Almega PDF

CONTROLLER MAINTENANCE
Chapter1 Notes on Safety
Chapter2 Components
Chapter3 Replacement and Adjustment of Components
Chapter4 Periodic Inspection
Chapter5 Parts Layout and Electrical Circuit
Chapter6 Error Code
Chapter7 Welding Specifications
Chapter8 Specifications of External Axis

CONTENS
CONTENTS
Chapter 1 Notes on Safety

1.1 Safe Use of the Robot System .................................................................................................. 1-1
1.1.1 Safety Measures on Robot................................................................................................... 2
1.1.2 Safety Measures on Teaching and Inspection ..................................................................... 6
1.1.3 Safety Measures on Test Operation ..................................................................................... 8
1.1.4 Safety Measures on Automatic Operation............................................................................ 9
1.1.5 Relocation, Transfer and Sale of Robot ............................................................................. 11
1.1.6 Disposition of Robot ........................................................................................................... 11
1.1.7 Labels on Robot and Robot Controller............................................................................... 12
Chapter 2 Components
2.1 Component Layout in AX-C Controller ...................................................................................... 2-1
2.1.1 Component Layout in AX-C Controller .............................................................................. 2-1
2.2 Block Diagram of AX-C Controller ............................................................................................. 2-3
2.2.1 Block Diagram of AX-C Controller ..................................................................................... 2-3
2.2.2 Outline and Specifications of Components ....................................................................... 2-4
2.3 Function of Components and Units ........................................................................................... 2-8
2.3.1 Multi Power Supply Unit (L8810A00) ................................................................................ 2-8
2.3.2 CPU Board (L8800C00) .................................................................................................... 2-9
2.3.3 Storage Board (L8800S00).............................................................................................. 2-11
2.3.4 I/O Board (L8800M00).....................................................................................................2-12
2.3.5 Riser Board (L8800R00) ................................................................................................. 2-13
2.3.6 Sequence Board (L8800F00) .......................................................................................... 2-14
2.3.7 IPM Drive Unit ................................................................................................................. 2-18
2.3.8 High-power Unit............................................................................................................... 2-21
2.3.9 Teach Pendant................................................................................................................. 2-22
2.3.10 Operation Box and Start Box (Option)........................................................................... 2-23
2.4 Function of Optional Items....................................................................................................... 2-24
2.4.1 Relay Unit ........................................................................................................................ 2-24
2.4.2 Step-down Transformer (Floor-installation type) ............................................................. 2-29
2.4.3 Robot I/F Board ............................................................................................................... 2-34
2.4.4 CAN I/F Board (Option) ...................................................................................................2-36
2.4.5 Welding Power Supply I/F ............................................................................................... 2-37
Chapter 3 Replacement of Components and Adjustment

3.1 Replacement of Components .................................................................................................... 3-1
3.1.1 Replacement of Board and Multi Power Unit .................................................................... 3-2
3.1.2 Replacement of Sequence Board ..................................................................................... 3-4
3.1.3 Replacement of IPM Drive Unit ......................................................................................... 3-5
3.1.4 Replacement of High-power Unit ...................................................................................... 3-6
3.1.5 Replacement of Battery ..................................................................................................... 3-7
3.1.6 Replacement of Cooling Fan............................................................................................. 3-8
3.2 Adjustment ................................................................................................................................. 3-9
3.2.1 Adjustment of Power System ............................................................................................ 3-9
3.2.2 How to Replace Primary Power Supply .......................................................................... 3-10
1
CONTENTS
Chapter 4 Periodic Inspection

4.1 Periodic Inspection Schedule .................................................................................................... 4-1
4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair............................. 4-1
4.1.2 Inspection Schedule .......................................................................................................... 4-3
4.1.3 Notes on Periodic Inspection.............................................................................................4-3
4.1.4 Warrantee Period .............................................................................................................. 4-3
4.1.5 Inspection Item .................................................................................................................. 4-4
4.1.6 Inspection before Long Vacation ....................................................................................... 4-5
4.2 Maintenance Parts..................................................................................................................... 4-6
4.2.1 Maintenance Parts............................................................................................................. 4-6
4.2.2 AXC*** ............................................................................................................................... 4-7
4.2.3 Operation Box AXOP-00** ............................................................................................ 4-10
4.2.4 Start Box AXST-00** ..................................................................................................... 4-11
4.2.5 Welding Power Supply I/F (2CH specifications) AXWF-00** ....................................... 4-12
4.2.6 Welding Power Supply I/F (4CH specifications) AXWF-01** ....................................... 4-12
4.2.7 Control Cables................................................................................................................. 4-13
4.2.8 Alarm Display................................................................................................................... 4-17
Chapter 5 Parts Layout and Electrical Circuit

5.1 Parts Layout and Electrical Circuit Diagram of AXCMN1.......................................................... 5-1
5.1.1 General View of AXCMN1 ................................................................................................. 5-1
5.1.2 Parts Layout of AXCMN1................................................................................................... 5-2
5.1.3 Electrical Connection of AXCMN1 (Whole) ....................................................................... 5-3
5.1.4 Electrical Connection of AXCMN1 (for Power).................................................................. 5-4
5.1.5 Electrical Connection of AXCMN1 (for Welding Power Supply)........................................ 5-5
5.1.6 Electrical Connection of AXCMN1 (for Encoder)............................................................... 5-6
5.1.7 Electrical Connection of AXCMN1 (for Motor)................................................................... 5-7
5.1.8 Electrical Connection of AXCMN1 (for Operation/Start Box) ............................................ 5-8
Chapter 6 Error Code 6

6.1 When fault has occurred............................................................................................................ 6-1
6.2 Concerning the fault details ....................................................................................................... 6-2

6.2.1 Fault category.................................................................................................................... 6-2
6.2.2 Concerning criticality codes and fault codes ..................................................................... 6-2
Chapter 7 Welding Specifications

7.1 Connecting Welding Power Supply ........................................................................................... 7-1
7.1.1 Connecting Almega Digital Welding Power Supply........................................................... 7-1
7.1.2 Connecting Digital Welding Power Supply ........................................................................ 7-9
7.1.3 Connecting Welding Power Supply I/F............................................................................ 7-13
Chapter 8 Specifications of External Axis

8.1 External Axis .............................................................................................................................. 8-1
8.1.1 Specifications of External Axis........................................................................................... 8-1
8.1.2 External Axis Cable ........................................................................................................... 8-3
8.1.3 Connecting External Axis Cable ........................................................................................ 8-5
2
CONTENS
3
Chapter 1 Notes on Safety
This chapter describes the notes on safety of the robot system.

These are only the general notes and procedures about safety, not giving full
instructions. Create the safety control standards or equivalent on your own,
containing the work regulations.
Perform the safety control to secure the safety of operators.
1.1 Safe Use of the Robot System....................................................................1-1

1.1.1 Safety Measures on Robot....................................................................... 2
1.1.2 Safety Measures on Teaching and Inspection.......................................... 6
1.1.3 Safety Measures on Test Operation ......................................................... 8
1.1.4 Safety Measures on Automatic Operation................................................ 9
1.1.5 Relocation, Transfer and Sale of Robot ................................................. 11
1.1.6 Disposition of Robot ............................................................................... 11
1.1.7 Symbols on Robot and Robot Controller................................................ 12
1.1 Safe Use of the Robot System

Before installation, operation, maintenance and inspection, read this manual and other attached documents
thoroughly to fully understand the knowledge of each equipment, safety information and all the notices.
In this instruction manual, following signs respectively show the importance of the contents.
If handling the robot in a wrong way, an user may die or get severely injured.
Besides, in the case of the exigencies of alarming in a danger situation (a level of
DANGER urgency) is quite high, which is a limitative occasion.
If handling the robot in a wrong way, an user may die or get severely injured.
WARNING
If handling the robot in a wrong way, an user may get slightly injured or only the
property damage may occur.
CAUTION
Additionally, the following mark is used in this manual for a special important notice.
This is a notice especially to take the utmost care.
Notes on safe adjustment, operation and maintenance

(1) An operator must wear a working uniform, a helmet, a pair of safety shoes etc.
(2) Before turning the power ON, check that no operator is inside the robot work area.
(3) Before operating in the robot work area, check that the power is OFF.
(4) There may be a case that an operator has to perform the inspection, maintenance and other
operations with the power ON. In this case, be sure to perform at least by two persons in a pair so
that one person can keep the position for pressing the emergency stop button anytime. And the
other, performs the required operation quickly with carefully watching the robot work area and its
motion.
Besides, make sure that the evacuation route is clear before operation.
A robot is enabled to safely stop with the self diagnostic function and the error detection function in the event
of the error. However, accidents cannot be perfectly avoided.
Here are some examples of the possible robot accident.
･An operator performed Automatic operation without making sure that no

one was inside the robot work area.
･A robot suddenly started moving after entering the robot work area still in
Automatic operation mode.
･An operator only concentrated in the robot only under his/her nose but not
another one.
Points in common among the accidents above are ;
･Safety procedures were neglected.

･A robot performed an abrupt motion even though it seemed all right.
1-1
In short, these accidents are all resulted from human errors such as careless mistake, failure of following
the instructions etc. For these kinds of “abrupt happenings”, an operator cannot evade the accidents by
performing Emergency stop, running away etc. This will highly possibly result in a serious accident.
Here are some cases.
･ The speed of robot motion changed from low to high.

･ Other personnel carelessly operated.
･ A robot moved by the wrong program because of the abnormal action of peripheral equipment or the
program error.
･ Abnormal motion because of the noise, trouble, fault etc.
･ Mis-operation
･ A robot moved at a high speed even though intended at low speed.
･ Workpiece being transported by a robot dropped and flew in directions.
･ A robot was on standby waiting for the interlock, however the interlocking was released and the robot
suddenly moved.
･ The robot adjacent to or at the rear started its operation.
There will be more of “abrupt happenings” patterned accidents. In most practical situations, it is impossible to
stop the robot that has once started moving or to run away from it.
Therefore, thoroughly understand and follow the notices below to avoid those accidents.
Do not approach to the robot. If the robot abruptly moved, and the personnel is
touched or caught, then a death or serious accident will occur.
DANGER
When the robot is not supposed to move, it must not be enabled. If the robot
abruptly moved, and the personnel is touched or caught, then a serious accident
DANGER will occur.
When the robot should move, appoint a monitor to always monitor the safety. If
the robot abruptly moved, and the personnel is touched or caught, then a death or
DANGER serious accident will occur.
When the robot should move, always be ready to press the emergency stop button
while you work.
If the robot abruptly moved, and the personnel is touched or caught, then a death
DANGER or serious accident will occur.
1.1.1 Safety Measures on Robot
The robot must be designed and manufactured with suitable material and structure for its use
environment, containing no unnecessary protrusions or sharp edges. Also, it has provided with the
fail-safe function with no damage or accident occurs during operation.
Besides, the robot should maintain a good level of safety with functions as follows.
･Function to detect the incorrect motion and stop the robot
･Emergency stop function
･Interlocking function to prevent the dangerous situation caused by robot in the abnormal
action of peripheral equipment
1-2
The robot is of multi-articular structure, which allows each articulation always to form a
variety of angles depending on the robot motion.
Take great care especially in teaching so that you won’t get pinched in the articulations.
WARNING
(Note : Mechanical stoppers are provided at the end of movable range of articulation,
which is highly dangerous to be pinched in.)
Besides, the arm may fall by its own weight or move in unexpected directions if motors
are removed or the brakes are released. Be sure to take measures to prevent it from
falling and check that the surrounding is in a safe condition before you start operating.
The arm may fall if removing the motor without properly holding it.
Be sure to properly hold it before removing the motor.
WARNING
If removing the motor without The arm will drop.

properly holding the arm…,
For securing the arm, do not rely on the positioning pin only since it may be inserted in a
wrong way or only a half way. Use a wooden block, a sling or other items to hold the
arm securely before removing the motor. However, do NOT support the arm by
human hands.
A balance spring device is internally compressed under the normal condition.

Therefore, do NOT remove or disassemble it. It is a hazardous act.
CAUTION
To fabricate the end effector and equipment on the arm, use designated bolts; desired
size and number and tighten them with a torque wrench by a specified torque.
Besides, be sure to use clean and rust-free bolts, otherwise, the bolts will be
CAUTION loosened to result in a serious accident with an incorrect way.
To fabricate the end effector, set the weight and the static load moment within the range
of the allowable moment and of inertia on wrist axis of the robot.
CAUTION
Provide a fail-safe mechanism to ensure that the workpiece will be held even if when
the power or air supply to the end effector is shut off.
Be sure to sharp edges or protrusions so that the damage to either personnel or object
CAUTION can be avoided.
3
Supply the electric power, plant air and welding cooling water to drive the robot,
following specifications. Failure to follow the specifications will cause problems;
affecting the robot performance, and causing the abnormal behavior or trouble.
CAUTION Be sure to follow the specifications.
As for the electromagnetic disturbance, there are no measures to completely cut it with
the technology today, no matter the kind or the strength of the electromagnetic wave.
Follow the notes for applying the power during robot operation.
CAUTION With the electromagnetic wave, other noises or the defective board, recorded programs
may be sometimes erased.
As a safeguard, back up programs or constants in a compact flash card or other storage
media.
4
~ Brake Positive Release ~
If the operators are pinched in the robot, follow the procedures to save them.
(1) Press the emergency stop button immediately and stop the robot.
(2) Turn OFF the robot controller.
(3) The robot brakes are all released by performing the following procedures. To prevent the robot arm from
falling off, sling the 2nd and the 3rd axis arm with a wire rope or other items
(4) Remove the brake positive release connector (CNBKSW) fixed on the IPM drive unit in the robot controller.
To release the brake of robot arm, connect the brake positive release connector with the connector
(CNBKSW) on the IPM drive unit of robot controller. (Refer to the following figure.)
(5) Brakes on all the axes are released when turning the power ON. Check that the arms have been secured
before turning ON. Then, turn ON the robot controller.
Do not apply the servo power.
(6) Operate the arms manually to save the personnel pinched in a robot.
(7) After saving the personnel, be sure to remove the brake positive release connector.
And, fix them again onto the IPM drive unit.
Position of the brake positive release connector
Follow the notes below when applying the primary power with the controller door
opened due to the brake positive release etc.
Otherwise, the robot and its controller will malfunction or cause a trouble.
WARNING 1. Do not expose the controller to the direct sunlight.
2. After opening the door, do not apply the strong sunlight such as a penlight to the
internal parts of controller.
5
1.1.2 Safety Measures on Teaching and Inspection
Robot must be operated by only those who have taken the specified training and are
fully aware of safety and functions of robots. If unskilled personnel operated the robot,
accidents may occur due to mishandling of the robot.
CAUTION
When entering the robot work area with Motors ON, the emergency stop button must be
within reach of operators. In addition, be sure to position the monitor outside the robot
work area, being ready to immediately press the emergency stop button.
CAUTION Then, an emergency stop can be immediately made in the event of the abnormality.
Wear protective equipment such as a helmet or safety shoes when operating the
robot or the robot work area.
WARNING
When you enter the robot work area, carry the key SW, for switching the robot
operation to Automatic, and the safety plug with you, so that nobody may accidentally
WARNING start Automatic operation resulting in serious accident.
Display a sign “Teaching Under Way” on each operation panel so that other workers
are enabled aware of that the teaching operation is under way.
WARNING Otherwise, they may start Automatic operation, resulting in serious or fatal accidents.
When a number of operators are engaged in the teaching operation, the one with the
teach pendant must give orders to other operators to follow. If more than one
personnel give different orders at the same time, each operator will perform wrong
CAUTION operation, maybe causing accidents.
When a number of operators are engaged in the teaching operation in the large robot
system, be sure to establish how to communicate exactly in a distance such as by
gesture. Accidents may occur due to poor communication among operators because
CAUTION of noises around.
Operators must be provided with the escape route to immediately escape in an

emergency.
CAUTION
Always watch out the robot motion, performing the operation facing the front.
Do not work with your back toward the robot. because the operator may not notice
WARNING the start of robot motion.
Press the emergency stop button immediately if you notice anything abnormal.
Please make this action thoroughly known to every operator. Otherwise you may be
in imminent danger of the abrupt robot motion if you are just watching something
WARNING abnormal.
Prepare an appropriate working prescription and checklist for startup, the way of
operation and the actions to be taken in an emergency of robot according to its
installation location and working condition. Then, follow the working prescription to
CAUTION operate the robot. If not, but operating by the operator’s memory and knowledge only,
accidents may occur due to the wrong idea or the mistakes.
If the robot motion is not necessary, turn OFF the power before operating.
Then, the robot will not even accidentally work.
CAUTION
Check the program No. and the step No. before teaching. Editing the wrong
program or step No. will sometimes cause accidents.
CAUTION
Protect the completed programs by such as the memory protect function so that no
operators will edit afterwards by mistake. (AX controller is equipped with the memory
protect function forbidding the editing performance by each program or constant file.)
CAUTION
After completing the teaching operation, check the robot motion at low speed using the
check go/ back function and the velocity override function. If operating the robot
at a full speed in the playback mode without this check, a program error or other errors
CAUTION may possibly cause collision.
After completing the teaching operation, clean up the area within the safety fence and
check that anything is not left as tolls. A workplace foul with oil and grease or with
scattered tools will sometimes cause the accidents; falling down, slipping on them.
CAUTION Neatness is the first step for safety.
7
1.1.3 Safety Measures on Test Operation

In the taught program, jigs, sequence etc., some design-originated errors, teaching errors or
manufacturing errors may be contained. Therefore, when performing the test run, more careful
actions must be taken for safety. See below for some points.
At first, perform the motion check on all the buttons and the signals; emergency stop
button and other stop buttons essential to halt the robot motion. Then, perform it on
the error detecting –related functions. Confirming the ability of robot halt is the
WARNING first priority.
Unless otherwise the robot can come to a halt in emergency situations, serious
accidents are never preventable.
Before the test run, perform the motion check at low speed (approx. 5%~10%), using
the velocity override function. Repeat this check 2 to 3 cycles and correct the errors
immediately, if found.
Then, gradually increase speed (50%→70%→100%) and repeat the motion check
respectively 2 to 3 cycles.
CAUTION Operating the robot at high speed from the beginning will cause accidents since the
robot cannot immediately stop even if teaching errors are found.
Never perform the motion check within the safety fence since unexpected
happenings may occur during the test run. At the stage of test run, unpredictable
DANGER errors may occur due to low reliability, mostly resulting in the accidents.
8
1.1.4 Safety Measures on Automatic Operation
At the beginning and end of the work, clean up the workplace and keep everything
neat If the workplace is foul or messy, operators may fall down.
CAUTION
At the beginning of a day, ensure to perform the specified daily inspection following
the checklist so that the errors can be found to prevent the accidents in advance.
(Refer to the MAINTENANCE INSTRUCTION MANUAL for daily inspection items.
CAUTION Also, create a checklist on yourself based on this information for a thorough inspection.)
Display ”OFF LIMITS” sign at every entrance of the safety fence to keep operators
away from the fence even if the robot is not in motion.
CAUTION
Be sure there is no one within the safety fence before starting Automatic operation.
Accidents caused by neglecting this check is the most typical type of accidents.
DANGER
Before Automatic operation, confirm that the condition is ready for Automatic
operation including the program No., step No., mode and startup select.
If starting without noticing the wrong program or step is selected, robot may perform
CAUTION unpredictably and result in an accident.
Before Automatic operation, be sure that the robot is in a position to start Automatic
operation. Check both the program No. and the step No. match the robot position.
sIf not, the robot will abnormally behave to result in an accident.
CAUTION
Before startup, make sure the emergency stop button can be immediately pressed.
This is essential when unexpected robot movement occurred.
CAUTION
Operators must be always familiarized with motion path, operating condition,

running noise of the robot so that abnormalities can be immediately observed.
Since the robot will sometime shows signs before the failure, be fully aware of the
CAUTION normal condition to detect these signs in advance.
Make an emergency stop immediately if any abnormalities are observed. And,

report it to superiors or the personnel in charge of maintenance to take proper actions.
Rush attitude “Robot is moving anyway. That’ll be fine.” may cause not only a halt in
WARNING production by the trouble but also a serious injury to personnel.
9
When performing the motion check after the measures taken to the initial failure, be sure
that the failure has completely remedied. Do not operate the robot if somebody is
WARNING inside the safety fence, until this was confirmed, even at low speed.
Since this is still under the low reliable condition, another related errors may occur.
10
1.1.5 Relocation, Transfer and Sale of Robot
Hand over all the manuals including maintenance manuals and other related
documents to a new owner when relocating, transferring and selling the robot.
Particularly when this action is to be done overseas, the original user is responsible for
preparing and supplying all the documents in their languages, revising the display
CAUTION
languages, applying to their local legislation and others. If you fail to complete this
process, the new owner may operate the robot without the proper information, resulting
in accidents.
When the robot is relocated or transferred overseas and sold in either domestic or
overseas, the initial contractual terms on sale are not transferred to the new owner
including the safety related items unless otherwise special agreement has been
CAUTION concluded.
The original user and the new owner must conclude a new agreement on their own.
1.1.6 Disposition of Robot
Do not disassemble, heat or burn batteries already used for the robot and robot
controller. They may ignite, explode or burn.
CAUTION
Do not disassemble the robot controller into smaller than PCBs or units. It may burst or
you may be injured with a sharp edge or electric wires.
CAUTION
Do not disassemble the wire harness and the robot external wirings into further smaller
than disconnecting from connectors or terminal blocks.
Semiconductors and other pieces may cause injury to your hands or eyes.
CAUTION
Take the utmost care when scrapping robots to avoid accidents such as pinching your
hands or fingers.
CAUTION
Discard scrapped items with utmost care to avoid injury.

CAUTION
11
1.1.7 Labels on Robot and Robot Controller
Robots and robot controllers of DAIHEN robots “Almega series” are labeled with alarm signs for safe use.
Do not tear them off, damage them or cover. If it is the case, contact our engineers for making an order.
For how to order, inquire of our sales engineers in your local area.
The following shows the alarm signs attached to robot and robot controller. (Labels partly differ depending on
the types.)
Attaching alarm signs to MV6/MV6L/MV16
12
Attaching alarm signs to MG3
13
Attaching alarm signs to MH3
Attaching alarm signs to MS3
14
Attaching alarm signs to robot controller
15
Chapter 2 Components
This chapter describes the components of robot controller.
2.1 Component Layout in AX-C Controller........................................................2-1

2.1.1 Component Layout in AX-C Controller ..................................................2-1
2.2 Block Diagram of AX-C Controller...............................................................2-3
2.2.1 Block Diagram of AX-C Controller.........................................................2-3
2.2.2 Outline and Specifications of Components............................................2-4
2.3 Function of Components and Units.............................................................2-8
2.3.1 Multi Power Supply Unit (L8810A00) ....................................................2-8
2.3.2 CPU Board (L8800E00) ........................................................................2-9
2.3.3 Storage Board (L8800S00) ................................................................. 2-11
2.3.4 I/O Board (L8800M00) ........................................................................2-12
2.3.5 Riser Board (L8800R00) .....................................................................2-13
2.3.6 Sequence Board (L8800F00)..............................................................2-14
2.3.7 IPM Drive Unit.....................................................................................2-18
2.3.8 High-power Unit ..................................................................................2-21
2.3.9 Teach Pendant ....................................................................................2-22
2.3.10 Operation Box and Start Box (Option)...............................................2-23
2.4 Function of Optional Items ........................................................................2-24
2.4.1 Relay Unit ...........................................................................................2-24
2.4.2 Step-down Transformer (Floor-installation type) .................................2-29
2.4.3 Robot I/F Board...................................................................................2-34
2.4.4 CAN I/F Board (Option).......................................................................2-36
2.4.5 Welding Power Supply I/F...................................................................2-37
2.1 Component Layout in AX-C Controller

AX-C controller varies in its component layout depending on the series. Before performing the maintenance,
fully understand the function of each unit and component layout in the controller.
2.1.1 Component Layout in AX-C Controller
The outline drawing of AX-C robot controller is shown below.
Outline drawing of AX-C
2-1
The component layout in AX-C controller is shown below.
AX-C component layout
Details of unit
2-2
2.2 Block Diagram of AX-C Controller
2.2.1 Block Diagram of AX-C Controller

The block diagram of AX-C controller is shown below.
Block diagram
2-3
2.2.2 Outline and Specifications of Components

The table below shows the outline of each component.
Outline of components
No. Component Function
1 Multi power supply unit ・Power interruption detecting circuit
(L8810A00) ・DC+5V power supply
・DC+12V power supply
・DC+24V power supply
・DC+3V power supply (Option)
2 Riser board (L8800R00) ・Bus connection and power supply between each board
3 CPU board (L8800C00) ・Microprocessor and its surrounding circuit
・Fixed disk I/F (IDE)
・Floppy disk I/F
・LCD I/F
・RS422
・RS232C
・Ethernet
・PCI bus
・SA bus
4 Storage board (L8800S00) ・Compact flash card (For system use)
・Compact flash card (For user data backup)
・Teach pendant I/F
・CAN I/F
5 I/O board (L8800M00) ・Internal I/O circuit
・External interlocking I/O circuit
6 Sequence board ・Internal sequence circuit ・I/O circuit
(L8800F00) ・Emergency stop safety circuit
7 High-power unit ・Magnet switch control for motor power supply
(L8811A00) ・ Brake power supply
・Encoder power supply
8 IPM drive unit ・Servo control CPU
(L8800J00) ・Encoder I/F
・Motor drive power supply
・Motor drive circuit
・Brake control circuit
・Magnet switch control
9 Teach pendant ・Operation switch circuit
(Emergency stop, Auto/ teach select, Deadman switch)
・Teaching, Keyboard for multiple settings, LCD, Touch panel circuit
(option)
The table below shows the specifications of AX-C controller.
Specifications of AX-C controller
Item Specifications
Name AX-C
AXCMN1 (For MV6), ACXML1 (MV6L, MV16)
Model
AXCMG1 (For MG3), AXCSN1 (MH3, MS3)
Teaching system Teaching/ playback system
Driving system AC servo motor
Number of control axes Total independent simultaneous control (Max. 54 axes)
Control Positioning system PTP (Fast-forward) / CP (welding) control
system Speed control system Constant speed control of torch tip (Independent control of Max. 6 paths)
Joint coordinates, Right angle coordinates (Machine coordinates, Tool coordinates,
Coordinate system Workpiece coordinates, World coordinates (Absolute coordinates)),
User-defined coordinates
2-4
Item Specifications
Storage media Compact flash card
Memory capacity 160,000 instructions (by PTP instruction in a single mechanism)
Position (Positioning, Straight line, arc)
Memory contents
Condition (Welding condition, Weaving condition, Timer, I/O etc.)
Memory Number of task 9999
programs (The max. sequences per program is 9999 within the memory capacity.)
Compact flash card or PC
External storage
(Connection cables and the dedicated software are optional. PC is prepared by
media
customer’s arrangements.)
Welding power
supplies in Maximum 4
connection
Condition setting Direct value setting, Designation of welding condition files
CO2, MAG/ MIG, TIG welding
Welding method (Note: Configuration of welding peripheral equipment varies when applied in MIG or TIG
welding.)
Pre-flow time : 0.0∼9.9 seconds (set by 0.1 sec.)
Welding Welding current : 0 ∼500A (set by 1A)
control Arc voltage : 0.0∼50.0V (set by 0.1V)
Welding condition
function Crater time : 0.0∼9.9 seconds (set by 0.1 sec.)
Post-flow time : 0.0∼9.9 seconds (set by 0.1 sec.)
Gas OFF delay time : 0.0∼9.9 seconds (set by 0.1 sec.) (Note : 1)
Welding signal Wire outage, Shortage of gas pressure, Cooling water outage, Wire inching/ retracting
input etc.
Welding signal
Arc outage, Wire outage, Shortage of gas pressure, Cooling water outage etc.
output
Fixed patterned weaving (Linear function, Trigonometric function, Arc)
Weaving method
Joint weaving, Teaching weaving (Option)
Interpolation
Linear interpolation, Circular interpolation (3 dimensions)
function
CHECK GO, CHECK BACK
Checking operation
Sequence jump function
Joint coordinates : 5-step selection
Manual operation (Limited to 250mm/sec or lower at the torch tip.)
Operation
speed Right angle coordinates : 5-step selection including the pitch feeding (per 0.1mm)
(Limited to 250mm/sec or lower at the torch tip.)
Checking operation
5-step selection
speed
Wire inching/
Available (Individually applied to each welding power supply on Teach pendant.)
retracting function
Editing function Copy, Add, Delete, Cut-and-paste, Modify, Undo, Redo
Symmetrical shift, Parallel, Axis angle shift, Mirror image, Zoom, 3-dimension
Shifting function : Value input by the mechanism operation (Standard equipment)
Edit
External axis shift (Option)
Program call Call, Jump, Condition jump (Condition setting is available by constants or variables.)
Hot edit Program editing function available during playback
Arc retry
Welding error
Overlap function
recovery function
Auxiliary Automatic wire stick release function
welding The optimum welding conditions (current/ voltage/ speed) are automatically selected by
function Welding condition inputting the thickness, the groove shape and other factors of workpiece.
guidance function (Note : Available with CPDRA, CPDPAS and DM under the condition of “CO2/MAG
welding, Wire φ:1.2, Parallel fillet”.)
(Note: 1)
Post-flow time : Period of time since the robot has stopped until the gas flow ends.
Gas OFF delay : Period of time until the gas is shut off after the post-flow time.
When setting both Post-flow time and Gas OFF delay to 0sec. enables to prevent the corrosion of wire tip and
improve the arc start performance.
2-5
Item Specifications
Condition setting
Setting the direct general-purpose logical I/O port in the task programs
system
Allocation setting Allocating the dedicated logical I/O signals to arbitrary physical I/O port in the I/O
system conversion table
Dedicated physical Output : 4 points
External
I/O Input : 7 points
control
input General purpose
Relay unit : Expandable to 64 points by 32 points in each input and output (Option)
physical I/O
Electrical input
ON/OFF switching (DC24V, 10m)
specifications
Electrical output
Relay contact (Dry contact) output : AC100V or 30V, 1A Minimum current : 5V 1mA
specifications
Condition setting
Editing the LD program files on Teach pendant
system
32K words
Software Program capacity
( = 3.2k words /file × 10 files)
PLC
Full support for 5 of “IEC1131-3” languages
Sequence
<Note> The workbench (option) is separately required to use the languages other than
command
LD. LD is the only language that can be displayed and edited on Teach pendant.
Start support unit Starting by designation of the task program No. or from the user-defined sequence.
Automatic In positioning : Refer to the specifications of manipulator to be used.
operation speed In welding : 1∼999cm/min (Setting is available by 1cm/min.)
Start system Selecting the multi-station system or the program No. direct designation system
1 station (Standard)
Number of stations
Max. 4 stations by adding the start box (Option)
Designating the program No. by BCD code (Number of start available programs : 9999)
Program No. direct
Designating the program No. by Binary code (Number of start available programs : 9999)
designation
Discrete system (1∼16) : Directly starting the programs that support bit 1∼16
Start reservation is available for the task programs currently not in operation or
Start reservation
reservation. (Multi station system)
function
FIFO system (External signal)
Online modification
Automatic Modification or record of the welding current, Arc voltage and the welding speed is
of welding
operation available during automatic operation.
conditions
In automatic operation –
During positioning : Robot slows down and stops.
Temporary stop During welding : Robot stops welding performance and its motion.
Program editing is available after a temporary stop. And then after editing, restart can be
made from the designated sequence or position.
Function to shut off the motor voltage and then allow the operator to enter into the robot
Emergency stop
motion area. (Emergency stop button)
Machine lock, Dry run, Speed override (Switching the playback speed Low/High), Weld
Playback function
ON/OFF, Weaving ON/OFF, 1 step playback, Nonstop step playback, Cycle playback
Cycle time
Welding time
Control function
Production amount counter
In-section time measurement function
Door interlock, Mat switch, Safety plug
Safety function
Teach mode interlock, Auto mode interlock, Deadman switch
Mechanical shock sensor
Servo shock sensor (Option)
Mechanical stopper
Overrun limit switch
Protection function
Software limit switch
Internal temperature monitor
Power voltage monitor
Interference area check
Inspection due notification
Error history log
Maintenance function
Arc monitor (Only when using CPDRA､CPDACA､CPDPAS､CPDA or DM)
Automatic backup
2-6
Item Specifications
Emergency stop error
Control sequence error
CPU board related error
Servo error
Amplifier unit error
Encoder error
Error detection function Teach pendant error
PLC error
User error
Operation error
Spot welding error
Arc welding error
Sensor error
Connection check between Robot controller and Teach pendant
Connection check between Robot controller and Robot dedicated welding power supply
Diagnostic function Connection check between Robot controller and Manipulator
Internal circuit check inside Robot controller
Internal circuit check inside Teach pendant
Origin restoration is not required when the power turned ON supported by the battery-backup
Origin restoration absolute position detection function
(Note: Replacement of the battery is required every three years.)
Cooling system Indirect cooling system (Robot controller is a closed structure.)
Acoustic noise 70dB or less
Ambient temperature
0∼45℃
range
Ambient humidity range 20∼80%RH (Non-condensing)
1.5 kVA (for Almega AX-S3)
1.5 kVA (for Almega AX-H3)
3-phase AC200V
2 kVA (for Almega AX-G3)
Power supply +10%､ -15%
3 kVA (for Almega AX-V6)
50/60Hz
6 kVA (for Almega AX-V6L)
6 kVA (for Almega AX-V16)
Grounding D-type or higher robot dedicated grounding system
External dimensions of
558m (W) × 503mm (D) × 865mm (H)
controller
Outside dimensions with
1114m (W) × 503mm (D) × 865mm (H)
External axis controller
Weight Approx. 80 kg
Color Manipulator/ Panel : 10GY9/1, Ｍunsell scale
2-7
2.3 Function of Component
2.3 Function of Components and Units

The function of each component and unit is described in the following.
2.3.1 Multi Power Supply Unit (L8810A00)

This unit supplies DC power to use in the robot controller. Also, this is equipped with the primary power
monitoring circuit to interrupt into CPU in the occurrence of power interruption.
~Function~
・DC+5V power
・DC+12V power
・DC+24V power
・DC+3V power (Option)
・Primary power monitoring circuit
~General appearance~
~Connection~
Connector Function Connection destination
CNP DC+24V power output Connected to the sequence board
CNP5V DC+5V power output Connected to IPM drive unit
CNSWO AC200V power output Connected to IPM drive unit
CNAC AC200V power input Connected to the high-power unit
CNPS Power supply to the rack board Connected to the riser board
Be sure to check the motion of each switching regulator using the riser board (2.3.5 Riser Board (L8800R00))
by its LED.
The value of output voltage for checking in each switching regulator is as follows.
・DC5V 5.1±0.05V
・DC12V 12.0±0.5V
・DC24V 24.0±1V
2-8
2.3.2 CPU Board (L8800C00)

CPU board is not only to control the robot but also communicate with the user-interfaced peripheral equipment.
~Function~
･Microprocessor and its surrounding circuit
･Fixed disk I/F (IDE)
･Floppy disk I/F
･LCD I/F
･RS422
･RS232C
･Ethernet
･PCI bus
･ISA bus
DIMM1 CN1
DIMM2 CN2 CN3 CN4
JP1
JP2 JP3
CN12 LAN
CN5
JP4
JP5
CN6 MOUSE
CPU
CN7
JP9 VGA
Battery
CN9
JP8 バッテリ JP7

CR203
CN10 2
CN11 KEY
~Connection~
CN1 Parallel port No connection
CN2 RS232C No connection
CN3 RS422 Connected to the storage board (L8800S00)
CN4 USB Connected to the drive unit
CN5 LCD Connected to the storage board (L8800S00)
CN6 Mouse No connection
CN7 VGA No connection
CN9 CPU fan Connected to CPU fan on board
CN10 External battery No connection
CN11 Keyboard No connection
CN12 LAN No connection
2-9
~Jumper (JP) setting~

×：Open (single-ended) ○：Short-circuit
Location Status Description

1-2 ○
3-4 ×
5-6 ○
7-8 ○
9-10 ×
11-12 ○
JP1
13-14 ○
15-16 ×
17-18 ○ Setting COM2(CN3) to RS-422.
19-20 ○
21-22 ×
23-24 ○
1-3 ○
2-4 ×
JP2 5-6 ○
7-8 ○
9-10 ○
1-2 ×
3-4 × Terminating resistor on with RXD/TXD when
JP3
5-6 ○ using RS422.
7-8 ○
1-2 ○
JP4 Disk-on-chip address : D000H∼D1FFH
3-4 ○
1-2 ×
3-4 ○
JP5 Display mode TFT 640×480
5-6 ×
7-8 ×
JP6 1-2 ○ Setting the output of WDT to NMI
JP7 1-2 ○ Onboard LAN : ON
JP8 1-2 ○ CMOS details hold
JP9 1-2 ○ Onboard VGA : ON
2-10
2.3.3 Storage Board (L8800S00)

Storage board (L8800S00) is a memory board equipped with the compact flash card, the compact flash card I/F
and the teach pendant interface circuit (RS422 is connected through the storage board.). The compact flash card
is for storing the system software and the task programs, and the compact flash card I/F is for the user data
backup.
~Function~
・Compact flash card (for storing the system software and the task programs)
・Compact flash card (for user data backup)
・Teach pendant interface
・CAN I/F (For communication with the welding power supply)
CN CNCAN
TPC
CNPC CNSIO
CN422
CNLCD
CNCF
CNISA
~Connection~
CNCF IDE signal Compact flash card for storing the system software and the
task programs is mounted.(For L8800E: 256M)
CNPC PCMCIA signal Compact flash card I/F for user data backup is connected.
(For L8800U: 64M)
CNISA CPU bus Connected to the riser board (L8800R).
CNTPC Panel link signal Connected to the teach pendant.
RS422 signal
CNLCD LCD signal Connected to CN5 on CPU board. (LCD I/F)
CN422 RS422 signal Connected to CN3 on CPU board. (RS422)
CNCAN CAN communication Connected to the welding power supply.
~DSW setting ~
Setting location Setting status
Board No. 1 2 3 4 5 6 7 8
Storage board DIPSW1 OFF OFF OFF OFF OFF OFF - -
~Jumper(JP) setting~ ×：Open (single-ended) ○：Short-circuit

Setting location Status
J1 1-2 ×
J2 1-2 ×
J3 1-2 ○
J4 1-2 ×
J13 1-2 ○
J14 1-2 ○
J15 1-2 ○
J16 1-2 ×
J17 1-2 ○
J18 1-2 ○
2-11
2.3.4 I/O Board (L8800M00)

I/O board (L8800M00) is to control the digital I/O signals in the robot controller and also to and from the
peripheral equipment.
~Function~
・Internal I/O circuit
・I/O circuit for the external interlock
CNIN CNSQ CNOUT
P2 P1
~Connection~
CNIN Digital input Connected to the external input signals.
CNOUT Digital output Connected to the external output signals.
I/O circuit
CNSQ Digital I/O Connected to the sequence board (L8800F).
No connection if using as an extension I/O.
P1 CPU bus Connected to the riser board (L8800R) for CPU bus signal connection.
P2 CPU bus Connected to the riser board (L8800R).
~DSW setting~
Setting location Setting status Description
Board No. 2 1
OFF OFF 1st I/O board (Default)
I/O board SW1
OFF ON 2nd I/O board
2-12
2.3.5 Riser Board (L8800R00)

Riser board (L8800R00) is a backplane board to mount CPU board, the storage board, I/O board, the multi
power supply unit, PCI card and other components.
Storage board LED circuits
I/O board
Multi-power
unit
CPU board
PCI slot
~LED~
LED Description
K12V LED Lights while the switching regulator (12V) in the multi power
supply unit properly works.
K3V LED Lights while the switching regulator (3V) in the multi power supply
unit (Option) properly works.
K5V LED Lights while the switching regulator (5V) in the multi power supply
unit (Option) properly works.
K MLX LED Lights while CPU board is properly mounted.
2-13
2.3.6 Sequence Board (L8800F00)

Sequence board (L8800F00) is to control the sequences in the robot controller. The emergency stop circuit is
a dual circuit supporting ANSI/RIA15.06.
~Function~
・Sequence circuit in the robot controller
・Emergency stop safety circuit
~Connection~
Connector Signal Description

CNP DC+24V power input Connected with the multi power supply unit.
CNSQ Digital I/O signal Connected with I/O signals.
CNTP TP switch signal Connected with Teach pendant.
CNOP Operation box signal Connected with the operation box.
If not using the operation box, joint the short connector.
CNSV Servo amplifier I/O signal Connected with IPM drive unit.
CNOPT Option Optional connector
CNWEL Welding power supply signal Connected with the robot dedicated welding power supply.
2-14
・ TBEX3 (User connection)
Pin No. Signal Description

8 M2 External power ground
7 P2 External power 24V input
6 HPB Magnet ON signal output (Dry “b” contact) -
5 Magnet ON signal output (Dry “b” contact) +
4 HPA Magnet ON signal output (Dry “a” contact) -
3 Magnet ON signal output (Dry “a” contact) +
2 M1 24V ground
1 P1 24V
Pin No. Signal Description Common

11 RMD_EN External mode select (IN10) M1
10 E.H-TEACH External high-speed (IN11) MONCOM
9 E.MODE External teach/ playback (IN8） MONCOM
8 E.MON External Motors ON (IN24) MONCOM
7 MONCOM Motors ON common −
6 CPU.ERROR CPU error output - −
5 CPU error output + −
4 E.STOP.OUT2 Emergency stop output 2 - −
3 Emergency stop output 2+ −
2 E.STOP.OUT1 Emergency stop output 1- −
1 Emergency stop output 1+ −

Be sure to make a dual contact when applying either of the external emergency stop, the safety plug or Mat
SW.
< Example > When applying the external emergency stop : Pin1-2 and Pin3-4
Pin No. Signal Description

12 MATSW2 Mat SW input 2-
11 Mat SW input 2+
10 MATSW1 Mat SW input 1-
9 Mat SW input 1+
8 SFP2 Safety plug input 2-
7 Safety plug input 2+
6 SFP1 Safety plug input 1-
5 Safety plug input 1+
4 E.STOP2 External emergency stop input 2 -
3 External emergency stop input 2 +
2 E.STOP1 External emergency stop input 1 -
1 External emergency stop input 1 +
Jumper setting on Terminal block (Default)

Terminal block Terminal No.
Description
for short circuit
1-2 External emergency stop input 1
3-4 External emergency stop input 2
TBEX1 5-6 Safety plug input 1
7-8 Safety plug input 2
9-10 Mat SW input 1
11-12 Mat SW input 2
2-15
2-16
~LED~
LED No Function Details

LED1 Teach/playback mode Lights in the playback mode.
LED2 Motors ON Lights with Motors ON.
LED3 Motors ON enable Lights when the software is in “Motors ON” status.
LED4 Internal/ external Lights while the external signal has been controlling “Motors ON/OFF”
select signal.
LED5 MS ON enable Lights when the software enables the servo power ON.
LED6 TP enable Lights in the playback mode, interlocking with the selector SW on
Teach pendant.
LED7 External mode select Lights when the external mode is selected.
LED8 Deadman ON Lights when both Deadman switches are gripped.
LED9 Deadman OFF Lights when either one, or both, of Deadman switches is released.
LED10 Emergency stop Lights when EMG from TP, the operation box or the external EMG
input is released.
LED11 Safety plug Lights when the safety plug is short-circuited.
LED12 Servo ON -1 Lights while the servo power is being supplied to the drive unit.
LED13 Servo ON -2 Lights while the servo power is being supplied to the drive unit.
LED14 Servo ON Lights while the servo power is being supplied to the drive unit.
LED16 Over travel LS2 Lights when the over travel LS is short-circuited.
LED17 Over travel LS Lights when the over travel LS is short-circuited.
LED18 Emergency stop -1 Lights unless the emergency stop button on Teach pendant or the
operation box is depressed, interlocking with the emergency stop
output signal of TPEX2.
LED19 Emergency stop -2 Lights unless the emergency stop button on Teach pendant or the
operation box is depressed, interlocking with the emergency stop
output signal of TPEX2.
LED20 WPS check Lights when the software allows the inching/retracting function of the
welding power supply.
LED21 OFF check Lights while the magnet SW is OFF. LED does not light up when the
magnet SW or the relay in the emergency stop circuit is in contact
stick.
LED26 CPU error Lights when the CPU error occurs.
LED30 24V power Lights while 24V power is being supplied.
JP setting
×：Open (Single-ended) ○：Short-circuit
Setting location Setting status

JP1A 1-2 : ○
JP1B 1-2 : ○
JP2 1-2 : ○
JP3 1-2 : ○
JP5A 1-2 : ○
2-17
2.3.7 IPM Drive Unit

IPM drive unit is a servo amplifier to drive the motor, consisting of the encoder I/F, the motor drive circuit, the
brake control circuit and other components.
~Function~
・Servo control CPU
・Encoder interface
・Motor drive power supply
・Motor drive circuit
・Brake control circuit
~General appearance ~
2-18
∼Connection∼
Connector Function Details

CNRST Motor power input Connecting to the high-power unit.
CNAP Built-in power input Connecting to the multi power supply unit.
CNPN Motor power output Connecting to the additional axis dedicated drive unit.
CNR Regeneration discharge Connecting to the regeneration discharge resistor.
resistor I/F
CNP1∼5 Motor I/F Connecting to the manipulator motor.
CNEC1 Encoder I/F Connecting to the manipulator encoder.
CNEC2 Encoder I/F Connecting to the encoder of external axis (7th axis).
CNP5E Encoder power input Connecting to the encoder power inside IPM drive unit.
CNP5V 5V control power input Connecting to the multi power supply unit.
CNUSB Upper CPU communication Connecting to CN4 on CPU board.
I/F
CNSV Sequence board I/F Connecting to the sequence board (UM213).
CNMS High-power unit I/F Connecting to the high-power unit.
CNBK90 Brake power DC90V output (AC100V full-wave rectification)
A1-B1 Output For 1st ∼3rd axis
A2-B2 For 4th ~ 6th axis
A3-B3
th
A4-B4 For 7 axis
A5-B5
A6-B6
CNBKSW Brake positive release input Connecting to the brake positive release connector.
CNDB Dynamic brake I/F Containing the output signal that can control the short-circuit
relay used as a dynamic brake.
(Both the dynamic brake and the short-circuit relay are
external items for connection.)
Note that only the type MS3,MH2 and MG3 allow to connect
the dynamic brake.
CNBKA Additional axis brake signal Connecting to the additional axis dedicated IPM drive unit.
CNSVA Additional axis sequence Connecting to the additional axis dedicated IPM drive unit.
signal
CNACI Brake power input AC100V input
CNACO Brake power output AC100V output
(For the brake positive release unit : Option)
CNSHK Shock sensor signal input Connecting to the shock sensor of manipulator.
CNSHLA Additional axis shock sensor Connecting to the additional axis dedicated IPM drive unit.
signal
CNEX Additional axis servo signal Connecting to the additional axis dedicated IPM drive unit.
~LED display~
(UM221)
LED No Function Details LED color

LED1 Clock stop Flashes during the initial diagnosis. Orange
LED2 Communication CPU Lights when the communication CPU error occurs. Red
error
LED3 Communication CPU Flashes while the communication CPU normally works. Green
motion monitor
LED4 Main axis servo CPU Flashes while the main axis servo CPU normally works. Green
motion monitor
LED5 Wrist axis servo CPU Flashes while the wrist axis servo CPU normally works. Green
motion monitor
2-19
(L8800Y)
LED No Function Details

LED1 Brake release (DC) Lights while the brake voltage on DC side is ON.
LED3 Servo error Lights when the servo error occurs.
LED4 M1–1 Lights when J1~J3 axis are effective.
LED5 M1 –2 Lights when J4~J6 axis are effective.
LED6 M1 –3 Lights when J7 axis is effective.
LED8 Teach/playback mode Lights in the playback mode.
LED9 Over travel Lights when Over travel LS is ON, however, not when the signal is dual.
LED10 Servo ON Lights when the servo power is supplied to the drive unit.
LED101 Brake release (AC1) Lights while the brake voltage on AC side (relay) of J1∼J3 axis are ON.
LED102 Brake release (AC2) Lights while the brake voltage on AC side (relay) of J4∼J6 axis are ON.
LED103 Brake release (AC3) Lights while the brake voltage on AC side (relay) of J7 axis is ON.
LED111 Brake voltage check 1 Lights while the brake voltage on AC side (relay) of J1∼J3 axis are normal.
LED112 Brake voltage check 2 Lights while the brake voltage on AC side (relay) of J4∼J6 axis are normal.
LED113 Brake voltage check 3 Lights while the brake voltage on AC side (relay) of J7 axis is normal.
LED114 Brake voltage check Lights when AC100V is input from CNACI with the normal fuse.
~Check pin~
No. Details
Servo board (UM221)
CTP5 5V control power
CTM0 GND of 5V/15V control power
CTP15 15V control power
P5E 5V encoder power
M5E 5V encoder GND
CH1-4 Analog monitor (Option)
Brake board (L8800Y)
CTP1 24V power
CTM1 24V GND
~JP settings~
（UM221）
Setting location Default setting Remarks
J2 1-2 ○ Do not change the preset default setting.
（L8800Y）
Setting location Default setting Remarks
Brake timing switch
J1 1-2 ○ Emergency stop delay ON：1-2
Emergency stop delay OFF：2-3
1-2 ○ Overrun system switch
J2 1 system：1 – 2 ○, 4 - 5 ○
4-5 ○ 2 systems：2 - 3 ○, 4 - 5 ×
The alternative of 2 emergency stop output systems
J101 1-2 × Controlling by the additional axis brake board：×
Controlling by the main board ：○
If independently controlling MS3 and 4 of the additional axis with the
J103 1-2 ○ individual mechanism servo function, applying the additional axis : ×
Also when using the external 2-axes unit : ×
If independently controlling MS5 and 6 of the additional axis with the
J104 1-2 ○ individual mechanism servo function, applying the additional axis : ×
Also when using the external 2-axes unit : ×
2-20
~Fuse~
（L8800Y）
Setting location Rating
F101 250V 2A (φ 5.2×20)
2.3.8 High-power Unit

High-power unit consists of the following items.
・ Power unit (Supplying AC200V input to each part in the controller)
・ Magnet SW (Controlling the power applied to the drive unit by signals from the brake board.)
・ Current limiting resistor (Limiting the inrush current when the servo turned ON.)
~Function~
・Motor power supply magnet SW control
・Noise filter function
・Inrush current limiting function
2-21
2.3.9 Teach Pendant
This part describes the technical information of AX-C teach pendant.
F1 F7
F2 F8
F3 F9
F4
F5
F6
X- X+ RX- RX+
Y- Y+ RY- RY+
Z- Z+ RZ- RZ+
７８９
４５６
ON OFF
１２３ ENTER
+ -
０・ BS
FN
General appearance of AX-C teach pendant
~Switches provided in Teach pendant~
(1) LCD unit
LCD screen displays the details of operation currently being performed, the error log and others.
(2) Sheet key
A variety of keys including Numerical key, Function key, Axis key, Command key are allocated to the sheet keys.
See the instruction manual about how to use each key, operation procedures and so on.
(3) Selector switch
This switch enables the servo power to be applied from Teach pendant. To apply the servo power, set the
change-over SW in the operation box to Teach mode and this SW to the Teach side, and grip Deadman SW.
If the change-over SW in the operation box had been set to Playback mode, set this SW also to the Playback
side to turn the servo ON, no matter the status of Deadman SW.
Unless the change-over SW in the operation box and this selector SW are set at the same status, no servo can
be applied.
(4) Emergency stop button
Depress this button to urgently stop the robot. The servo power is shut off and the brake works by pressing
this button. To release the emergency stop, then pull up this button.
If you wish to bring the robot ready for the operation again, you need to press “Motors ON” button.
(5) Deadman switch
Gripping the teach pendant with both hands, Deadman switch is the one equipped in your left hand side.
This switch can be operated only in Teach mode, by gripping for the servo ON and releasing for OFF.
Servo power can be ON again by gripping Deadman SW only in the case that the servo power was turned OFF
by releasing this SW. For the safety sake, Deadman switch should not be invalidated.
2-22
2.3.10 Operation Box and Start Box (Option)
Brief diagrams of the operation box and the start box are shown below.
Operation box Start box
General appearance of the operation box and the start box
~ Switches provided in Operation box and Start box~
(1) Teach/playback switch (TEACH/PLAYBACK)
This switch is used when switching the mode of robot operation to TEACH/PLAYBACK. To keep the servo
power ON, in Playback mode, set the selector switch on TP to “PLAYBACK” and press “Motor ON” button. In
Teach mode, set it to “TEACH” and press “Motor ON” button. Then, grip Deadman switch.
(2) Motors ON switch (MOTOR ON)
By pressing this button, the robot operation mode changes to “Motors ON” status, changing its condition from
OFF to flashing. When the servo power is ON, this button lights up.
(3) Start switch (START)
The taught program starts running by pressing this button in PLAYBACK mode. This button lights while that
program is running.
(4) Temporary stop switch (STOP)
A robot temporarily stops by pressing this button during playback operation. This button lights while the robot
is temporarily in halt.
(5) Emergency stop switch (EMERGENCY STOP)
Press this button to urgently stop the robot. Then, the servo power is shut off and the brake works. To
release this emergency stop, turn this switch to the arrow direction.
2-23
2.4 Function of Optional Items
2.4.1 Relay Unit
With the Relay unit (L9110), the general-purpose physical I/O can be connected on the terminal board, and the
general-purpose physical output can be output at the relay contact. A relay unit can be connected to I/O board
by one-to-one, which means the extension of relay unit requires the same number of I/O board.
Condition setting Setting the direct general-purpose logical I/O port in the task programs.
External control input
Allocation setting Allocating the logical I/O port to the physical I/O port in the I/O conversion table.
General-purpose Relay unit : Extension is available up to 64 I/O points by a unit of 32 points (Option).
physical I/O (2 units maximum in a single case)
Electrical input
ON/OFF of DC24V, 10mA
specifications
Electrical output Relay contact (Dry contact) output : AC100V or DC30V, 1A
specifications Note) Minimum : DC5V, 1mA
Note) This value is only a rough standard for the minimum load.
It may vary in a practical operation depending on the switching frequency, the ambient condition and the
expected reliability. Be sure to check with the actual load.
2-24
~Allocation on Terminal block~

・Input signal
AX-C controller (Standard specifications) is equipped with 32 points of DC24V input signals.
These signals can be arbitrarily allocated to either general-purpose input signals or status input signals
(significant such as the external start signals). The following table shows the default at the factory shipment.
List of input signals (TBIN1)

Signal name
TB pin No. Description
(IN*)
1 IN1 General input signal
5 IN COM1 Common for Pin No.1∼4 (IN1∼IN4)
21 24V Internal power supply 24V
22 EX 24VA External power input (24V)
23 EX 24VB External power output (24V)
List of input signals (TBIN2)
Signal name
(IN*)
1 EX 0VB External power output (0V)
2 EX 0VA External power input (0V)
3 0V Internal power 0V
4 IN17 Program select bit 1
14 IN25 Program strobe U1
21 IN31 External stop (Input a signal when not used.)
22 IN32 External “Motors” OFF
2-25
24V CNIN TBIN1,TBIN2

P1
EXP1(24V)
TBIN1-22pin
EXP1(24V)
TBIN1-23pin
IN1
Signal input from the
external jigs etc.
IN2
.....
.....
.....
.....
.....
.....
.....
INCOM
EXM1(0V)
TBIN2-1pin
EXM1(0V)
TBIN2-2pin
M1
I/O board Relay board
Basic configuration of input circuit
1 2
TBIN2 TBIN1 TBIN2 TBIN1
3 21 3 21
2 22 2 22
1 23 1 23
TBIN2 TBIN1
3 21
2 22
External power 1 23 External power
supply input(0V) supply input(24V)
4
TBIN2 TBIN1
3 21
2 22
External power 1 23 External power
supply output(0V) supply output(24V)
Idea about the external 24V power supply
(1) Check that the short-circuit cable is connected to TBIN1 and TBIN2.
(2) Unfix the short-circuit cable connected to each TBIN1 and TBIN2.
(3) Connect the terminals for external power input (24V) and (0V) as shown in (3) above.
If applying multiple relay units or supplying 24V power to another, connect the 24V output terminal as shown
in (4) above.
2-26
･Output signal
AX control unit (standard specifications) is equipped with 32 points of DC24V output signals. These signals
can be arbitrarily allocated to either the general-purpose output signals or the status output signals (significant
signal such as “In starting-up”). The following table shows the default at the factory shipment.
List of output signals (TBOUT1)

Signal name
( OUT*)
1 OUT1 General output signal
5 OUT COM1 Common for Pin No.1∼4 (OUT1∼OUT4)
List of output signals (TBOUT2)

Signal name
( OUT*)
3 OUT19 Unit READY U1
4 OUT20 Program end U1
6 OUT21 Error U1
7 OUT22 Interlock alarm U1
8 OUT23 Alarm U1
9 OUT24 On emergency stop
11 OUT25 In teach mode
12 OUT26 On starting U1
13 OUT27 External programs are selected.
14 OUT28 External startup is selected.
16 OUT29 Motors ON
17 OUT30 Status output 1
18 OUT31 Task origin position 1 U1
19 OUT32 Information U1
2-27
EXP1
TBOUT1
OUTCOM
Signal output to the

CNOUT OUT4 external jigs etc.
.....
.....
.....
.....
OUT1
.....
EXM1
.....
.....
I/O board Relay board
Standard configuration of output circuit
2-28
2.4.2 Step-down Transformer (Floor-installation type)
The primary-side input voltage of the standard robot controller is 3-phase AC200V+10％, -15％(50/60Hz). With
any other higher input voltage, this transformer enables to step down the spplied voltage to 200V by being
connected with the robot controller.
・ Types of step-down transformer
The following table shows types of step-down transformer (TF10).

Two of them in the table, except L8472A, are the individual-installation type set up separately with the robot
controller.
Types of step-down transformer
Type Capacity Applicable system configuration (Note) Remarks

AX-MV6/MG3/Roboland series (single unit) Installed at the
L9095 3 kVA
AX-MV6/MG3/ bottom of controller
(Note) The applicable system configurations in the table above are only the examples. For selecting a step-down
transformer applying to your system, contact our company.
・ Connection of step-down transformer
Mounting location and connection way of the step-down transformer (3kVA capacity type) is shown below.
Mounting location and connection way of the step-down transformer
2-29
Connection of step-down transformer
2-30
・ Voltage switching tap of Auxiliary transformer (TF10)
The auxiliary transformer (TF10) supports the primary input voltage of AC190, 200, 208, 220, 230, 240, 380,
400, 415, 440, 460, 480 and 575V. To choose one of these voltage alternatives, the auxiliary transformer
(TF10) is provided with the voltage switching tap as shown in Fig 2.16.3.1.
Connect the jumper wire as shown in the table 2.16.3.1 according to the power voltage to be applied for
switching the tap.
U U1 U2 U3 U4 U5 U6 U7 V V1 V2 V3 V4 V5 V6 V7 W W1 W2 W3 W4 W5 W6 W7
U8 U9 U10U11U12 U13 U14U15V8 V9 V10V11 V12V13 V14V15 W8W9W10 W11W12W13W14W15
R R1 R2 S S1 S2 T T1 T2 Sh
Voltage switching tap of Auxiliary transformer (TF10)
2-31
U 190V
V W
190V
190V
190V
190V
190V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
0V
0V
0V
0V
0V
0V
(W10)
(W11)
(W12)
(W13)
(W14)
(W15)
(U10)
(U11)
(U12)
(U13)
(U14)
(U15)
(V10)
(V11)
(V12)
(V13)
(V14)
(V15)
(W1)
(W2)
(W3)
(W4)
(W5)
(W6)
(W7)
(W8)
(W9)
(U1)
(U2)
(U3)
(U4)
(U5)
(U6)
(U7)
(U8)
(U9)
(V1)
(V2)
(V3)
(V4)
(V5)
(V6)
(V7)
(V8)
(V9)
(W )
(U)
(V)
200V
220V
200V
220V
200V
220V
0V
0V
0V
(R1)
(R2)
(S1)
(S2)
(T1)
(T2)
(R)
(S)
sh
(T)
R S T
Internal circuit of the auxiliary transformer (TF10)
To avoid the electric shock hazard, be sure that the auxiliary transformer has not
been impressed before switching the voltage switch tap. In addition, hang up a sign
“Under operation” or others beside the power supply switch for enough
CAUTION safety measures.
Connection of jumper wires by the primary-side power voltage

Primary power Connection of the jumper wires
voltage Primary-side tap Secondary-side tap
190V U-U8, U1-U9, U1-V, V-V8, V1-V9, V1-W, W-W8, W1-W9, W1-U
240V U-U8, U6-U14, U6-V, V-V8, V6-V14, V6-W, W-W8, W5-W13, W5-U R-T1
380V U1-U8, U9-V, V1-V8, V9-W, W1-W8, W9-U R1-S
400V U2-U8, U10-V, V2-V8, V10-W, W2-W8, W10-U S1-T
415V U3-U8, U11-V, V3-V8, V11-W, W3-W8, W11-U
440V U4-U8, U12-V, V4-V8, V12-W, W4-W8, W12-U
460V U5-U8, U13-V, V5-V8, V13-W, W5-W8, W13-U
480V U6-U8, U14-V, V6-V8, V14-W, W6-W8, W14-U
575V U7-U8, U15-V, V7-V8, V15-W, W7-W8, W15-U
2-32
(U) 0V (U) 0V
U
U
(U1) 190V (U1) 190V
(U2) 200V (U2) 200V
(R)
0V (U3) 207.5V (U3) 207.5V
(R)
R
0V
(U4) 220V (U4) 220V
R
(U5) 230V (U5) 230V
(U6) 240V (U6) 240V
(U7) 287.5V (U7) 287.5V
(U8) 0V (U8) 0V
(R1)
200V (R1)
CAUTION
200V
(U9) 190V (U9) 190V
(R2)
220V (R2) (U10) 200V
(U10) 200V
220V
(U11) 207.5V (U11) 207.5V
(U12) 220V (U12) 220V
(U13) 230V (U13) 230V
(U14) 240V (U14) 240V
(U15) 287.5V (U15) 287.5V
(V) 0V (V) 0V
V
V
(V1) (V1) 190V
190V
(V2) (V2) 200V
(S) 200V
0V 207.5V (S) (V3) 207.5V
(V3) 0V
S
(V4)
S
(V4) 220V 220V
(V5) 230V
(V5) 230V
(V6) 240V
(V6) 240V
(V7) 287.5V
(V7) 287.5V
(V8) 0V
(S1) (V8) 0V
200V (S1)
200V
(V9) 190V
(S2) (V9) 190V
220V (S2) (V10) 200V
(V10) 200V 220V
(V11) 207.5V
(V11) 207.5V
(V12) 220V
(V12) 220V
(V13) 230V
(V13) 230V
(V14) 240V
(V14) 240V
(V15) 287.5V
power voltage and are in a proper connection.

(V15) 287.5V
(W) 0V
(W) 0V
W
(W1) 190V
(W1) 190V (W2) 200V
(W2) 200V
(T) (T) (W3) 207.5V
0V (W3) 207.5V 0V
Connection example of the case - 415V input voltage -

Connection example of the case - 240V input voltage -
T
T
(W4) 220V
(W4) 220V (W5) 230V
(W5) 230V 240V
(W6)
(W6) 240V
(W7)
287.5V
(W7)
287.5V (W8) 0V
(T1) (W8) 0V (T1)
200V 200V
Robot controller may be damaged with the impression of over voltage.

(W9) 190V
(T2) (W9) 190V (T2) (W10)
220V 220V 200V
(W10) 200V (W11) 207.5V
(W11) 207.5V (W12) 220V
(W12) 220V (W13) 230V
(W13) 230V (W14) 240V
(W14) 240V (W15) 287.5V
sh
sh (W15) 287.5V
Before turning the power ON, check that the jumper wires suit to the actually supplied
2-33
2.4.3 Robot I/F Board
This is to control the communication between the robot controller and the welding power supply.
Applicable combination of welding power supplies and robot I/F boards are shown in the table below.
Type of Welding power supply and Robot I/F board

Welding power supply Robot I/F board
CPDRA-351 L8268R00
CPDRA-501 L8268R00
CPDPAS-351 L8268P00
CPDPAS-501 L8268P00
CPDACA-201 L8268M00
ADPA-301 L8268T00
~Connection~
Connector Connection destination
CN 52 CN 52 on Robot I/F board
CN 53
CN 54 When applying a sensor
CN 55
CN 56 When applying Arc sensor
CN 57 CN 27 on Relay unit
CN 58 2nd welding power supply (L8268C CN58)
CN 59 Terminal resistor
CN 60 For maintenance (CAN flash writer card & cable)
CN 61 For maintenance (PC cable)
FC 51 Welding power supply (P6840P CN 1)
~Test pin~
Test pin No. Connected to :
TP 1 15G
TP 2 -15V
TP 3 +15V
TP 4 GND
TP 5 +5V
~Jumper pin~
Setting Setting status
Function Remarks
location (at shipment)
1-2 Short-circuit Setting the interrupt port to sensor from the
3-4 robot I/F.
5-6 1-2 :IRQ 9 3-4 :IRQ 70 5-6 :IRQ 5
Do not change from the 7-8 :IRQ 4 9-10 :IRQ 3
JP1 7-8 Open
standard setting. IRQ 9 is fixed set.
9-10
Do not change the standard setting.
1-2 Short-circuit Communication circuit section:

For switching power supply (5V)
Do not change from the Short-circuit:
JP2
standard setting. Using the internal power supply
Open: Using the external power supply
1-2 Short-circuit Communication circuit section:
For switching power supply (GND)
Do not change from the Short-circuit:
JP3
standard setting. Using the internal power supply
Open: Using the external power supply
2-34
~Connection of emergency stop signal~
Follow the instructions below for connecting the emergency stop signals to the welding power supply.
(1) For CPDPAS-351/501, CPDACA-201 and CPDRA-351/501
Terminal block Terminal No. Cable

CN5 7 EMG+: Blue
8 EMG-: White
Print board
プリント板
Terminal端子台NO.→
block No. 8 7 1
P6981Q
＋＋＋
CN5
(2) For ADPA-301

CN1 1 EMG-: White
2 EMG+: Blue
Terminal block No. 2 1 プリント板

Print board
端子台NO.→
P10216Q
＋＋
CN1
~Dip SW on Robot I/F Board~
Normal
Dip Switch 1 2 3 4 5 6 7 8
0 1 2 CKP MD RD BT U2
Robot I/F board 1 OFF OFF OFF OFF OFF ON OFF OFF
Robot I/F board 2 OFF ON OFF OFF OFF ON OFF OFF
2-35
2.4.4 CAN I/F Board (Option)
CAN I/F board (option) is required when connecting DM power supply and the robot controller.
~Connection~
Connector No. Remarks
CN 1 24V power supply
CN 2 Communication connector
CN 3 CAN input connector
CN 4 CAN output connector
~Test pin~
Test pin No. Remarks
CH101 24V
CH102 0V (GND of 24V and CAN5V)
CH103 CAN5V
CH104 D5V
CH105 D0V
~Connection of the emergency stop signal~
Stop signals to the welding power supply must be connected as follows.
< For DM350 >

CN2 1 EMG +: Blue
2 EMG -: White
Print
プリント板 board
端子台NO.→
Terminal block No. 4 3 2 1
P10260T
＋＋＋＋
CN2
2-36
2.4.5 Welding Power Supply I/F
< Welding power supply I/F AXWF-0005 >
Welding power supply I/F is required when applying the robot coupling with the general semi-automatic welding
power supply that does not build in the robot I/F function.
~Function of welding power supply I/F~
(1) Following the robot task programs to send out the start instruction to the welding power supply.
(2) Calculating the welding conditions taught in the task programs by following the welding characteristics data
stored in the system parameters, and outputting the command voltage to the welding power supply.
(3) Controlling the wire feed unit and the gas solenoid valve.
(4) Detecting Arc start failure, Arc outage and Wire stick in the welding end position.
To install the welding power supply I/F, screw 4 pieces of locking nuts (M8) to the anchor bolt.
General appearance of welding power supply I/F
~Details of welding power supply I/F~
Power lamp
AC200V power is supplied to the welding power supply I/F from the robot controller.
The lamp provided in the front panel of welding power supply I/F as shown above lights up when the proper
power is supplied.
If this lamp does not light up even though the robot controller is turned ON, check that either the fuse F1 in the
welding power supply I/F or the fuse F10 in the power cable is not blown.
2-37
~About Print board (L8770L) in the welding power supply I/F~
Components layout on Print board (L8770L)
(1) Display of motion status on Print board (L8770L)

LED function on the print board (L8770L), to display the motion status of the welding power supply I/F, is shown below.
Motion status LED on Print board (L8770L)

Inching Motion status
Retracting
checking
Gas
Welding
end
At welding
stop
emergency
During
LED No. Color Function Description
Emergency stop Lights off during OFF

LED 1 Green Lights off while inputting the emergency stop
emergency stop signal.
Green Arc start Lights on during ON ON
Lights on while the Arc start welding performance
LED21
command signal is being output
to the welding power supply.
Green Wire inching Lights on during wire ON ON
LED22 Lights on while operating inching/ retracting
inching/ retracting directly on TP. operation
Green Wire feed Lights on during ON ON ON ON
Lights on while the wire feed welding performance
LED23 command signal is output to the and wire inching/
wire feed unit and the welding retracting operation
power supply.
Green Wire feed motor +/- rotation Lights on during wire ON
LED24 Lights on when rotating the retracting
LED29 motor of wire feed unit the other
way.
Green Wire stick Lights on when the
Lights on while the welding welding performance
power supply I/F is detecting ends. However, it
LED25 wire stick. lights out if the wire
stick detection function
has been set to OFF in
the system parameter.
Green Gas valve motion Lights on during gas ON ON ON
Lights on while the opening checking or welding
LED27
command for gas solenoid valve performance
is being output.
2-38
(2) Setting SW on Print board (L8770L)
The switches in the table below are provided on the print board (L8770L) inside the welding power supply I/F to
specify the command voltage and the polarity for each welding power supply.
Switch on Print board (L8770L)

Switch Function Description
JP11 Welding current This is to switch the setting of base current
(REF1 switch) designated switch command signal.
JP12 Welding voltage This is to switch the setting of filler wire feeding
(REF2 switch) designated switch command signal.
Select the range of command signal voltage from 0 ∼ 5V, 0 ∼ 10V and 0 ∼ 15V and the polarity from either
positive (+) or negative (-).
Refer to the table below to properly connect the jumper pins.
Range of command voltage for each welding power supply

Welding current command SW Welding voltage command SW
Welding power supply
Voltage range Polarity Voltage range Polarity
TIG welding
AVP-300P / 500P 15V Positive 15V Negative
power supply
Plasma cutter TRC-121 10V Positive - -
2-39
~ Motion sequence of welding power supply I/F ~
Welding power supply I/F outputs a signal to the welding power supply by the timing as shown below, using the
setting of system parameters and the commands such as Arc start/ end or wire inching given from the robot
controller.
Information in the table below is only an example of motion sequence of the welding power supply I/F. The
actual motion may differ depending on the type of welding power supply to be used and the setting details of
system parameters.
1. If coupling the welding power supply and the robot both from DAIHEN, the default setting of wire slow down,
hot start voltage and hot start time are all set in advance to the optimum values for each welding power
supply.
For this reason, these parameters cannot be changed on the robot side.
2. If coupling the welding power supply from other companies and our robot, wire slow down, hot start voltage
and hot start time can be even specified on the robot side.
Example of the motion sequence of welding power supply I/F

Signal Specifications Timing chart
Dry contact (relay CR21) ON
Welding start OMRON LY2,DC24V
(Torch SW) MAX :5A, AC110V, DC24V OFF
MIN :0.1A, DC5V
Dry contact (relay CR22)
FUJITSU COMPONENT ON
Wire inching
VS-24MB
ON/OFF OFF
MAX :2.5A, AC110V, DC24V
MIN :0.1A, DC5V
0∼15V DC Wire slow down

ワイヤスローダウン
Current value MAX :50mA
command (A polarity differs depending on Crater
クレータフィ filler
ラ
(REF 1) the type of welding power supply.)
0∼15V DC Hotホッ
start voltage
トスタート電圧
MAX :50mA Anti wire stick

アンチスティック
Current value ワイヤ溶着解除の為の
Anti wire ッ
stick
(A polarity differs depending on アンチスティク for
command releasing the wire stick
the type of welding power supply.)
(REF 2)
ホットスタート時間
Hot start time
Dry contact (relay CR22)
ON
OMRON LY2,DC24V
Wire feeding motor
MAX :5.0A, AC110V, DC24V
ON/OFF OFF
MIN :0.1A, DC5V
DC24V Output Pre-flow

プリフロー Post-flow
アフターフロー
Gas valve MAX :300mA

ON/OFF
AS AE
100mA
Wire stick detection DC24V Output
current MAX :100mA
0∼500A(MAX)
(Depending on the welding
Welding current
power supply)
WCR-ON WCR-OFF
2-40
Chapter 3 Replacement of
Components and Adjustment
This chapter describes how to replace and adjust the components.
3.1 Replacement of Components .....................................................................3-1

3.1.1 Replacement of Board and Multi Power Unit ........................................3-2
3.1.2 Replacement of Sequence Board .........................................................3-4
3.1.3 Replacement of IPM Drive Unit.............................................................3-5
3.1.4 Replacement of High-power Unit ..........................................................3-6
3.1.5 Replacement of Battery.........................................................................3-7
3.1.6 Replacement of Cooling Fan.................................................................3-8
3.2 Adjustment ..................................................................................................3-9
3.2.1 Adjustment of Power System ................................................................3-9
3.2.2 How to Replace Primary Power Supply ..............................................3-10
3.1 Replacement of Components

For replacement of the print board and the unit in AX controller, it takes about 10 minutes or less respectively.
Be sure to obey the following notes to safely perform the operation.
Before replacing the components, be sure that 5 minutes or more has passed since
the primary power was shut off.
Do not perform the operation with wet hands, otherwise, you may sustain a serious
WARNING injury or be shocked to death by electricity.
Replacement operation must be performed only by the engineers who have taken our
robot school (maintenance course).
Inexpert operators may be shocked to death by electricity or caught in an
WARNING unexpectedly moved robot to result in a serious injury or a fatal accident.
Before operation, short-circuit between the operator’s hands and “G terminal” in the
robot controller, to make the same level of electric potential.
WARNING Otherwise, you may sustain a serious injury or be shocked to death by electricity.
When replacing the connectors, be sure not to make wrong connection or skip any of
them. Each print board is connected with multiple connectors.
Any mistakes in connection may cause the electric shock or burning down to result in
WARNING a serious injury or a fatal accident.
Do not damage the cables when replacing the components.

Do not touch any electrical parts on the print board or any contact parts of the
connector. When you hold the print board, do it with the edges.
If you accidentally touch the electrical parts, you may sustain a serious injury or be
WARNING shocked to death by electricity.
Follow the notes below when applying the primary power with the controller door
opened due to the maintenance work etc.
Otherwise, the robot and its controller will malfunction or cause a trouble.
1. Do not expose the controller to the direct sunlight.
2. After opening the door, do not apply the strong sunlight such as a serchlight to the
WARNING internal parts of controller.
3-1
3.1.1 Replacement of Board and Multi Power Unit
Before operation, be sure to check that 5 minutes or more has passed since the primary power was shut off.
Otherwise, an electric charge must be still remained on a board and an electrolytic condenser.
How to remove :
(1) Loosen 2 pieces of screws at the base of AX-C robot controller. (These screws are fixing the rack.)
After this operation, remove the cable and other items connected to the rack and pull it out to this side.
(2) Each board can be taken out by removing the screws fixing the metal fittings.
3-2
How to install :
(1) Insert a board into the rack along the board rail. Next, push it down until the connector goes in, and then
fix it with screws.
(2) Slide the rack into the base of AX-C controller. Be sure that the rack has slid under the stopper at the
base as shown in the figure below. Then, fix it with 2 pieces of screws and reconnect the cables.
3-3
3.1.2 Replacement of Sequence Board

How to remove :
(1) Remove all the connectors jointed to the sequence board (L8800F00).
(2) Remove the screws that fix the sequence board. (6 locations)
How to install :
(1) Fix the sequence board with screws.

(2) Attach the connectors originally connected to the sequence board.
Note :
・ Do not damage the removed connectors during operation.
・ Attach all the required connectors. Otherwise, it will cause a trouble.
3-4
3.1.3 Replacement of IPM Drive Unit
How to remove :
(1) Remove all the external connectors.

(2) Remove 4 pieces of screws that fix IPM drive unit.
(3) Pull out the IPM drive unit to the front. When doing this operation, do not touch the board and the
electrolytic condenser but hold the can part.
How to install :
(1) Insert IPM drive unit from the front of robot controller.
(2) Fix IPM drive unit with screws.
(3) Attach the connectors originally connected to IPM drive unit.
Note :
・ Do not hit the heat sink on the back.
・ Do not damage the removed connectors.
・ Do not drop IPM drive unit at your feet. It weighs about 15kg.
・ Attach all the required connectors. Otherwise, it will cause a trouble.
3-5
3.1.4 Replacement of High-power Unit
How to remove :
(1) Remove all the connectors jointed to the high-power unit.

(2) Remove the screws that fix the high-power unit. (2 locations as shown in the figure below.)
(3) Pull out the high-power unit to the front.
How to install :
(1) Insert the high-power unit from the front of robot controller.
(2) Fix the high-power unit with screws.
(3) Attach all the necessary connectors for connecting the high-power unit.
Note :
・ Do not damage the removed connectors.
・ Fix all the required connectors. Otherwise, it will cause a trouble.
3-6
3.1.5 Replacement of Battery
How to remove :
(1) Follow the information in 3.1.1 (Replacement of Board and Multi Power Unit) to pull out CPU board.
(2) Remove the battery (CR2032) attached on the board.
How to install :
(1) Mount the battery (CR2032) on CPU board.

(2) Follow the information in 3.1.1 (Replacement of Board and Multi Power Unit) to install CPU board.
Note :
After replacing the battery (CR2032), reset the date and time.
DIMM1 CN1
DIMM2 CN2 CN3 CN4
JP1
JP2 JP3
CN12 LAN
CN5
JP4
JP5
CN6 MOUSE
CPU
CN7
JP9 VGA
CN9
Bttery
JP8 JP7
CR203
2
CN10
CN11 KEY
Battery for replacement
3-7
3.1.6 Replacement of Cooling Fan
Before operation, check that 5 minutes or more has passed since the primary power was shut off.
How to remove :
(1) Detach the panel on the back of robot controller, the cooling unit and the rack.
(2) Remove the power cable of fan.
(3) Detach the panel, on which the fan is fixed, from the controller.
(4) Finally, remove the fan from the panel.
How to install :
(1) Fix the fan onto the fan-fixing panel.
(2) Attach the panel, on which the fan is fixed in ①, onto the controller.
(3) Fix the power cable of fan.
(4) Attach the panel on the back of robot controller, the cooling unit and the rack.
Note :
Consider the direction when fixing the fan so that the air convection occurs upwards.
3-8
3.2 Adjustment
3.2 Adjustment
AX controller usually does not require the adjustment except the replacing the power components.
The points of adjustment and its locations are described as follows. Note that you should not touch any
adjustment parts, unless otherwise required. Do not perform the adjustment operation before thoroughly
inspecting the cause of trouble even if a trouble or fault occurs..
3.2.1 Adjustment of Power System

When a trouble occurs in the power system or after the battery was replaced, measure the voltage of each
power supply by inserting a tester check pin into the wire part of connector. Perform an adjustment if the
measured value is out of the range of reference value. Use a digital voltmeter for the measurement.
Power Measurement location Reference value Adjustment point

(See the following page.)
Primary Specified Switching the primary power supply
power supply Breaker CB1
voltage ±10% (Note 1)
P1−M1 Sequence board (L8800F) DC24V±1.0V None
Terminal block TBEX3 : If the measured value is out of range of
P1 (P24V) - M1 (N0V) the reference value, replace the DC
power unit.
P5−M0 Drive unit (CNP5V connector) : DC5.1V＋0.1V / The volume on the switching power in
P5 - M0 -0.0V the multi power supply unit.
P5E−M0E Encoder power on IPM drive DC5.3V The volume on the IPM drive unit
unit (CNP5E connector) : The voltage P5E - M0E is DC5.1V±0.1V
P5E – M0E in the closest part to the robot encoder.
This value in the controller differs
depending on a type of robot. It is
about 5.3V if the wire harness is 5m.
(Note 1) For how to switch the primary power supply, refer to the following page.
3-9
3.2 Adjustment
3.2.2 How to Replace Primary Power Supply
< How to replace the primary power supply>
(1) Shut off the primary power supply.

(2) Take out the high-power unit.
(3) Change the connector of power unit to the one according to the desired voltage.
Connector pins differ depending on the voltage specifications in each primary power supply.
3-10
Chapter 4 Periodic Inspection
This chapter describes the periodic inspection.
4.1 Periodic Inspection Schedule......................................................................4-1

4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair .4-1
4.1.2 Inspection Schedule..............................................................................4-3
4.1.3 Notes on Periodic Inspection ................................................................4-3
4.1.4 Warrantee Period ..................................................................................4-3
4.1.5 Inspection Item......................................................................................4-4
4.1.6 Inspection before Long Vacation...........................................................4-5
4.2 Maintenance Parts......................................................................................4-6
4.2.1 Maintenance Parts ................................................................................4-6
4.2.2 AXC*** ..................................................................................................4-7
4.2.3 Operation Box AXOP-00**................................................................4-10
4.2.4 Start Box AXST-00**......................................................................... 4-11
4.2.5 Welding Power Supply I/F (2CH specifications) AXWF-00** ............4-12
4.2.6 Welding Power Supply I/F (4CH specifications) AXWF-01** ............4-12
4.2.7 Control Cables ....................................................................................4-13
4.2.8 Alarm Display ......................................................................................4-17
4.1 Periodic Inspection Schedule

Perform the daily and periodic inspection to prevent troubles, ensure the safety and maintain the performance.
This section describes the notes and details on periodic inspection operation.
4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair
To perform the inspection, maintenance, adjustment and repair of AX controller, you may be required to enter
the robot work area or to operate with the primary/ servo power ON.
Be sure to follow the notes below in all cases.
Do not enter the robot work area while the power is ON.
Do not approach the robot while it is moving.
Approaching the moving robot may cause a fatal accident resulting in a serious injury
WARNING or death.
Do not touch any live electrical parts.

If you touch them, you may receive a fatal electric shock hazard or a burn.
WARNING
Keep your hands, fingers, hair, clothes and other belongings away from the revolving
part. If you bring them to the parts such as the feed roll of wire feeder or the revolving
WARNING part of the fan, you may be caught in a revolving part and get injured.
(1) To ensure your safety, perform the inspection, maintenance, adjustment and repair with wearing proper clothes
specified by laws and regulations such as a protective hard hat, a pair of safety shoes, a pair of gloves and so on.
(2) Before operation, be sure to check that the robot can certainly stop when needed by testing the emergency stop or
temporary stop. Also, check that the fail-safe devices such as the safety plug or deadman SW, if equipped, properly
work.
If errors occur, stop the operation and immediately shut off the power supply. Then, inspect the cause of trouble to
take remedies appropriate to the situation.
(3) Inexpert operators must not approach the robot safety fence.
(4) Before operation, hang out a noticeable sign INSPECTION IN

“INSPECTION IN PROGRESS” as shown on the right to notify the operators
of that the inspection is going. PROGRESS
(5) Do not use any devices to possibly cause electromagnetic noises in and around the area where the inspection is
going on.
(6) Operations including the inspection must be performed by 2 or more persons; one for the practical operation and the
other as a monitor.
(7) Only the operators who have been trained for the function, operation and maintenance of robots can perform the
work such as inspection, maintenance, adjustment, repairs and so on. Also, if the special equipment is provided, be
fully acquainted with the equipment in details.
(8) Operators, even if qualified, must not perform the operation of the particular equipment without thorough knowledge.
4-1
(9) The signals and gestures used for the inspection operator, monitor and other operators of related devices must be
carried out based on the safety management standards of each user.
(10) Monitors must follow the notes below.
(A) Be in a position to overlook the entire robot work area to pay full attention for monitoring.
(B) Always carry the emergency stop button with you so that you can immediately press it when the error occurs.
(C) Do not allow anybody else to approach the robot work area unless they are engaged in the operation such as
inspection.
(11) Operators to perform the inspection and other works must follow the notes below.
(A) Be sure to check if it is possible to perform some operations outside the robot work area. If it is the case,
perform all the operations outside that area.
(B) Normally, turn off the robot before performing the inspection etc. If you have no choice but to operate while the
robot is working, be sure to report to the safety manager to ask for permission. After you obtain permission, then
perform the operation outside the robot work area.
(C) If you are required to perform the operation with the robot stand-by, check the procedures beforehand to safely
carry them out. If not specially required, shut off the input power supply of robot controller, welding power supply
etc. before operation. Besides, shut off the input power supply of jigs and peripheral equipment, or make it
invalid unless the special procedure is needed.
(D) When entering the robot work area, prepare for the malfunction of robot so that you can immediately press the
emergency stop button.
(E) Be sure to check the safety around your feet before operation. Do not work in an insecure or elevated (2m or
higher) scaffold.
(F) When working in the robot work area, be sure that you could see the entire robot motion. Never turn your back
to the robot.
(G) When replacing the print board inside the robot controller or the teach pendant, take the antistatic measures such
as using a static protective sheet and so on.
(12) Follow the notes below when an error occurs during the operation.
(A) If you find any abnormal motions of robot, press the emergency stop button immediately.
(B) Inform a monitor of the abnormality and turn off the robot controller.
Then, hang out the sign ”Do not turn ON.” Shown on the left. Do not turn ON.
(C) Check that the peripheral equipment has also been turned off.
(D) If you are required to enter the safety fence, be sure to remove the safety plug and keep it by yourself during
operation.
(E) Even if the robot automatically stops by the abnormalities in such as the voltage supply to robot, oil pressure in
the peripheral equipment, air pressure or other factors, be sure to make it completely stop.
Then, inspect the cause of trouble to take the measures against it.
(F) If the fail-safe function of the emergency stop button. does not work, shut off the main power immediately and
inspect the cause of trouble to take the measures against it.
(G) When restarting after the emergency stop, inspect the cause of trouble and take the remedies first. Then, insert
the safety plug again and restart from the outside the fence.
(13) When you finish the work, be sure to always check that the required connectors, covers and panel are properly fixed
and connected.
4-2
4.1.2 Inspection Schedule
Periodic inspection is essential to efficiently operate Almega series.
Perform the inspection following the schedule as shown below.

3-year
inspection
1-year 1-year 1-year
inspection inspection inspection
3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month
inspection inspection inspection inspection inspection inspection inspection inspection inspection inspection inspection inspection
Daily inspection
1 year & 1 year & 1 year & 2 years & 2 years & 2 years &
0 3 months 6 months 9 months 1 year 2 years 3 years ~
3 months 6 months 9 months 3 months 6 months 9 months
4.1.3 Notes on Periodic Inspection

① Only the operators who have taken our robot school (maintenance course) can perform the inspection
operation.
② Before operating the inspection, be sure to have the required parts, tools and a drawing.
③ Use our specified parts for replacement.
④ Before inspecting the robot, be sure to turn OFF the power.
⑤ Be sure that the primary power has been turned off before opening the controller door.
Pay great attention to avoid as much dust from the outside.
⑥ Wash your hands thoroughly before touching the parts in the controller. Especially when you touch the
print board and the connectors, pay great attention not to break IC parts by the discharge of static
electricity etc.
⑦ Never enter the robot work area when you perform the inspection with robot working.
⑧ Measure the voltage only at the specified location and take the utmost care about an electric shock and a
short-circuit of wire.
⑨ Do not perform the inspection for robot and controller at the same time. Do it one after another.
⑩ After the inspection finishes, be sure to idle the robot for a while to check its motion and then perform the
normal operation.
4.1.4 Warrantee Period
(1) We guarantee the robot system and provide the repair free of charge if the failures occurred within the
shorter period of the followings under the condition that the robot system has been properly operated and
periodically inspected as described in the instruction manual, and that the failures are due to the
manufacturing defects.
14 months after shipped from Japan if directly shipped from DAIHEN to the outside Japan
(1 year after shipped from DAIHEN if shipped from DAIHEN to other manufacturers, and then
exported to the outside Japan.)
Practical cumulative operating time of 2000 hours
(2) However, the warrantee policy shall not apply to the following cases even during the guarantee period.
Your repair will be charged.
(A) Failure due to an abuse or a misuse

(B) Failure due to unauthorized repairs or model changes made by other than DAIHEN
(C) Damage or failure due to act of God such as earthquake, fire and flood
(D) Failure due to improper transfer or storage after delivery
(E) Others similar to above
(F) Consumable or maintenance parts
4-3
4.1.5 Inspection Item

For performing the maintenance and inspection, refer to “3.2 Adjustment” and “5 Parts Arrangement”
in ”Maintenance Manual for AX-C Controller” and carry out the inspection on the items listed below.
No. Cycle Item Check point Means

3 months
6 months
3 years
1 year
Daily
1 ○ ○ ○ ○ ○ Whole outside • Adhesion of spatter, dust etc. Visual observation and cleaning
2 ○ ○ ○ ○ ○ Display • Peeling, staining Visual observation and cleaning
Controller back side • Cleaning the fin of cooling fan and Visual observation and cleaning
turning check
3 ○ ○ ○ ○ ○
• Checking and cleaning of the
regeneration discharge resistance
Wire harness cable • Damage, crush Visual observation
4 ○ ○ ○ ○ ○ External cable • Looseness of connector Tightening up
Lead wire
5 ○ ○ ○ ○ ○ Operation SW • Function of push button etc. Visual observation and cleaning
Teach pendant • Display lamp Visual observation check
6 ○ ○ ○ ○ ○ Operation box
Start box
Teach pendant • Emergency stop motion Be sure to check that pressing
7 ○ ○ ○ ○ ○ Operation box the emergency stop button can
Start box shut off the servo power.
8 ○ ○ ○ ○ ○ Entire controller • Dust, grime Visual observation and cleaning
Transformer • Heat, abnormal noise and abnormal Visual observation, noise check
9 ○ ○ ○ ○
odor and touching
Lead wire on • Looseness of the lead wire on Visual observation and
10 ○ ○ ○ ○
terminal block terminal block and tightening up
Print board in the • Looseness Secure it firmly.
11 ○ ○ ○ ○
controller
Door gasket • Gap and modified shape of gasket Visual observation
12 ○ ○ ○ ○
Lock key • Key locking Visual observation
Teach pendant • Damage Visual observation
13 ○ ○ ○ ○ • Cleaning the operation sheet and Visual observation and cleaning
display check
14 ○ ○ ○ Earth • Looseness and damage Visual observation, tightening up
15 ○ ○ ○ Drive unit • Looseness of connector Tightening up
16 ○ ○ ○ Board connector • Looseness of connector Pushing by hands
Inside the controller • Dirt and deficit If damage is found by the visual
(Relay and power • Condition of contact observation, replace the parts
17 ○ ○ ○
relay) with new one.
Relay unit (Option)
Battery • Battery voltage 3.0V or more
18 ○ ○ ○
(Using a tester)
19 ○ ○ ○ Cooling fan • Adhesion of oil, fumes, dust etc. Visual observation and cleaning
Voltage • Primary power voltage Voltage specification±10%
measurement • R4-S4-T4 AC200V±10%
20 ○ ○ ○ • P5-M0 DC+5V+0.1V/ -0.0V
• P1-M1 DC+24V±1.0V
• P5E-M5E (Note 1) DC+5.1V±0.1V
21 ○ Magnetic contactor • Replacement of magnetic contactor
22 ○ Battery • Replacement of battery
(Note 1) The voltage at P5E-M0E is DC5.1V±0.1V on the robot side. Inside the robot controller, it slightly differs
depending on the type of robot. It is about 5.3V with 5m of wire harness.
4-4
4.1.6 Inspection before Long Vacation

Before entering the vacation, check the following points and then turn off the power of robot.
① Check if the error “W1016 Encoder failure” is listed in the error history. If it is, replace the manipulator
battery with new one. Refer to “Robot Maintenance Manual” for how to replace it.
Check that the controller door is closed
4-5
4.2 Maintenance Parts
4.2.1 Maintenance Parts
The print circuit board applies the highly reliable parts. Comply with the following notes in performing
maintenance.
• Storage temperature –10 ~ +50 degrees

When storing parts over the long term, it is recommended to keep in the range of 25±10 deg.
Besides, abrupt variations in temperatures (over 10deg./hr.) must be avoided.
• Storage humidity 20 ~ 85% RH

When storing parts over the long term, it is recommended to keep in the range of 45∼65%.
Besides, choose the location in which no sign of dew condensation and mold are shown.
• Prevention of static electricity

Store the parts in the antistatic bag. If storing them in the extremely dry condition, static electricity
likely to occur and maybe result in damaging the semiconductor by the shock of its electrical discharge.
• Other ambient conditions

Store the parts in the location with no harmful fumes and the minimal dust.
Besides, no load must be applied while they are in stores.
4-6
4.2.2 AXC***
For AXCNM1
Recommended
No. Item Type Part No. Remarks
Qt..
1 IPM drive unit L8800J00 L8800J00 1 (Note 1)
Fuse F101 FGMB250V-2A 4610-065 1 IPM drive unit
1-1
(Brake board)
CPU board L8800C00 L8800C00 1
2
(PC-686BXWLX)-F/D
Battery Distributed by CR2032 1 For CPU board
(Button cell) any manufacturer Replace the battery every
2-1
3 years no matter its
operating time.
3 CF card assembly L8800E00 L8800E00 For system(256M)
4 Print board L8800F00 L8800F00 1 Sequence board
5 Print board L8800M00 L8800M00 1 I/O board
6 Print board L8800R00 L8800R00 1 Riser board
7 Print board L8800S00 L8800S00 1 Storage board
8 Power unit L8810A00 L8810A00 1 Multi-power unit
8-1 Print board L8810P00 L8810P00 1 Multi-power board
Switching regulator LDA75F-5-XFJKC 4814-044 1
8-2
(75W 5V)
Switching regulator ZWS50-12/J 4814-043 1
8-3
(50W 12V)
Switching regulator LDA100W-24 5096-527 1
8-4
(100W 24V)
8-5 Fuse F3 GP-32 4610-066 1 Multi-power unit
9 High-power unit L8811A00 L8811A00 1
9-1 Power unit L8811C00 L8811C00
9-2 Magnetic contactor SN-N11 4340-116 2
9-3 Auxiliary contactor UN-AX11 4340-117 2
9-4 Fuse F1,2 FGMB250V-2A 4610-065 2 High-power unit
9-5 Fuse F3 FGMB250V-1A 4610-057 1 High-power unit
Auxiliary W-L01547 4810-914 1
10 transformer
11 Cooling fan 4715MS-20T-B50-B18 4805-075 6
12 Automatic breaker SA33C/30(3Φ) 1
13 Breaker handle BZ6N10C 4614-089 1
14 Terminal cover BZ6TS10C3 4614-090 1 Breaker part
15 Pilot lamp L9092G00 L9092G00 1
Regeneration L9092T00 L9092T00 1
16
resistor
(Note 1) Check the specification of the number of robot axes and the motor capacity of additional axes.
Type of drive unit depends on those factors.
4-7
For the following models, the other components other than described below are the same as that for AXCNM1.
For AXCNL1
Recommended
Qt.
1 IPM drive unit L8801J00 L8801J00 1
Regeneration L9171T00 L9171T00 1
16
resistor
For AXCNG1
Recommended
Qt.
1-3 Dynamic brake unit L8698A00 L8698A00 1
For AXCNS1
Recommended
Qt.
1 IPM drive unit L8802J00 L8802J00 1
1-3 L8698A00 L8698A00 1
4-8
4-9
4.2.3 Operation Box AXOP-00**
Recommended
Qt.
Press button SW HA1B-V2E2R
1 4250-124 1
(Emergency stop)
2 Selector SW AH164-P2B11 4250-125 1
Lighting press button SW AH164TLR11E3
3 4250-071 1
(Red) < Stop >
3-1 LED lamp (Red) AHX695-24R 4533-405 (1)
Lighting press button SW AH164TLG11E3
4 4250-071 2
(Green) < Start/Motor ON >
4-1 LED lamp (Green) AHX695-24G 4533-406 (2)
5 Waterproof cover AHX668 5096-051 1
6 Protection cover AHX669 5096-185 2
7 Case L9111B01 L9111B00 1
8 Panel L9111B02 L9111B02 1
9 Print board L9111C00 L9111C00 1
10 Cable (For AXOP-0005) L9111F00 L9111F00 1
Cable (For AXOP-0010) L9112F00 L9112F00 (1)
Cable (For AXOP-0015) L9113F00 L9113F00 (1)
11 Connector L9111G00 L9111G00 3
4-10
4.2.4 Start Box AXST-00**
Recommended
Qt..
Press button SW HA1B-V2E2R
1 4250-124 1
(Emergency stop)
Lighting press button SW AH164TLR11E3
2 4250-071 1
(Red) < Stop >
2-1 LED lamp (Red) AHX695-24R 4533-405 (1)
Lighting press button SW AH164TLG11E3
3 4250-071 1
(Green) < Start >
3-1 LED lamp (Green) AHX695-24G 4533-406 (1)
4 Waterproof cover AHX668 5096-051 1
5 Protection cover AHX669 5096-185 1
6 Case E6039B01 E6039B01 1
7 Panel L9115B02 L9115B02 (1)
Cable (For AXOP-0005) L9115E00 L9115E00 1
8 Cable (For AXOP-0010) L9116E00 L9116E00 (1)
Cable (For AXOP-0015) L9117E00 L9117E00 (1)
4-11
4.2.5 Welding Power Supply I/F (2CH specifications) AXWF-00**

Recommended
Qt.
1 Power board L8770E00 L8770E00 1
2 Analog I/F board L8770L00 L8770L00 1
3 Robot I/F board L8700C00 L8700C00 1
Constant-voltage power ZWS50-5/J
4 4814-033 1
supply 5V
Constant-voltage power ZWS50-24/J
5 4814-034 1
supply 24V
6 DC fan 3610KL-05W-B40-L00 5096-526 1
PS2 Constant voltage power supply

(24V) (top) 4
PS1 Constant voltatge power supply 6
(5V) (bottom)
2
1 3
(top)
(bottom)
4.2.6 Welding Power Supply I/F (4CH specifications) AXWF-01**

Recommended
Qt..
1 Power board L8775E00 L8775E00 1
2 Analog I/F board L8770L00 L8770L00 1
3 Robot I/F board L8700C00 L8700C00 2
4 Constant-voltage power 5V ZWS50-5/J 4814-033 1
5 Constant-voltage power 24V LDA100W-24 5096-527 1
6 DC fan 3610KL-05W-B40-L00 5096-526 1
7 DA extension board L8775L00 L8775L00 1
PS2 Constant voltage power supply

(24V) (top) 4
7 PS1 Constant voltage power supply 6
(5V) (bottom)
2
1 3 3
(2 layrs:top)
(2 layrs:bottom)
(3 layrs:bottom)
(3 layers:middle) (3 layrs:top)
4-12
4.2.7 Control Cables
Cables connecting Robot ~ Robot controller
Control cable 1, 2
For AX-MV6/MV6L/MV16/MG3/MH3
(1) AXRB-1003 L9101A (3m)

Ref. No. Item Type Qt. Part No.
① Control cable1 (3m) L9101B00 1 L9101B00
② Control cable2 (3m) L9101C00 1 L9101C00
(2) AXRB-1005 L9102A (5m)

(3) AXRB-1010 L9103A(10m)

(4) AXRB-1015 L9104A(15m)

4-13
For AX-MS3
(1) AXRB-1403 L9106A (3m)

(2) AXRB-1405 L9107A (5m)

(3) AXRB-1410 L9108A (10m)

(4) AXRB-1415 L9109A (15m)

Cables around the welding power supply (For Robot dedicated digital welding power supply series)
Control cable 4
(1) EXRB-4005 (5m)

③ Gas hose (5m) L2527B00 1 L2527B00
④ Torch-side welding cable (5m) L2527D00 1 L2527D00
⑤ Workpiece-side welding cable (5m) L3442B00 1 L3442B00
⑥ Control cable 4 (5m) CN4 L8905B00 1 L8905B00
(2) EXRB-4010 (10m)

③ Gas hose (10m) L3375T00 1 L3375T00
④ Torch-side welding cable (10m) L3375E00 1 L3375E00
Workpiece-side welding cable
⑤ L3375L00 1 L3375L00
(10m)
(3) EXRB-4015 (15m)

③ Gas hose (15m) L3375V00 1 L3375V00
④ Torch-side welding cable (15m) L3375G00 1 L3375G00
⑤ Torch-side welding cable (15m) L3375N00 1 L3375N00
4-14
Control cable 5
(1) AXRB-5001 (1.6m)

⑦ Control cable 5 (1.6m) L9130B00 1 L9130B00
(2) AXRB-5005 (5m)

⑦ Control cable 5 (5m) L9131B00 1 L9131B00
(3) AXRB-5010 (10m)

(4) AXRB-5005 (15m)

Cables around the welding power supply (For Digital welding power supply series)
Control cable 4
(1) AXRB-4105 (5m)

③ Gas hose (5m) L2527B00 1 L2527B00
④ Torch-side welding cable (5m) L9155C00 1 L9155C00
⑤ Workpiece-side welding cable (5m) L9155D00 1 L9155D00
(2) AXRB-4110 (10m)

③ Gas hose (10m) L3375T00 1 L3375T00
Workpiece-side welding cable
⑤ L9156D00 1 L9156D00
(10m)
(3) AXRB-4115 (15m)

③ Gas hose (15m) L3375V00 1 L3375V00
⑤ Torch-side welding cable (15m) L9157D00 1 L9157D00
4-15
Control cable 5
(1) AXRB-5101 (1.6m)

⑦ Control cable 5 (1.6m) L9150B00 1 L9150B00
(2) AXRB-5105 (5m)

(3) AXRB-5110 (10m)

(4) AXRB-5105 (15m)

When connecting multiple welding power supplies
Control cable 7
(1) AXRB-7101 (1m)

⑧ Control cable 7 (1m) L9140B00 1 L9140B00
(2) AXRB-7102 (2m)

(3) AXRB-7105 (5m)

(4) AXRB-7110 (10m)

(5) AXRB-7105 (15m)

4-16
4.2.8 Alarm Display

Almega series manipulator and robot controller are labeled an alarm display that mentions important notes so
that the robot can be safely operated. If it is peeled off or damaged, contact our engineers for order.
For how to make an order, contact your nearest distributor.
Labeling location Item Part No. Qt.

Alarm display NK3636 1
Alarm display NK3637 1
Robot controller Alarm display NK3638 1
Alarm display NB10402 1
Alarm display NB10424 1
Alarm display of robot controller
4-17
Chapter 5 Parts Layout and
Electrical Circuit
This chapter describes the parts layout and the electrical circuit diagram.
5.1 Parts Layout and Electrical Circuit Diagram of AXCMN1 ............................5-1

5.1.1 General View of AXCMN1.....................................................................5-1
5.1.2 Parts Layout of AXCMN1 ......................................................................5-2
5.1.3 Electrical Connection of AXCMN1 (Whole) ...........................................5-3
5.1.4 Electrical Connection of AXCMN1 (for Power) ......................................5-4
5.1.5 Electrical Connection of AXCMN1 (for Welding Power Supply) ............5-5
5.1.6 Electrical Connection of AXCMN1 (for Encoder)...................................5-6
5.1.7 Electrical Connection of AXCMN1 (for Motor) .......................................5-7
5.1.8 Electrical Connection of AXCMN1 (for Operation/Start Box) .................5-8
5.1 Parts Layout and Electrical Circuit Diagram of AXCMN1
5.1.1 General View of AXCMN1
General View of AXCMN1
5-1
5.1.2 Parts Layout of AXCMN1
Parts layout of AXCMN1
5-2
RAISER BOARD
PCB5
<- P5V
<- P12V
<- P5V
<- P5V
<- P12V
<- P12V
(<- P3V)
<- P5V
P5V ->
P12V ->
<- CP12V
NLX ISA ISA ISA
(P3V ->)
CP12V ->
NFB1
ISA
TEACH OPERATING
MULTI POWER PCI PCI PCI PENDANT BOX
STRAGE CPU
SUPPLY UNIT CN422 BOARD I/O BORAD
BOARD L9092L00
FAN PCB4 CN3
<- COM -> PCB2
FOR IPM
DRIVE UNIT PCB3 PCB1
P5V CNLCD
FAN FOR CN5
<- VGA
COOLING UNIT P12V
L9092C00
NL1 P24V
W
CNNFB1 CNNFB2
CNSWO CNP5V CNP CNAC CNCF CNPC CNSIO CNCAN CNDN CNTPC ＣＮ４ CNSQ CNIN CNOUT
FAN3
POWER
BOARD FAN4 FAN FOR
PCB11 CPU RACK
L8811J00
CNCON FAN5 CF CARD CF CARD
AC100V FAN1 FAN2 (EXT.MEMORY)
CN100P FAN6
P24V(P1) -> RELAY UNIT
OUT ->
P24V(P1) ->
CNFANS
AC200V ->
<- AC200V
L9092G00 <- IN
<- OUT, IN ->

CN200P
CNTP
CNPU
L9092H00
L9092X00 <- COM ->
P12V, VGA ->
CNACV L4798G00
<- USB ->
CNMSP2 CNMSP1 CNTF W.P.S
<- CAN ->
AC200V -> OR
EMG ->
W.I/F
ST
DSW
L8801R00
STOP
AUTO
L9092Q00
TPENB
<- EMG
<- EMG
CNWEL CNTP CNSQ CNOP

TBEX3
L9092U00
CHP(CNP) SEQUENCE
P24V(P1)-> TBEX2
BOARD
CNSV PCB6 CNLS TBEX1
AC200V ->
<- AC100V TF1
L9092T00
L9092E00 CNRA
L9092P00
L9092M00
AC200V(CONTROL) ->
SVERR->
R51
5.1.3 Electrical Connection of AXCMN1 (Whole)
<- P24V(P1) (L9092Y00)

LS, SHOCK ->
AC100V(FOR BRAKE) -> <- MSON, EMG (Normally disconnect) L9092S00
L9092N00 CNSHKA
CＮＵＳＢ CNACI CNAP CNSV CNR CNBKSW CNEC2
CNEC1 P5E ->
L9092K00 IPM DRIVE UNIT
CNP5V <- ENCODER,
P5V -> UNIT1 CNBK90 <- SHOCK,LS
L8811G00
CNMS CNP5
L8811F00
<- MSON MSA,MSB ->
CNP15V CNP4
P15V
<- BRAKE
CNP3
Electrical connection diagram of AXCMN1 (whole)

CNP5E CN2
P5E
L8811D00 L8811E00 CNP2
CNRST
AC200V(POWER) -> CNP1 MOTOR POWER ->
CN1
MS2 MS1
R11 MANIPULATOR
R12
R13
L8811H00
POWER UNIT
UNIT2
5-3
5.1.4 Electrical Connection of AXCMN1 (for Power)
Electrical connection diagram of AXCMN1 (for power)
5-4
5.1.5 Electrical Connection of AXCMN1 (for Welding Power Supply)
Electrical connection diagram of AXCMN1 (for welding power supply)
5-5
5.1.6 Electrical Connection of AXCMN1 (for Encoder)
Electrical connection diagram of AXCMN1 (for encoder)
5-6
5.1.7 Electrical Connection of AXCMN1 (for Motor)
Electrical connection diagram of AXCMN1 (for motor)
5-7
5.1.8 Electrical Connection of AXCMN1 (for Operation/Start Box)
Electrical connection diagram of AXCMN1 (for operation box and start box)
5-8
Chapter 6 Error Code
This chapter describes the symptom and its measures on the error code of
AX-C robot controller.
6.1 When fault has occurred
6.1 When fault has occurred

When fault has occurred in the robot, the fault monitor starts, and the details of the fault (name of its category,
date/ time of its occurrence, description and remedial action) are displayed on the teach pendant.
①
⑤
②
⑥
⑦
④
① Fault category The name of the fault category appears here.
② Fault code and cause The fault code and cause appear here.
The fault code is expressed in alphanumerics. In the example of the
screen shown above, “A2101” is the fault code.
③ Details and remedial action The details of the fault and the remedial action to be taken appear
here. Use the remedial action displayed here as a reference, and
eliminate the cause of the fault.
④ Release method The method used to release the fault display appears here. When
all the contents of ③ and ④ do not appear in the display area,
scroll the screen using [up or down].
⑤ Number of fault incidents The figure on the right indicates the number of fault incidents which
have occurred simultaneously. Only one fault incident is displayed
on the screen at one time. To view other types of trouble, press
[ENABLE] and [up or down].
⑥ Date/time of occurrence The date and time of the fault occurrence appear here.
⑦ f12 <Failure Reset> Press this to release the fault display. The fault display can also be
released by pressing [RESET/R] twice.
6-1
6.2 Concerning the fault details
6.2 Concerning the fault details
6.2.1 Fault category

The fault categories which are displayed at ① on the previous page are established to enable
where the fault has occurred to be pinpointed to some extent.
Table 6.2.1 Fault category

Fault category Main fault
Emergency stop fault Emergency stop triggered by input from overrun, shock sensor, etc.
Fault detected by monitoring of control systems such as magnet
Control sequence fault
switches and circuit protectors, etc.
CPU board failure Watchdog timer detection or other CPU board-related fault occurrence
Servo fault Fault detected by servo driver
Amplifier unit fault Fault detected by amplifier unit
Encoder fault Encoder-related fault
Teach pendant fault Fault detected by teach pendant
PLC fault Fault detected by PLC
User fault Fault defined by the operator
Operation fault Fault caused by error in operation made by operator
Spot welding fault Fault inherent to “spot welding function” (but not included above)
Arc welding fault Fault inherent to “arc welding function” (but not included above)
6.2.2 Concerning criticality codes and fault codes
The fault codes displayed at ② on the previous page are expressed using the following format.
[Example] Control sequence fault code E1103
E 1 1 0 3
(A) (B)
(A) Criticality codes

The fault detected by the robot is classified into three types by their level of criticality.
Table 6.2.2 Criticality codes

Type of fault Details
E (errors) Fault caused by parts failure or internal data fault which prohibits
continued operation until the cause of the fault is eliminated, and fault
which may potentially injure the operator or damage the robot system if
operation is continued are classified as errors.
A (alarms) Fault which may lead to an error at a future point in time, fault which
must be remedied now or fault requiring simple operations, checks
and/or remedial action before robot operation or movements are
continued even though it may not potentially injure the operator or
damage the robot system are classified as alarms.
I (Information) Fault requiring that the operator and ambient devices be informed of
the occurrence of irregularities even though they will not interfere with
continued robot operations or movements is classified as information.
Information may sometimes be conveyed not when fault has occurred
but when the robot is operating normally.
(B) Fault codes

These are 4-digit numbers used to identify fault. (See the following pages.)
6-2
No Classification Condition Contents Measure Release
4 CPU board Power failure auto- When Primary power is lost or Check that output from the power Error reset
failure saving fault during voltage drops the current status unit(SR1) on the PCB rack is 5V. If not
latest shut-down. of the controller is saved to replace power unit(SR1).
RESUME.DAT.
12 Servo failure The robot is not This error occurs when the robot There are another equipment and a Please do error reset
corresponding to the does not reach the position even possibility to interfere. or turn on the drive
record point. if ten seconds have passed preparation.
since the command position was
output to the robot
20 Servo failure Abnormal velocity Abnormal velocity command Modify abnormal axis motion to be After removal of
command. Modify data is calculated. minimized. Contact NACHI service failure, please carry
abnormal axis motion. department in case axis motion is not so out "failure-reset".
big.
21 Servo failure abnormal servo This failure occurs when the 1. Please confirm whether the power- After removal of
tracking robot does not follow to the supply voltage decreases. 2. Please failure, please carry
command position. confirm whether set value is different out "failure-reset".
from actual value of tool weight or tool
gravity center or tool inertia moment. It
is thought that there is a problem in the
robot manipurator or hardware besides
22 Servo failure Position Deviation error This failure occurs when the (1)Please confirm whether the robot After removal of
deviation between the command manipulator interferes in failure, please carry
and encoder data position something.(2)Please confirm that the out "failure-reset".
exceeds the set permissible Pay-load is within the nominal
deviation. rating.(3)If failure persists, the problem
may be a mechanical defect in the
manipulator contact NACHI service
23 Amplifier unit Encoder wiring This failure occurs when the (1)Please confirm whether connector After removal of
failure disconnection wiring for the encoder has been CNEC1/CNEC2 of servo substrate failure, please carry
disconnected, or there is no UM221 is correctly connected.(2)Please out "failure-reset".
encoder power supply. confirm the power supply voltage of the
encoder.(3)Please confirm whether
CNR4 is correctly connected.(4)Please
confirm wiring in the robot manipulator
referring to "Manipulator Maintenance
24 Amplifier unit Servo CPU stop This failure occurs when the (1)Please confirm servo substrate After removal of
failure servo CPU on servo substrate UM221 insertion.(2)Please confirm the failure, please turn on
UM221 stops. power supply of servo substrate power supply of the
UM221.(3)Please replace the drive unit. controller again.
25 Servo failure Encoder Bit jump This failure occurs when the (1)Please confirm whether connector After removal of
amount of the change of the CNEC1/CNEC2 of servo substrate failure, please carry
encoder data is abnormal UM221 is correctly connected.(2)Please out "failure-reset".
confirm the power supply voltage of the
26 Servo failure Interference detected This failure occurs when the (1)Please confirm whether the robot After removal of
robot manipulator collides with manipulator interferes in failure, please carry
something. something.(2)Please confirm that the out "failure-reset".
Pay-load is within the nominal
rating.(3)Please confirm the interference
detection level.(4)If failure persists, the
problem may be a mechanical defect in
the manipulator contact NACHI service
27 Servo failure Encoder data change This failure occurs when the (1)Please confirm whether connector After removal of
after stop encoder data continues to CNEC1/CNEC2 of servo substrate failure, please carry
change after the command UM221 is correctly connected.(2)Please out "failure-reset".
position is stops changing(i.e. confirm whether CNR4 is correctly
manipulator should not be connected.(3)Please confirm wiring in
moving). the robot manipulator referring to
"Manipulator Maintenance
Manual".(4)Please confirm the
manipulator is not obstructed by
anything (5)Please confirm that the Pay
28 Amplifier unit Low voltage of motor This failure occurs when the (1)Please confirm whether the supply After removal of
failure power Motor power supply voltage(P- voltage decreases more than a normal failure, please carry
N) are lower than regular setting value.(2)Please replace the drive unit. out "failure-reset".
30 Encoder failure Encoder absolute data This failure occurs when fault is (1)Please confirm the supply voltage of After removal of
failure detected in the encoder. the encoder refering to "AX controller failure, please turn on
maintenance manual".(2)Please confirm power supply of the
the wiring of the encoder.(3)Please reset controller again.
the encoder
31 Encoder failure Motor rotation too fast This failure occurs if at the time (1)Please confirm the supply voltage of After removal of
when turning Motors of turning Motors ON, the the encoder refering to "AX controller failure, please turn on
ON encoder speed is too fast. maintenance manual".(2)Please confirm power supply of the
the encoder
6-1
32 Servo failure Over current This failure occurs when the (1)Please confirm whether the robot After removal of
current in the drive unit exceeds manipulator interferes in failure, please carry
the rated value. something.(2)Please confirm that the out "failure-reset".
rating.(3)Please confirm the cable
between the controller and the robot
38 Servo failure Over load This failure occurs when the (1)Please confirm whether the robot After removal of
current in the motor or drive unit manipulator interferes in failure, please carry
exceeds the rated value. something.(2)Please confirm that the out "failure-reset".
rating.(3)Please confirm the cable
39 Servo failure Over rotation This failure occurs when the (1)Please confirm whether setting of the After removal of
number of rotations of motors Pay-load and center of gravity is failure, please carry
exceeds a maximum rotation correct.(2)Please confirm that the Pay- out "failure-reset".
speed limit. load is within the nominal rating.(3)If
failure persists, the problem may be a
mechanical defect in the manipulator,
contact NACHI service department
40 TP failure The abnormalities in CPU built in the teach pendant Please check whether there are any Control power supply
CPU in a T/P stopped. abnormalities in a T/P and a connection is re-switched on.
cable. Please reswitch on a power
supply. Please exchange a T/P, when
an error still comes out
42 Amplifier unit Over temperature of This failure occurs when the (1)Please confirm that the Pay-load is After removal of
failure motor motor temperature rises within the nominal rating.(2)Please failure, please carry
abnormally. confirm the wiring of the motor out "failure-reset".
thermostat refering to "Manipulator
Maintenance Manual".(3)Please stop the
robot in order to lowering the motor
temperature, and restart.(4)If failure
persists please lower the operation
43 Amplifier unit Over speed This failure occurs when the (1)Please confirm whether connector After removal of
failure rotation speed of motors is CNEC1/CNEC2 of servo substrate failure, please carry
abnormal. UM221 is correctly connected.(2)Please out "failure-reset".
confirm whether CNR4 is correctly
connected.(3)Please confirm wiring in
the robot manipulator referring to
"Manipulator Maintenance Manual"
44 Amplifier unit Over voltage of motor This failure occurs when the (1)Please confirm whether CNR is After removal of
failure power Motor power supply voltage(P- correctly connected.(2)Please confirm failure, please carry
N) are higher than regular that the Pay-load is within the nominal out "failure-reset".
setting level. rating.(3)Please confirm the cable
46 Amplifier unit Over temperature of This failure occurs when the (1)Check the fans are After removal of
failure regenerative discharge temperature of the regenerative operating.(2)Please secure space 20cm failure, please carry
resister discharge resister rises or more in backside of out "failure-reset".
abnormally. controller.(3)Please check wiring of the
thermostat for regenerative discharge
50 Encoder failure Encoder counter This failure occurs when the (1)Please confirm the supply voltage of After removal of
overflow/underflow counter overflow/underflow of the encoder refering to "AX controller failure, please turn on
the encoder is occured. maintenance manual".(2)Please confirm power supply of the
the encoder
51 Servo failure Encoder data This failure occurs when the (1)Please confirm whether connector After removal of
transmission failure communication data with the CNEC1/CNEC2 of servo substrate failure, please turn on
encoder is abnormal or the UM221 is correctly connected.(2)Please power supply of the
encoder has been disconnected. confirm the power supply voltage of the controller again.
52 Encoder failure Encoder battery charge This failure occurs when the (1)Please confirm the supply voltage of After removal of
low voltage of the battery in the the encoder refering to "AX controller failure, please turn on
encoder has decreased. maintenance manual".(2)Please confirm power supply of the
the encoder
54 Servo failure Encoder data abnormal This failure occurs when the (1)Please confirm the supply voltage of After removal of
change in the encoder data is the encoder refering to "AX controller failure, please carry
abnormal. maintenance manual".(2)Please confirm out "failure-reset".
the wiring of the encoder.
55 Encoder failure Motor rotation too fast Because the motor had been (1)Please confirm the supply voltage of After removal of
when power off rotated at high speed when the the encoder refering to "AX controller failure, please turn on
power off, the amount of the maintenance manual".(2)Please confirm power supply of the
rotation of the encoder was not the wiring of the encoder.(3)Please reset controller again.
able to be detected correctly the encoder
56 Servo failure Encoder pre-load This failure occurs if the pre-load (1)Please confirm the supply voltage of After removal of
failure operation of the encoder was the encoder refering to "AX controller failure, please carry
not correctly done. maintenance manual".(2)Please confirm out "failure-reset".
whether the robot manipulator interferes
in something.(3)Please confirm the
wiring of the encoder
6-2
57 Encoder failure Encoder count status This failure occurs when the (1)Please confirm the supply voltage of After removal of
failure Encoder data(absolute) is the encoder refering to "AX controller failure, please turn on
abnormal. maintenance manual".(2)Please confirm power supply of the
the encoder
61 Amplifier unit Circuit protector tripped This failure occurs when a circuit (1)Please confirm wire harness and After removal of
failure breaker trips. wiring in the robot manipulator. failure, please carry
(2)Please confirm whether the motor out "failure-reset".
power line does the short-circuit.
62 Control failure Emergency stop was Error occurs when it has a Turn power ON again and try again. After removal of
shortly input or condition that communication failure, please carry
Magnetic SW was cut cable, connection of Emergency out "failure-reset".
off. stop, Over travel limit switch,
Arm interference limit switch or
motor thermostats is open or
poor connection
63 CPU board Controller temperature Error occurs when the Check the fans are operating, or clean Failure reset by
failure fault. temperature of the core of the up the heat exchanger. "reset-key" is
controller becomes abnormality possible
64 Amplifier unit Drive unit power failure This failure occurs when drive Please replace the drive unit. After removal of
failure unit power VP15(+15V) was not failure, please turn on
supplied. power supply of the
controller again.
65 Amplifier unit Over travel limit switch This failure occurs when an axis (1) If no LS is physically being actuated After removal of
failure activated reaches the end of its travel and then wiring to a LS is disconnected or failure, please carry
actuates an Over travel limit cut off.(2) If LS is physically being out "failure-reset".
switch(LS). This error seldom actuated, then move the manipulator by
occurs because the Software the teach pendant operation while LS
limit usually stops the releasing switch ON.
manipulator before it reaches
66 Amplifier unit Low voltage of brake This failure occurs when brake (1)Please confirm the CNMS connector After removal of
failure power power supply PB(+24v) of the power unit is connected. failure, please turn on
decreases. (2)Please confirm the CNPW connector power supply of the
of the power unit is connected. controller again.
(3) Please confirm whether fuse (F2) of
72 Amplifier unit Drive unit IPM failure This failure occurs when current (1)Please confirm the cable between the After removal of
failure of power module (IPM) in the controller and the robot failure, please turn on
drive unit flows more than manipulator.(2)Please replace the drive power supply of the
permitted range. unit. controller again.
73 Amplifier unit Drive Unit heatsink This failure occurs when the (1)Please confirm whether the ambient After removal of
failure temperature fault temperature of the heatsink in temperature exceeds the specification. failure, please carry
the drive unit exceeds the (2) Please confirm the power-supply out "failure-reset".
permitted range. voltage is within ±10%. (3)Please
confirm the rear fan rotates. (4)Please
confirm whether the heat sink is
74 Amplifier unit Motor regeneration This failure occurs when the (1)Please confirm whether the CNR After removal of
failure circuit fault regenerative discharge circuit is connector of the drive unit is connected. failure, please turn on
disconnected by a large current (2)Please confirm resistance of the power supply of the
or heat. discharge register 5 ohm. controller again.
77 CPU board CPU fan fault. Error occurs when the fan of the Check the fans are operating, or Failure reset by
failure CPU becomes 2000 r.p.m. or exchange CPU board. "reset-key" is
78 CPU board CPU bord power fault. Error occurs when the power of Check the power supply unit, or Failure reset by
failure the CPU becomes 5% or less exchange the Power supply unit. "reset-key" is
79 CPU board CPU bord temperature Error occurs when the Check the fans are operating, or clean Failure reset by
failure fault. temperature of the CPU up the fans. "reset-key" is
becomes abnormality high. possible
82 Operational
99 Operational 5th axis operating Error occurs when 5th-axis Select [Constants][Machine constants] No reset operations
failure range exceeded. moves out of its Operating and use the correct axis operation keys neccesary.
range(not software motion to move back into the 5th-axis Operating
range!). The Operating range is range. Warning! damage can occur if
fixed by the machine design and 5th-axis hits arm 1.
is based on the angle of
interference between 5th-axis
and arm 1(not encoder value).
Operating range can be
exceeded when the 5th-axis(and
6th-axis) is moved via the
rotation of the 4th-axis. This
effect is due to the mechanical
105 Control failure Ext. Motors-off' signal Error occurs when Motors-ON Ensure that Motors-OFF is not being After removal of
is being given or button is pressed while the given when pressing Motors-ON button. failure, please carry
Motors-OFF button Motors-OFF button is held or out "failure-reset".
being held. external motors-OFF signal is
106 Operational The motors are not ON. The motors are not ON. Turn motors ON by pressing the Motor- No reset operations
failure ON button. neccesary
116 TP failure TP connect failure It becomes this failure when TP Connect TP properly. Exchange TP A power supply is
isn't connected and a cable is when it is out. turn on again.
121 Operational The robot's joint angle It will become this error if a robot Please move to software stroke within Error reset.
failure exceeded the software joint angle reaches the software the limits by manual operation (each
stroke range. stroke range. axis).
6-3
122 Servo failure The robot's joint angle It will become this error if a robot Please motor power on in machine Error reset.
exceeded the software joint angle reaches the software constant/software limit at the EXPERT
stroke range.(Current stroke range.(Current position) level and move to software stroke within
position) the limit by manual operation.
129 Operational The angle which an The 1st arm and the 2nd arm Please move in the direction where Error reset.
failure arm makes is too large. may cause interference with a interference does not take place by
position. manual operation.
130 Operational The angle which an The 1st arm and the 2nd arm Please move in the direction where Error reset.
failure arm makes is too small. may cause interference with a interference does not take place by
position. manual operation.
131 Control failure Collision sensor Error occurs when a signal is Remove obstruction, check condition of After removal of
actuated. received from the collision the tool, reset the collision sensor, and failure, please carry
sensor. restart robot. out "failure-reset".
132 Operational The robot's joint angle It will become this error if a robot Please move to link software stroke Error reset.
failure exceeded the link joint angle reaches the link within the limits by manual operation
software stroke range. software stroke range. (each axis).
173 Operational Shift value limit This error occurs if the allowable Reset the limit value[Constants][Shift No reset operations
failure exceeded. shift distance is too large. limit & evaluation value] and retry neccesary.
177 Emergency stop Primary power supply Error occurs when the Power Check the status of the Primary(mains) Error reset.
failure fault. detection unit on I/O board, power supply.
UM212, detects that primary
power is below nominal level.
179 Control failure An axis key was held This error occurs when an axis Input Motors-ON signal ensuring the After removal of
while 'Motors-ON' key on the teach pendant is axis keys are not held down. failure, please carry
signal was given. actuated while motors-ON signal out "failure-reset".
201 Palletize-end does not This error occurs when a Correct the sequence of Palletize and No reset operations
follow Palletize palletize-end function(M47) does Palletize end functions in the program. neccesary.
function. not follow Palletize
202 More than 32 When palletizing of 32 or more Please refer to Palletize function manual No reset operations
Palletizing routines not is executed at the same time, for details. neccesary.
allowed. this error is detected.
203 Palletize data is This error occured caliculate Please refer to palletize data. No reset operations
abnormal. shift value is failed from palletize neccesary.
243 Operational Designated command Error occurs when a shift Correct the program. No reset operations
failure position exceeds Robot function, etc. tries to send the neccesary.
operating area. robot out of the robot operating
244 Operational Danger of Robot Robot wrist may interfere with Correct the program. No reset operations
failure interference. under the part of manipulator neccesary.
257 Operational Pose calculation failed. This error occurs when all axis Check pose data. No reset operations
failure angles can not be calculated in neccesary.
robot language file.
367 PLC failure The error was detected It becomes this error when Built- Check the environment of Built-in PLC Unusual reset is
by Built-in PLC. in PLC detects an error. of operation. carried out after
changing Built-in PLC
into a running state.
379 Control failure Safety plug is not This error occurs when a Motors Insert the Safety plug in Auto mode. After removal of
inserted or the state of ON command(button) is given in failure, please carry
safety plug signal has Auto mode when the Safety plug out "failure-reset".
changed in teach is not inserted or the state of
mode. safety plug signal has changed
in teach mode
550 PLC failure It is scan time over of It detects, when the scanning Correct Ladder program. An error will be
Built-in PLC. time of Built-in PLC is too long. canceled if it is
download after
correcting ladder
program so that Scan
time may be set to
less than 30 msecs
674 Spot weld failure Welder communication Error occurs when the welder Check power supply of the welder and Error reset
fault(No reply). board is not correctly connected. communication cables, and power ON
again.
675 Spot weld failure Welder communication Error occurs when received data Check power supply of the welder and Error reset
fault(Check sum). from the welder board is communication cables, and power ON
abnormal. again.
676 Spot weld failure Welder communication Error occurs when received data Check power supply of the welder and Error reset
fault(Message wrong). from the welder board is communication cables, and power ON
abnormal. again.
677 Spot weld failure Major Welder fault. Error occurs when the welder Remove the cause of weld fault. Error reset
board generate the weld fault.
694 Spot weld failure Executive EPROM Error occurs when a system Install the system software once more. Turn off the power.
checksum error. software checksum error of
welder timer substrate is
695 Spot weld failure LCA EPROM Error occurs when a system Install the system software once more. Turn off the power.
checksum error. software checksum error of
welder timer substrate is
696 Spot weld failure Application EPROM Error occurs when an Install the system software once more. Turn off the power.
checksum error. application EPROM checksum
error of welder timer substrate is
697 Spot weld failure DPR error. Error occurs when a DPR error Install the system software once more. Turn off the power.
of welder timer substrate is
705 Operational The angle between 3rd The 3rd axis tended to operate Please move in the direction where 3rd Error reset.
failure axis and ground is exceeding 3rd angle incline. angle incline does not take place by
over. manual operation.
6-4
749 Spot weld failure Spot Welder SCR1 Failure occurs when the Check the Thermo. Temp. fault signal After removal of
thermal switch Thermo. Temp. fault signal is and the spot welding unit. failure, please carry
actuated. received by the controller. out "failure-reset".
750 Spot weld failure Spot Welder SCR2 Failure occurs when the Check the Thermo. Temp. fault signal After removal of
thermal switch Thermo. Temp. fault signal is and the spot welding unit. failure, please carry
actuated. received by the controller. out "failure-reset".
759 Spot weld failure Isolation contact failedFailure occurs when the Refer to the Welder timing Manual. After removal of
to pull in. isolation contact of the welder failure, please carry
fails to actuate correctly. out "failure-reset".
760 Spot weld failure Isolation contact stuck Failure occurs when the Refer to the Welder timing Manual. After removal of
close. isolation contact of the welder failure, please carry
fails to actuate correctly. out "failure-reset".
762 Spot weld failure Welder board not Error occurs if the welding timer Install the welder board. Error reset.
installed. PCB does not exists in the
controller when welding is
attempted.
777 Control failure Robot moved during This error occurs when shock Check manipulator arm interference with After removal of
Motors-on sequence. sensor actuated while torch jig. if error persists, abort Motor-on and failure, please carry
touches a work. contact NACHI dept. out "failure-reset".
783 CPU board Motion stop. It becomes this error when main Turn on the power again. If the error is Turn on the power
failure CPU detects a motion stop. not released, reinstall the system. again.
785 CPU board I/O timeout. It becomes this error when main Turn on the power again. If the error is Turn on the power
failure CPU detects a I/O system stop. not released, reinstall the system. again.
898 Servo failure Servo command stop This failure occurs when the Please refer to the troubleshooting of After removal of
update of the command value the controller maintenance manual. failure, please carry
transmitted to the servo stops out "failure-reset".
during a certain time.
902 Amplifier unit serveo clock halted This failure occurs when the (1)Please confirm the supply voltage of After removal of
failure clock of servo substrate UM221 the servo substrate UM221.(2)Please failure, please turn on
halted. replace the drive unit. power supply of the
controller again.
903 Amplifier unit Servo communication This failure occurs when the (1)Please confirm whether connector After removal of
failure stop communication between CPU CNUSB of servo substrate UM221 is failure, please carry
substrate and the servo correctly connected.(2)Please confirm out "failure-reset".
substrate stops. the supply voltage of the servo substrate Wait more than 5
UM221.(3)Please replace the drive unit. seconds for next
motor power on
956 The communication The details of a communication An unusual cause is removed based on Unusual reset is
error occurred. error should check a sub code. a sub code. carried out after
removing an unusual
957 The system error was The details of a communication Please inform system service of a sub Unusual reset is
detected. error should check a sub code. code. carried out after
removing an unusual
958 The error was detected They are the abnormalities of a The defect of a communication board is A communication
with the self check of a communication board. Please considered. board is exchanged.
communication board. check the details of
abnormalities to system service.
959 A communication board The communication board Please check the slot ID of a field bus The setting value of a
is not found. specified on the constant setting hardware setup. field bus hardware
screen is not found. setup is changed.
960 A part or all I/O links Since the between title has Please check the device which the If a problem is
are stopping. occurred in the I/O device, a problem has generated by the field bus solved, it will restore
robot cannot be started. monitor. automatically. (In
order to solve a
problem, the re-
injection of a power
supply may be
967 Control failure T/P selector switch is Playback is impossible while T/P Set T/P selector switch to AUTO. After removal of
MANUAL. selector switch is set to failure, please carry
MANUAL. out "failure-reset".
975 Control failure Magnetic switch is not Error occurs when a signal from Please exchange sequence board After removal of
active. a magnetic switch is not UM213. failure, please carry
received within the specified out "failure-reset".
time after Motors ON signal is
### Control failure Analog input board is Although analog input (output) Turn off the power and connect analog Error reset.
not installed. Or analog board is not installed, analog Input (output) board correctly.
output board is not input (output) function is
installed. executed.
### Control failure PWM of the This error occurs when PWM is There are some problems in the brake After removal of
disconnected not turned off even if a certain and the PWM control circuit of sequence failure, please carry
mechanism has been time passes after the PCB. Please replace the sequence PCB out "failure-reset".
turned on. mechanism diconnection. or the drive unit.
### Encoder failure Manipulator battery This warning occurs when the Please exchange the battery referring to
After the battery is
warning voltage of the battery in the "Robot Manipulator Maintenance exchanged, please
robot manipulator decreases. Manual". carry out "failure-
reset" and then turn
on the power supply
of the controller
### Control failure Safety unit circuit is Error occurs when the Turn power OFF and ON again. After After removal of
abnormal. disagreement detection or wiring is confirmed, safety unit is failure, please carry
abnormal of the relay is detected exchanged when the error occurs again. out "failure-reset".
with safety unit.
6-5
### Spot weld failure This IWB does not Error occurs when the IWB Replace new version. After removal of
support MFDC version is old. failure, please carry
out "failure-reset".
### Analog output board Analog output board is not exists Install the analog output board. Error reset.
not installed. in the controller.
### Control failure Playback unavailable Error occurs when input playbk Please input playback command after After removal of
because motors-off command while it is executing motors-on is thrown. failure, please carry
sequence is executing. the motor-off sequence. out "failure-reset".
### Spot weld failure Spot welding function The mistake of the method of Please record spot welding function After recording the
can not be carried out. recording the welding function is after step 1.Or, you tried to drive the move step, Please
found. GUN mechanism which was not able to Check Go.
be driven with this unit.
### Control failure T/P selector switch is Manual operation is impossible Set T/P selector switch to MANUAL. After removal of
AUTO. while T/P selector switch is set failure, please carry
to AUTO. out "failure-reset".
### Spot weld failure The change in the tip The difference between the Check the lack of gun tip. If it is no Error reset
consumption detected consumption detected by search trouble, execute gun search 1.
by search 3 is 3 and the consumption detected
abnormal. by search 1 exceeded the
search 3 abnormal tip change
### Spot weld failure The encoder data of The servo gun axis did not stop Please reconsider the recorded position. Error reset
gun axis is not steady. while waiting to reach the If the position has no problem, replace
specified pressure. the Drive Unit
### Spot weld failure Ready to weld status Welder power turned off or Check the peripheral system or welder. Error reset.
from welder board isn't welder error occurred, a weld-
completed, or a weld- enabled signal not given.
enabled signal isn't
### Operational There is a possibility Setting rectangular coordinate Please set the tool constant (length and The error is not
failure that the interpolation system is different registering center of gravity) again by present released until
operation and the de- the tool and now. rectangular coordinate system. Or, measures are
and acceleration please change setting rectangular executed.
control are not correctly coordinate system.
done due to a set
disagreement of
rectangular coordinate
### Operational The memory medium is The detection reason is that the Whether the device such as memory An error will be
failure not prepared. specified device was not cards and floppy disks specified by the canceled if some
detected when the file operation file operation menu is correctly installed keys are pushed.
is done. is confirmed.
### Operational The memory medium is When it is going to copy a file to Please prepare the memory medium to An error will be
failure read-only. a write-protected floppy disk which writing is made and perform a canceled if some
etc., this error sets. copy from the beginning once again. keys are pushed.
### Operational It cannot process in the It was going to copy to the same Please change a file name or a device An error will be
failure same device. device by the same file name. and redo copy operation again. canceled if some
keys are pushed.
### Operational Stop or External stop Error occurs when a Start Release Stop button or External stop Error reset.
failure signal being given. command is given while the signal(if External stop signal cable is cut
Stop button is being held or the external stop signal is considered as
External stop signal is being being given.
### Operational The emergency stop Where an emergency stop Please cancel an emergency stop Abnormalities are
failure button or the external button or an external emergency button and an external emergency stop reset.
emergency stop is stop signal is inputted, it detects, signal.
inputted. when the Motors-ON signal or
the External Motors-ON signal is
inputted
### Operational Motors-OFF button or In the state where the Motors- Please cancel a Motors-OFF button and Abnormalities are
failure external Motors-OFF is OFF button or the external an external Motors-OFF signal. reset.
inputted. Motors-OFF signal is inputted,
when the Motors-ON signal or
the external Motors-ON signal is
### Operational Playback unavailable The start is impossible, because Please start after turning on MSHP. Abnormalities are
failure because servo system the start operation is done reset.
has not been turned on before MSHP is turned on.
yet.
### Operational It is not possible to start This It is prohibited to start Please start after specifying the move abnormally resets.
failure by specifying the specifying the function because step.
function step there is the position where the
function is executed is not an
original position but a possibility
### Operational The internal operation It detects, when starting Please operate it after setting starting Abnormalities are
failure signal was inputted in selection tends to push the selection or program selection as an reset.
the state of external Motors-ON button or a starting inside.
selection. button in the state of the exterior
or it is going to choose a
program from TP in the state of
### Operational The external operation It detects, when the Motors-ON Please perform external operation after Abnormalities are
failure signal was inputted in or the start signals are inputted setting up starting selection or program reset.
the state of internal from the exterior in the state of selection outside.
selection. an inside of start selection or a
program selection signal is
inputted from the exterior in the
state of the inside of program
6-6
### Shift register contains Error occurs when data aren't Setting data in shift register. abnormally resets.
no data. established in specified shift
register.
### Operational Setting the call This error occurs when the Please correct the program so that the
This error is released
failure instruction is improper. number of step call and return number of call return instructions isif the step set do over
instruction is match or the corresponding, and a multiple call again and restart
multiple call exceeds eight should not exceed eight times. playback.
### Operational The unit composition is This error occurs when the Please correct the called program This error is released
failure a different program. program jump or call instruction number value. if the correct program
directly jumps or calls the set do over again and
program that the unit is different. restart playback.
### Operational Program number This error occurs when the Check the desired program number and No reset operations
failure selected is not program number designated is retry. neccesary.
available. more than 9999.
### Operational There is no end. If there is no end mark when Please record the end instruction. This error is released
failure playback executing, this error is if restart playback.
detected after the last step is
executed.
### Operational Program is too large. Error occurs when number of Edit program in order to reduce its size. No reset operations
failure bytes of a program is too large. neccesary.
### Operational The program or the file This error occurs when the Please correct the program number to a This error is released
failure does not exist. program number is specified correct value the jump call ahead. if a correct program
which does not exist in the is setted again and
program jump call instruction. restart playback.
### Operational The step does not This error is detected when the Please correct the step number to a This error is released
failure exist. step number which does not correct value at the jump destination. if the correct step set
exist in the step jump call do over again and
instruction is specified. restart playback.
### Operational Change of a coordinate This error occurs if a coordinate Please teach by the same coordinate This error will be
failure system cannot be system is changed during system during circular. canceled if a program
performed during circular. is corrected and
circular. restarted.
### Operational Change of a tool This error occurs if a tool is Please teach by the same tool during This error will be
failure cannot be performed changed during circular. circular. canceled if a program
during circular. is corrected and
restarted.
### Operational The file is protected. All protected files or files Because the specified file (program or Please release
failure partially protected (program or constant) contains important data, protecting the file
constant) tried to be corrected protecting is put so that (program or
### Operational The reproduction It detects, when it is going to The specified work program is not a When you start,
failure protection of the carry out reproduction or check program which should be used for please choose Step 1
program is carried out. GO of the work program which operation operation. from T/P.
required reproduction protection
from a head step (Step 0)
### Operational The amount of the When there is no point or less Recreate the 10 point program (4 point Error reset
failure movement of each axis 10 point data effective to the under tool constant setting only)
is too small in the calculation, and the program is ensuring the recorded points are exactly
automatic tool constant not clearly recorded the same the same point in space.
setting. Or, the number point excluding the error by the
of record steps does teaching
### Preventive There is an axis of less In the state of the present Please exchange the slowdown machine Abnormalities are
maintenance than 1,000 hours till operation, the life-expectancy of the axis displayed as early as reset.
message overhaul cycle time (time until it reaches a life) possible. Please clear "the consumption
attainment. of the displayed axis turned into time by present" zero with an overhaul
1,000 or less hours. cycle prediction menu after exchange.
(The qualification more than Expert is
### Shift value limit This error occurs if the allowable Reset the limit value[Constants][Shift No reset operations
exceeded. shift distance is too large. limit & evaluation value] and retry neccesary.
### Operational Step number selected This error occurs when Check the desired step number and No reset operations
failure is not available. designated step number does retry. neccesary.
### Operational The program is not This error occurs when the Please start after recording the program This error is released
failure recorded nor selected. program which is not recorded is or selecting other programs. if it sets a correct
selclted and start playback. program and restart
playback.
### Palletize-end does not This error occurs when a Correct the sequence of Palletize and No reset operations
follow Palletize palletize-end function(M47) does Palletize end functions in the program. neccesary.
function. not follow Palletize
### More than 32 When palletizing of 32 or more Please refer to Palletize function manual No reset operations
Palletizing routines not is executed at the same time, for details. neccesary.
allowed. this error is detected.
### Palletize data is This error occured caliculate Please refer to palletize data. No reset operations
abnormal. shift value is failed from palletize neccesary.
### Multiplex palletize over. This error occured multiplex Please confirm a robot program. No reset operations
palletize beyond 8 is carried out. neccesary.
### Operational The step data is This error occurs when the value Please set a correct parameter again. This error is released
failure abnormal. which is not permitted as a if a correct program
parameter of the function or step is setted and
instruction is setted while restart playback.
playback executing and the
### Operational The program can not This error occurs when the The number of program reservation Please do error reset.
failure reserve any more. number of program reservations should cope with it by the sequence etc.
exceeds ten. not to accumulate too much.
6-7
### Spot weld failure Analog input override Error occurs when analog input Check the program, and delete function. Error reset.
and digital input override (FN169) and digital
override can not be input override (FN277) are
used at same time. played at the same time.
### Spot weld failure No signal input while The specified interruption signal Please confirm the state of the sensor, Error reset
executing FN227 was not input whiel executing the connection with the controller and
FN227. the number of the signal.
### Operational There is no referring to This error occurs when the Please start after recording a move This error will be
failure point for the circle program on which the move command before or after the circle canceled if a program
middle point (C1). command is not recorded before middle point (C1). is corrected and
or after the circle middle point restarted.
(C1) is started
### Operational There is no referring to This error occurs when the Please start after recording a move This error will be
failure point for the circle end program on which the move command before the circle end point canceled if a program
point (C2). command is not recorded before (C2). is corrected and
the circle middle end (C2) is restarted.
started
### Operational It is protected with the It detects, when it is going to Since the specified file (program or Please release
failure password. correct or delete the file (a constant) contains important data, protecting the file
program, constant) protected protection is applied (program or
with the password. constant).
### Playback mode of This error occurs when Search Select <1 cycle> mode. No reset operations
Search write function is write function is attempted when neccesary.
not corrected. not in <1 cycle> mode.
### Search range This error occurs when the robot Modify(enlarge) the search range or No reset operations
exceeded. moves beyond search range program to rectify error. neccesary.
### Search base step This error occurs if a Search is The Search base step position(s) will be No reset operations
position is not defined. attempted without the existence automatically written into the functions. neccesary.
of the Search base step
### Search Start not This error occurs when a Search Alter program to give correct Search No reset operations
followed by Search start does not follow a Search start/end sequence. neccesary.
End. End function.
### Operational The setting of a case This failure occurs when a case Please check a case jump and This failure is
failure jump function is jump and a case jump end do correspondence of a case jump end. released if a correct
unsuitable. not correspond while playback program is setted
executing, and the robot will and restart playback.
### Operational It was going to jump This failure occurs when the Please set a correct parameter again. This failure is
failure beyond the case jump condition value of a case jump is released if a correct
range. too large and there is no jump program is setted
step in the program while and restart playback.
playback executing, this
abnormality is detected and the
### PLC failure Scan of Built-in PLC Although Built-in PLC status is Built-in PLC status is set as <RUN> by Unusual reset is
has stopped. except <Disabled>, when scan constant mode, and scan is started. carried out after
of Built-in PLC has stopped, it changing Built-in PLC
becomes this error at the time of into a run state.
robot operation
### PLC failure Connection with Built-in It becomes this error when Please check the environment of Built-in Unusual reset is
PLC cannot be connection with Built-in PLC PLC of operation. carried out after
performed. cannot be performed. changing Built-in PLC
into a starting state.
### PLC failure Built-in PLC cannot be It becomes this error when Built- Please check the environment of Built-in Unusual reset is
started. in PLC cannot be started. PLC of operation. carried out after
### PLC failure Built-in PLC cannot be It becomes this error when Built- Please check the environment of Built-in Unusual reset is
stopped. in PLC cannot be stopped. PLC of operation. carried out after
### PLC failure There is no resource It will become this error if a Download a PLC ladder program. After download, it
performed by Built-in starting demand is performed in changes into a
PLC. the state where there is no starting state and
resource performed by Built-in unusual reset is
### PLC failure PLC-Engine has not It becomes this error when it is Please check the environment of Built-in Again, a starting
been started. not able to start by the starting PLC of operation. setup is carried out, it
demand of PLC-Engine. changes into a
starting state, and
unusual reset is
### PLC failure The error was detected It becomes this error when an Please carry out program check by [3 Unusual reset is
by Program check at error is detected by Program PLC program check] of [14 PLC carried out.
the time of PLC-Engine check at the time of PLC-Engine program Edit] of Service.
starting. starting.
### Operational The function data is This error occurs when the Please set the function again. This error is released
failure abnormal. function instruction which is not if a correct program
permitted is setted while or step is setted and
playback executing, and the restart playback.
### 3 of the step points for Error occurs when 3 step points Designate step positions not in the same Designate step
On-transfer are in line. are situated along the same line line for the On-line transfer function. positions not in the
for the On-line same line for the On-
Transfer(M53,M54). line transfer function.
### Operational User failure is not The error file was not found. Please define Failure by [Service]→[25 Error reset
failure defined. Robot diagnosis]→[6 User error].
6-8
### There is the axis in 0 The life time of the axis Exchange the axis. After that 0 clearing Please do error reset.
hours for overhaul. displayed with present operated of "Consumption time until present".
(time to reaching to longevity)
became 0 hour or less.
### Spot weld failure The specified welder The servo gun connected with Modify the program. Error reset
cannot be used with the specified welder is not
this unit. defined as a mechanism of this
### Spot weld failure The servo gun is not The welder with which the servo Modify the program. Error reset
connected with the gun was not connected when
specified welder. the servo gun function was used
was specified.
### Spot weld failure Abnormal panel Dramatic difference of panel Check the weld condition data and real This error is released
thickness detected. thickness exists between work piece thickness. if restart playback.
recorded value in weld condition
and detected value.
### RIO detected the An abnormal communication Please check the connection and the Error reset.
communications error. was generated by the RIO link. RIO scanner of the communication
### The RIO interface is There is no answer from the RIO Please exchange the RIO interface. Error reset.
abnormal. interface.
### Operational Step number not This error occurs when a Please designate a step number and This error is released
failure designated. command only valid after retry. if a correct program
designating a step number is or step is setted and
attempted without step restart playback.
### Operational The memory medium is When memory media, such as a By Service / File Manager / Format It will be canceled if
failure not discriminable. FIROPPI disk and an memory memory card/Floppy disk, please use it some keys are
card, are not initialized, this error after initializing a memory medium. pushed.
### Spot weld failure Welder fault. Error occurs when a Welder Check the welder unit. This error is released
fault input signal is received by if restart playback.
the controller after the
completion of a welding
### Spot weld failure Welding time exceeded Error occurs if a Weld competed Check the welder is operating normally. This error is released
limit. signal is not input before the if restart playback.
designated time period.
### Spot weld failure The gun not open. Error occurs if the Gun closed Check the GUN or welding unit. This error is released
signal is received after the if restart playback.
welding sequence ends.
### Spot weld failure The gun is not half Error occurs if the Gun half-open Check the GUN or welding unit. This error is released
open. signal is not received after Open if restart playback.
gun half signal is output by the
controller.
### Spot weld failure The gun is not fully Error occurs if the Gun full-open Check the GUN or welding unit. This error is released
open. signal is not received after Open if restart playback.
gun fully signal is output by the
controller.
### Spot weld failure Stuck Weld GUN Error occurs if the System fault Error occurs if the Weld stuck signal is This error is released
detected. signal is detected after received when the welding sequence if restart playback.
completion of a welding ends.
### Spot weld failure Coolant fault #1. Error occurs if the Water flow Check the GUN or welding unit. This error is released
switch #1 signal is detected after if restart playback.
### Spot weld failure Coolant fault #2. Error occurs if the Water flow Check the GUN or welding unit. This error is released
switch #2 signal is detected after if restart playback.
### Spot weld failure Air pressure fault. Error occurs if the Air pressure Check the GUN or welding unit. This error is released
switch signal is detected after if restart playback.
### Spot weld failure Transformer Error occurs if the Thermo. Check the GUN or welding unit. This error is released
temperature fault. temp. fault signal is detected if restart playback.
after completion of a welding
### Spot weld failure Peripheral system fault. Error occurs if the System fault Check the GUN or welding unit. This error is released
signal is detected after if restart playback.
### Spot weld failure Both of half-open and Error occurs if both the Gun Check the GUN or welding unit to This error is released
full-open signals are half-open signal and Gun full- determine the cause of the two if restart playback.
given. open signal are received simultaneous signals.
simultaneously after Open gun
half signal is output by the
### Operational Servo gun auto-setting It is not possible to compute the (1)Please make the servo gun position No reset operations
failure gets abnormal data. servo gun inertia using current more wildly between pose 1 and pose 2. neccesary.
gathered by parametor auto- (2)Please confirm the servo parameters
setting of target servo gun mechanism.
### Operational User coordinate does Failure occurs when use of User Define User coordinate system(s) in No reset operations
failure not exist. coordinate is attempted without [Service][10 User Coord. neccesary.
the coordinate system being Definition]before attempting to use it.
pre-defined.
### Spot weld failure Tip dresser abnormal. This error occurs when normal Please check the normal input signal This error is released
input signal from tip dresser is from the tip dresser. if restart playback.
lost during tip dress function.
### Operational Data level too low for In the automatic tool center of (1)Teach points that enough unbalanced No reset operations
failure Auto tool load center gravity set function, it is not torque is exerted on J3,J5 and J6 axis. neccesary.
setting. possible to calculate by the (2)Make the wrist posture vary greatly
gathered current value. between step 1 and step 2 positions.
6-9
### Spot weld failure Servo gun pressure is Error occurs when the set gun Error occurs when the set gun pressure This error is released
not achieved. pressure is not achieved within is not achieved within the time period set if restart playback.
the time period set in in [Constant][General characteristic of
[Constant][General Servo Gun].
characteristic of Servo Gun]
### Spot weld failure WI signal does not Error occurs when a WI signal, Check the welder is operating normally. This error is released
become off. from the last weld sequence, if restart playback.
remains on more than 5s after a
GUN or WELD signal is output
by the controller
### Spot weld failure Weld control is not Error occurs when the weld Install the latest software version. Error reset.
supported by MEDLAN control software is too old.
command.
### Spot weld failure Different spot welding Error occurs when a gun Correct the program, otherwise attach Error reset
gun mounted. different from the gun specified the correct gun before using Spot
in a Spot welding function is welding function.
### Spot weld failure Servo Gun Move-tip Servo Gun Move-tip Replace the worn Move-tip and detect Error reset
consumption exceeded consumption exceeded the tip consumption again.
maximum limit. maximum limit.
### Spot weld failure Servo Gun Settle-tip Servo Gun Settle-tip Replace the worn Settle-tip and detect Error reset
consumption exceeded consumption exceeded the tip consumption again.
maximum limit. maximum limit.
### Operational Mechanism is not Error occurs when a mount Attach a mechanism before using a Error reset
failure mounted. mechanism function is mount mechanism function.
attempted without a mechanism
being attached. Or, the sub-
mechanism input signal line has
been disconnected
### Operational Sub-mechanism cannot Because two or more Please input the submechanism input Error reset
failure be selected. submechanism input signal has signal correctly, and using a mount
been turned on, the connected mechanism function.
mechanism cannot be selected.
### Operational Mechanism number is The mechanism number which Please set the mechanism number Error reset
failure wrong. was not able to change the correctly.
mechanism was selected.
### Operational Different mechanism Error occurs when a mechanism Please correct the program. Error reset
failure mounted. different from the mechanism
specified in a step is detected.
### Operational Conflict of mechanism Error occurs when the change Please correct the program. Error reset
failure change. function was executed for the
mechanism using other units.
### Spot weld failure The specified welder is The specified welder is not Modify the welder number. Error reset
not effective. effectively set by the spot
welding constant.
### Spot weld failure Spot welding gun is not It was judged that spot welding Connect gun mechanically. When gun is Error reset
mechanically gun was not mechanically connected, check the disconnection of
connected connected because the the signal line.
connection signal was not input.
### Operational Signals of multi input Error occurs when a multi input Create the multi input conditions, or Please carry out
failure are not designated. function was attempted playback replace the function to normal input. "failure-reset".
with no condition number.
### User coordinate It is necessary to select user Execute [FN113 Change coordinate for No reset operations
number is not selected. coordinate number before shift shift] before shift functions. neccesary.
function at user coordinate.
### Operational Stationary tool is not Failure occurs when Stationary Please select stationary tool using No reset operations
failure selected. tool is not selected although FN67. neccesary.
step is Stationary tool
### Operational Pause or External Error occurs when a Start Release Pause or External pause No reset operations
failure pause signal being command is given while the signal(if External pause signal cable is neccesary.
given. pause signal is being held or cut the external pause signal is
External pause signal is being considered as being given.
### Control failure Far distance between a Since stopping during high- If a limit for error detection is too small, Robot can restart
current position and a speed playback and so on, robot change the value in constant setting. from there without
position at putting couldn't normally stop on the Position Recovery is invalidated setting reset operation.
servo-power off. trajectry. Since the distance is both recovery limit values to zero.
over the limit for error detection
value robot can't recovery
### Spot weld failure Weld tip may be worn. This warning occurs when the Check the Gun tip and reset the No reset operations
Weld counter exceeds the limit counter. neccesary.
value.
### Control failure Too far distance Since stopping during high- If a limit for error detection is too small, After carry out
between a current speed playback and so on, robot change the value in constant setting. "failure-reset", robot
position and a position couldn't normally stop on the can restart.
at putting servo-power trajectry. Since the distance is
off. over the limit for error detection
value robot can't recovery
### Operational Take care of not Since the position for recovery There is no way. No reset operations
failure recovering position at couldn't recorded, never recover neccesary.
the next servo on. the position at the next servo on
without related to distance. This
might be occured at servo off
during recovery position
6-10
### Operational Abnormality occurred The thing backed up Please confirm the state of the storage No reset operations
failure while backing up automatically cannot be done. medium. neccesary.
automatically. The storage medium is not
prepared, and read-only and
memory capacity shortage etc
### Operational The memory medium is When it is going to copy a file to Please prepare the memory medium to An error will be
failure read-only. a write-protected floppy disk which writing is made and perform a canceled if some
etc., this error sets. copy from the beginning once again. keys are pushed.
### Operational The memory medium is The detection reason is that the Whether the device such as memory An error will be
failure not prepared. specified device was not cards and floppy disks specified by the canceled if some
detected when the file operation file operation menu is correctly installed keys are pushed.
is done. is confirmed.
### Operational It cannot process in the It was going to copy to the same Please change a file name or a device An error will be
failure same device. device by the same file name. and redo copy operation again. canceled if some
keys are pushed.
### Operational Number of axes miss- Failure occurs when the number Check the program file type is comptible No reset operations
failure matched. of axes used in a program is not with the constants currently in use. neccesary.
compatible with the unit constant
files.
### Operational Data given is incorrect. Data keyed-in is out of range or Input suitable data. No reset operations
failure not defined. neccesary
### Spot weld failure Servo Gun Dramatic tip Warning is given when the set Check the lack of gun tip. No reset operations
consumption change warning limit for gun tip neccesary.
detected. consumption is exceeded. Tip
consumption warning signal is
outputted
### Spot weld failure Welder version is Welder version is unmatched. Initialize welder data. No reset operations
unmatched. neccesary.
### Spot weld failure Welder backup file is Welder backup file is not found. Initialize welder data. No reset operations
not found. neccesary.
### Spot weld failure Welder error occurred. Welder detects ALERT or Refer to the Welder Manual. No reset operations
FAULT. neccesary.
### Preventive There is an axis which The presumption generation 1.Change to ratings or less when the Please do error reset.
maintenance exceeds the allowance torque exceeded a permissible robot load condition is investigated, and
message and maximum torque. value by displayed program step weight and the wrist torque exceed it to
and axis. ratings. (Gravity setting is used)2.There
is a possibility to exceed the
acceleration which can be used. (Check
the step before and after)3.There is a
possibility with a large interference
torque too (Drop the acceleration of the
### Preventive It is a program which In the displayed program, 1.Change to ratings or less when the Please do error
maintenance remarkably shortens longevity is within at 5000 robot load condition is investigated, and reset.(Override
message longevity. hours.There is a possibility weight and the wrist torque exceed it to function is used)
which is the program of ratings. (Gravity setting is used)
call/jump origin when the
### Operational The program or the file This error occurs when the Please correct the program number to a This error is released
failure does not exist. program number is specified correct value the jump call ahead. if a correct program
which does not exist in the is setted again and
program jump call instruction. restart playback.
### Spot weld failure Servo Gun Move-tip Warning is given when the set Check the Gun tip. If tips are good No reset operations
consumption warning for Move-tip check the setting otherwise change the neccesary.
approaching limit. consumption limit is exceeded. tip to the new one, and detect tip
Tip consumption warning signal consumption again.
### Spot weld failure Servo Gun Settle-tip Warning is given when the set Check the Gun tip. If tips are good No reset operations
consumption warning for Settle-tip check the setting otherwise change the neccesary.
approaching limit. consumption limit is exceeded. tip to the new one, and detect tip
Tip consumption warning signal consumption again.
### Operational The file is protected. All protected files or files Because the specified file (program or Please release
failure partially protected (program or constant) contains important data, protecting the file
constant) tried to be corrected protecting is put so that (program or
### Preventive There is the axis in The life time of the axis Exchange the axis early. After that 0 Please do error reset.
maintenance 1000 hours for displayed with present operated clearing of "Consumption time until
message overhaul. (time to reaching to longevity) present".
became 1,000 hours or less.
### Preventive There is the axis in 0 The life time of the axis Exchange the axis. After that 0 clearing Please do error reset.
maintenance hours for overhaul. displayed with present operated of "Consumption time until present".
message (time to reaching to longevity)
became 0 hour or less.
### Operational It was going to start, This error occurs if it starts when Please check unit ready signal output This error is released
failure when unit was not unit is not ready. conditions, and start after making it the if it starts again after
ready. unit ready. making it the unit
### Spot weld failure Abnormal panel Dramatic difference of panel Check the weld condition data and real No reset operations
thickness detected. thickness exists between work piece thickness. neccesary.
recorded value in weld condition
and detected value.
### CPU board Controller temperature Information occurs when the Check the fans are operating, or clean No reset operations
failure fault. temperature of the core of the up the heat exchanger. neccesary.
controller exceeds 60℃. If this
state lasts 10 min, motor power
will be automatically shutdown
and E0063 displayed
6-11
### Spot weld failure Re-weld is not allowed. You did re-weld except for the Please restart after set a step in auto No reset operations
time of abnormal welding. mode, or do manual weld. neccesary.
### Operational The program is not This error occurs when the Please reserve after recording the This error is released
failure recorded nor selected. program which is not recorded is program or selecting other programs. if it sets a correct
selclted and reserve playback. program and reserve
playback.
### Operational Command not possible This command is not able to be Stop the program and retry the No reset operations
failure while running program. used during the execution of a command. neccesary
program.
### Operational The memory medium is When memory media, such as a By Service / File Manager / Format It will be canceled if
failure not discriminable. FIROPPI disk and an memory memory card/Floppy disk, please use it some keys are
card, are not initialized, this error after initializing a memory medium. pushed.
### Spot weld failure Welder fault. Error occurs when a Welder Check the welder unit. No reset operations
fault input signal is received by neccesary.
the controller after the
### Spot weld failure Welding time exceeded Error occurs if a Weld competed Check the welder is operating normally. No reset operations
limit. signal is not input before the neccesary.
designated time period.
### Spot weld failure The gun not open. Error occurs if the Gun closed Check the GUN or welding unit. No reset operations
signal is received after the neccesary.
welding sequence ends.
### Spot weld failure The gun is not half Error occurs if the Gun half-open Check the GUN or welding unit. No reset operations
open. signal is not received after Open neccesary.
gun half signal is output by the
controller.
### Spot weld failure The gun is not fully Error occurs if the Gun full-open Check the GUN or welding unit. No reset operations
open. signal is not received after Open neccesary.
gun fully signal is output by the
controller.
### Spot weld failure Stuck Weld GUN Error occurs if the System fault Error occurs if the Weld stuck signal is No reset operations
detected. signal is detected after received when the welding sequence neccesary.
completion of a welding ends.
### Spot weld failure Coolant fault #1. Error occurs if the Water flow Check the GUN or welding unit. No reset operations
switch #1 signal is detected after neccesary.
### Spot weld failure Coolant fault #2. Error occurs if the Water flow Check the GUN or welding unit. No reset operations
switch #2 signal is detected after neccesary.
### Spot weld failure Air pressure fault. Error occurs if the Air pressure Check the GUN or welding unit. No reset operations
switch signal is detected after neccesary.
### Spot weld failure Transformer Error occurs if the Thermo. Check the GUN or welding unit. No reset operations
temperature fault. temp. fault signal is detected neccesary.
after completion of a welding
### Spot weld failure Peripheral system fault. Error occurs if the System fault Check the GUN or welding unit. No reset operations
signal is detected after neccesary.
### Spot weld failure Both of half-open and Error occurs if both the Gun Check the GUN or welding unit to No reset operations
full-open signals are half-open signal and Gun full- determine the cause of the two neccesary.
given. open signal are received simultaneous signals.
simultaneously after Open gun
half signal is output by the
### Spot weld failure Manual axis moving Error occurs if manual axis Please releasing WI. Please release the
cannot be operated moving during waiting for WI. WI.
during waiting for WI.
### Operational It stopped in the home It will generate, if it comes to the Please carry out manual operation No reset operations
failure stop position. position registered by setup of a again. neccesary
home stop position function.
### Arc weld failure Communication timeout The welding power supply didn't Check the connection of the welding Turn on the controller
occurred between the respond. power supply to the controller. and the welding
controller and the power supply again.
### Arc weld failure Received data failure. The data which are received Check the connection of the welding Turn on the controller
from the welding power supply power supply to the controller. and the welding
are incorrect. power supply again.
### Arc weld failure Can't communicate The communication between the Check the connection of the welding Turn on the controller
with the welding power controller and the welding power power supply to UM204. and the welding
supply. supply is shutdown. power supply again.
### Arc weld failure Can't communicate The communication driver Check the connection of the welding Turn on the controller
with the welding power detected the failure. power supply to the controller. And and the welding
supply. check the connection of UM204 board. power supply again.
### Arc weld failure The registration of the The kind of registered WPS and Register WPS correctly, or set Dip After
welding power supply is actual WPS are not same, or the switch of Robot I/F board correctly. registeration/setting,
incorrect. Dip switch setting of Robot I/F turn on the controller
board inside the welding power and the welding
supply is wrong power supply again
### Emergency stop Alarm carried out Alarm carried out number-of- Please fix failure from the cause of Error reset
failure number-of-times times generating of regulation, alarm.
generating of and was breaking down.
regulation, and was
6-12
### Arc weld failure The welding current The difference between the Check the welding conditions(wire Reset failure.
value has exceeded welding current value measured extension etc). There is possibility of
the allowable limit. by the welding power supply and missmatch the welding characteristic
the taught one has exceeded data to your environment if this failure
the allowable limit set by the arc occurs over and over again. In such
constants. case, adjust the welding characteristic
data by the adjudstment of welding
### Arc weld failure The welding voltage The difference between the Check the welding conditions(wire Reset failure.
value has exceeded welding voltage value measured extension etc). There is possibility of
### Arc weld failure The welding power The controller couldn't Turn on the welding power supply. In Reset failure.
supply has been turned communicate with the welding case the welding power supply has been
off. power supply. already turned on, check the connection
of the welding power supply to the
### Arc weld failure Arc start failure. No arc is generated after Check the workpiece's condition, wire's This failure is
retrying. condition, and connection of the cable. released if restart
### Arc weld failure Arc outage was Arc outage occurred during Eliminate all causes of arc outage, for This failure is
detected. welding. instance by adjusting the wedling released if restart
conditions, fixing wire feed failure, and playback.
### Arc weld failure Wire stick was Wire is stuck. Cut stuck wire. This failure is
detected. released if restart
### Arc weld failure Low gas pressure. Low gas pressure signal is Supply gas. Reset faliure.
inputted.
### Arc weld failure Lack of wire was Wire not fed signal is inputted. Supply wire. Reset failure.
detected.
### Arc weld failure Lack of water was Cooling water signal is inputted. Supply water. Reset faliure.
detected.
### Arc weld failure Arc welding The registered welding Reisger the welding characteristic data Reset faliure.
characteristic data characteristic data isn't for the for the using one.
failure. connected welding power
### Arc weld failure Welding voltage Welding voltage adjustment Modify the task program. Reset faliure.
adjustment method method has been changed from
can't be changed while the synergetic control to the
welding. individual control, and vise versa
while welding
### Arc weld failure Failure of the welding W.P.S failure signal is inputted, Read through the welding power supply Reset faliure.
power supply occurred. or failure of the welding power instruction manual and eliminate all
supply occurs. causes.
### Arc weld failure Input voltage shortage The primary input voltage of the Refer to the instruction manual of the Reset failure.
failure ocurred in the welding power supply is less welding power supply(Failure Name:
welding power supply. than 80 % of the normal value. Input voltage shortage error) and
eliminate all causes.
### Arc weld failure Output overcurrent The average current used for Refer to the instruction manual of the Reset faliure.
occurred in the welding the inner control of the welding welding power supply (Failure Name:
power supply. power supply exceeds the limit. Output overcurrent) and eliminate all
### Arc weld failure Thermal overload The surface temperature of the Refer to the instruction manual of the Reset faliure.
occurred in the welding heat sink of the welding power welding power supply (Failure Name:
power supply. supply exceeds 90oC. Thermal overload) and eliminate all
### Arc weld failure Input overvoltage The primary input voltage of the Refer to the instruction manual of the Reset faliure.
occurred in the welding welding power supply exceeds welding power supply (Failure Name:
power supply. 115 % of the rated value. Input overvoltage) and eliminate all
### Arc weld failure Loss of phase occurred Loss of phase in the primary Refer to the instruction manual of the Reset faliure.
in the welding power input of the welding power welding power supply (Failure Name:
supply. supply. Loss of phase) and eliminate all causes.
### Arc weld failure Inverter drive circuit The failure occurs around the Refer to the instruction manual of the Reset failure.
failure occurred in the inverter drive circuit of the welding power supply (Failure Name:
welding power supply. welding power supply. Inverter drive circuit error) and eliminate
all causes.
### Arc weld failure Arc voltage detecting The failure(contact failure, Refer to the instruction manual of the Reset faiuler.
line failure occurred in broken wire, wrong electrode) welding power supply (Failure Name:
the welding power occurs in arc voltage detecting Arc voltage detecting line error) and
supply. cable of the welding power eliminate all causes.
### Arc weld failure Microcomputer failure The failure occurs in the welding Refer to the instruction manual of the Reset failure.
occurred in the welding power supply. welding power supply (Failure Name:
power supply. Microcomputer failure) and eliminate all
causes.
### Arc weld failure Encoder failure was Failure exists in the encoder of a Refer to the instruction manual of the Reset failure.
detected by the welding wire feed unit or encoder cables welding power supply (Failure Name:
power supply. are not connected. Encoder error) and eliminate all causes.
### Arc weld failure Current detection line The failure(the connector is Refer to the instruction manual of the Reset failure.
failure occurred in the disconnected etc) exists in the welding power supply (Failure Name: 9.
welding power supply. current detecting cable of the Current detection error).
### Arc weld failure Gas check failure The gas check switch of the Turn OFF the gas check switch of the Reset failure.
occurred in the welding welding power supply is ON for welding power supply.
power supply. more than two minutes without a
break.
6-13
### Arc weld failure Secondaly transistor The surge power of the second Refer to the instruction manual of the Reset failure.
failure occurred in the transistor for the welding power welding power supply (Failure Name:
welding power supply. supply is abnormally high. Secondaly transistor failure) and
### Arc weld failure Water pressure failure Cooling water flow is not Refer to the instruction manual of the Reset failure.
occurred in the welding sufficient when using a water welding power supply (Failure Name:
power supply. cooled torch. Water pressure error) and eliminate all
### Arc weld failure Secondaly transistor The surge power of the second Refer to the instruction manual of the Reset failure.
failure occurred in the transistor for the robot welding welding power supply (Failure Name:
welding power supply. power supply is abnormally high. Secondaly transistor failure) and
### Arc weld failure The specified welding The specified welding power Register the welding power supply which Reset failure.
power supply can't use supply isn't defined in this unit. is specified by the task program, or
in this unit. modify the task program.
### Arc weld failure A control power supply A control power supply wrong Refer to the instruction manual of the Reset failure.
wrong point occurred in point occurred in welding power welding power supply (Failure Name:
welding power supply. supply. Control power supply) and eliminate all
causes.
### Arc weld failure An electric detection It has the possibility that a Refer to the instruction manual of the Reset failure.
vessel wrong point connector inside welding power welding power supply (Failure Name:
occurred in welding supply is missing. The first･second electric current error)
power supply. and eliminate all causes.
### Arc weld failure The excess wrong Inside temperature of the Refer to the instruction manual of the Reset failure.
point of the use rate welding power supply rises. welding power supply (Failure Name:
occurred in welding The excess of the use rate) and
power supply. eliminate all causes.
### Arc weld failure A temperature wrong An unusual fever appears on the Refer to the instruction manual of the Reset failure.
point occurred in the wire feed control circuit of the welding power supply (Failure Name:
wire feed control circuit welding power supply. The temperature wrong point of the wire
ing the welding power feed control circuit) and eliminate all
### Arc weld failure The load of wire feed It exceeded the allowable value A load is on the wire feed department by Reset failure.
exceeded allowable which the load of wire feed was wear of the liner, the chip defect, and so
value. set up to by the welding fixed on. Get rid of load factors.
### Arc weld failure The control power The control power supply of the It has the possibility that an input voltage Reset failure.
supply of the welding welding power supply was reset. on the first side decreases momentarily.
power supply was Confirm voltage capacity on the first
### Arc weld failure The welding If the welding characteristic data Turn on the welding power supply again. Reset failure.
characteristic data are are not installed, Arc function
not installed. commands can't be execute.
### Arc weld failure The arc characteristic The arc function attempted Please modify the task program. Reset failure.
can't be changed while changing the arc characteristic
arc welding. into the incorrect one.
### Arc weld failure The incorrect welding The welding method of the arc Please modify the task program. Reset failure.
method is specified. function and the welding method
of the arc characteristic aren't
the same.
### Arc weld failure The arc characteristic Read file failure occurs while Please initialize the arc characteristic Reset failure.
file can't be read. reading the arc characteristic file.
### Arc weld failure The wire feed Read file failure occurs while Please initialize the wire feed Reset failure.
characteristic file can't reading the wire feed characteristic file.
be read. characteristic file.
### Arc weld failure The arc welding wave Read file failure occurs while Please initialize the arc welding wave Reset failure.
control file can't be reading the arc welding wave data file.
read. control file.
### Arc weld failure The arc constant file Read file failure occurs while Please initialize the arc constant file. Reset failure.
can't be read. reading the arc constant file.
### Arc weld failure Welding voltage The voltage adjusting method Modify the task program. Reset faliure.
adjustment method currently taught differs from the
differs. voltage adjusting method of
characteristic data.
### Arc weld failure WCR Short-circuit WCR of W-I/F had connected Please check the state of W-I/F, and a This failure is
Error too hastily at the time of an arc welding power supply. released if restart
### Arc weld failure The electrode short- The electrode and the work are Please modify the task program. Reset failure.
circuited failure. short-circuited while arc welding.
### Operational Resources were not It passed over the waiting time Starting and a branch-unit outside An unusual release
failure securable at the time of of resources reservation. command need to be looked again. key is pushed.
starting.
### Arc weld failure The welding current The difference between the Check the welding conditions(wire Reset failure.
value has exceeded welding current value measured extension etc). There is possibility of
### Arc weld failure The welding voltage The difference between the Check the welding conditions(wire Reset failure.
value has exceeded welding voltage value measured extension etc). There is possibility of
### Arc weld failure Arc start failure. No arc is generated after Check the workpiece's condition, wire's This failure is
retrying. condition, and connection of the cable. released if restart
6-14
### Arc weld failure Arc outage was Arc outage occurred during Eliminate all causes of arc outage, for This failure is
detected. welding. instance by adjusting the wedling released if restart
conditions, fixing wire feed failure, and playback.
### Arc weld failure Wire stick was Wire is stuck. Cut stuck wire. This failure is
detected. released if restart
### Arc weld failure Wire shortage was Not enough wire signal is Supply wire. No reset operations
detected. inputted. neccesary.
### Arc weld failure The load of wire feed It exceeded the allowable value A load is on the wire feed department by No reset operations
exceeded allowable which the load of wire feed was wear of the liner, the chip defect, and so neccesary.
value. set up to by the welding fixed on. Get rid of load factors.
### Arc weld failure The battery of welding The battery of welding power Exchange a battery because it can't be No reset operations
power supply is supply is exhausted. connected any more with the welding neccesary.
exhausted. power supply.
### Arc weld failure WCR Short-circuit WCR of W-I/F had connected Please check the state of W-I/F, and a This failure is
Error too hastily at the time of an arc welding power supply. released if restart
### Operational It was going to start the It will generate, if the unit under Please start after waiting for the Special release is not
failure unit under starting. starting is started. completion of starting. required.
### CPU board System Error (MailBox System Error. MailBox Timeout. Turn on the power again. If the error is Turn on the power
failure Timeout Error). not released, reinstall the system. again.
### CPU board Motion process is not Can't recongnize Motion Turn on the power again. If the error is Turn on the power
failure recognized. process. not released, reinstall the system. again.
### CPU board I/O system is not Can't recognize I/O system. Turn on the power again. If the error is Turn on the power
failure recognized. not released, reinstall the system. again.
### CPU board Servo communication This failure occurs when the (1)Please confirm whether connector After removal of
failure initialization failure communication between CPU CNUSB of servo substrate UM221 is failure, please turn on
substrate and the servo correctly connected.(2)Please confirm the power supply of
substrate cannot begin. the supply voltage of the servo substrate the controller again.
UM221 (3)Please replace the drive unit
### Amplifier unit Brake fuse off This failure occurs when the Please exchange the brake fuse. After removal of
failure fuse F1-1 or F1-2 or F1-3 on failure, please carry
brake control substrate UM222 out "failure-reset".
### Amplifier unit Brake fuse This failure occurs when the Please exchange the brake fuse. After removal of
failure off.(additional axis) fuse F1-1 or F1-2 on brake failure, please carry
control substrate UM226 was out "failure-reset".
### Amplifier unit Contact of brake power This failure occurs when the Please exchange the brake control After removal of
failure control relay was stuck contact of brake power control substrate UM222 referring to "AX failure, please turn on
relay (CRBC1) on brake control controller maintenance manual". power supply of the
substrate UM222 was stuck. controller again.
### Amplifier unit Drive unit power failure This failure occurs when drive Please replace the drive unit. After removal of
failure unit power PG15(+15V) was not failure, please turn on
supplied. power supply of the
controller again.
### Amplifier unit Over temperature of This failure occurs when the (1)Please confirm that the Pay-load is After removal of
failure motor.(additional axis) motor temperature rises within the nominal rating.(2)Please failure, please carry
abnormally. confirm the wiring of the motor out "failure-reset".
thermostat refering to "Manipulator
Maintenance Manual".(3)Please stop the
robot in order to lowering the motor
temperature, and restart.(4)If failure
persists please lower the operation
### Amplifier unit Over temperature of This failure occurs when the (1)Check the fans are After removal of
failure regenerative discharge temperature of the regenerative operating.(2)Please secure space 20cm failure, please carry
resister.(additional discharge resister rises or more in backside of out "failure-reset".
axis) abnormally. controller.(3)Please check wiring of the
thermostat for regenerative discharge
### Amplifier unit Servo shared memory This failure occurs when reading Please replace the drive unit. After removal of
failure abnormal or wrinting data to the shared failure, please turn on
memory between servo power supply of the
communication CPU and servo controller again.
CPU was not successfully
### CPU board Servo CPU(#2) DP Servo CPU(#2) D.P.memory Replace the Drive Unit. No reset operations
failure memory error. error
### CPU board Servo CPU(#3) DP Servo CPU(#3) D.P.memory Replace the Drive Unit. No reset operations
failure memory error. error
### CPU board Servo CPU(#1 axis) is Nothing acknowledge form Replace the Drive Unit. No reset operations
failure not ready. servo CPU(#1 axis)
6-15
Chapter 7 Welding Specifications
This chapter describes the welding specifications of welding power supply.
7.1 Connecting Welding Power Supply.............................................................7-1

7.1.1 Connecting Almega Digital Welding Power Supply ...............................7-1
7.1.2 Connecting Digital Welding Power Supply ............................................7-9
7.1.3 Connecting Welding Power Supply I/F................................................7-13
7.1 Connecting Welding Power Supply
7.1.1 Connecting Almega Digital Welding Power Supply

This section describes how to connect the robot dedicated welding power supply, using CPDRA-351 as an
example.
1. Types of Almega Digital Welding Power Supply
Type
Robot dedicated CO2/MAG/MIG CPDRA-351/501
welding power supply CPDACA-201
CPDPAS-351/501
TIG welding power supply ADPA-301
2. Connection Cable for Welding Power Supply

To connect the robot dedicated welding power supply, the external connection cables shown in the following
are required.
Control cable 4 ：Connection cable ( Robot - Robot controller )

Component
Torch-side Workpiece-side
Type Gas hose Control cable4 Specifications
welding cable welding cable
EXRB-4005 (Standard) L2527B L2527D L3442B L8905B Length: 5m
EXRB-4010 L3375T L3375E L3375L L8906B Length: 10m
EXRB-4015 L3375V L3375G L3375N L8907B Length: 15m

Type Specifications
AXRB-5005 (Standard) Length: 5m
AXRB-5010 Length: 10m
Fig 7.1.1 Connecting Almega Digital Welding Power Supply
7-1
3. How to connect cables
Turn OFF the primary power and the breaker of robot controller.
Check that the voltage of primary power meets the voltage specification of controller.
The voltage of controller is indicated beside the breaker.
WARNING
(a) Control cable5 : Connection cable (Robot controller - Welding power supply)
(1) Drawing Control cable 5 (AXRB-5005)
Draw the connector of control cable 5 from the inlet, the shaded part in Fig 7.1.2, into the robot controller.
Then, fix the cable flange.
(2) Connecting Control cable 5 (AXRB-5005) -- (1)
Joint the connector CNCAN drawn into the robot controller with the connector CNCAN on the storage board,
and the connector CNWEL with CNWEL on the sequence board.
Clamp the shield part of control cable 5.
Fig 7.1.2 Drawing Control cable 5 (AXRB-5005)
7-2
・ Remove the top cover from the welding power supply.

・ Draw the control cable 5 into the welding power supply through its back, and then fix the cable flange using
the supplied tapping screws.
・ Joint the connector to the connector CN57 on PCB (L8268C), and the crimp-style terminal to the terminal
block (No. 7&8) on PCB (P6981Q).（See Fig 7.1.3）
・ After connecting the cables, connect the grounding and then fix the top cover.
(Refer to
・
・ Fig 7.1.1 for the location of PCB.)
Fig 7.1.3 Terminal Block (P6981Q)
(b) Control cable 4 (L8905B) : Connection cable (Robot – Robot controller )
Joint the control cable 4 to the connector ICN4 in welding power supply and to the connector CN4 in
manipulator.
(c) Workpiece-side welding cable (L3442B) : Connection cable (Welding power supply – Workpiece )
Connect the workpiece-side welding cable to the (-) terminal of the welding power supply.
(d) Torch-side welding cable (L2527D) : Connection cable (Welding power supply – Robot )
Connect the torch-side welding cable to the (+) terminal of the welding power supply.
1. For the outline drawing, the internal structure and others about a welding power supply,
see the instruction manual attached to each welding power supply.
:Important
2. For the maintenance of welding power supply, see the instruction manual attached to
each welding power supply.
7-3
4. Modifying Parameters
CPDRA-351/501
7-4
CPDACA-201
7-5
CPDPAS-351/501
7-6
ADPA-301 (with no Filler wire feeder)
7-7
ADPA-301 (with Filler wire feeder)
7-8
7.1.2 Connecting Digital Welding Power Supply

This chapter describes how to connect the digital welding power supply, using DM-350 as an example.
1. Types of Digital Welding Power Supply
Type
CO2/MAG Welding Power Supply DM-350
2. Connection Cable for Welding Power Supply

To connect the robot dedicated welding power supply, the following external connection cables are required.

Type Component
Torch-side Workpiece-side
Gas hose Control cable4 Specifications
welding cable welding cable
AXRB-4105 L2527B L9155C L9155D L9155B Length: 5m
AXRB-4110 L3375T L9156C L9156D L9156B Length: 10m
AXRB-4115 L3375V L9157C L9157D L9157B Length: 15m

Type Specifications
AXRB-5105 (Standard) Length: 5m
CAN I/F board : Communication board (Robot controller – Welding power supply)
Type Specifications
L9129C Welding power supply CANI/F board
Fig 7.1.4 Connecting the Digtal Welding Power Supply
7-9
The voltage of controller is indicated beside the breaker.
WARNING
(a) Control cable5 : Connection cable (Robot controller - Welding power supply)
(1) Drawing Control cable 5 (AXRB-5105)
Draw the connector of control cable 5 from the inlet, the shaded part in Fig 7.1.5, into the robot controller.
Then, fix the cable flange
and the connector CNWEL with CNWEL on the sequence board.
Clamp the shield part of control cable 5.
Fig 7.1.5 Drawing Control cable 5 (AXRB-5105)
7-10
・ Remove the top cover from the welding power supply.

・ Draw the control cable 5 into the welding power supply through its back, and then fix the cable flange using
the supplied tapping screws.
・ Joint the connector to the connector CN3 on PCB (L9129C), and the crimp-style terminal to the terminal
block (No.1&2) on PCB (P10260T). (See Fig 7.1.6)
・ After connecting the cables, connect the grounding and then fix the top cover.
(Refer to Fig 7.1.4 for the location of PCB.)
Fig 7.1.6 Terminal Block
(e) Control cable 4 (L9155B) : Connection cable (Robot – Robot controller )
Joint the control cable 4 to the connector ICN4 in welding power supply and to the connector CN4 in
manipulator.
(b) Workpiece-side welding cable (L9155D) : Connection cable (Welding power supply – Workpiece)
Connect the workpiece-side welding cable to the (-) terminal of the welding power supply and secure it by
turning the connector.
(c) Torch-side welding cable(L9155C) : Connection cable (Welding power supply – Robot)
Connect the torch-side welding cable to the (+) terminal of the welding power supply and secure it by turning
the connector.
:Important
2. For the maintenance of welding power supply, see the instruction manual attached to
each welding power supply.
After connecting cables, be sure to modify the setting of welding parameters.

For how to modify the parameters, refer to “APPLICATION MANUAL (ARC WELDING)”
1. Arc voltage detecting cable (+ side ) is included in the control cable 4.

2. Arc voltage detecting cable (- side ) is required when the to-and-fro length of
welding cable is 30m or longer.
CAUTION 3. To use the arc voltage detecting cable (- side ), connect it away from the
workpiece cable.
4. Wire feed unit attached with encoder can be combined with a fixed bracket, but
not with a rotational bracket.
7-11
DM-350
7-12
7.1.3 Connecting Welding Power Supply I/F

This section describes how to connect the analog welding power supply.
1. Types of Analog welding power supply
Type
CPVB-350
VRTP-200/300
AEP-300
AVP-200/300/500
D-12000 TRC-120
D-8000 VRC-81
2. Connection cables for welding power supply
Type Length
AXWF-0005 (Standard) Length: 5m
Welding power supply I/F
AXWF-0010 Length: 10m Power cable, Communication cable
AXWF-0015 Length: 15m
Type of welding power supply Connection cable
CPVB-350 E5642B E5642C L8786D

<With no filler wire feeder>
VRTP-200/300
E5243E E5243F L8786B L8786C L8786E
AEP-300
AVP-200/300/500
<With filler wire feeder> Filler wire
VRTP-200/300 feed
E5239E E5239F L8786B L8786C L8786E
ﾊﾟﾙｽｺﾝﾊﾟ AEP-300 control unit
AVP-200/300/500 E5223A
D-12000 TRC-120 E5769B L8786F
D-8000 VRC-81 E5641F L8786F
WARNING The voltage of controller is indicated beside the breaker.
(a) Communication cable/ Power cable : Connection cable (robot controller – Welding power supply I/F)
(1) Drawing the communication cable (L9500B) and the power cable (L8792B)
Draw the connector of each cable from the inlet, the shaded part on the left side in Fig 7.1.7, into the robot
controller. Then, fix the cable flange.
(2) Connecting the communication cable (L9500B) and the power cable (L8792B) – (1)
and the connector CNWEL with CNWEL on the sequence board. In addition, connect the power cable to the
breaker.
(3) Connecting the communication cable (L9500B) and the power cable (L8792B) – (2)
Clamp the shield part of communication cable.
7-13
Fig 7.1.7 Drawing the communication cable (L9500B) and the power cable (L8792B)
(4) Connection inside the welding power supply I/F

・ Remove the cover of welding power supply I/F.
・ Draw the control cable from the specified inlet on the welding power supply I/F. And then, secure the
cable flange with the attached tapping screw.
・ Next, see Fig 7.1.8 and joint each connector. After completing cable connections, connect the grounding
and fix the cover.
Fig 7.1.8 Connection inside the welding power supply I/F

:Important 2. For the maintenance of welding power supply, see the instruction manual attached to each
After connecting cables, be sure to modify the setting of welding parameters.

For how to modify the parameters, refer to “APPLICATION MANUAL (ARC WELDING)”
7-14
Chapter 8 Specifications of External Axis
This chapter describes the specifications of external axis.
8.1 External Axis ...............................................................................................8-1

8.1.1 Specifications of External Axis ..............................................................8-1
8.1.2 External Axis Cable...............................................................................8-3
8.1.3 Connecting External Axis Cable............................................................8-5
8.1 External Axis
8.1 External Axis
8.1.1 Specifications of External Axis
To use the manipulator combining with the peripheral jig equipment such as positioner or slider, the optional
external axis unit is needed to extend. This unit is called “External axis unit (for motor of 1500w or smaller)”.
Building this unit inside the standard robot controller enables to extend the maximum of 3 external axes.
(Refer to Note3) below the table.)
Item Details
Name External axis unit
Driving system AC servo
< For connecting the robot dedicated peripheral jig unit
controlling without the motor of 1500W or smaller >
Combination of applicable motor Type
500W∼1500W × 1 axis L9171
Number and type of 500W∼1500W × 2 axes L9172
control axes
500W∼1500W × 3 axes L9171 + L9172
(Note 1,2 and 3)
< For connecting the robot dedicated peripheral jig unit
controlling with the motor of 1500W or smaller >
Combination of applicable motor Type
1500W ×1axis +1500W (or smaller) ×1 axis L9172
Automatic operation For positioning : Refer to the specifications of peripheral jig unit.
speed For welding : 10cm ∼ 999cm/min. (Setting is available by 1cm /min.)
Not necessary -- Provided with the absolute position detecting function by battery
Origin return
backup. (Note 4)
3-phase AC200V+10%, -15% 50/60Hz
Power supply (Note 5) Type Rating Type Rating
L9171 2kVA L9172 4kVA
Standard robot controller + L9171 : Approx. 80kg
Weight Standard robot controller + L9172 : Approx. 88kg
Standard robot controller + L9171+L9172 : Approx. 88kg
Note1) The number and type of external axes depend on your peripheral jig equipment. When you order, be
sure to select the suitable one for your system.
Note2) If the combination of external axes in your system is not in the example above, contact our sales
engineer.
Note3) By extending the additional external axis unit, the maximum of 48 external axes can be extended (total of
54 axes).
Note4) The duration of the absolute encoder battery is approx. 3 years with the power OFF. This may be even
shorter depending on the ambient temperature, the use condition etc.
After this duration period, be sure to perform “Absolute offset setting” and replace the battery.
Note5) The rating of the primary power indicated here is only of the external axis unit. The rating of the total
robot system is the addition of this value and the rating of robot controller.
Remember this note when performing the power construction.
8-1
8.1 External Axis
We provide the products shown in Table 8.1.1 below as the peripheral jig unit to combine with the robot.
Table 8.1.1 Robot dedicated peripheral unit
Item Type Specification

AX-1PB250 Max. payload 250 kg
1-axis Headstock Positioner AX-1PB500 Max. payload 500 kg
AX-1PB1000 Max. payload 1000 kg
AX-2PE150 Max. payload 150 kg
2-axes Double Support Positioner
AX-2PE300 Max. payload 300 kg
AX-2PT500 Max. payload 500 kg
2-axes Tilting Positioner
AX-2PT1000 Max. payload 1000 kg
AX-1SB10 Stroke 1.0 m
Linear Slider (Light type)
AX-1SB20 Stroke 2.0 m
AX-1SR29 Stroke 2.9 m
Linear Slider (Standard type)
AX-1SR19P Stroke 1.9 m
Linear Slider (with carriage type) AX-1SR39P Stroke 3.9 m
The standard controller can be connected with the peripheral jig unit of 3 axes of the maximum. This system
must be the combination of 1 axis or 2 axes jig. As for the standard combination of 1 axis and 2 axes, see Table
8.1.2.
Table 8.1.2 System configuration

Peripheral jig
Number of required external axis
Number of Example of configuration cables for peripheral jigs
axes Jig 1 Jig 2
1-axis positioner −
1 axis
1-axis slider − External axis cables for 1 and 2 axes
2-axes positioner − (1 set)
2 axes
1-axis positioner 1-axis positioner
External axis cables for 1 and 2 axes
3 axes 1-axis slider 2-axes positioner
(2 sets)
8-2
8.1 External Axis
8.1.2 External Axis Cable
When connecting the peripheral jig unit with the external axis controller, the external cables shown in Table
8.1.3 are required.
This external axis cable for connecting a single peripheral jig unit consists of two cables; one motor cable
(External axis cable 1) and one encoder cable (External axis cable 2).
Table 8.1.3 External axis cable

Length of external
Type Item Part No. Remarks
axis cable
External axis cable 1 L9125B00
3m L9125
External axis cable 2 L9125C00 For using the motor of
External axis cable 1 L9126B00 1500W or smaller
5m L9126
External axis cable 2 L9126C00
External axis cable 1 L9127B00 External axis cables for the
10m L9127 external 1 axis and 2 axes jig
External axis cable 1 L9128B00 are common.
15m L9128
When applying jigs from other manufacturer, additional external axis relay cable is required other than the
external axis cable. As for the cable length and the type of external axis relay cable, see Table 8.1.4 and Table
8.1.5.
Besides, see Fig 8.1.1 for the relay cable.
Table 8.1.4 External axis relay cable - Motor cable -

Cable length and part No. Remarks
Cable name Motor rating Part No.
0.2 0.3 0.5 1 2 3 4 5 6 7 8 9 10
Relay connector
cable for external L7464○00 B B
axis motor
External axis relay For motor of 750W or Use

L7465○00 B C D E F G H J K L M N
motor cable smaller L7464B.
External axis relay For motor of 1.2KW Use
L7466○00 B C D E F G H J K L M N
motor cable ∼2KW or smaller L7464B.
External axis
For motor of 750W or
extension motor L7467○00 B C D E F G H J K L M N
smaller
cable
Table 8.1.5 External axis relay cable - Encoder cable -
Cable length and part No. Remarks

Cable name Motor rating Part No.
0.2 0.3 0.5 1 2 3 4 5 6 7 8 9 10
Relay connector
cable for external With LS wire L7468○00 B B
axis encoder
External axis relay Use

With LS wire L7469○00 B C D E F G H J K L M N
encoder cable L7468B
Joint the short-circuit connector “L6390K” to the end of encoder cable (jig side) when the overrun function is OFF (not used).
< Part No. >

Part No. is described such as “L7465○00”. The ○ part indicates the length of cable using an alphabet. For example, the
part No. for “External axis relay motor cable 4m” is L7465G00.
8-3
8.1 External Axis
Fig 8.1.1 External axis relay cable
8-4
8.1 External Axis
8.1.3 Connecting External Axis Cable

This section describes how to connect the external axis cable.
1. Specifications for 7 axes (Example: Using a single 1-axis slider)
.
Check that the primary power voltage meets the voltage specification of the controller
indicated beside the breaker.
WARNING
Joint the wire harness (External axis cable 1 and 2) connected on the jig side to the robot controller.
See Fig 8.1.2 for the inlet of wire harness and the connector position.
・ Shut off the power supply and turn OFF the breaker of the unit.
・ Draw the wire harness (External axis cable 1 and 2) from the side of robot controller to the inside.
Then clamp the shield part of the control cable 1 and fix the grounding cable, for the external cable 2, to
the earth stud on the left flank side of controller.
When drawing the cable, use the inlet shown in Fig 8.1.2.
・ Joint the connector, referring to Fig 8.1.2.
Fig 8.1.2 Connecting wire harness (External axis cable 1 and 2)
Arrange the wire harness (External axis cable 2) away from both the primary power cable
and the wire harness connected to the Arc welding power supply.
･When wiring inside the robot controller, keep the both wire harness; Control cable 1 and
2, away from each other. Do not bind these two wire harnesses together.
CAUTION ･Do not use the wire harness (control cable 2) for the movable/flexion part such as in the
cable bare of slider since this cable is not made movable.
If you need to use it for that purpose, contact our sales engineers.
After connecting the cables to a robot controller, be sure to close the door. If it is not
completely closed, the controller will be exposed to dust, dirt etc. and result in a trouble.
CAUTION
8-5
8.1 External Axis
2. Specifications for 8 axes (Example: Using a single 2-axes positioner)
WARNING indicated beside the breaker.
Fig 8.1.3 Connecting wire harness (External axis cable 1 and 2)
CAUTION
･Do not use the wire harness (control cable 2) for the movable/flexion part such as in the
CAUTION
8-6
8.1 External Axis
3. Specifications for 8 axes (Example: Using two 1-axis sliders)
st
~ 1 slider ~
st
Fig 8.1.4 Connecting wire harness (External axis cable 1 and 2) 1 slider
8-7
8.1 External Axis
nd
~2 slider ~
Fig 8.1.5 Connecting wire harness (External axis cable 1 and 2) 2nd slider
･Do not use the wire harness (control cable 2) for the movable/flexion part such as in the
CAUTION cable bare of slider since this cable is not made movable.
CAUTION
8-8
8.1 External Axis
4. Specifications for 9 axes (Example: Using a single 1-axis slider and 2-axes positioner)
~ Slider ~
See
Fig 8.1.6 for the inlet of wire harness and the connector position.
When drawing the cable, use the inlet shown in

・ Fig 8.1.6.
・ Joint the connector, referring to

・ Fig 8.1.6.
Fig 8.1.6 Connecting wire harness (External axis cable 1 and 2) Slider
8-9
8.1 External Axis
st
~ 1 positioner ~
See
Fig8.1.7 for the inlet of wire harness and the connector position.
When drawing the cable, use the inlet shown in

・ Fig8.1.7.
・ Joint the connector, referring to
・ Fig8.1.7.
st
Fig8.1.7 Connecting wire harness (External axis cable 1 and 2) 1 positioner
CAUTION ･Do not use the wire harness (control cable 2) for the movable/flexion part such as in the
CAUTION
8-10

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CONTROLLER MAINTENANCE

Chapter1 Notes on Safety

Chapter3 Replacement and Adjustment of Components

Chapter4 Periodic Inspection

Chapter5 Parts Layout and Electrical Circuit

Chapter6 Error Code

Chapter7 Welding Specifications

Chapter8 Specifications of External Axis

Chapter 1 Notes on Safety

Chapter 3 Replacement of Components and Adjustment

Chapter 4 Periodic Inspection

Chapter 5 Parts Layout and Electrical Circuit

Chapter 6 Error Code 6

6.2 Concerning the fault details ....................................................................................................... 6-2

Chapter 7 Welding Specifications

Chapter 8 Specifications of External Axis

This chapter describes the notes on safety of the robot system.

1.1 Safe Use of the Robot System....................................................................1-1

1.1 Safe Use of the Robot System

This is a notice especially to take the utmost care.

Notes on safe adjustment, operation and maintenance

･An operator performed Automatic operation without making sure that no

Points in common among the accidents above are ;

･Safety procedures were neglected.

Here are some cases.

･ The speed of robot motion changed from low to high.

1.1.1 Safety Measures on Robot

If removing the motor without The arm will drop.

A balance spring device is internally compressed under the normal condition.

~ Brake Positive Release ~

(2) Turn OFF the robot controller.

Position of the brake positive release connector

1.1.2 Safety Measures on Teaching and Inspection

Operators must be provided with the escape route to immediately escape in an

1.1.3 Safety Measures on Test Operation

1.1.4 Safety Measures on Automatic Operation

Operators must be always familiarized with motion path, operating condition,

Make an emergency stop immediately if any abnormalities are observed. And,

1.1.5 Relocation, Transfer and Sale of Robot

1.1.6 Disposition of Robot

Discard scrapped items with utmost care to avoid injury.

1.1.7 Labels on Robot and Robot Controller

Attaching alarm signs to MV6/MV6L/MV16

Attaching alarm signs to MG3

Attaching alarm signs to MH3

Attaching alarm signs to MS3

Attaching alarm signs to robot controller

This chapter describes the components of robot controller.

2.1 Component Layout in AX-C Controller........................................................2-1

2.1 Component Layout in AX-C Controller

2.1.1 Component Layout in AX-C Controller

The outline drawing of AX-C robot controller is shown below.

Outline drawing of AX-C

The component layout in AX-C controller is shown below.

AX-C component layout

2.2 Block Diagram of AX-C Controller

2.2.1 Block Diagram of AX-C Controller

2.2.2 Outline and Specifications of Components

The table below shows the specifications of AX-C controller.

Specifications of AX-C controller

2.3 Function of Components and Units

2.3.1 Multi Power Supply Unit (L8810A00)

2.3.2 CPU Board (L8800C00)