T S R S B A

6

T A B

5 D S 8 1

3 5 V 5 E

5

6 T S R S B A

7

2 V E

6 V 5 E

5 D S +

1 5 D S -

4

1 3

5 D S +

3

V E

3 B

2

2 B

6 D S -

1 B

1

V E 2 2

1 A

2 0 1 2

6 D S +

2 3

5 7 2 N C

6 7 2 N C

2 A

1 0 1 2

3 V 5 E

0 4 A _ V 2 1 C A

3 A

5 V 5 E

1 A

2 0 4 2

0 0 1 2 1 0 4 2

1 5 1 B C P

0 0 4 2

)t ni U o v er S (

1 2 3 4 5 B B B B B 3 3 3 E E E C R A B C N G

1

6 0 2 N C & 5 0 2 N C

5 0 2 N C

e n a pl ck a B

1 2 3 4 5 A A A A A 3 3 3 0 0 0 C R A B C N G

4 D S +

3 B

3 A

2 B

2 A

1 B

1 A

2 0 5 2

2 0 2 2 1 0 5 2

1 0 2 2

1 N U R V O

1 D S +

2 V 5 E

F

4

G

3

B

V E

C

2

A

2 D S -

I

1

E

2 D S +

D N U R V O

C D

V W E

T A B

B

T E S E R

U

C C V

A

3 B

4 0 2 N C & 3 0 2 N C

3 0 2 N C

0 0 2 2

2 3

1 7 2 N C

2 7 2 N C

2 N C

1 N C

2 B 2 0 3 2

1 B

D N G

3 A

D S -

2 A

D S + BK-

1 A

1 0 3 2 0 0 3 2 2 0 6 2 0 0 6 2


1 0 6 2

M O C S L N U R V O

BK+

2 0 2 N C & 1 0 2 N C

1 2 3 4 5 A A A A A 1 1 1 0 0 0 C R A B C N G

0 0 5 2

V E

K B

F E

2 5 1 B C P

1 0 2 N C


2 1

+ K B

2 0 3 N C

)t ni U o v er S (

0 6 1 B C P


5 1 2 N C

1 2 3 4 5 A A A A A 2 2 2 0 0 0 C R A B C N G

1 T S R B A

K B 6 B 4 B 2 B

A 7 N C

+ K B 6 A 4 A 2 A

)t ni U o v er S (

1 N C

5 B 3 B 1 B

5 N C

d ar C T E N C R A

5 A 3 A 1 A

0 2 2 N C

Electrical Connection Diagram of External Axes Controller (When Adding One Standard 1-axis Positioner) (2/2A)

3 B C P

1 N C

1 N C

1

8 1 N C

3 5 1 B C P

e ul ) d nti 2 o 5 MU B o orl vr C P nt e o S ( C

e ) ul nti d oU Mo v ert er er S v ( nI

2 1 2 N C

). C . P (

2 e ul d o M ert er v nI

1 N C

1 N C

4 5 1 B C P


d ar o B er h ot M

4 1 2 N C

2 5 1 B C P

3 B C P

5 1 )t 6 2 i N ne n 51 1 B 2 C apl U C N 0 k ov P C 2 ac r 2 B Se( N C

)t ni U o v er S (

3 1 2 N C

0 1 C F

0 1 C F

4 N C

1 1 1 N C

6 5 1 B C P

1 T B

d ar 2 o B B C P

1

n ai M

2 2

e ul )ti d n oU M o R vr e WS S (

4 2 2 N C

F)/ I W S D (

2

3 C F

0 5 C F


7 2

e ul d o M ort ci a p a C

9 4 1 N C

)t ni U o v er S (

2 2 2 N C

1 K B V S

A 7 6 N C

3

2 0 3 N C

4

1 0 3 N C

y ) pl p ti 9 u n 5 S U 1 e B er ul o C d vr P wo o e P MS (

2

d ar o B 2 0 1 F/ B I C o P v er S

1 # 3 0 1 B C P

8 5 1 B C P

1 2 2 N C

9 3 N C 4 B 5 B 1

2

3

4

T)I N U E K A R B (

3 B B V 0 9 C D

A 0 8 N C

2 B A V 0 9 C D

8

6 D S +

1 B K B V S

3 3

V E

5 A V 4 2

4 3

6 V 5 E

4 A V 0

2

T A B

3 A K B V S

1

T A B

2 A . C . N

4 2

2() V 2 1 C A

1 A 7 _ M O C V O

3 2

1() V 2 1 C A

V 4 2

8 2

V 0

2 _ M O C 2 K H S

7 2

P M A L

P M A L

8 2

1 M O C K H S

N 0V S

6 2

N _I K C O H S

7 N U R V O

3 1

1 M O C V O

2 K C O H S

5 2

1 N U R V O

0 8 N C

1 8 N C

6 D S 9 1

4

K B

3 A

3

2 A

+ K B

1 A 1 8 B V 2 1 C A

6

4 D S +

B V 0 9 C D

9 2

V E

A V 0 9 C D

0 3

4 V 5 E 4 D S 7 1

A

1 B B

2 B 1 8 A V 2 1 C A

3 B

4

2 D S +

V 0 0 1 C A

0 1

V E

V 0 0 1 C A

1 2

2 V 5 E

0 4 N C

2 D S 5 1

0 4 N C

6

7

8 9

0 1 B V 2 1 C A

5

B

4

V 2 1 C A

3

A

0 1

2

V 2 1 C A

1

9

9

8

4 M O C V O

8

7

4 N U R V O

7

6

T A B

6

5

4 T S R S B A

5

4 V 5 E

4

4

3

V E

2

3

1

4 D S -

A V 2 1 C A

2

3 M O C V O

0 1 B V 2 1 C A

4 D S +

3 N U R V O

B

1

T A B

V 2 1 C A

3 T S R S B A

A

0 1

I

3 4 5 B B B

J

V W E G H

2 B

2 0 2 2

3 B

1 B 0 0 2 2 1 B

1 0 2 2

2 B

U

3 V 5 E

V 2 1 C A

C D

V W E

3 4 5 A A A

3 A

V E

9

T

B

2 A 1 0 5 2 2 A

6 0 2 N C & 5 0 2 N C

3 D S -

8

2 M O C V O

F

U

1 A 0 0 5 2 1 A

M

3 B

M O C _ V 0 X E

3 A

K B V S

d ar o B er h ot M

1 5 1 B C P

0 1

B V 2 1 C A

0 1 B V 2 1 C A

V 0 6 B

2 B

O C _ K S X E

2 A

5 B

1 B

0 4 B _ V 2 1 C A

1 A

1 K C O L 4 B

V 4 2

4 A

N 0 V S 6 A

3 A

N U R V 0 X E P M A L 5 A

2 A

3 B

K C O H S X E

2 B

1 A

1 B M O C _ V 0 X E

6 B

6 A M O C _ K S X E

V 0

5 A 0 4 B _ V 2 1 C A

5 B

4 A V 4 2

K B V S

P M A L

4 B 1 K C O L

N 0 V S

1 D S 4 1

V 2 1 C A

N U R V 0 X E

3

9

K C O H S X E

9

V 1 D E S +

8

6 M O C V O

0 4 A _ V 2 1 C A

0 2

3 D S 6 1

1 V 5 E

5

9

3 D S +

8 A V 2 1 C A

1 1

7 5 M O C V O

V E

6 5 N U R V O

2 2

5 T A B

7

6 N U R V O

5 D S 8 1

4 5 T S R S B A

6

T A B

7

3 5 V 5 E

5

6 T S R S B A

5 D S +

2 V E

6 V 5 E

1 3

1 5 D S -

4

V E

5 D S +

3

V E

)t ni U o v er S (

A 6 D S -

3 4 5 B B B

3 B

2

2 B

6 D S +

1 0 1 2 2 B

1 B

1 B

0 0 1 2

1

2 3

5 7 2 N C

6 7 2 N C

2 0 1 2

3 V 5 E

0 4 A _ V 2 1 C A

3 A

3 4 5 A A A

2 0 4 2

5 V 5 E

er n oi t si o P

2 A

2 A

1 0 4 2

s xi A 2-

1 A

1 A

e n a pl k c a B

3 3 3 2 2 2 5 3 3 3 3 2 2 2 0 0 0 0 C R E E E C R 0 0 0 0 C R E E E C R 2 A B C N G A B C N G 2 A B C N G A B C N G N N C C

4 0 2 N C & 3 0 2 N C

3 D S +

7

2 N U R V O

G

+) T( E S E R

A V 2 1 C A

6

T A B

J

C C V

1 M O C V O

5

2 T S R S B A

H

D N G

1 N U R V O

2 V 5 E

M

D S -

T A B

4

L

D S +

1 T S R S B A

3

V E

R M

A

2 0 3 2

3 B 1 0 3 2

2 B 0 0 3 2

1 B

O C S L N U R V O

1 V 5 E

2 D S -

N N U R V O

3 A

V E

2

C T A B

2 A 2 0 6 2

1 D S -

2 D S +

D T E S E R

1 A 1 0 6 2

1 D S +

1

B C C V

0 0 6 2


4 7 2 N C

A D N G

BKBK+

2 0 2 N C & 1 0 2 N C

1 2 3 4 5 1 A A A A A 0 2 01 01 01 C R N A B C N G C

0 0 4 2

D S -

2 0 5 2

D S +

3 7 2 N C

2 3

2 5 1 B C P

2 N C

2 7 2 N C

1 7 2 N C

V E

K B

E

F

2 1

+ K B

2 0 3 N C

)t ni U o v er S (

0 6 1 B C P

el u d o M orl nt o C

5 1 2 N C

1 N C

1 T S R B A

K B 6 B 4 B 2 B

A 7 N C

+ K B 6 A 4 A 2 A

)t ni U o v er S (

1 N C

5 B 3 B 1 B

5 N C

d ar C T E N C R A

5 A 3 A 1 A

0 2 2 N C

Electrical Connection Diagram of External Axes Controller (When Adding One Standard 2-axis Positioner) (2/2B)

3 B C P


6.2

Electrical Connection Diagram for External Axes Controller for 4.5 kW Motor

General Electrical Connection Diagram of External Axes Controller for 4.5 kW Motor (L5930-L5932)

INPUT 3 AC200V

No Fuse Breaker NFB1 R S T

CN251

1 3 5

P

2 4 6

CN211 +17V 1 +17VGND 2

A1 A2 A3 B1 B2 B3

CN101

ZR4

ZR5

ZR6

ZR1

1 2 3 4

ZR2 C2

ZR3

9 13 14 220V

1 3 5 C4

5

C5 C6

C8

CN104

C7

3 1 5 4 2 6 7

C9 7

CN106 MS1

26 70

NC

8 9

1 2 3

DR1

CN306 MS2 NC

NC

NC

NC

7 8

4 3 32 2 27 1

Constant Voltage 3 Power 1 1 Supply 2 3 PS1 4 5 (DC5V)

100V

0V

0V

Main Board

8.5V NC

PCB61

PCB62

CN38 20 3 21 4 10 1 11 2

PCB2

NC

Constant Voltage 1 Power 3 1 Supply 3 2 4 5 PS2 (DC24V)

AC12V

27 26 25 26 70

CN110

1 2

AC100V

PCB3

1 +5V 2 GND 3 +24V 4 0V

Regenerative Resistor RG1

5 MS1_A 6 MS1_B

1

1 2 3

DR2

2 3

NC 4

CN105 A1

7

A2

9

A3

Power Unit

1

Ro

3

NC To

2

FM11

B1 B2 B3

Power Supply Module (Servo Unit)

FM12

CN107 8

1

PCB59 FM7

7

FM5

CN203 A4 B4

Ro To

Small Signal Backplane

FM13

PCB61

FM6 FM14

1 2 CN 113

1 2 1 2 CN CN 114 115

1 2

1 CN 112

2 CN 116

Cooling Fan3

Touch Sensor 7

9 FM1

7

9 FM2

7

9 FM3

Cooling Fan4

7

9 FM4

W

Power Indicator NL1

Cooling Fan4

5

6

TB283

TB282

PCB1

2

20 21

Mother Board

CN41

NC NC

AC Outlet TBP1

CN150

RG2

RG1 RG2 P N

5

GR R S T

1

6 7 8

2 3 4

1 2 3

CN252

Large- Current Backplane

TF1 12V

32

7 8

NC

200V

CN11 0V

1 2

Small- Signal Backplane Auxiliary Transformer

4 W2 AC220V 3 W1 AC200V 2 1 W

L1 2 4 6

CN109 7

CN108

C1 C3

CN253

RGOH1 RGOH2 GND


Electrical Connection Diagram of External Axes Controller for 4.5 kW Motor (1/3)

MS1

4 5 6

N

1 2 3

Operation Box

Emergency Stop

CN1 11

2

NC

3

3

CR2 (EMG)

5

NC

14

7

15

408

15

23

307

6 Optical Fiber

IC138

5

CN16 203

4

202 201

2

200 Servo ON

25

0V TBRST

25

TBENB

81

NC NC

82 NC

8

17

5

Mother Board PCB3

6

4 5

JP2

62

3

302

7

303

19

300

2 8

68

301

1 6

61

18 25

4 5

25 24

1

1

11

7

403

2

12

8

402

6

9

401

8

10

400

3

14 CN1

JP3

(PCB) CN18

G

R

Y R

Y

CN19

CN111

Servo ON

CN80

Servo ON Indicator

CN73 (EX.PW.UNIT)

Auto Mode Selection

FC10

Stop

CN40

Teach Mode Selection

(M- NET I/F)

(SENSOR)

Start 1

FC27

7 4 5

(P.C.)

(DSW I/F)


7

16

(BRAKE UNIT) CN94

14

COM

FC2

406

24E

2

13

Auto Mode Indicator

27

13

Teach Mode Indicator

BT1

FC10

Main Board PCB2

306

3

2

Stop Indicator

CN4

22

15

(EX.AXES)

1

10

2

CN216

22

405

16

CN220 CN215

Memory Battery

12

7

13

80

Backplane (Servo Unit) PCB51

5

4

0V

CN1 Control Module (Servo Unit) PCB52

305

3

55

TBCON

21

2 8

6 9

1 6

1

55 404

9

26

16

50

11

10

24V

308

304

63

26

JP1

8

20

64

24V

1

1

56 Emergency Stop

(T/B)

3

2

12 407

24

Teach Pendant

CN2

4 CN30

4

52

3 2

1

NC 53

1

Emergency Stop

NC

Start Indicator 1

Electrical Connection Diagram of External Axes Controller for 4.5 kW Motor (2-3)

Robot Dedicated Welding Power Supply CN31

CN32 51

Starting Box 2

902

52

903

Emergency Stop

304

914

Start 2

301

924

Stop

25

909

COM

24

910

404

913

401

923

CN33 52

903

53

904

305

916

301

924

25

909

24

910

405

915

401

923

CN34 53

904

24E G

Start 2 Indicator Stop Indicator

R

Starting Box 3 Emergency Stop Start 3 Stop COM 24E G


R

Starting Box 4

54

905

Emergency Stop

306

918

Start 4

301

924

Stop

25

909

COM

24

910

406

917

401

923

24E G R


Electrical Connection Diagram of External Axes Controller for 4.5 kW Motor (3/3)


Electrical Connection Diagram for External Axes Cable

6.3 (1)

External axes cable 1 for 1-axis peripheral jig External Axes Controller CN201 B1 B2 B3

CN67 A

E Brake (+) F Brake (-)

B

GND

Positioner CN1 A U B V C W D GND

E

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.

(2)

External axes cable 2 for 1-axis peripheral jig External Axes Controller CN272

Positioner CN2

+SD 1

D +SD

-SD 2

E -SD

E0V 3

I GND

E5V 4

A VCC

ABSRST 5

C RESET(+)

BAT 6

B BAT

OVRUN 7

G OVRN LS-1

OVCOM 8

F OVRN LS-COM

AC12V A 9

J RESET(-)

AC12V B 10

H SHIELD

GND

E

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.

(3)

External axes cable 1 for 2-axis peripheral jig Positioner CN1 A U B V C W D GND

External Axes Controller CN201 B1 B2 B3

CN203 B1 B2 B3

CN67 1 2

G H I J

U V W GND

E F

Brake (+) Brake (-)

GND 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 jig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.

(4)

External axes cable 2 for 2-axis peripheral jig External Axes Controller CN272 +SD1 1 -SD1 2 E0V 3 ABSRST1 5 E5V1 4 BAT 6 OVRUN1 OVCOM1 AC12VA AC12VB

Positioner CN2 A +SD B -SD D GND N RESET(+)

C VCC R BAT

7 8 9

L OVRN LS-1 M OVRN LS-COM

10

K N.C.

CN274 +SD2 1 -SD2 2 E0V 3 ABSRST2 5 E5V2 4 BAT 6 OVRUN2 7 OVCOM2 8 AC12VA 9

H J G T F

+SD -SD GND RESET(+) VCC

P RESET(-) S RESET(-)

AC12VB 10

E SHIELD GND

E

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 jig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors. MAINTENANCE (EXTERNAL AXES CONTROLLER) 6-13

(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 axis 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. For External axes cable 2 for 1-axis 4.5 kW motor, use external axes cable 2 for 1-axis peripheral jig.

6 Electrical Connection Diagram CONTENTS 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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