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 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

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
L5563
1500 W x 2 axes + 800 W or below x 2 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
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
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
Door Key
5
2
5


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"
External Axes
Controller
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
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
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
Fig. 2.3.1.1
Installation Dimensions of Robot Controller with External Axes Controller
720
500
4 16
438
518
View 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
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
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

3.2.1
3.2.2

3.3
3.4

3.4.1
3.4.2
3.5


3.5.1
3.5.2
3.5.3

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
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
2 set
1-axis slider
2-axis positioner

1 set
3 axes
4 axes
2-axis positioner
2-axis positioner
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.
L5372B00
L5372C00
L5373B00
L5373C00
L5374B00
5374C00
L5375B00
L5375C00
External Axes Cable 1
L5376B00
L5376C00
L5377B00
L5377C00
L5378B00
L5378C00
L5379B00
L5379C00
L5919B00
L5372C00
L5920B00
L5373C00
L5921B00
L5374C00
L5922B00
L5375C00
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
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
1
JP223
CN7A
CN1A
<PCB103 External Axes Board>

(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

for 4.5kW Motors
CN151
CN50
JP1
FC10
CN50
CN302
PCB102
Servo I/F Board
CN1 CN7
IC138
CN151
CN250
FC10
TB1
CN18
CN302
CN251
PCB102
Servo I/F Board
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

3.4.2 Connecting External Axes Controller to Robot Controller

(1) Connecting signal cables
<When connecting the Robot Controller and External Axes Controller>
Robot Controller
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
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
PCB103 Control Module
< 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
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
PCB102
Servo I/F Board
PCB3
Mother board
TB1
CN80
CN40
Fig. 3.4.2.1 Connecting External Axes Controller to Robot Controller

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

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
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

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
PCB152
Control Module
CN67A
CN81
CN39 CN40
CN41A
CN149
SW301
CN271
CN302
CN301
CN29A
CN203
CN276
CN205
Power Cable
3
CN306
CN106
CN201
CN1A
CN7A
Primary- side Power Cable
PCB12
POWER RELAY
PS1,PS2
CN104
EX.POWER RELAY
3
CN110
CN101A
Connected to the
upper- side of this
connector.
CN272
CN273
CN274
CN275
CN108
1
TRANSFORMER
A3
1
CN107
B3
CN105
SERVO POWER
1 A1
CN115
CN114
CN113
Grounding Stud [M4]

PE
PILOT
LAMP
2
B1
B3
FAN
A3

CN101
3
AC200V IN

3 2 1 0
CN116
CN112
CN109

FAN
B I MD
TOUCH SENSOR
FAN

3 2 1 0

FAN
INPUT VOLTAGE CONNECT

1PIN 2PIN
AC200V
1PIN 4PIN
AC220V
1PIN 3PIN
AC230V

PCB101

3 2 1 0
Power Unit
View B
NFB1
PCB2
Primary- side Power

Cable
No Fuse
Breaker
Main Board
4
CN151
CN50
CN250
JP1
FC10
CN302
CN251
Robot Controller
or
for 4.5kW Motors
PCB102
Servo I/F Board
"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"

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
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
CN67A
CN81
CN201
CN1A
CN7A
CN29A
External Axes Board

PCB103
CN302
CN301
CN203
CN276

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
N
A
F
CN205
Control Module
PCB152
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
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
Inlet for Primaryside Power Cable
NFB1
No Fuse
Breaker
CN50
CN151
CN250
JP1
FC10
To the upper-side of the connector

CN101A on power unit in the External
Axes Controller
3
B
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

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
A1
3
CN110
To the secondaryside of Aux.

transformer TF10
Panel
A3
CN114
SERVO POWER
FAN
2
POWER RELAY
CN109
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
3
CN306

1PIN 2PIN
AC200V
1PIN 4PIN
AC220V
1PIN 3PIN
AC230V
(from the back of panel)
Aux. Transformer
TF10
Step-down Transformer
L4794
R
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"
CN80A
Connector
CN101A
Connected to the upper- side
of this connector.
CN67A
CN81
CN39 CN40
CN41A
CN149
SW301
3
CN306
B3
1
CN107
PILOT
LAMP
2
B1
A1
CN115
CN114
FAN
CN113
CN116
3 AC200V IN
CN101
CN112
Control Module
PCB152
A3
TOUCH SENSOR
CN205
CN109
CN108
TRANSFORMER
A3
B3
CN105

FAN
CN203
CN276
CN106
FAN
External Axes Board

PCB103
CN302
CN301
CN7A
CN29A

FAN
CN201
CN1A

1PIN 2PIN
AC200V
AC220V
1PIN 4PIN
AC230V
1PIN 3PIN
3
CN110
PCB12
CN104
POWER RELAY
EX.POWER RELAY
PS1,PS2
SERVO POWER
CN271
CN272
CN273
CN274
CN275
PCB101 Power Unit

View B
Primary- side Power Cable
for 4.5kW Motors
Grounding Stud [M4]
PE
PCB2
Main Board
NFB1
No Fuse
Breaker
CN50
CN151
FC10
JP1
CN302
Servo I/F Board

PCB102
CN101
Power Unit
PCB1
PCB3
Mother Board
Connector
Connected to the
CN101A
right- side of this
connector.
Primary- side
Power Cable
A3
3 AC200V IN
CN101
B3
NFB
External Axes Board

PCB003
CN80A
CN104
FAN
CN39 CN40
CN14A
PS1,PS2
CN67A
CN81
CN112
CN149
FAN
2
1
CN113
CN271
CN272
CN273
CN274
CN275
CN1A
PCB12
B3
CN105
A1
3
CN110
A3
CN114
SERVO POWER
FAN
2
1
1
3
CN106
PILOT
LAMP
2
TRANSFORMER
1
TOUCH SENSOR
CN276
POWER RELAY
CN109
1
CN115
CN7A
CN107
CN108
1
EX.POWER RELAY
4

AC200V
1PIN 2PIN
1PIN 4PIN
AC220V
1PIN 3PIN
AC230V
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
B1 B2 B3 B4 B5 B6
For Brake Cable(s)

of External Axis/Axes Cable 1
CN201
For Encoder Cable(s)
CN271
CN272
CN273
CN274
10
CN275
11
CN276
12
CN203
CN201
E7
CN203
10 9
712
Driver Nos.
CN205
CN7A
CN205
712
Driver Nos.
12 11
For Motor Cable(s)

Fig. 3.5.1.2
Connectors for External Axis/Axes Cables
Front
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
CN272
CN273
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
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
B1
1
2
B1, B3
1
2
3
B1, B3, B5
1
2
3
4
B1 B4
1
2
3
4
5
B1 B5
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
For Brake Cable

of External Axis Cable 1
For Encoder Cable
CN271
7
CN272
CN273
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
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
External Axis Controller
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
PCB152
Control
Module
CN41A
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN7A
CN302
CN203
CN29A CN276

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.

Jig 1 Cannon plug
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
PCB152
Control
Module
CN14A
CN149
SW301
CN271
CN272
CN273
CN201
CN1A
CN274
CN275
CN301
CN7A
CN302
CN203
CN29A CN276

CN205

PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.2.3 Connecting External Axis Cable 2 when Adding 1 External Axis
CAUTION
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
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

CN271
CN272
CN273
CN274
10
CN275
11
CN276
12
CN203
10 9
E7
Shaded rectangles: indicate where

to connect respective wires.
CN205
12 11
CN7A
External Axes Board

For Motor Cables
Fig 3.5.3.1

Jig 1 Cannon plug
CN1
Connector CN201-8
Connector CN203-10
Connector CN67A-B1
Grounding cable
(a) Connect CN1 of External Axes Cable 1 to the corresponding connector CN1 of jig 1.
(b) Lead connectors CN201, CN203, CN67 (2) and the grounding cable into the External Axes
Controller through the shaded area on the right side of the External Axes Controller as shown in
Fig. 3.5.3.2, and then fix the cable flange in place without leaving any clearance with that 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
External Axes
Controller
PCB152
Control
Module
CN14A
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN7A
CN29A CN276
CN302
CN203

CN205

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
(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.
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)
Front
"A"
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
External Axes
Controller
View "A" "A"
PCB152
Control
Module
CN14A
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN7A
CN29A CN276
CN302
CN203

CN205

PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.3.3 Connecting External Axes Cable 2 when Adding One 2-Axis Jig
CAUTION
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.)
consultation.

CONTENTS
3.1
3.2

3.2.1
3.2.2

3.3
3.4

3.4.1
3.4.2
3.5


3.5.1
3.5.2
3.5.3

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

for External Axis 1

for External Axis 2
CN67A
CN201
B1 B2 B3 B4 B5 B6
8
For Brake Cables

For Encoder Cables
CN271
7
CN272
CN203
10 9
CN273
CN274
10
CN275
11
CN276
12
E7
Shaded rectanagles: indicate where

CN205
12 11
CN7A
External Axes Board

For Motor Cables
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.
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.
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
PCB103
External Axes Board
CN67A
CN39 CN40
External Axes
Controller
CN201
CN80A
CN81
PCB152
Control
Module
CN14A

for External Axis 2
for External Axis 2
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN29A CN276
CN203
CN205

for External Axis 1

for External Axis 1
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
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.)
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
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.
CAUTION
corresponding overrun limit switch.
Right Side (inside)
Front
View "A" "A"

"A"
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
External Axes
Controller
PCB152
Control
Module
CN14A

for External Axis 2
for External Axis 2
CN149
SW301
CN271
CN272
CN273
CN201
CN1A
CN274
CN275
CN301
CN302
CN7A
CN29A CN276
CN203
CN205

for External Axis 1

for External Axis 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
welding cable.
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
CN1 of jig 2.
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.
Right Side (inside)
Front
Connect here
View "A" "A"

"A"
CN67A
Connect here
PCB103
External Axes Board
CN67A
CN39 CN40
External Axes
Controller
CN203
CN80A
CN81
PCB152
Control
Module
CN14A

for External Axis 2
for External Axis 2
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN29A CN276
CN203
CN205

for External Axis 1
Clamp this groundning cable with

for External Axis 1
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
welding cable.
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
CN2 of jig 2.
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.
(d) If a peripheral jig such as a positioner or a slider connected to CN274 is equipped with an
the pin .
CAUTION
side of the pin .
(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
corresponding overrun limit switch.
Right side (inside)
Front
View "A" "A"

"A"
PCB103
External Axes Board
Grounding Stud
CN80A
CN67A
CN81
CN39 CN40
External Axes
Controller
PCB152
Control
Module
CN14A

for External Axis 2
for External Axis 2
CN149
SW301
CN271
CN272
CN273
CN201
CN1A
CN274
CN275
CN301
CN7A
CN29A CN276
CN302
CN203
CN205

for External Axis 1

for External Axis 1
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
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

for Slider
Motor Cable

for Slider
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
2-axis positioner
CN203-10
CN205-12
CN67A-B3
Tilt axis
CN274
Table axis
CN276
CN67A
CN201
B1 B2 B3 B4 B5 B6
8
For Brake Cables

For Encoder Cables
CN271
CN272
CN273
CN274
10
CN275
11
CN276
12
CN203
10 9
E7

CN205
12 11
CN7A
External Axes Board

For Motor Cables
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.
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.
Right Side (inside)
Front
Connect here
View "A" "A"

"A"
CN67A
Connect here
PCB103
External Axes Board
CN67A
CN39 CN40
External Axes
Controller
CN201
CN80A
CN81
PCB152
Control
Module
CN14A

for 2-axis Positioner
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN29A CN276
CN203
CN205

for Slider
Clamp this gounding cable with

for Slider
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
welding cable.
2. Arrange External Axis Cable 1 as far apart as possible from the External Axis Cable 2 inside the
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
(2) Connecting External Axis Cable 2 for a slider

Slider Cannon plug
(External Axis 1)
CN2
Connector CN272
PCB103 External Axes Board
Grounding cable
(a) Connect CN2 of the External Axis Cable 2 for a slider to the corresponding connector CN2 of a
slider.
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.
(d) If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with an
side of the pin.
CAUTION
side of the pin.
(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
View "A" "A"

"A"
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
External Axes
Controller
PCB152
Control
Module
CN41A

CN149
SW301
CN271
CN272
CN273
CN201
CN1A
CN274
CN275
CN301
CN302
CN7A
CN29A CN276
CN203
CN205

for Slider

for Slider
PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.4.3
CAUTION
Connecting External Axis Cable 2 for Slider (External Axis 1)

welding cable.
2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 inside the
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
(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.
Right Side (inside)
Front
View "A" "A"

Connect here
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
External Axes
Controller
Connect here
"A"
CN67A
PCB152
Control
Module
CN41A

for Positioner
for Positioner
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN29A CN276
CN203
CN205

for Slider

for Slider
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)
welding cable.
2. Arrange External Axes Cable 1 as far apart as possible from the External Axes Cable 2 inside the
3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it in
(4) Connecting External Axes Cable 2 for 2-axis Positioner

2-axis Positioner Cannon plug CN2
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
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
and/or JP206 by reinserting only one side of the pin(s). (Refer to Table 3.3.0.1.)
CAUTION
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
View "A" "A"

"A"
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
External Axes
Controller
Grounding stud
PCB152
Control
Module
CN41A

for Positioner
CN149

for Positioner
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN7A
CN29A CN276
CN302
CN203
CN205

for Slider
for Slider
PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.4.5 Connecting External Axes Cable 2 for 2-axis Positioner

CAUTION
welding cable.

CONTENTS
3.5.3.2 Adding Two 1-axis Peripheral Jigs ................................................................................. 3-31
3.5.4
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.
10
Where to connect External Axes Cables is shown in Table 3.5.5.3.

Table 3.5.5.3
Cable name
Constituents

for Positioner 1
Motor cable
Tilt axis for Positioner 1
CN201-7
Table axis for Positioner 1
CN201-8
Positioner 1
Brake cable
for Positioner 1
for Positioner 2
Encoder cable
Motor cable
Encoder cable
CN67A-B1
CN271
CN272
CN203-9
CN203-10
Positioner 2
CN67A-B3
Brake cable
for Positioner 2
Where to Connect
Cables
Axis Name
CN273
CN274
CN67A
CN201
B1 B2 B3 B4 B5 B6
8
For Encoder Cables

CN271
CN272
CN273
CN274
10
CN275
11
CN276
12
For Brake Cables

CN203
10 9
E7

CN205
12 11
CN7A
External Axes Board

For Motor Cables
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
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
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.
Right Side (inside)
Front
Connect here
View "A" "A"

"A"
CN67A
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
PCB152
Control
Module
CN41A

for Positioner 2
for Positioner 2
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN203
CN29A CN276
CN205

for Positioner 1

for Positioner 1
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
welding cable.
Connector CN271
Connector CN272
Grounding cable
of Positioner 1.
External Axes Cable 1 for Positioner 1.
(c) Connect CN271 and CN272 to the corresponding connectors CN271 and CN272 on the External
Axes board.
CAUTION
CAUTION
corresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN271 and
CN272, in Teach mode.
Right Side (inside)
Front
"A"
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
PCB152
Control
Module
CN41A
CN149
View "A" "A"

for Positioner 2
for Positioner 2
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN203
CN29A CN276
CN205


for Positioner 1
for Positioner 1
PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.5.3
CAUTION

welding cable.
Connector CN203-9
Connector CN203-10
Connector CN67A-B3
Grounding cable
of Positioner 2.
(b) Lead connectors CN203-9, CN203-10, CN67 x 2 and the grounding cable into the External Axes
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.

Front
Connect here
"A" "A"

"A"
CN67A
PCB103
External Axes Board
CN67A
CN80A
CN81
CN39 CN40
PCB152
Control
Module
CN41A

for Positioner 2
for Positioner 2
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN302
CN7A
CN203
CN29A CN276
CN205

for Positioner 1

for Positioner 1
PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.5.4
CAUTION

welding cable.
Connector CN273
Connector CN274
Grounding cable
of Positioner 2.
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.
CAUTION
If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN273 and/or CN273
CAUTION
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
PCB152
Control
Module
CN41A

for Positioner 2
for Positioner 2
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN201
CN1A
CN301
CN7A
CN29A CN276
CN302
CN203
CN205

for Positioner 1
for Positioner 1
PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.5.5
CAUTION

welding cable.
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
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"
CN67A
PCB103
External Axes Board
CN80A
CN67A
CN81
CN39 CN40
PCB152
Control
Module
CN41A
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN250
CN1A
CN301
CN302
CN7A
CN29A CN276
CN251

for Manipulator
for Manipulator

PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.6.1
CAUTION
Connecting External Axes Cable 1 when Adding One Manipulator
welding cable.
(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
(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
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)
Front
"A"
PCB103
External Axes Board
View "A"--"A"
CN80A
CN67A
CN81
CN39 CN40
PCB152
Control
Module
CN41A
CN149
SW301
CN271
CN272
CN273
CN274
CN275
CN250
CN1A
CN301

for Manipulator
CN302

for Manipulator
CN7A
CN29A CN276
CN251

PCB2
Main Board
Robot Controller
"A"
Fig. 3.5.6.2
Connecting External Axes Cable 2 when Adding One Manipulator
CAUTION
welding cable.
moving / bending sections of a slider, etc. If it is to be used in such moving sections, please
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

CN271
CN272
CN273
CN274
10
CN275
11
CN276
12
E7
CN7A
Fig. 3.5.7.1

4.5kW Motor Cannon plug CN1
(for motor)
Connector CN257
Connector CN67-B2
Grounding cable

for 4.5kW Motor
for 4.5kW Motor
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
3.5.7.2
CAUTION
Connecting External Axes Cable 1 when adding 4.5kW Motor
welding cable.
moving / bending sections of a slider, etc. If it is to be used in such moving sections, please contact
us for consultation.

4.5kW Motor
Cannon plug CN2

(for Encoder)
Connector CN272
Grounding cable

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
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

side of the pin. If it is short-circuited, the overrun limit switch connected to CN202 does not
operate.
CAUTION
Right Sideinside
Front
"A"
PCB003
External Axes Board
View "A" "A"
CN80A
CN67A
CN81
CN39 CN40
CN14A
CN149

for 4.5kW Motors
CN271
CN272
CN273
CN274
CN275
CN7A
CN29A CN276
"A"
Fig. 3.5.7.3
CAUTION
welding cable.
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
Cable name
Constituents
Connect Cables
Motor cable
CN257
for External Axis 1
Brake cable
CN67-B2
Encoder cable CN272
for External Axis 2
Motor cable
CN256
for External Axis 1
Brake cable
CN67-B1
Encoder cable CN271
for External Axis 2
External Axes Board
Encoder Cable for External Axes

(External Axes Cable 2)
CN271
CN272
CN273
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

for 4.5kW Motor
for 4.5kW Motor
(a) Connect Connector of the External Axes Cable 1 to the corresponding Cannon plug CN1
(for motor) of 4.5kW motor
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.
3.5.8.2
CAUTION
welding cable.
(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

for 4.5kW Motor
(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector of a peripheral jig of
External Axes 1.
(d) If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with 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

operate.
CAUTION
corresponding overrun limit switch of the peripheral jig, which is connected to CN271, in Teach
mode.
Right Sideinside
Front
"A"
PCB003
External Axes Board
View "A" "A"
CN80A
CN67A
CN81
CN39 CN40
CN14A
CN149

for 4.5kW Motors
CN271
CN272
CN273
CN274
CN275
CN7A
CN29A CN276
"A"
Fig. 3.5.8.3
Connecting External Axes Cable 2 for External Axes 1 when adding 4.5kW motor
CAUTION
welding cable.
(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

for 4.5kW Motor
Connector CN67-B1
PCB 003 External Axes Board
Grounding cable

for 4.5kW Motor
(a) Connect Connector of the External Axes Cable 2 to the corresponding connector of a peripheral jig
of External Axes 2.
in Fig. 3.5.8.4, and then fix the cable flange in place.
3.5.8.4
CAUTION
welding cable.
(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

for 4.5kW Motor
(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector of a peripheral jig of
External Axes 2.
CAUTION

operate.
(d) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of the
CAUTION
Right Side (inside)
Front
"A"
PCB003
External Axes Board
View "A" "A"
CN80A
CN67A
CN81
CN39 CN40
CN14A
CN149

for 4.5kW Motor
CN271
CN272
CN273
CN274
CN275
CN7A
CN29A CN276
"A"
3.5.8.5
CAUTION
welding cable.

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)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L4798U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
P.C.B. (Servo I/F Board)
L4805C00
L4805C00
(7)
P.C.B. (External Axes Board)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Charging Unit
L4797P00
L4797P00
(9)
Charging Battery
L6390N00
L6390N00
(10)
Protective Cover
L4805F01
L4805F01
(11)
Door Key Handle
A-120-1
4739-273
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
1
1
13
0
1
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)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L4798U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Charging Unit
L4797P00
L4797P00
(9)
Charging Battery
L6390N00
L6390N00
(10)
Protective Cover
L4805F01
L4805F01
(11)
Door Key Handle
A-120-1
4739-273
Note
1. Increasing the number of protective axes by one requires an increase of both an inverter
2. Servo I/F board (Ref. No. (6)) is not installed on the External Axes Controller but is installed on
4-4
PARTS LIST
2
1
1
13
0
1
8
43
23
53
33
63
Fig. 4.2.0.1
PARTS LIST
4-5
4.3

Item
Ref. No.
DWG. No. & Model
Q'ty
Parts No.
(1)
Power Relay
G7J-4A-B(DC24V)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L4798U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Charging Unit
L4797P00
L4797P00
(9)
Charging Battery
L6390N00
L6390N00
(10)
Protective Cover
L4805F01
L4805F01
(11)
Door Key Handle
A-120-1
4739-273
Note:
4-6
PARTS LIST
2
1
1
13
5
4
0
1
8
43
53
23
63
33
Fig. 4.3.0.1
PARTS LIST
4-7
4.4

Item
Ref. No.
DWG. No. & Model
Q'ty
Parts No.
(1)
Power Relay
G7J-4A-B(DC24V)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L4798U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Protective Cover
L4805F01
L4805F01
(9)
Door Key Handle
A-120-1
4739-273
Note:
4-8
PARTS LIST
2
13
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)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L5002U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Charging Unit
L4797P00
L4797P00
(9)
Charging Battery
L6390N00
L6390N00
(10)
Protective Cover
L4805F01
L4805F01
(11)
Door Key Handle
A-120-1
4739-273
2. Servo I/F board (Ref. No. (6)) is not installed in the External Axes Controller but is installed on
4-10
PARTS LIST
2
1
1
13
0
1
8
43
23
53
63
Fig. 4.5.0.1
33
PARTS LIST
4-11
4.6

Item
Ref. No.
DWG. No. & Model
Q'ty
Parts No.
(1)
Power Relay
G7J-4A-B(DC24V)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L5002U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Charging Unit
L4797P00
L4797P00
(9)
Charging Battery
L6390N00
L6390N00
(10)
Protective Cover
L4805F01
L4805F01
(11)
Door Key Handle
A-120-1
4739-273
2. Servo I/F board (Ref. No. (6)) is not installed in the External Axes Controller but is installed on
4-12
PARTS LIST
2
1
1
13
0
1
8
43
23
53
33
63
Fig. 4.6.0.1

PARTS LIST
4-13
4.7

Item
Ref. No.
DWG. No. & Model
Q'ty
Parts No.
(1)
Power Relay
G7J-4A-B(DC24V)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L5002U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Charging Unit
L4797P00
L4797P00
(9)
Charging Battery
L6390N00
L6390N00
(10)
Protective Cover
L4805F01
L4805F01
(11)
Door Key Handle
A-120-1
4739-273
Note:
4-14
PARTS LIST
2
1
1
13
5
4
0
1
8
43
53
23
63
33
Fig. 4.7.0.1
PARTS LIST
4-15
4.8

Item
Ref. No.
DWG. No. & Model
Q'ty
Parts No.
(1)
Power Relay
G7J-4A-B(DC24V)
4341-134
(2)
Cooling Fan
4715PS-22T-B30-B18
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
L5002U00
(5)
P.C.B. (Power Unit)
L4800P00
L4800P00
(6)
L4805C00
L4805C00
(7)
L4805D00
L4805D00
(7)-1
Glass Tube Fuse
2A, AC250V
(3)
4610-009
(8)
Protective Cover
L4805F01
L4805F01
(9)
Door Key Handle
A-120-1
4739-273
Note:
4-16
PARTS LIST
2
13
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
4810-278
(2)
Power Unit
L4800P00
L4800P00
(3)
Electromagnetic Contactor
SC-3N (AC100V)
4340-083
(4)
Surge Killer
CR-20151
4516-011
(5)
Constant Voltage Power Supply (5V)
ZWS50-5/J
4814-033
(6)
Constant Voltage Power Supply (10V) ZWS50-24/J
4814-034
(7)
Relay (Servo ON)
G4W-11123A-US-TB8
4340-616
(8)
Cooling Fan
4715PS-22T-B30-B18
11
4805-033
(9)
Pilot Lamp
NPA10-2H-WS
4600-341
(10)
AC Outlet Assy.
L4798R00
L4798R00
(11)
Servo Unit
L5003J
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
L5573U00
(13)
P.C.B (Main Board)
L5000C00
L5000C00
CPU Cooler
W-L01066
(3)
4805-047
P.C.B (Mother Board)
L5000C00
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
L4805D00
(16)
Memory Battery
L3391V00
5096-095
(17)
Auto-breaker
SA103B-40A (3)
4614-071
(18)
Operation Handle
BZ-N35B
4739-329
(19)
Door Key Handle
A-120-1
4739-273
(20)
Eyebolt
M12-ZMC
3364-005
(21)
Relay (Brake)
G7L-2A-TUB
4340-617
(22)
Charging Unit
L4797P00
L4797-P00
(23)
Charging Battery
L6390N00
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

5.2.1
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

Relays on External Axes Board ............................................................................................. 5-12
Servo Unit ...................................................................................................................................... 5-15

5.3.1
5.3.2
5.4
Functions 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


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

Relays on External Axes Board.............................................................................................. 5-12
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
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
PCB2
Main board
PCB154
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)
J2
CN94
CN306
CN107
Power Unit
PCB1
AC200V 3
Regenerative Resistor
R51
PE
CN1
NL1
W
CN5
Control Module
PCB52
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
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
<Robot Controller>
CN302
Servo
I/F Board
PCB102
BT1
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
Control Module
PCB152
MACB_#1
CN215
<External Axes Controller>
Cooling Fan
CN101
CN109
CN106 CN105 CN306

CN104
Power Unit #1
PCB101
CN110
Power
Relay #1
MS101
CN210
Servo Unit #1
PCB156 SWR 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
Control Module
PCB52
MACB_#0
CN215
CN227
R51
PCB56 SWR Module

Power Unit
PCB1
CN106 CN105
CN104
Breaker
NFB1
CN1
CN1
Power Relay
MS1
CN210

CN205 CN203 CN201 Servo Unit #0
CN251 CN250
CN1
(Power Line)
External Floppy
Disk Drive
Auxiliary
Transformer
TF1
PS2
CN2
DC24V
PS1
CN2
DC5V
CN209 GR
Backplane #0
PCB51
TBP1
AC100V
(MAX0.5A)
CN150
CN80
CN38
CN41
CN1
Mother Board
PCB3
PCB2
Main Board
CN7
CN67
FC10
FC10
CN50
CN4
FC2
<Robot Controller>
CN302
Servo
I/F Board
PCB102
BT1
CN2
(Signal Line)
Manipulator
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
Charging Battery #1
BT102
CN209 GR
Backplane #1
PCB151
Cooling Fan
E
CN101
CN109
CN201
CN227
Regenerative Resistor #1
CN201/
CN202
Ex.Ax- 1
CN1
CN5
CN301
CN302
ARCNET Card #1
PCB160
PCB152
Control Module
MACB_#1
CN215
Cooling Unit
CN107
CN106 CN105 CN306

CN104
Power Unit #1
PCB101
CN110
Power
Relay #1
MS101
CN210
CN203
CN203/
CN204
Ex.Ax- 3
Servo Unit #1
PCB156 SWR Module
CN205
CN205/
CN206
Ex.Ax- 5
Ex
Ex
Ex
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
R51
PE
Cooling Unit
CN107
CN1
NL1
W
CN5
Control Module
PCB52
MACB_#0
CN215
CN227
Servo Unit #0
PCB56 SWR Module
CN106 CN105 CN306

CN104
Power Unit
CN110
PCB1
Power Relay
MS1
CN210

CN205 CN203 CN201
CN251 CN250
CN1
(Power Line)
CN1
External Floppy
Disk Drive
Auxiliary
Transformer
TF1
CN2
DC24V
PS2
PS1
CN2
DC5V
CN209 GR
Backplane #0
PCB51
TBP1
AC100V
(MAX0.5A)
CN150
CN80
CN38
CN41
CN1
Mother Board
PCB3
Main Board
PCB2
CN7
CN67
FC10
FC10
CN50
CN4
FC2
<Robot Controller>
CN302
Servo
I/F Board
PCB102
BT1
CN2
(Signal Line)
Manipulator
CN80A
External Axes
Board #1
PCB103
CN40 CN39
CN271
CN272
CN273
CN274
CN275 CN1A
CN276
CN7A
CN41A
CN67A
CN81
CN29A
Ex.Ax- 1 to 6
Backplane #1
PCB151
CN203
Cooling Fan
E
CN101
CN109
CN201
CN227
CN1
CN301
CN302
ARCNET Card #1
PCB160
CN5
Control Module
PCB152
MACB_#1
CN215
Cooling Unit
CN107
CN106 CN105 CN306

CN104
Power Unit #1
PCB101
CN110
Power
Relay #1
MS101
CN210
CN205
CN250
Servo unit #1
PCB156 SWR Module
CN251
Ex.Ax:1- 6

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
Charging Battery
BT2
CN7A
CN29A
CN276
TF1
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 Customers 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
TP13A
TP14A TP15A
JP221
TP12A
JP222
F7
F6
LED
100A
CN40
CN39
CN14A
CN149
TP3A
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

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).
connected to CN272.
slider or a positioner) which is connected to CN272, set this jumper pin
at "ON" (OPEN).
connected to CN273.
at "ON" (OPEN).
connected to CN274.
at "ON" (OPEN).
connected to CN275.
at "ON" (OPEN).
connected to CN276.
at "ON" (OPEN).
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.
Qty
Parts No.
Remarks
Backplane
W-L00950
5096-204
1
Control module
W-L00958
5096-225
Inverter module
W-L00956
4
5096-224
1
SW Regulator module
W-L00953
5096-207
1
Capacitor module
W-L00954
5096-208
1
Power supply module
W-L01146
5096-321
1
Module name
Table 5.3.1.2 Configuration of Servo Unit for External Axes Controller L5561L5564
DWG No.
Qty
Parts No.
Remarks
Backplane
W-L00950
5096-204
1
Control module
W-L00958
5096-225
Inverter module
W-L00960
4
5096-305
3
SW Regulator module
W-L01170
5096-338
3
Capacitor module
W-L00954
5096-208
1
Power supply module
W-L01146
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.
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
A1
3
CN110
A3
CN114
SERVO POWER
FAN
2
CN115
PILOT
LAMP
2
POWER RELAY
CN109
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
3
CN306
INPUT VOLTAGE
AC200V
AC220V
AC230V
CONNECT
1PIN 2PIN
1PIN 3PIN
1PIN 4PIN
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

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
CR1
0
3
N
C
TP1
2
3
N
C
VR1
TP2
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.
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.
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 <such as P999>
and make sure that the origin position is in alignment with a matchmark <>. If not, mark that
position.
(2)
With the control power of the robot controller ON, remove the two bolts (M58) that are fixing
the charging battery to the External Axes Controller in order to remove the battery.
(3)
Remove the tab-on terminals of the connecting cable from the charging battery.

WARNING
(1) Disconnecting the charging battery with the control power OFF results in a loss of 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 <namely, the wire identification mark
[+]
(white wire) to the plus terminal of the charging battery, and the mark [-] (blue wire)
to the minus
terminal, respectively>.
Fix the charging battery in position using the two bolts (M58) that were removed in procedure
(3).
5-23
Front
Charging Battery
BT2
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)
External Axes Encoder

(Signal Line)
CN1
(Power Line)
Ex.Ax- 3 Ex.Ax- 2 Ex.Ax- 1

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

Ex.Ax- 2
Ex.Ax- 3
Ex.Ax- 1
R51
CN205/
CN206
CN251 CN250
FC2
Backplane #0
PCB51
Main Board
PCB2
BT1
Servo
I/F Board
PCB102
CN205 CN203 CN201

J2
CN210
CN209 GR
CN4
Backplane #1
PCB151
CN227
Servo Unit #0
PCB56 SWR Module
CN209 GR
CN215
MACB_#0
Control Module
PCB52
Power Relay
MS1
Charging Battery #1
BT102
CN205
CN203/
CN204
CN203
CN201/
CN202
Regenerative
Resistor #1
CN227
CN201
Servo Unit #1
PCB156 SWR Module
CN210
CN215
MACB_#1
Power
Relay #1
MS101
Control Module
PCB152
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
External Axes
Board #1
PCB103
Cooling Fan
Cooling Unit
<Robot Controller>
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)
CN106 CN105 CN306

CN104
Power Unit #1
PCB101
CN110
CN40 CN39
CN150
TBP1
AC100V
(MAX0.5A)
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)

Manipulator
CN2
Ex
Ex
Ex
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
CN1
(Power Line)
(Signal Line)
Ex.Ax- 5
Ex.Ax- 3
Ex.Ax- 1
R51
CN205/
CN206
CN251 CN250
FC2
J2
PCB2
BT1
Servo
I/F Board
PCB102
Backplane #0
PCB51
Main Board
CN210
CN209 GR
CN4
Backplane #1
PCB151
CN227
CN205 CN203 CN201 Servo Unit #0

PCB56 SWR Module

CN209 GR
CN215
MACB_#0
Control Module
PCB52
Power Relay
MS1
Charging Battery #1
BT102
CN205
CN203/
CN204
CN203
CN201/
CN202
CN227
CN201
Servo Unit #1
PCB156 SWR Module
CN210
CN215
MACB_#1
Control Module
Power
Relay #1
MS101
PCB152
CN50
FC10
PS1
CN2
DC5V
CN302
FC10
CN41
Mother Board
PCB3
PS2
CN2
DC24V
CN5
CN1
CN106 CN105
CN104
CN1
CN110
CN306
Power Unit
PCB1
CN29A
CN41A
CN67A
CN81
Auxiliary
Transformer
TF1
CN109
CN107
CN7A
CN80A
CN101
CN271
CN272
CN273
CN274
CN275 CN1A
CN276
CN1
CN7
CN40
CN80
Cooling Fan
<Robot Controller>
External Axes
Board #1
PCB103
Cooling Unit
Breaker
NFB1
CN106 CN105 CN306

CN104
Power Unit #1
PCB101
CN110
CN109
ARCNET Card #1
PCB160
CN301
CN302
CN107
E
CN101
Cooling Fan
Cooling Unit
NL1
W
CN94
AC200V 3
Ref.1)
CN5
CN40 CN39
CN150
TBP1
AC100V
(MAX0.5A)
CN1
Charging Unit #1
CN30 CN31 PCB104
CN67
CN38
CN32
CN1
External Floppy
Disk Drive
PE
Extended Manipulator
Manipulator
CN2
(Signal Line)
CN1
(Power Line)
Ex.Ax- 1 to 6
Ex.Ax:1- 6
R51
CN251 CN250
General Electrical Connection Diagram of External Axes Controller

(L4808 / L5524: Manipulator Extended) (1/1)
FC2
BT1
Servo
I/F Board
PCB102
Backplane #0
PCB51
Main Board
PCB2
CN205 CN203 CN201

J2
Backplane #1
PCB151
CN227
Servo Unit #0
PCB56 SWR Module
CN210
CN209 GR
CN4
CN251
CN209 GR
CN215
CN205
CN250
CN203
CN210
CN215
MACB_#0
MACB_#1
Power
Relay #1
MS101
Control Module
PCB52
Power Relay
MS1
CN227
CN201
Servo unit #1
PCB156 SWR Module
Control Module
PCB152
CN50
FC10
CN1
PS1
CN2
DC5V
CN302
PS2
FC10
CN41
Mother Board
PCB3
CN2
DC24V
CN1
CN106 CN105 CN306

CN104
Power Unit
CN110
PCB1
CN29A
CN41A
CN67A
CN81
CN67
CN38
CN7
CN80
Auxiliary
Transformer
TF1
CN109
CN107
CN7A
CN80A
CN101
CN271
CN272
CN273
CN274
CN275 CN1A
CN276
CN1
CN40
Cooling Fan
<Robot Controller>
Ref.1)
CN5
CN106 CN105 CN306

CN104
Power Unit #1
PCB101
CN110
CN109
ARCNET Card #1
PCB160
CN301
CN302
CN107
E
CN101
CN40 CN39
CN150
TBP1
AC100V
(MAX0.5A)
CN1
CN5
CN1
External Axes
Board #1
PCB103
Cooling Unit
Breaker
NFB1
Cooling Fan
Cooling Unit
NL1
W
CN94
AC200V 3
External Floppy
Disk Drive
PE
V
0
0
2
C
A

3
1
er B
k
a F
Br N
T
U
P
NI
S
4
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
5
R
Z
4
R
Z
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
A
9
2
N
C
1
2
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
T
A
B
V
2
1
C
A
2
A
1
3
N
C
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
4
C
-TAB
+TA
1
L
A
1
4
N
C
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
D
N
G
6
2
4
1
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B
C
P
1
R
D
0
7
t
ni
U
g
n
gi
ar
h
C
C
N
6
0
1
N
C
1
S0
M1
6
2
0
1
1
N
C
6
0
3
N
C
C
N
2
R
D
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
C
N
3
A
2
A
0 1
9 9
1 2
A A
8
1
3
1
1
A
7
1
3
2
4
1
3
3
1
0
1
S 4 4
M 3 2
5
0
1 7 8 9
N
C 1 2 3
T
4
B
0
C 0
N 6
1 2
B B
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
T
U
O
V
5
+
4
N
VI
3
3.
+
5
C
N
1
5
1
B
C
P
D
N
G
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
e
ul
d
o
M
orl
nt
o
C
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
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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
+
2
N
U
R
V
O
+)
T(
E
S
E
R
A
V
2
1
C
A
T
A
B
C
C
V
1
M
O
C
V
O
2
T
S
R
S
B
A
D
N
G
1
N
U
R
V
O
2
V
5
E
D
S
-
T
A
B
D
S
+
1
T
S
R
S
B
A
V

E
R
M
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
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
+
B
C
C
V
0
0
6
2
1 2 3 4 5
B B B B B
1 1 1
E E E C R
A B C N G
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
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

(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
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
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
2
3
DR2
2
3
NC
4
CN105
A1
A2
A3
Power Unit
Ro
NC
To
FM11
B1
B2
B3
Power Supply
Module
(Servo Unit)
FM12
CN107
8
PCB59
FM7
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
9
FM2
9
FM3
Cooling Fan4
9
FM4
Power Indicator
NL1
Cooling Fan4
TB283
TB282
PCB1
20
21
Mother Board
CN41
NC
NC
AC Outlet
TBP1
CN150
RG2
RG1
RG2
P
N
GR
R
S
T
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
1
2
3

Operation Box
Emergency Stop
CN1
11
NC
CR2
(EMG)
NC
14
15
408
15
23
307
6
Optical Fiber
IC138
CN16
203
202
201
200
Servo ON
25
0V
TBRST
25
TBENB
81
NC
NC
82
NC
17
Mother Board
PCB3
4
5
JP2
62
302
303
19
300
2
8
68
301
1
6
61
18
25
4
5
25
24
11
403
12
402
401
10
400
14
CN1
JP3
(PCB)
CN18
Y
R
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)
External
Floppy
Disk
Drive
16
(BRAKE UNIT)
CN94
14
COM
FC2
406
24E
13
Auto Mode Indicator
27
13
Teach Mode Indicator
BT1
FC10
Main Board
PCB2
306
Stop Indicator
CN4
22
15
(EX.AXES)
10
CN216
22
405
16
CN220 CN215
Memory
Battery
12
13
80
Backplane
(Servo Unit)
PCB51
0V
CN1
Control
Module
(Servo Unit)
PCB52
305
55
TBCON
21
2
8
6
9
1
6
55
404
26
16
50
11
10
24V
308
304
63
26
JP1
20
64
24V
56
Emergency Stop
(T/B)
12
407
24
Teach Pendant
CN2
4
CN30
52
3
2
NC
53
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
Starting Box 3
Emergency Stop
Start 3
Stop
COM
24E
G
Start 3 Indicator
Stop Indicator
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
Start 4 Indicator
Stop Indicator

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

CN201
B1
B2
B3
CN67
A
E Brake (+)
F Brake (-)
GND
Positioner
CN1
A U
B V
C W
D GND
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)

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
(3)

Positioner
CN1
A U
B V
C W
D GND

CN201
B1
B2
B3
CN203
B1
B2
B3
CN67
1
2
G
H
I
J
U
V
W
GND
E
F
Brake (+)
Brake (-)

GND
(4)

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

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

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GENERAL CONTENTS

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

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

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

2. FOUNDATION WORK AND INSTALLATION

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

3. CONNECTING ROBOT PERIPHERAL JIGS

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

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

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

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

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

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

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

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

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

External Axes Controller (L5382) .................................................................................................... 4-6

External Axes Controller (L5554) .................................................................................................... 4-8

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

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

External Axes Controller (L5563) .................................................................................................. 4-14

External Axes Controller (L5564) .................................................................................................. 4-16

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

MAINTENANCE (EXTERNAL AXES CONTROLLER)

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

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

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

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

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

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

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

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

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

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

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

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

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

ELECTRICAL CONNECTION DIAGRAM

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

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

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

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

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

1.1 What is External Axes Controller?

Specifications of External Axes Controller

External Axes Controller

Number of axes / model

(Controlling the External Axes Controller without a combination

800 W or below x 1 axis

800 W or below x 2 axes

800 W or below x 3 axes

800 W or below x 4 axes

800 W or below x 5 axes

In the case of connecting robot peripheral jigs

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

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

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

4500 W x 2 axes + 1500 W x 1 axis

4500 W x 1 axis + 1500 W x 2 axes

4500 W x 3 axes + 1500 W x 1 axis

In the case of connecting a manipulator made by DAIHEN Corporation

Automatic Operation Speed

During positioningRefer to the corresponding specification for each

Origin return is not required because of the absolute position

During positioningRefer to the corresponding specification for each

Indirect cooling methoda sealed type controller

2080 %RhNo dew condensation