ROBOT

RC5 CONTROLLER
INTERFACE MANUAL
Copyright © DENSO WAVE INCORPORATED, 2002
All rights reserved. No part of this publication may be reproduced in any form or by any means without
permission in writing from the publisher.
Specifications are subject to change without prior notice.

All products and company names mentioned are trademarks or registered trademarks of their respective
holders.
 Preface
Thank you for purchasing this high-speed, high-accuracy assembly robot.
This manual covers interfacing required when you integrate your robot system configured with the RC5
robot controller into your facilities.
Before use, read this manual carefully together with related manuals to safely get the maximum benefit
from your robot in your assembling operations.

Robot models covered by this manual

All robot models configured with RC5 controller

Important
To ensure operator safety, be sure to read the precautions and instructions in "SAFETY PRECAUTIONS."

i
How the documentation set is organized
The documentation set consists of the following books. If you are unfamiliar with this robot and option(s),
please read all books and understand them fully before operating your robot and option(s).

GENERAL INFORMATION ABOUT ROBOT

Provides the packing list of the robot and outlines of the robot system, robot unit, and robot
controller.

INSTALLATION & MAINTENANCE GUIDE

Provides instructions for installing the robot components and customizing your robot, and
maintenance & inspection procedures.

BEGINNER'S GUIDE
Introduces you to the DENSO robot. Taking an equipment setup example, this book guides you
through running your robot with the teach pendant, making a program in WINCAPSII, and
running your robot automatically.

SETTING-UP MANUAL
Describes how to set-up or teach your robot with the teach pendant, operating panel, or
mini-pendant.

WINCAPSII GUIDE
Provides instructions on how to use the teaching system WINCAPSII which runs on the PC
connected to the robot controller for developing and managing programs.

PROGRAMMER'S MANUAL (I), (II)

Describes the PAC programming language, program development, and command
specifications in PAC.

RC5 CONTROLLER
INTERFACE MANUAL - this book -
Describes the RC5 controller, interfacing with external devices, system- and user-input/output
signals, and I/O circuits.

ERROR CODE TABLES

List error codes that will appear on the teach pendant, operating panel, or PC screen if an error
occurs in the robot series or WINCAPSII. These tables provide detailed description and
recovery ways.

OPTIONS MANUAL
Describes the specifications, installation, and use of optional devices.

ii
How this book is organized
This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS
and chapters one through nine.

SAFETY PRECAUTIONS
Defines safety terms and related symbols and provides precautions that should be observed. Be sure to
read this section before operating your robot.

Chapter 1 Outline of the RC5 Controller

Provides an outline of the RC5 controller. The robot controller is available in several models that will differ
in detailed specifications to match robot models to be connected.

Chapter 2 General Information about the Interface

Introduces you to the interface required for connecting the robot controller with a PLC or other external
equipment. It describes two I/O allocation modes available--standard mode and compatible mode, and
the switching procedure between those modes.
Describes declaration of I/O variables and user I/O signals.

Chapter 3 System I/O Signals in Standard Mode

Describes system I/O signals available in standard mode, and describes I/O signals that execute I/O
commands.

Chapter 4 System I/O Signals in Compatible Mode

Describes the functions, terminal numbers, and on/off conditions of system I/O signals in compatible
mode.

Chapter 5 I/O Circuits and Connectors (NPN type)

Describes the I/O circuits and connector pin layout of an NPN I/O board (source input and sink output).
The NPN I/O board is designed for the use in Japan.

Chapter 6 I/O Circuits and Connectors (PNP type)

Describes the I/O circuits and connector pin layout of a PNP I/O board (sink input and source output).

Chapter 7 I/O Wiring

Describes I/O cables and wiring.

iii
 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
Be sure to observe all of the following safety precautions.

Strict observance of these warning and caution indications are a MUST for preventing accidents, which
could result in bodily injury and substantial property damage. Make sure you fully understand all
definitions of these terms and related symbols given below, before you proceed to the text itself.

WARNING Alerts you to those conditions, which could result

in serious bodily injury or death if the instructions
are not followed correctly.

CAUTION Alerts you to those conditions, which could result

in minor bodily injury or substantial property
damage if the instructions are not followed
correctly.

Terminology and Definitions

Maximum space: Refers to the volume of space encompassing the maximum designed movements of
all robot parts including the end-effector, workpiece and attachments. (Quoted from the RIA*
Committee Draft.)
Restricted space: Refers to the portion of the maximum space to which a robot is restricted by limiting
devices (i.e., mechanical stops). The maximum distance that the robot, end-effector, and workpiece
can travel after the limiting device is actuated defines the boundaries of the restricted space of the
robot. (Quoted from the RIA Committee Draft.)
Motion space: Refers to the portion of the restricted space to which a robot is restricted by software
motion limits. The maximum distance that the robot, end-effector, and workpiece can travel after the
software motion limits are set defines the boundaries of the motion space of the robot. (The "motion
space" is DENSO WAVE-proprietary terminology.)
Operating space: Refers to the portion of the restricted space (or motion space in Denso robot) that is
actually used by the robot while performing its task program. (Quoted from the RIA Committee Draft.)

Task program: Refers to a set of instructions for motion and auxiliary functions that define the specific
intended task of the robot system. (Quoted from the RIA Committee Draft.)

(*RIA: Robotic Industries Association)

1. Introduction This section provides safety precautions to be observed during
installation, teaching, inspection, adjustment, and maintenance
of the robot.

2. Installation Precautions

2.1 Insuring the proper

installation environment

2.1.1 For standard type The standard type has not been designed to withstand
explosions, dust-proof, nor is it splash-proof. Therefore, it
should not be installed in any environment where:
(1) there are flammable gases or liquids,
(2) there are any shavings from metal processing or other
conductive material flying about,
(3) there are any acidic, alkaline or other corrosive gases,
(4) there is cutting or grinding oil mist,
(5) it may likely be submerged in fluid,
(6) there is sulfuric cutting or grinding oil mist, or
(7) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other
sources of electrical noise.

2.1.2 For dust-proof, splash- The dust-proof, splash-proof type is an IP54-equivalent

proof type structure, but it has not been designed to withstand explosions.
(The HS-E-W and the wrist of the VM-D-W/VS-E-W are an
IP65-equivalent dust-proof and splash-proof structure.)
Note that the robot controller is not a dust- or splash-proof
structure. Therefore, when using the robot controller in an
environment exposed to mist, put it in an optional protective
box.
The dust-proof, splash-proof type should not be installed in any
environment where:
(1) there are any flammable gases or liquids,
(2) there are any acidic, alkaline or other corrosive gases,
(3) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other
sources of electrical noise,
(4) it may likely be submerged in fluid,
(5) there are any grinding or machining chips or shavings,
(6) any machining oil not specified in this manual is in use, or
Note: Yushiron Oil No. 4C (non-soluble) is specified.
(7) there is sulfuric cutting or grinding oil mist.

2.2 Service space The robot and peripheral equipment should be installed so that
sufficient service space is maintained for safe teaching,
maintenance, and inspection.
 SAFETY PRECAUTIONS

2.3 Control devices The robot controller, teach pendant, and operating panel should
outside the robot's be installed outside the robot's restricted space and in a place
where you can observe all of the robot’s movements when
restricted space
operating the robot controller, teach pendant, or operating
panel.

2.4 Positioning of gauges Pressure gauges, oil pressure gauges and other gauges should
be installed in an easy-to-check location.

2.5 Protection of electrical If there is any possibility of the electrical wiring or

wiring and hydraulic/pneumatic piping being damaged, protect them with a
cover or similar item.
hydraulic/pneumatic
piping

2.6 Positioning of Emergency stop switches should be provided in a position

emergency stop where they can be reached easily should it be necessary to
stop the robot immediately.
switches
(1) The emergency stop switches should be red.
(2) Emergency stop switches should be designed so that they
will not be released after pressed, automatically or
mistakenly by any other person.
(3) Emergency stop switches should be separate from the
power switch.

2.7 Positioning of Operating status indicators should be positioned in such a way

operating status where workers can easily see whether the robot is on
temporary halt or on an emergency or abnormal stop.
indicators
2.8 Setting-up the safety A safety fence or enclosure should be set up so that no one can
fence or enclosure easily enter the robot's restricted space. If it is impossible,
utilize other protectors as described in Section 2.9.
(1) The fence or enclosure should be constructed so that it
cannot be easily moved or removed.
(2) The fence or enclosure should be constructed so that it
cannot be easily damaged or deformed through external
force.
(3) Establish the exit/entrance to the fence or enclosure.
Construct the fence or enclosure so that no one can easily
get past it by climbing over the fence or enclosure.
(4) The fence or enclosure should be constructed to ensure
that it is not possible for hands or any other parts of the
body to get through it.
(5) Take any one of the following protections for the entrance/
exit of the fence or enclosure:
1) Place a door, rope or chain across the entrance/exit of
the fence or enclosure, and fit it with an interlock that
ensures the emergency stop device operates
automatically if it is opened or removed.
2) Post a warning notice at the entrance/exit of the fence
or enclosure stating "In operation--Entry forbidden" or
"Work in progress--Do not operate" and ensure that
workers follow these instructions at all times.
When making a test run, before setting up the fence or
enclosure, place an overseer in a position outside the
robot’s restricted space and one in which he/she can
see all of the robot’s movements. The overseer should
prevent workers from entering the robot's restricted
space and be devoted solely to that task.

2.9 Positioning of rope or If it is not possible to set up the safety fence or enclosure
chain described in Section 2.8, hang a rope or chain around the
perimeter of the robot’s restricted space to ensure that no one
can enter the restricted space.
(1) Ensure the support posts cannot be moved easily.
(2) Ensure that the rope or chain’s color or material can easily
be discerned from the surrounds.
(3) Post a warning notice in a position where it is easy to see
stating "In operation--Entry forbidden" or "Work in progress
--Do not operate" and ensure that workers follow these
instructions at all times.
(4) Set the exit/entrance, and follow the instructions given in
Section 2.8, (3) through (5).
 SAFETY PRECAUTIONS

2.10 Setting the robot's The area required for the robot to work is called the robot's
motion space operating space.
If the robot’s motion space is greater than the operating space,
it is recommended that you set a smaller motion space to
prevent the robot from interfering or disrupting other equipment.
Refer to the "INSTALLATION & MAINTENANCE GUIDE."

2.11 No robot modification Never modify the robot unit, robot controller, teach pendant or
allowed other devices.

2.12 Cleaning of tools If your robot uses welding guns, paint spray nozzles, or other
end-effectors requiring cleaning, it is recommended that the
cleaning process be carried out automatically.

2.13 Lighting Sufficient illumination should be assured for safe robot

operation.

2.14 Protection from objects If there is any risk of workers being injured in the event that the
thrown by the end- object being held by the end-effector is dropped or thrown by
the end-effector, consider the size, weight, temperature and
effector
chemical nature of the object and take appropriate safeguards
to ensure safety.

2.15 Affixing the warning Place the warning label packaged

label with the robot on the exit/entrance
of the safety fence or in a position
where it is easy to see.
3. Precautions Touching the robot while it is
while robot is Warning in operation can lead to
running serious injury. Please ensure
the following conditions are
maintained and that the
cautions listed from Section
3.1 onwards are followed
when any work is being
performed.

1) Do not enter the robot's restricted space when the robot

is in operation or when the motor power is on.
2) As a precaution against malfunction, ensure that an
emergency stop device is activated to cut the power to
the robot motor upon entry into the robot's restricted
space.
3) When it is necessary to enter the robot's restricted
space to perform teaching or maintenance work while
the robot is running, ensure that the steps described in
Section 3.3 "Ensuring safety of workers performing jobs
within the robot's restricted space" are taken.

3.1 Creation of working When entering the robot’s restricted space to perform teaching
regulations and or maintenance inspections, set "working regulations" for the
following items and ensure workers adhere to them.
assuring worker
adherence (1) Operating procedures required to run the robot.
(2) Robot speed when performing teaching.
(3) Signaling methods to be used when more than one worker
is to perform work.
(4) Steps that must be taken by the worker in the event of a
malfunction, according to the contents of the malfunction.
(5) The necessary steps for checking release and safety of the
malfunction status, in order to restart the robot after robot
movement has been stopped due to activation of the
emergency stop device
(6) Apart from the above, any steps below necessary to
prevent danger from unexpected robot movement or
malfunction of the robot.
1) Display of the control panel (See Section 3.2 on the
following page)
2) Assuring the safety of workers performing jobs within
the robot's restricted space (See Section 3.3 on the
following page)
 SAFETY PRECAUTIONS

3) Maintaining worker position and stance

Position and stance that enables the worker to confirm
normal robot operation and to take immediate refuge if
a malfunction occurs.
4) Implementation of measures for noise prevention
5) Signaling methods for workers of related equipment
6) Types of malfunctions and how to distinguish them
Please ensure "working regulations" are appropriate to the
robot type, the place of installation and to the content of the
work.
Be sure to consult the opinions of related workers, engineers at
the equipment manufacturer and that of a labor safety
consultant when creating these "working regulations".

3.2 Display of operation To prevent anyone other than the worker from accessing the
panel start switch or the changeover switch by accident during
operation, display something to indicate it is in operation on the
operating panel or teach pendant. Take any other steps as
appropriate, such as locking the cover.

3.3 Ensuring safety of When performing jobs within the robot’s restricted space, take
workers performing any of the following steps to ensure that robot operation can be
stopped immediately upon a malfunction.
jobs within the robot's
restricted space (1) Ensure an overseer is placed in a position outside the
robot’s restricted space and one in which he/she can see
all robot movements, and that he/she is devoted solely to
that task.
Q An emergency stop device should be activated
immediately upon a malfunction.
R Do not permit anyone other than the worker engaged
for that job to enter the robot’s restricted space.
(2) Ensure a worker within the robot's restricted space carries
the portable emergency stop switch so he/she can press it
(the robot stop button on the teach pendant) immediately if
it should be necessary to do so.
3.4 Inspections before Before starting work such as teaching, inspect the following
commencing work items, carry out any repairs immediately upon detection of a
malfunction and perform any other necessary measures.
such as teaching
(1) Check for any damage to the sheath or cover of the
external wiring or to the external devices.
(2) Check that the robot is functioning normally or not (any
unusual noise or vibration during operation).
(3) Check the functioning of the emergency stop device.
(4) Check there is no leakage of air or oil from any pipes.
(5) Check there are no obstructive objects in or near the
robot’s restricted space.

3.5 Release of residual air Before disassembling or replacing pneumatic parts, first release
pressure any residual air pressure in the drive cylinder.

3.6 Precautions for test Whenever possible, have the worker stay outside of the robot's
runs restricted space when performing test runs.

3.7 Precautions for (1) At start-up

automatic operation Before the robot is to be started up, first check the following
items as well as setting the signals to be used and perform
signaling practice with all related workers.
1) Check that there is no one inside the robot’s restricted
space.
2) Check that the teach pendant and tools are in their
designated places.
3) Check that no lamps indicating a malfunction on the
robot or related equipment are lit.
(2) Check that the display lamp indicating automatic operation
is lit during automatic operation.
(3) Steps to be taken when a malfunction occurs
Should a malfunction occur with the robot or related
equipment and it is necessary to enter the robot's restricted
space to perform emergency maintenance, stop the robot’s
operation by activating the emergency stop device. Take
any necessary steps such as placing a display on the
starter switch to indicate work is in progress to prevent
anyone from accessing the robot.
 SAFETY PRECAUTIONS

3.8 Precautions in repairs (1) Do not perform repairs outside of the designated range.
(2) Under no circumstances should the interlock mechanism
be removed.
(3) When opening the robot controller's cover for battery
replacement or any other reasons, always turn the robot
controller power off and disconnect the power cable.
(4) Use only spare tools specified in this manual.

4. Daily and periodical (1) Be sure to perform daily and periodical inspections. Before
starting jobs, always check that there is no problem with the
inspections robot and related equipment. If any problems are found,
take any necessary measures to correct them.
(2) When carrying out periodical inspections or any repairs,
maintain records and keep them for at least 3 years.

5. Management of (1) Carefully handle and store the "Initial settings" floppy disks
packaged with the robot, which store special data
floppy disks exclusively prepared for your robot.
(2) After finishing teaching or making any changes, always
save the programs and data onto floppy disks.
Making back-ups will help you recover if data stored in the
robot controller is lost due to the expired life of the back-up
battery.
(3) Write the names of each of the floppy disks used for storing
task programs to prevent incorrect disks from loading into
the robot controller.
(4) Store the floppy disks where they will not be exposed to
dust, humidity and magnetic field, which could corrupt the
disks or data stored on them.
 Contents

Preface......................................................................................................................................................... i

How the documentation set is organized ................................................................................................... ii

How this book is organized ....................................................................................................................... iii

SAFETY PRECAUTIONS

Chapter 1 General Information about RC5 Controller

1.1 Controller Model Name on Nameplate .......................................................................................... 1

1.2 Names of the Robot Controller Components ................................................................................. 4
1.3 Robot Controller Specifications...................................................................................................... 7
1.4 Controller System Configuration..................................................................................................11
1.4.1 Internal Circuits of the Controller (Typical configuration) ..................................................11
1.4.2 Typical Robot System Configurations .................................................................................. 12

Chapter 2 General Information about the Interface

2.1 Standard Mode and Compatible Mode ........................................................................................ 14

2.2 Switching between Modes ............................................................................................................ 14
2.3 Types and General Information about I/O Signals ..................................................................... 22
2.3.1 Standard Mode...................................................................................................................... 22
2.3.2 Compatible Mode .................................................................................................................. 23
2.4 Using User I/O Signals (common to both modes) ........................................................................ 24
2.4.1 I/O Type Variable Declaration .............................................................................................. 24
2.4.2 I/O Type Global Variables ..................................................................................................... 24
2.4.3 I/O Type Local Variables....................................................................................................... 24
2.4.4 User Input Commands.......................................................................................................... 24
2.4.5 User Output Commands....................................................................................................... 25

Chapter 3 System I/O Signals Standard Mode

3.1 Types and Functions of System Output Signals (Standard Mode)............................................. 26

 3.2 Usage of System Output Signals (Standard Mode)..................................................................... 27
3.2.1 Robot Initialization Complete (Output) ............................................................................... 27
3.2.2 Auto Mode (Output) .............................................................................................................. 28
3.2.3 External Mode (Output) ....................................................................................................... 29
3.2.4 Servo ON (Output) ................................................................................................................ 30
3.2.5 Robot-in-operation (Output) ................................................................................................. 31
3.2.6 Normal CPU (Output)........................................................................................................... 32
3.2.7 Robot Failure (Output) ......................................................................................................... 33
3.2.8 Robot Warning (Output) ....................................................................................................... 34
3.2.9 Dead Battery Warning (Output)........................................................................................... 35
3.2.10 Continue Start Permitted (Output)...................................................................................... 36
3.2.11 SS mode (Output).................................................................................................................. 36
3.2.12 Emergency Stop (Output from a contact)............................................................................. 37
3.3 Types and Functions of System Input Signals (Standard Mode)................................................ 38
3.4 Usage of System Input Signals (Standard Mode) ....................................................................... 39
3.4.1 Enable Auto (Input) .............................................................................................................. 39
3.4.2 Robot Stop (Input)................................................................................................................. 40
3.4.3 Step Stop (All Tasks) (Input) ................................................................................................ 41
3.4.4 Instantaneous Stop (All Tasks) (Input)................................................................................ 42
3.4.5 Interrupt Skip (Input)........................................................................................................... 43
3.5 Command Execution I/O Signals Dedicated to Standard Mode ................................................. 45
3.5.1 General Information about Commands................................................................................ 45
3.5.2 Processing I/O Commands .................................................................................................... 46
3.5.3 I/O Commands Details.......................................................................................................... 52
3.6 Example of Using System I/O Signals in Standard Mode .......................................................... 65

Chapter 4 System I/O Signals Compatible Mode

4.1 Types and Functions of System Output Signals (Compatible Mode) ......................................... 69
4.2 Usage of System Output Signals in the Compatible Mode ......................................................... 70
4.2.1 Robot Power ON Complete ................................................................................................... 70
4.2.2 Auto Mode (Output) .............................................................................................................. 71
4.2.3 Servo ON (Output) ................................................................................................................ 72
4.2.4 CAL Complete (Output)........................................................................................................ 73
4.2.5 External Mode (Output) ....................................................................................................... 74
4.2.6 Teaching (Output) ................................................................................................................. 75
4.2.7 Program Start Reset (Output).............................................................................................. 76
4.2.8 Robot-in-operation (Output) ................................................................................................. 77
4.2.9 Single-Cycle End (Output).................................................................................................... 78
4.2.10 Normal CPU (Output)........................................................................................................... 79
4.2.11 Robot Failure (Output) ......................................................................................................... 80
4.2.12 Robot Warning (Output) ....................................................................................................... 81
4.2.13 Dead Battery Warning (Output)........................................................................................... 82
4.2.14 Error No. (Output) ................................................................................................................ 83
4.2.15 Continue Start Permitted (Output)...................................................................................... 84
4.2.16 SS mode (Output).................................................................................................................. 84
4.2.17 Emergency Stop (Output from a contact)............................................................................. 85
4.3 Types and Functions of System Input Signals (Compatible Mode) ........................................... 86
4.4 Usage of System Input Signals in Compatible Mode .................................................................. 87
4.4.1 Enable Auto (Input) .............................................................................................................. 87
4.4.2 Operation Preparation Start (Input).................................................................................... 88
4.4.3 Program No. Select (Input)................................................................................................... 90
4.4.4 Program Start (Input)........................................................................................................... 92
4.4.5 Program Reset (Input) .......................................................................................................... 98
4.4.6 Robot Stop (Input)............................................................................................................... 100
4.4.7 Step Stop (All Tasks) (Input) .............................................................................................. 101
4.4.8 Instantaneous Stop (All Tasks) (Input).............................................................................. 102
4.4.9 Clear Robot Failure (Input) ................................................................................................ 103
4.4.10 Interrupt Skip (Input)......................................................................................................... 104
4.4.11 Continue Start (Input) ........................................................................................................ 105
4.5 Example of Using System I/O Signals in Compatible Mode ..................................................... 106
Chapter 5 Connector Pin Assignment and I/O Circuits (NPN type)

5.1 Connector Pin Assignment (NPN type) ......................................................................................110

5.1.1 Connector Pin Assignment Common to Both Modes (NPN type).......................................110
5.1.2 Connector Pin Assignment in Standard Mode....................................................................112
5.1.3 Connector Pin Assignment in Compatible Mode ................................................................114
5.2 Robot Controller I/O Circuits (NPN type) ..................................................................................116
5.2.1 User-Input, System-Input and Hand-Input Circuits (NPN type) ......................................116
5.2.2 Robot Stop and Enable Auto Input Circuits........................................................................119
5.2.3 User-Output, System-Output, and Hand-Output Circuits (NPN type) ............................ 120
5.2.4 Emergency Stop Circuit...................................................................................................... 124
5.2.5 I/O Power Connector (NPN type) ....................................................................................... 126
5.3 Wiring Notes for Robot Controller I/O Connectors (NPN type) ................................................ 128

Chapter 6 Connector Pin Assignment and I/O Circuits (PNP type)

6.1 Connector Pin Assignment (PNP type)...................................................................................... 130

6.1.1 Connector Pin Assignment Common to Both Modes (PNP type) ...................................... 130
6.1.2 Connector Pin Assignment in Standard Mode................................................................... 132
6.1.3 Connector Pin Assignment in Compatible Mode ............................................................... 134
6.2 Robot Controller I/O Circuits (PNP type) .................................................................................. 136
6.2.1 User-Input, System-Input and Hand-Input Circuits (PNP type)...................................... 136
6.2.2 Robot Stop and Enable Auto Input Circuits....................................................................... 139
6.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP type)............................. 140
6.2.4 Emergency Stop Circuit...................................................................................................... 144
6.2.5 I/O Power Connector (PNP type) ........................................................................................ 146
6.3 Wiring Notes for Robot Controller I/O Connectors (PNP type)................................................. 148

Chapter 7 I/O Wiring

7.1 Multi-core Cables with Connectors............................................................................................ 150

7.2 Wiring of Primary Power Source ............................................................................................... 152

Index
 Chapter 1
General Information about RC5 Controller
The RC5 controller is available in several models which differ in detailed
specifications to match robot models of **-D/-E series.

1.1 Controller Model Name on Nameplate

The model name of the controller is printed on the nameplate attached to the side of
the controller as shown below. The model name is coded as listed below.

Nameplate
(Sample)

Coding of Controller Model Name

RC5 - VSE 6 B A - P
(a) (b) (c) (d) (e)

Position Code Denotes: Coding

sample
(a) VSE Robot model name VM: VM-D, VS: VS-D, VSE: VS-E, VC: VC-E,
H: HM/HS-D, HSE: HS-E, HME: HM-E, HC: HC-D,
XYC:XYC-D
EAH: HM/HS-D with extended-joint support
EAHC: HC-D with extended-joint support
EAXYC: XYC-D with extended-joint support
EAVS: VS-D with extended-joint support
(b) 6 No. of controllable axes 4: 4 axes, 5: 5 axes, 6: 6 axes
(c) B Engineering symbol 1 A: Encoders connected via parallel interface to CN13
B: Encoders connected via bus to CN12
(d) A Engineering symbol 2 Blank or A
(e) P Types Blank: I/O of NPN type
P: I/O of PNP type
AN: Robot System “Type A” and I/O of NPN type
(Note: For Robot System “Type A” refer to next page.)
AP: Robot System “Type A” and I/O of PNP type
BN: Global type (:Dual emergency stop type +
Robot System “Type A”) and I/O of NPN type
BP: Global type (:Dual emergency stop type +
Robot System “Type A”) and I/O of PNP type

1
<Notes for Robot System “ Type A”>

1 Modified Deadman Switch Functions in Robot System "Type A"

In Robot System "Type A" designed for the RC5 controller, the functions of the
deadman switches provided on the optional devices have been partially modified
regarding the motor power ON/OFF control. Accordingly, the description given in the
instruction manuals that come with "Type A" is different from the actual functions.
When reading the deadman switch related sections, be careful with the following
modification.

1.1 Deadman switches on optional devices

(Teach pendant, operating panel, and mini-pendant)

Deadman switches are located as shown below.

Deadman switch
Deadman switches
Deadman
switch

Teach pendant
Operating panel Mini-pendant

1.2 Modified deadman switch functions

When you operate the teach pendant, operating panel, or mini-pendant in Manual
mode or Teach check mode, the deadman switch controls the motor power ON/OFF
function in Robot System "Type A," while it does not in the description given in the
instruction manuals.

Robot System "Type A" Description given in the instruction manuals

(1) Unless the deadman switch is held down, (1) Unless the deadman switch is held down,
you may neither operate the robot nor turn you may not operate the robot, but you may
the motor power ON. turn the motor power ON.

(2) When the robot is in operation, releasing (2) When the robot is in operation, releasing
the deadman switch will stop not only the the deadman switch will stop the robot but
robot but also turn the motor power OFF. not turn the motor power OFF (servo lock).

How to identify your robot system as "Type A"

Check the controller model on the nameplate located on the side of the robot controller or the
robot model shown on the status bar of the teach pendant screen. The model name of "Type A"
contains letter "A" as shown below.
Robot controller example: RC5-H4A-A N
Robot example: HM-40702D A Symbol denoting "Type A"

2
2 “Single point of control” function

The “Single point of control” function is added only for Robot System “Type A”.
This function limits the robot-start that other equipments except specified one device
(for example: Teach Pendant) cannot enable to start the robot.
The “Auto mode” of this function is usable in either “Internal Auto Limited Mode” or
“External Auto Limited Mode” by setting the parameter.

2.1 Internal Auto Limited Mode

The operational permit of “Internal Auto Limited Mode” is the same range as the
“Internal Auto Mode”. Program Start can be executed from the teach pendant, but
cannot be executed from the external device.
The switching between Internal Auto and External Auto cannot be operated by the
teach pendant.

2.2 External Auto Limited Mode

The operational permit of “External Auto Limited Mode” is the same range as the
“External Auto Mode”. Program Start can be executed from the external device, but
cannot be executed from the teach pendant.
The switching between Internal Auto and External Auto cannot be operated by the
teach pendant.

2.3 Setting the parameter

Access: [Top screen] - [F4 I/O] - [F6 Aux.] - [F1 Set H/W] - [F3 Jump To] - “31”

Select the Internal Auto Limited Mode (Int:0) or the External Auto Limited Mode
(Ext:1).
TIP: Before shipping from the factory, the single point of control is set to 0
(Internal Auto Limited Mode) by default.

Type A

Setting parameter

3
1.2 Names of the Robot Controller Components
The following figures show the names of the robot controller components.

n For VM-D/HM-E series

<Front>
Floppy disk drive (option)
CN1 CN2 CN3 CN4 CN5

FG
terminal

Robot stop button

Memory backup
battery holder

Pilot lamp
CN12

CN6 CN7 Fuse box

CN8
CN11
CN9 CN10 Power
Output IC box switch

<Left side> <Right side>

Filters (exhaust)

Radiating fin
Filters (air intake)

Names of Robot Controller Components (VM-D/HM-E series)

4
n For robot series except VM-D/HM-E

<Front>
Floppy disk drive (option)

FG terminal
Robot stop button

Memory backup
battery holder

Pilot lamp

Fuse box

Output IC box Power switch

<Left side> <Right side>

Filters (exhaust) Radiating fin

Filters (air intake)

Note: CN13 is not provided on the VS-E and HS-E series.

Names of Robot Controller Components (Robot series except VM-D/HM-E)

5
 ∗-E series (Encoders connected via bus)
Connectors for the VM-D, VS-E, and H∗

Connector Marking Name Connector Marking Name

No. No.

CN1 RS232C Serial interface CN7 I/O Power connector for

connector POWER I/O

CN2 CRT CRT connector CN8 INPUT Connector for user input
or system input
CN3 KEYBD Keyboard connector CN9 HAND I/O Connector for end-
effector I/O
CN4 MOUSE Connector for PS/2 CN10 OUTPUT Connector for user output
mouse or system output
CN5 PENDANT Connector for teach CN11 INPUT AC Power connector
pendant
CN6 PRINTER Printer connector CN12 MOTOR Connector for
(Not used.) motor/encoder

∗-D and XYC-D series (Encoders connected via parallel interface)

Connectors for the VS-D, VC-E, H∗

Connector Marking Name Connector Marking Name

No. No.

CN1 RS232C Serial interface CN8 INPUT Connector for user input
connector or system input
CN2 CRT CRT connector CN9 HAND I/O Connector for end-
effector I/O
CN3 KEYBD Keyboard connector CN10 OUTPUT Connector for user
output or system output
CN4 MOUSE Connector for PS/2 CN11 INPUT AC Power connector
mouse
CN5 PENDANT Connector for teach CN12 MOTOR Motor connector
pendant
CN6 PRINTER Printer connector CN13 ENCODER Encoder connector
(Not used.)
CN7 I/O Power connector for
POWER I/O

Caution: The robot controller connectors are of a screw-lock type or

ring-lock type. Lock the connectors securely. If even one of
the connectors is not locked, weak contact may result
thereby causing an error.
Be sure to turn the robot controller OFF before connecting/
disconnecting the power connector or motor connector.
Otherwise, the internal circuits of the robot controller may be
damaged.

6
1.3 Robot Controller Specifications
[ 1 ] Specifications
The table below lists the robot controller specifications.

Robot Controller Specifications

Item Specifications
Control system
PTP, CP 3-dimensional linear, 3-dimensional circular
(NOTE 1)
H∗-D/-E, XYC-D: Up to four axes simultaneously
No. of controllable axes
VC-E (5-axis models): Up to five axes simultaneously
(NOTE 1)
V∗-D/-E: Up to six axes simultaneously
Drive system All axes: Full-digital AC servo
Memory capacity 1.25 MB (equivalent to 5000 steps, 13,000 points)
Language used DENSO robot language (conforming to SLIM)
No. of teach programs
255
loadable to the memory
Teaching system 1) Remote teaching 2) Numerical input (MDI)
External Input signal 20 user open points (PLC 12, hand input 8) + 36 fixed system points
signals
(I/O) Output signal 32 user open points (PLC 24, hand output 8) + 33 fixed system points

External RS-232C: 1 line

communication Ethernet: 1 line (option)
Timer function 0.02 to 10 sec. (in units of 1/60 sec.)
Self-diagnosis
Overrun, servo error, memory error, input error, etc.
function
Error codes will be displayed on the external I/O or the operating panel (option).
Error display
Error messages will be displayed in English on the teach pendant (option).
All RC5 models: 3-phase, 200 VAC-15% to 230 VAC+10%, 50/60 Hz
RC5 for VS-D/-E, H∗-D/-E, XYC-D: Single-phase, 230 VAC-10% to 230 VAC+10%,
Power source 50/60 Hz
RC5 for VC-E: Single-phase, 200 VAC-10% to 230 VAC+10%,
50/60 Hz
Power capacity VM-D/HM-E: 3.3 kVA H∗-D: 2.0 kVA VS-E: 1.9 kVA HS-E: 1.8 kVA
(NOTE 1) VS-D, XYC-D: 1.5 kVA VC-E: 0.6 kVA
Environmental conditions Temperature: 0 to 40°C
(in operation) Humidity: 90% RH or less (no condensation allowed)

Degree of protection IP20

VM-D, VS-E, H∗-E: Standard: 4 m, 6 m High strength: 6 m, 12 m (selectable)

Robot control
VS-D, H∗-D, XYC-D: 3 m, 6 m (selectable)
cable
VC-E: 4 m, 6 m (selectable)
Cables
(option)
I/O cable 8 m, 15 m

Power cable 5m
VM-D: Approx. 19 kg (excluding attached cables)
Weight VS-D/-E, VC-E, HS-E: Approx. 17 kg (excluding attached cables)
H∗-D/E, XYC-D: Approx. 16 kg (excluding attached cables)

NOTE 1: For extended-joint support controllers, refer to the manual "SUPPLEMENT

Extended-Joints Support" separately issued.

7
WARNING
⋅ DO NOT touch fins. Their hot surfaces may cause severe
burns.
⋅ DO NOT insert fingers or foreign objects into openings.
Doing so may cause bodily injury.
⋅ Before opening the controller cover and accessing the
inside of the controller for maintenance, be sure to turn off
the power switch, disconnect the power cable, and wait 3
minutes or more. This is for protecting you from electric
shock.
⋅ DO NOT connect or disconnect connectors to/from the
controller while the power switch is on. Doing so may cause
electric shock or controller failure.

CAUTION IN INSTALLATION
⋅ This controller is not designed to be dust-proof, splash-
proof, or explosion-proof.
⋅ Read operation manuals before installation.
⋅ Do not place anything on the controller.

8
[ 2 ] Outer Dimensions
The outer dimensions of the robot controller are shown below.

Outer Dimensions of Robot Controller (for VM-D/HM-E series and extended-joint support)

Outer Dimensions of Robot Controller (for robot series except VM-D/HM-E)

9
n Location of IPM boards
The table below shows the location of IPM boards for robot series or models.

Rear view of the controller

Location
Series &
(8) (7) (6) (5) (4) (3) (2) (1)
models
Item

VM-6070D Joints - 1 6 5 4 3 2 -
IPM model - M SS SS SS S L -
Motor capacity (W) - 750 100 200 200 400 1500 -
VM-6083D/ Joints - 2 6 5 4 3 1 -
VM-60B1D IPM model - M SS SS SS S L -
Motor capacity (W) - 750 100 200 200 400 1500 -
VS-D Joints - - 6 5 4 3 2 1
IPM model - - SS SS SS S S S
Motor capacity (W) - - 50 50 50 200 400 400
VS-E Joints - - 6 5 4 3 2 1
IPM model - - SS SS SS S S M
Motor capacity (W) - - 50 80 100 200 400 750
VC-E Joints - - 6 5 4 3 2 1
IPM model - - SS SS SS SS SS SS
Motor capacity (W) - - 30 30 30 80 80 80
HM/HS-D Joints - - - - 4 3 2 1
IPM model - - - - SS S M M
Motor capacity (W) - - - - 200 200 750 750
HM-E Joints - - 4 3 2 1
IPM model - - M M LL LL
Motor capacity (W) - - 300 300 600 1000
HS-E Joints - - - - 4 3 2 1
IPM model - - - - S S M L
Motor capacity (W) - - - - 150 200 400 750
HC-D Joints - - - - 4 3 2 1
IPM model - - - - SS SS S M
Motor capacity (W) - - - - 50 100 400 750
XYC-D Joints - - - - 4 3 2 1
IPM model - - - - SS S S S
Motor capacity (W) - - - - 50 200 400 200
NOTE 1: No IPM board are installed to locations marked with "-." Those locations
are covered with blank caps.
NOTE 2: For details about extended-joint support controllers, refer to the manual
"SUPPLEMENT Extended-Joints Support."

10
1.4 Controller System Configuration
1.4.1 Internal Circuits of the Controller (Typical configuration)
The block diagram below shows the internal circuits of an RC5 controller designed for
a 6-joint robot.

11
1.4.2 Typical Robot System Configurations
The block diagrams below show typical robot system configurations.
To connect encoders via a time-division multiplexed bus: Connect the robot controller
(CN12) to the robot unit with a motor/encoder cable (see below).
To connect encoders via parallel interface: Connect the robot controller (CN12 and
CN13) to the robot unit with a motor cable and encoder cable, respectively.

n Robot system configuration with encoders connected via a multiplexed bus

(VM-D, VS-E, HS-E, and HM-E)

Robot System Configuration

12
n Robot system configuration with encoders connected via a parallel interface
(VS-D, VC-E, H*-D, and XYC-D)

System Configuration Example

13
 Chapter 2
General Information about the Interface
2.1 Standard Mode and Compatible Mode
The robot controller can be operated in two different modes – standard mode and
compatible mode. The default is standard mode. Select either mode before operating
the robot controller.
In the standard mode, all of the advantages can be expected from the new model of
the robot controller by simultaneously running two or more programs with
multitasking.
The compatible mode focuses on compatibility with conventional DENSO robots. Use
this mode whenever compatibility is required. For example, when replacing a
conventional robot with a new model. However, there are some restrictions on the
use of new functions, such as multitasking, in this mode.

2.2 Switching between Modes

Switch from one mode to the other using the teach pendant or the PC teaching
system.

Caution: After switching between those modes, restart the robot controller to
make the new setting go into effect.

14
[ 1 ] Switching from the Teach Pendant
Follow the procedure below when switching from one mode to the other from
the teach pendant:

On the top screen, press [F4 I/O].

"STEP 1 The I/O Monitor window appears.

F6

Press [F6 Aux.].

The Auxiliary Functions (I/O) window appears as shown below.

"STEP 2

F2

Press [F2 I/O Assign]. (For Version 1.6 or later)

NOTE: For Version 1.5 or earlier, press [F1 Set H/W] and select the
Allocation mode field in the I/O Hardware Settings window.

15
 The Choose allocation window appears as shown below.
"STEP 3 NOTE: If your robot controller has a built-in DeviceNet master, the Select
Port Assignment window will appear instead of the Select I/O Assignment
Mode window. Refer to the DeviceNet Master Unit user's manual, Chapter
3, "I/O Assignment."

Using the jog dial or cursor keys, select the desired assignment
mode. Then press OK.

The following system message appears.

"STEP 4

Press OK.

The screen returns to the Auxiliary Functions (I/O) window.

"STEP 5 Turn the controller power OFF.

Turn the controller power ON again.

"STEP 6 The I/O assignment mode is switched.

16
[ 2 ] Switching from the Computer
Follow the procedure below when switching from one mode to the other from
the computer.

Start WINCAPSII on the computer. Log in with Programmer.

"STEP 1 Start WINCAPSII according to the procedure given in WINCAPSII GUIDE,
Chapter 3, Section 3.1.
For details on the user level of Programmer, refer to the WINCAPSII
GUIDE, Chapter 1, Section 1.3.

Click on the DIO Manager button in the System Manager.

"STEP 2 DIO Manager starts and the DIO Manager window opens.

17
 Select the SETTING command from the Tools menu of DIO Manager.
"STEP 3 The Options window will appear as shown below.

Click on the Hardware tab in the Options window.

"STEP 4 The hardware settings will appear.

18
 Select the desired assignment mode from the right-hand popup menu
"STEP 5 in the I/O Allocation frame (Ver. 1.6 or later).

Click on OK in the Options window.

"STEP 6 The Options window closes.

Click on the Connect button to connect the computer to the robot

"STEP 7 controller.
The Connect button appears in a pressed state.

19
 Click on the Transfer button.
"STEP 8 The Transfer Environment Table window appears.

Check off the check box by clicking on the Hard setting field.
"STEP 9

Click on the Transfer button.

The following message window appears confirming that you are sure to
"STEP 10 update the data.
Click on the Yes button.

20
 The Transmitting hard setting table window appears displaying a bar graph
"STEP 11 that indicates the transfer progress.

After the Transmitting hard setting table window disappears, turn the
"STEP 12 controller power OFF.

Turn the controller power ON.

"STEP 13 The I/O assignment mode is switched.

21
2.3 Types and General Information about I/O Signals
This section describes the I/O signals for the Robot Controller.
The I/O signals are grouped into user I/O signals and system I/O signals.
User I/O signals are compatible with conventional signals, including the pin
pattern, in compatible mode. Note that the connector pin meanings are different
between standard mode and compatible mode. Some of the signal lines used
for user I/O in compatible mode are used for system input in standard mode.
Additionally, part of the signal lines used for system I/O in compatible mode is
used for command execution I/O signals in standard mode.

2.3.1 Standard Mode

In standard mode, 30 input points for command execution are used to direct
program start and other instructions as I/O commands.
The table below lists the types of I/O signals used in standard mode.

Types of System I/O Signals Used in Standard Mode

Fixed by system

No. of
Type Function
points

Robot stop, Enable Auto, interrupt skip, instantaneous stop (all tasks),
System input 5
step stop (all tasks)
Robot initialization complete, automatic operation mode, external mode,
servo ON, robot-in-operation, normal CPU, robot failure, robot warning,
System output 12
dead battery warning, continue start permitted, SS mode, emergency
stop
Input for command Command (4 bits) data area 1 (8 bits), data area 2 (16 bits), odd parity
30
execution bit, strobe signal

Output for command

18 Command processing complete, status area (16 bits), odd parity bit
execution

Controlled by user program

No. of
Type Function
points

Inputs to read the external I/O status with an IN command or IO [ ]

variable.
User input 12
Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.
Outputs to issue a signal to the external device during program execution
User output 24
with a SET command, RESET command, etc.

Inputs to read the external I/O status with an IN command or IO [ ]

Hand input 8 variable.
Used to confirm the end-effector check status, etc.
Outputs to issue a signal to the external device with a SET command,
Hand output 8 RESET command, etc.
Used to control the opening and closing of the end-effector.

22
2.3.2 Compatible Mode
In the compatible mode, the input and output points are arranged in disregard
of compatibility with conventional VS series robots.
The table below lists the types of I/O signals used in compatible mode.

Types of I/O Signals Used in Compatible Mode

Fixed by system

No. of
Type Function
points

Inputs to turn ON the power to the robot from the external device (PLC),
System input 22 start CAL or select and start a program instead of operations by the
operating panel or teach pendant.

Outputs to inform the external device (PLC) of the robot status, such as
System output 27
robot-in-operation or occurrence of an error.

Controlled by user program

No. of
Type Function
points

Inputs to read the external I/O status with an IN command or IO [ ]

variable.
User input 25
Used for analysis condition identification, condition satisfaction wait, data
input from the external device, etc.
Outputs to issue a signal to the external device during program execution
User output 24
with a SET command, RESET command, etc.

Inputs to read the external I/O status with an IN command or IO [ ]

Hand input 8 variable.
Used to confirm the end-effector check status, etc.
Outputs to issue a signal to the external device (valve) with a SET
Hand output 8 command, RESET command, etc.
Used to control the opening and closing of the end-effector.

23
2.4 Using User I/O Signals (common to both modes)

To use user I/O signals you need to first declare, in the program, the use of user I/O
as I/O type variables with a DEFIO command. Next, access the user I/O by writing it
to the I/O type variables or reading it.

2.4.1 I/O Type Variable Declaration

I/O type variables are classified into I/O type global variables that are available
without any declaration, and I/O type local variables that are not available without a
declaration.

2.4.2 I/O Type Global Variables

I/O type global variables are used to refer to or change user I/O signals bit by bit.
Since they are global variables, they can be used without any declaration.
I/O type global variables are expressed in either of the following two ways:
IO[nn] (nn: terminal number) Example: IO[104]
IOnn (nn: terminal number) Example: IO104

2.4.3 I/O Type Local Variables

I/O type local variables are used to collectively refer to or change 1-bit, 8-bit, 16-bit or
32-bit user I/O signals starting from a specified terminal number.
I/O type local variables require a declaration, which will be made with a DEFIO
command, before they are used. For further information about declarations with a
DEFIO command, refer to the PROGRAMMER'S MANUAL (I), Chapter 9, Section
9.7 "DEFIO (Statement) [Conforms to SLIM]."

2.4.4 User Input Commands

There are two types of user input commands, IN and WAIT. The IN command
substitutes the input result for a variable. The WAIT command waits until the input
result meets specified conditions.

• IN Command
The IN command inputs a signal from the user input specified by an IO type variable
and substitutes it for an arithmetic variable.
For further information about the IN command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "IN."

• WAIT Command
The WAIT command suspends the execution of the program until specified
conditions are met. If an I/O type variable is used for the conditional statement, this
command suspends the execution of the program until the status of the signal from a
specified user input is checked and meets the specified conditions. For further
information about the WAIT command, refer to the PROGRAMMER'S MANUAL (I),
Chapter 12, Section 12.5 "WAIT."

24
2.4.5 User Output Commands
There are three types of user output commands, SET, RESET and OUT. The SET
and RESET commands turn ON and OFF all user outputs specified by I/O type
variables. The OUT command outputs data to a specified user output.

• SET Command
The SET command turns ON all user outputs specified by I/O type variables.
For further information about the SET command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "SET."

• RESET Command
The RESET command turns OFF all user outputs specified by I/O type variables.
For further information about the RESET command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "RESET."

• OUT Command
The OUT command outputs data to the user output specified by an I/O type variable.
For further information about the OUT command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "OUT."

25
 Chapter 3
System I/O Signals Standard Mode
3.1 Types and Functions of System Output Signals (Standard
Mode)
The table below lists the system output signals used in standard mode.

Types and Functions of System Output Signals to be Used in Standard Mode

Application Signal name Function

Robot initialization Outputs when preparations for operation are ready to

complete start.

Auto mode Outputs when the robot is in Auto mode.

Start-up

External mode Outputs when the robot is in external mode.

Servo ON Outputs when the power to the motor is turned ON.

Outputs when the robot is in operation (the program is

Program execution Robot-in-operation
being executed).
Outputs when the CPU (hardware) of the Robot
Normal CPU
Controller is normal.
Outputs when a serious error, such as a servo error
Robot failure
and a program error, occurs.
Error/Warning
Robot warning Outputs when a slight error occurs.

Outputs when the voltage of the encoder back-up

Dead battery warning
battery or memory back-up battery dangerously low.
Continue start
Continue start Outputs when Continue Start is enabled.
permitted
Outputs when the robot is in SS mode. Refer to the
Safe start function SS mode SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6
"SS (Safe Start) Function."
Outputs from a contact exclusively designed for an
Emergency stop Emergency stop
emergency stop circuitry.

26
3.2 Usage of System Output Signals (Standard Mode)
The usage of each system output signal in standard mode is described below:

3.2.1 Robot Initialization Complete (Output)

(1) Function
The signal outputs to the external device that a MODE SWITCHING
COMMAND is ready to execute from the device.
(2) Terminal number
No.5 of connector CN10.

(3) Usage
The "mode switching command" will be executed as soon as this signal and
the auto mode signal are turned ON, after the power is turned ON.

(4) ON conditions
 The signal will be turned ON when the system program for the Robot
Controller normally starts, after the power, is turned ON and the mode
switching command is ready to execute.
‚ The signal will be turned ON when a robot failure is cleared by the
CANCEL key of the operating panel or teach pendant or by a CLEAR
ROBOT FAILURE command, after the power is turned OFF.
(5) OFF condition
The signal will be turned OFF when a robot failure or robot warning signal
is turned ON.

⋅ A robot error is cleared with the OK or CANCEL

key of the operating panel or teach pendant.
⋅ The system properly started to ⋅ A robot error is cleared with a CLEAR ROBOT
operate after the power was FAILURE command from an external device.
turned ON.

ROBOT POWER ON
COMPLETE output

⋅ Robot error or robot warning

Robot Power ON Complete Output

27
3.2.2 Auto Mode (Output)
(1) Function
The signal outputs to the external device that the robot is in auto mode.

(2) Terminal number

No.6 of connector CN10.
(3) Usage
Starting the program from the external device requires an EXTERNAL
MODE SWITCHING BY MODE SWITCHING COMMAND input and a
PROGRAM START BY PROGRAM OPERATION COMMAND input. The
signal is used to monitor the auto mode output signal and determine
whether to execute the command.
(4) ON condition
The signal will be output when the robot enters auto mode by setting the
mode selector switch of the operating panel or teach pendant to AUTO.

(5) OFF conditions

The signal will be turned OFF under the following conditions.
 The mode selector switch of the operating panel is set to MANUAL or the
teach pendant is set to MANUAL or TEACH CHECK.
‚ The Enable Auto OFF is input..
(Note: The signal will not be turned OFF in the pendantless state
described in the OPTIONS MANUAL, Chapter 1, Subsection 1.3.3.)

Caution: The signal will not be turned OFF with INSTANTANEOUS STOP,
STEP STOP or CYCLE STOP commands.

⋅ When the mode selector switch of the operating panel or teach

pendant is set to AUTO.

Auto mode
output

⋅ When the mode selector switch of the operating panel is set

to MANUAL or that of the teach pendant is set to MANUAL
or TEACH CHECK.
⋅ When Enable Auto OFF is input

Auto mode Output

28
3.2.3 External Mode (Output)
(1) Function
The signal outputs to the external device that the robot is in external mode.

(2) Terminal number

No.7 of connector CN10.
(3) Usage
Starting the program from the external device requires an EXTERNAL
MODE SWITCHING BY MODE SWITCHING COMMAND input and a
PROGRAM START BY PROGRAM OPERATION COMMAND input. The
signal is used to confirm that the robot is in external mode.
(4) ON conditions
 The signal will be turned ON under the following conditions.
The external mode is selected on the teach pendant.
‚ The EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL ON state.
ƒ The EXTERNAL MODE SWITCHING BY MODE SWITCHING
COMMAND is input from the external device.

(5) OFF conditions

The signal will be turned ON under the following conditions.
 When internal mode is selected on the teach pendant.
‚ When the mode selector switch of the teach pendant is set to MANUAL
or TEACH CHECK in external mode.
ƒ When EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL OFF state.
„ When ROBOT STOP is input.
When ROBOT FAILURE is outputted.

Caution: The signal will not be turned OFF with INSTANTANEOUS STOP,
STEP STOP or CYCLE STOP.

† When an Enable Auto input is turned OFF.

⋅ When the mode is switched to external mode on the teach pendant.

⋅ When EXTERNAL/INTERNAL is input on the operating panel.
⋅ When a MODE SWITCHING COMMAND (EXTERNAL MODE SWITCHING)
is input from an external device.

External mode
output

⋅ When internal mode is selected on the teach pendant.

⋅ When the mode selector switch of the teaching pendant is set to
MANUAL or TEACH CHECK.
⋅ When EXTERNAL/INTERNAL is input on the operating panel.
⋅ ROBOT STOP or ROBOT ERROR
⋅ When an Enable Auto input is turned OFF.

External Mode Output

29
3.2.4 Servo ON (Output)
(1) Function
The signal outputs to the external device that the power to the motor of the
robot is turned ON.

(2) Terminal number

No.4 of connector CN10.
(3) Usage
Starting the program requires the power to the motor to be turned ON. This
signal is used to light the motor power ON indicator lamp on an external
operating panel.
(4) ON conditions
The signal will be turned ON when the power to the motor is turned ON.
 When the MOTOR key of the operating panel or teach pendant is
activated; or
‚ When the motor runs with a MOTOR ON AND CAL EXECUTION BY
MODE SWITCHING COMMAND input from the external device.

(5) OFF conditions

The signal will be turned OFF when the power to the motor is turned OFF.
 When the MOTOR key of the operating panel or teach pendant is
deactivated and the ROBOT STOP button is operated;
‚ When ROBOT STOP is input from the external device; or
ƒ When a ROBOT FAILURE is outputted. If errors 0 × 6071 to 607B, 0 ×
6671 to 667B, 0 × 607F occur, the servo will be turned OFF in automatic
or external mode but will not be turned OFF in the manual or the teach
check mode.

⋅ When the MOTOR key of the operating panel or teach pendant is activated.
⋅ When MOTOR ON AND CAL EXECUTION WITH MODE SWITCHING
COMMAND is input from an external device.

ON
Servo ON output OFF

⋅ When the MOTOR key of the operating panel or teach pendant is

deactivated and the ROBOT STOP button is operated.
⋅ When ROBOT STOP is input from an external device.
⋅ When a ROBOT FAILURE occurs.

Servo ON Output

30
3.2.5 Robot-in-operation (Output)
(1) Function
This signal outputs to the external device that the robot is in operation.

(2) Terminal number

No.2 of connector CN10.
(3) Usage
The signal is used to light the robot operating indicator lamp of an external
operating panel.
Since the signal is turned OFF with STOP ALL PROGRAMS, outputs to
the external device that all programs are stopped.

(4) ON conditions
The signal will be turned ON during execution of the program and also
while in the WAIT STATE with a condition branch or timer command.
(5) OFF conditions
The signal will be turned OFF with STOP ALL PROGRAMS.

Caution: STOP ALL PROGRAMS means the operation of the ROBOT

STOP or STOP button of the operating panel or teach pendant
and INSTANTANEOUS STOP (ALL TASKS), STEP STOP (ALL
TASKS) and ROBOT STOP inputs.

31
3.2.6 Normal CPU (Output)
(1) Function
The signal outputs to the external device that the Robot Controller CPU
(hardware) is normal.

(2) Terminal number

No.1 of connector CN10.
(3) Usage
 The signal is used to light the Robot Controller external operating panel
error indicator lamp.
‚ The signal is used when a normal CPU SIGNAL is turned OFF because
of an error and the PLC corrects it.
(4) ON conditions
The signal will be turned ON by the hardware when the Robot Controller
CPU operates normally with the power turned ON.

(5) OFF conditions

The signal will be turned OFF by the hardware when the CPU does not
operate normally.

Caution: The OFF state of this signal indicates that the Robot Controller
internal arithmetic circuit may be damaged. Therefore, ROBOT
ERROR, ERROR NUMBER, and other outputs may not be
correct.

⋅ Power ON (CPU operating properly)

Normal CPU output

Abnormal CPU (hardware error)

Normal CPU Output

32
3.2.7 Robot Failure (Output)
(1) Function
The signal outputs to the external device that a problem (such as a servo
error or a program error) occurs with the robot.

(2) Terminal number

No.3 of connector CN10.
(3) Usage
 The signal is used to light the robot external operating panel error
indicator lamp of an.
‚ The signal is used to help the PLC clear an error in response to a
ROBOT FAILURE signal.
(4) ON conditions
As shown below, the signal will be turned ON under the following
conditions.
 When an error, such as a servo error, a program error or program
undefined, occurs at the start of the program and during execution of
the program.
‚ When an error occurs during execution of the program in internal
operation by the operating panel or the teach pendant or in external
operation by the PLC.

Caution: The signal will not be outputted when an error, such as a

program input error occurs in manual operation, except when
a servo error occurs in manual operation. For further
information, see the "ERROR CODE TABLES."

(5) OFF conditions

As shown below, the signal will be turned OFF under the following
conditions.
 When a CLEAR ROBOT FAILURE command is inputted and the
existing error is cleared.
‚ When the existing error is cleared by operating the OK or Cancel key
on the operating panel or the teach pendant.

⋅ Program number, parity error, or undefined

ƒpƒŠ ƒprogram
ƒ B [
e ƒ number,
ƒ ‰ [ Aat
G
external start.
⋅ Robot failure during automatic operation (both internal operation
and external operation)

Robot failure

⋅ When a CLEAR ROBOT FAILURE command is inputted.

⋅ When the OK or Cancel key of the operating panel or teach
pendant is operated.

Robot Failure Output

33
3.2.8 Robot Warning (Output)
(1) Function
The signal outputs to the external device that a minor error occurs with an
I/O command or during servo processing.

Caution: The signal will not be outputted if a minor error, such as a

program selection error occurs by the operation of the teach
pendant or operating panel.
(2) Terminal number
No.9 of connector CN10.
(3) Usage
⋅ The signal is used to light the robot warning indicator lamp of the external
operating panel.
⋅ The signal is used to help the PLC clear an error in response to a
ROBOT WARNING signal.
(4) ON condition
As shown below, the signal will be turned ON if a minor error occurs
during I/O processing, execution of the program or servo processing,
irrespective of the operation mode.

(5) OFF conditions

As shown below, the robot-warning signal will be turned OFF under the
following conditions.
⋅ When a CLEAR ROBOT WARNING command is inputted from the
external device and the existing error is cleared.
⋅ When operating the OK or Cancel key on the operating panel or the
teach pendant clears the existing error.

⋅ When a slight error occurs during I/O processing, execution of the

program or servo processing.

Robot warning

⋅ When a CLEAR ROBOT WARNING command is inputted from an

external device and the existing error is cleared .
⋅ When the existing error is cleared by operating the OK or Cancel key
of the operating panel or teach pendant.

Robot Warning Output

34
3.2.9 Dead Battery Warning (Output)
(1) Function
The signal will be output when the voltage of the encoder back-up battery
or memory back-up battery becomes lower than acceptable.

(2) Terminal number

No.8 of connector CN10.
(3) Usage
The signal is used to check the timing battery replacement. For example,
the battery voltage becomes lower than acceptable.

(4) ON condition
The signal will be turned ON when the voltage of the encoder back-up
battery or memory back-up battery becomes lower than acceptable.

Caution: The operating panel shows any of ERROR64A1 to 64A6 when

the encoder back-up battery voltage is low. Meanwhile, the
teach pendant shows ERROR6103 when the memory back-up
battery voltage is low.

(5) OFF condition

The signal will be turned OFF when the power is turned ON after the dead
battery was replaced.

Power ON Power OFF Power ON Power OFF Power ON

Robot power ON state

⋅ The voltage of the

encoder backup
battery or memory
back-up battery
becomes dangerously
low.

Dead battery
warning output

⋅ Battery replaced

Dead Battery Warning Output

35
3.2.10 Continue Start Permitted (Output)
(1) Function
The controller will output this signal when the continue start is permitted.

(2) Terminal number

No.10 of connector CN10.
(3) Usage
Use this signal when you want to know whether the continue start is
permitted.

(4) ON condition
This signal comes on when the continue start is permitted. For details,
refer to the SETTING-UP MANUAL.

(5) OFF condition

This signal goes off by carrying out the "Task Status Change Operation."

3.2.11 SS mode (Output)

(1) Function
The controller will output this signal during the SS mode.
This mode is effective when the slow mode is selected.
(2) Terminal number
No.11 of connector CN10

(3) Usage
This signal is used to warn workers that the robot is in the SS mode by
beeping or lighting the lamp.
(4) ON condition
This signal comes on when the SS mode is selected.
(5) OFF condition
The signal goes off when the TS time passes so as to cancel SS mode.
This function is effective when the slow mode is selected.
Note: If the TS time passes, this signal goes off even when the robot is
operation in the slow mode. After this signal goes off, the robot runs at the
original speed.

36
3.2.12 Emergency Stop (Output from a contact)
(1) Function
This signal outputs from a contact exclusively designed for an emergency
stop circuitry you may configure. It allows red mushroom buttons provided
on the front panel of the robot controller, on the teach pendant, and on the
operating panel to be used as emergency stop buttons of the facilities.
A 0.3A fuse is built in the contact.
(2) Terminal number
No. 65 of connector CN10: Emergency stop (+)
No. 66 of connector CN10: Emergency stop (-)

(3) Usage
This signal is used to stop the facilities or robot in an emergency. (Refer
to Subsection 5.2.4 "Emergency Stop Circuit.")
(4) Contact
This contact is a normal close one (b contact). If any of the emergency
stop buttons is pressed, then the contact turns off to output an emergency
stop signal.

37
3.3 Types and Functions of System Input Signals (Standard
Mode)
The table below lists the system input signals to be used in standard mode:

Types and Functions of System Input Signals to be Used in Standard Mode

Application Signal Name Function

Start-up Enable Auto Enables switching to automatic operation.

Robot stop Stops the robot with canceling signals.

Instantaneous Immediately stops all programs being executed with

Stop
stop (all tasks) canceling signals.

Step stop (all Step-stops all programs being executed with canceling
tasks) signals.

Interrupts the execution of the current step and starts

Program interrupt Interrupt skip
executing the next step.

38
3.4 Usage of System Input Signals (Standard Mode)
The usage of each system input signal in standard mode is described below.

3.4.1 Enable Auto (Input)

(1) Function
 The signal enables switching of the robot mode to auto mode (shorted
state).
‚ The signal enables switching of the robot mode to manual mode or
teach check mode (open state).

(2) Terminal number

No. 4 of connector CN8.
(3) Usage
The signal is used for the AUTO/TEACHING selector switch of an external
operating panel and can be combined with a safety fence switch.

(4) Input conditions and operation

 As shown below, the selectable operation mode depends on whether
this input is shorted or open.
‚ If the input becomes open during automatic operation, the mode will be
switched to manual mode and ERROR21FC will be displayed.
ƒ If manual operation or a teach check is conducted with this input
shorted, ERROR21F2 will be displayed.
„ If the mode selector switch of the teach pendant or operating panel is
set to AUTO with this input open, ERROR21F3 will be displayed.
Since this state is shown as × in the table below, this error will remain
displayed until the robot exits this state.
Although ERROR21FD or ERROR21FC will be displayed when the
state is changed from ¡ to ∆ or ×, they will not be displayed when the
state is changed from ∆ or × to ¡.
† When the input is turned OFF (open) in external mode, the external
mode output will also be turned OFF.
Relationship Between Enable Auto Input and Selectable Mode
Enable Auto
Operation mode Application
ON (shorted) OFF (open)
Manual operation with the operating panel or the teach
Manual mode ∆ ¡
pendant.
Teach check mode Program check with the teach pendant. ∆ ¡
Automatic operation with the operating panel or teach
Internal auto mode ¡ ×
pendant.
External auto mode Automatic operation with the external device. ¡ ×
Note: ¡ = Mode selectable × = Mode not selectable
∆ = Mode selectable but manual operation program not executable

Caution: In the pendantless state, auto mode is valid even if the Enable Auto
input is open. (The external mode cannot be switched and the
program cannot begin execution.)
Perform the following when operating the robot in the pendantless
state:
Q Set the robot so that it will not start to operate when the Enable
Auto input is open.
R Enable Auto input open state and auto mode output (See
Subsections 4.2.2 and 6.2.2 "Auto Mode".)
Set the equipment to make an emergency stop in an AND state.
Add Q and R with the external sequence circuit.

39
3.4.2 Robot Stop (Input)
(1) Function
 The signal stops the robot from the external device by opening the
robot stop input.
‚ The signal readies the power to the robot motor to be turned ON by
shorting the robot stop input.

(2) Terminal number

No.2 of connector CN8.
(3) Input conditions and operation
 The robot stops with this input OFF (open).
‚ The power to the robot motor is made ready to be turned ON with this
input ON (shorted).
ƒ Irrespective of whether internal mode, operation by the teach pendant,
or external mode, remote operation by the external device, is selected,
the power to the robot motor cannot be turned ON with this input OFF
(open) and neither manual nor automatic operation can be performed
until this input is turned ON (shorted). (ERROR2008 will be displayed.)
„ By turning OFF (open) this input the following conditions may result.
1) The power to the motor will be turned OFF irrespective of whether
manual, automatic, internal or external mode is selected.
2) During execution of the program (Robot-in-operation signal ON), the
power to the motor will be turned OFF and the mode will be
switched to internal mode after the robot decelerates to a stop;
3) When the program is not executed in manual and auto modes in
manual and auto modes, everything will be the same except the
power to the motor will be turned OFF. The power to the motor can
be turned ON and the suspended operation can, therefore, be
resumed by shorting the ROBOT STOP input. (However, the
program will be executed from the beginning.)
Opening the ROBOT STOP input and pressing the ROBOT STOP
button of the operating panel or the teach pendant function is the same.
(4) Timing of the input
This input will be processed prior to all commands and input signals.

40
3.4.3 Step Stop (All Tasks) (Input)
(1) Function
Input this signal to step-stop the program being executed from the
external device. All tasks will be step-stopped.

(2) Terminal
No.5 of connector CN8.
(3) Input conditions and operation
 If the state of this signal is changed from ON (shorted) to OFF (open),
the robot will stop all tasks as soon as the ongoing step is completed,
and the Robot-in-operation signal will be turned OFF. However, auto
mode or external mode will remain valid, and the suspended program
will be resumed by inputting a program operation command (start). See
the figure given below.
‚ For resuming the program after a step stop, see Chapter 5, Subsection
5.3.2 "Program Operation Command (0001)".

Robot status
1-cycle operation

Operating halfway At step-stop Performing

Remaining operation

Program start signal (input) ON (shorted)

OFF (open)

Step-stop signal (input) ON (shorted)

OFF (open)

Robot-in-operation (output) ON (shorted)

OFF (open)

Step Stop Signal

41
3.4.4 Instantaneous Stop (All Tasks) (Input)
(1) Function
Input this signal to instantaneously stop the running programs from an
external device. All tasks will stop.

(2) Terminal number

No.7 of connector CN8.
(3) Input conditions and operation
 If the state of this signal is turned from ON (shorted) to OFF (open), the
robot will immediately stop in the middle of the ongoing step, and the
Robot-in-operation signal will be turned OFF. However, auto mode or
external mode will remain valid, and the suspended programs will be
resumed by inputting Program start signal.
‚ For resuming the program after an instantaneous stop, see Chapter 5,
Subsection 5.3.2 "Program Operation Command (0001)".
ƒ The minimum required pulse width is 50 milliseconds (msec.) or more.

ON (shorted)

Halt OFF (open)

50 ms. or more required

Minimum Instantaneous Stop Pulse Width

42
3.4.5 Interrupt Skip (Input)
(1) Function
If this signal is turned ON (shorted) during execution of the robot operation
command, within the range between INTERRUPT ON and INTERRUPT
OFF in the program, the correct step operation will immediately stop and
the next step will start.

Caution: For further information about the INTERRUPT ON and OFF

commands, see the PROGRAMMER'S MANUAL (I), Chapter 12,
"12.3 INTERRUPT ON/OFF (Statement)."
For further information about the robot operation command,
see the PROGRAMMER'S MANUAL (I), Chapter 12, "Robot
Control Statements."

(2) Terminal number

No.9 of connector CN8.
(3) Usage
See the PROGRAMMER'S MANUAL (I), Chapter 12, "12.3 INTERRUPT
ON/OFF."

(4) Input conditions and operation

If this signal is turned ON (shorted), the robot will immediately stop the
current operation and start executing the next step.

INTERRUPT ON
Command Operating halfway Next operation
Robot status

50 ms. or more required

Interrupt skip signal (input) ON (shorted)

OFF (open)

Input Conditions and Operation of Interrupt Skip

43
 Caution: When turning ON (shorting) the interrupt skip signal, at a
minimum either the program reset signal or the program
start signal must be turned OFF (open). If the interrupt
skip signal is turned ON, the robot interprets the program
start signal as immediately turned OFF (open).
Consequently, the program selected with the program No.
selection signal will be executed from the beginning. (See
the figure given below.)

Robot status Executing cycle halfway Executing cycle from beginning

Interrupt skip signal (input) ON (shorted)

OFF (open)

Program start signal (input) ON (shorted)

OFF (open)

Program reset signal (input) ON (shorted)

WRONG
OFF (open)

Program No. select signal (input) ON (shorted)

OFF (open)

Example of Operation When an Interrupt Skip is Input

44
3.5 Command Execution I/O Signals
Dedicated to Standard Mode

In standard mode the I/O commands can be executed using command execution I/O
signals. I/O commands execute the following.
⋅ Operate (start and stop) a program for each task.
⋅ Refer to or change variables from the external device.
⋅ Refer to or change inputs and outputs from the external device.

3.5.1 General Information about Commands

The table below shows the I/O commands functions.

I/O Command Functions

Command Description of function

⋅ Starts the program cycle (specified program).
⋅ Step-stops the program (specified program/all programs).
Program operation ⋅ Immediately stops the program (specified program/all
programs).
⋅ Resets the program (specified program/all programs).
⋅ Sets the external speed.
Speed setting ⋅ Sets the external acceleration.
⋅ Sets the external deceleration.
Error number read ⋅ Outputs the error number to the system I/O area.

Type I variable write ⋅ Reads a value from the system I/O area and substitutes it for a
Type I variable.
Type I variable read ⋅ Outputs a Type I variable to the system I/O area.

Mode switching ⋅ Switches the robot operation mode.

Clear robot failure ⋅ Clears a robot failure from the external device.

Internal I/O write ⋅ Sets the state of internal inputs and outputs.

Internal I/O read ⋅ Outputs the state of internal inputs and outputs to the system I/O
area.

45
3.5.2 Processing I/O Commands

3.5.2.1 General Information about Processing

I/O commands to be executed are processed as shown below.

⋅ Command Area (input)

Q X
⋅ Data Area (input)
⋅ Command and Data Area
Odd Parity (input) S

⋅ Strobe Signal (input) R

Note  1 ms or more Y
⋅ Status Area (output)
⋅ Status Parity (output)

⋅ Command processing complete (output) V

Note „ 100 ms. or less

⋅ Robot Error (output) V

Outline of I/O Command Processing

46
 Set a command area, a data area (if necessary) and command and data
area odd parity for the command execution I/O signal from the external
device to the Robot Controller.

‚ After the setting is completed, turn ON the strobe signal.

Caution: Q The data to be set in Q must be defined more at least 1

msec. before the strobe signal is turned ON.
R Perform command input with a strobe signal after the
system output signal ROBOT INITIALIZATION COMPLETE is
output.

ƒ The controller reads the command area, the data area and the command
and data area odd parity as the strobe signal is input.

„ The controller starts processing based on the command it read.

If the command is one that outputs a status, the controller sets the status
area and status parity.

† After command processing has been completed and a status area has
been set, the controller turns ON the command processing complete
signal.
If an error occurs in the while processing, a robot failure signal will be
outputted together with the command processing complete signal.

‡ The PLC waits until the command processing complete signal is input, and
receives the status of the status area, if necessary. In this case,
confirmation that no error exists with the robot.

ˆ After the PLC has read the status, it turns OFF the command and data
areas and the strobe signal.

‰ As soon as the strobe signal is turned OFF, the controller turns OFF the
status area and the command processing complete signal.
The robot failure signal, which is outputted due to a command processing
error, remains ON until a CLEAR ROBOT FAILURE command is executed.

Caution: S The maximum time taken until the status area and the
command processing complete signal are turned OFF, after
the strobe signal is turned OFF in X, is 100 msec.
T If the strobe signal is turned OFF before the command
processing complete signal is turned ON in V, the
command processing complete signal and the status area
will be output and then turned OFF within 100 msec.

47
3.5.2.2 Using Each Signal Line

[ 1 ] Command and Data Areas

This section describes the usage of the command area (4 bits, input), data
area 1 (8 bits, input), data area 2 (16 bits, input) and command and data area
odd parity (input).

(1) Function
Specifies the commands to be executed by the Robot Controller.
Sets the command area at all times, and data areas 1 and 2, if necessary.

(2) Terminal numbers

Command area: No.35 to No.38 of connector CN8.
Data area 1: No.11 to No.18 of connector CN8.
Data area 2: No.19 to No.34 of connector CN8.
Command and data area odd parity: No.10 of connector CN8.

(3) Input conditions and operation

 Set the command area whenever I/O commands are to be executed.
Set data for data areas 1 and 2 if commands require them.
‚ "Shorted" represents the bit value = 1.
"Open" represents the bit value = 0.
"Parity bit " is odd parity.
ƒ Input the command area, data areas 1 and 2, and command and data
area odd parity before the strobe signal (1 msec. or more). Retain the
status until the command processing complete signal is output.
„ Input 1 or 0 as the parity bit so that the total of 1s existing in the
command area, data areas 1 and 2 and the command and data area
odd parity will be odd
The data areas count even commands, which do not require any data
area, in a check sum calculation.
Checksum can be set valid or invalid using a parameter. When
checksum is invalid, no checksum check will be performed.

48
[ 2 ] Strobe Signal (Input)

(1) Function
This signal informs the Robot Controller that the command area, data
areas 1 and 2, and the command and data area odd parity bit have been
set. Additionally it directs the start of command processing.

Caution: Perform command input with a strobe signal after the system
output signal ROBOT INITIALIZATION COMPLETE is output.

(2) Terminal number

No. 8 of connector CN8.

(3) Input conditions and operation

 By turning ON this input in automatic or external mode, the Robot
Controller reads the command area, data areas 1 and 2, and the
command and data area odd parity bit starts processing.
‚ Retain the status until a command processing complete signal is output
and the necessary status data is read. If the strobe signal is turned
OFF before a command processing complete signal is output, the
status area will not be output.
ƒ By turning OFF this input after the status is read, the command
processing complete output, the status area and the status parity will
be turned OFF.

49
[ 3 ] Command Processing Complete (Output)

(1) Function
The signal outputs to the external device that I/O command processing is
completed.

(2) Terminal number

No. 15 of connector CN10.

(3) Usage
The signal is used to confirm that I/O command processing is complete, or
as a timing signal for obtaining the result of I/O command processing.

(4) ON conditions
 The signal will be turned ON upon completion of processing the I/O
command given and determination of outputting the status area.
‚ If an error occurs as a result of executing an I/O command, the result
will not be output to the status area, but the robot failure signal and the
command processing complete signal will be turned simultaneously
ON.

(5) OFF conditions

 The signal will be turned OFF when the strobe signal is turned OFF.
‚ If the strobe signal is turned OFF, before command processing is
completed, the command processing complete signal will be output and
then turned OFF within 100 msec.

50
[ 4 ] Status Area
This section describes the usage of the status area (16 bits, output) and of
status area odd parity (output).

(1) Function
The signal outputs the result of I/O command processing to the external
device.

(2) Terminal numbers

Nos. 17 to 32 of connector CN10.

(3) Usage
The signal is used to execute an I/O command and obtain the result of the
PLC.

(4) ON conditions
 When processing of the I/O given is completed, the status
corresponding to the command will be set.
‚ "ON" represents the bit value = 1.
"OFF" represents the bit value = 0.
"Parity bit" is odd parity.
ƒ Input 1 or 0 as the parity bit so that the total of 1s existing in the
command area and status area parity will be odd.
The status area counts even commands, which do not require any data
area, in a parity calculation.
„ Parity can be set valid or invalid with a parameter. When parity is
invalid, no parity check will be performed.

(5) OFF conditions

 The signal will be turned OFF when the strobe signal is turned OFF.
‚ If the strobe signal is turned OFF, before command processing is
completed, the status signal will be output and then turned OFF within
100 msec.

51
3.5.3 I/O Commands Details

3.5.3.1 List of I/O Commands

The table below lists I/O commands.

List of I/O Commands

Command area Data area 1 Data area 2 Status area

0001 00000001 Program reset start Program number 
Program operation 00000010 Program start Program number 
00000100 Continue start (Note)
00010000 Step stop Program number 
00100000 Instantaneous stop Program number 
01000000 Reset Program number 
0010 00000001 Speed setting Set speed value 
External speed and 00000010 Acceleration setting Set acceleration 
acceleration setting 00000100 Deceleration setting value 
Set deceleration
value
0100   Error
Error read number
0101 Type I variable number Set variable value 
Type I variable (lower 16 bits)
write
0110 Type I variable number  Variable
Type I variable read value (lower
16 bits)
0111 00000001 Motor ON, CAL execution  
Mode switching 00000010 External speed 100
10000000 External mode switching
10000011 Execution of all above
(Motor ON→CAL→SP100→External)
1000   
Clear robot failure
1001 Set I/O value First internal I/O port 
I/O write address
1010  First internal I/O port I/O
I/O read address

(Note) In execution of Continue Start command, program numbers will be ignored.

52
3.5.3.2 Program Operation Command (0001)
(1) Function
This command controls the operating state of the program specified in
data area 2 based on the setting of data area 1.

(2) Format
Command area (4 bits, input)
0001

Data area 1 (8 bits, input)

00000001: Program reset start
00000010: Program start
00000100: Continue start
00010000: Step stop
00100000: Instantaneous stop
01000000: Reset
An error (ERROR2032) will occur if data is other than the above is set.

Data area 2 (16 bits, input)

Program number: Program number to start
When the number given in data area 2 is nn, the operating state of PR0nn
will be controlled as given in data area 1. If the program number is
negative in the case of a step stop, instantaneous stop or reset command,
all programs will stop or be reset. If the program number is negative with a
program reset start or program start command, ERROR73E4 will result.

Status area (16 bits, output)

Nothing will be output.

(3) Description
 Program reset start
This command is executable only in external mode. If executed in other
mode an error will occur.
This command initializes and starts the program of the program
number specified in data area 2. PRO0 to PRO32767 can be started.
If the program number specified in data area 2 is negative, an error
(ERROR73E4) will occur.
Either of the following operations takes place according to the
operating status of the program:
⋅ If the specified program is terminated (stopped), step-stopped or
immediately stopped, it will start from the beginning.
⋅ If the specified program is running, an error (ERROR21F5) will be
displayed, and the program will stop.

53
‚ Program start
This command is executable only in external mode. An error
(ERROR2032) will occur in other modes.
This command starts the program of the program number specified in
data area 2. PRO0 to PRO32767 can be started.
If the program number specified in data area 2 is negative, an error
(ERROR73E4) will occur.
One of the following operations takes place according to the operating
status of the program.
⋅ If the specified program is terminated (stopped), it will start from the
beginning.
⋅ If the specified program is step-stopped, it will resume from the step
following the suspended step.
⋅ If the specified program is immediately stopped, it will resume from
the step following the suspended step. When the program is
instantaneously stopped in while in execution of an operation
command, it will resume from the operation still undone.
⋅ If the specified program is running, an error (ERROR21F5) will be
displayed, and the program will stop.

ƒ Continue start
This command is executable only in external mode when the Continue
Start Permitted signal is on. The data area will be ignored.

„ Step stop
This command step-stops the program of the program number
specified in data area 2. PRO0 to PR032767 can be step-stopped.
If the program number specified in data area 2 is negative, all
programs being executed will step-stop.
Either of the following operations takes place according to the
operating status of the program.
⋅ If the specified program is terminated (stopped), step-stopped or
immediately stopped, nothing will happen.
⋅ If the specified program is running, it will step-stop. If started after a
step stop, the stopped program will resume from the step following
the suspended step.

Instantaneous top
This command immediately stops the program of the program number
specified in data area 2. PRO0 to PR032767 can be stopped
immediately.
If the program number specified in data area 2 is negative, all
programs being executed will step-stop.
Either of the following operations takes place according to the
operating status of the program:
⋅ If the specified program is terminated (stopped), step-stopped or
immediately stopped, nothing will happen.
⋅ If the specified program is running, it will immediately stop. If
started after an instantaneous stop, the stopped program will
resume from the suspended step. If the program is immediately
stopped in the middle of execution of an operation command, it will
resume, starting from the last uncompleted operation.

54
† Reset
This command immediately stops and also initializes the program of
the program number specified in data area 2. PRO0 to PR032767 can
be stopped.
This command cannot be used together with the program start
command.
To start a step-stopped or cycle-stopped program from the beginning,
use the program reset start command.
If the program number specified in data area 2 is negative, all
programs being executed will be reset.
One of the following operations takes place according to the operating
status of the program.
⋅ When the specified program is terminated (stopped), nothing will
happen.
⋅ When the specified program is step-stopped or immediately
stopped, it will be initialized. The initialized program will resume
from the beginning.
⋅ When the specified program is running, it will immediately stop and
also be initialized. If started after an instantaneous stop, the
stopped program will resume from the beginning.

55
3.5.3.3 External Speed and Acceleration Setting (0010)
(1) Function
This command sets the external speed, acceleration and deceleration
values selected in data area 1 to the values specified in data area 2.
This command is executable only in external mode. An error will occur in
other modes.

(2) Format
Command area (4 bits, input)
0010

Data area 1 (8 bits, input)

00000001: Speed setting
00000010: Acceleration setting
00000100: Deceleration setting
An error (ERROR2032) will occur if data other than the above is set.

Data area 2 (16 bits, input)

Set values: Speed, acceleration and deceleration to be set
Enter any of the external speed, acceleration and deceleration values
specified in data area 1.
The values must be between 1 and 100. If they are out of this range, an
error (ERROR2003) will occur.

Status area (16 bits, output)

Nothing will be output.

(3) Description
 Speed setting
The external speed is set to the value specified in data area 2. The
value must be between 1 and 100. An error (ERROR2003) will occur if
the value is out of this range.
The external acceleration and deceleration will be set simultaneously
as shown below by setting the external speed:
External acceleration and external deceleration = External speed2/100
(minimum value: 1)
‚ Acceleration setting
The external acceleration is set to the value specified in data area 2.
The value must be between 1 and 100. An error (ERROR2003) will
occur if the value is out of this range.
ƒ Deceleration setting
The external deceleration is set to the value specified in data area 2.
The value must be between 1 and 100. An error (ERROR2003) will
occur if the value is out of this range.

56
3.5.3.4 Error Read (0100)
(1) Function
This command outputs the existing error number to the status area.
This command is output to the status area only when the strobe signal
remains ON.

Caution: This command will not be output if a minor error occurs, such
as a program selection error, caused by the operation of the
teach pendant or the operating panel.

(2) Format
Command area (4 bits, input)
0100
Data area 1 (8 bits, input)
Nothing will be input.
Data area 2 (16 bits, input)
Nothing will be input.
Status area (16 bits, output)
The existing error code will be output.

(3) Hexadecimal codes

Refer to the figure given below.

×××× →0 סס → 5 ¡×¡× →A

××ס →1 ס¡× → 6 ¡×¡¡ → B
××¡× →2 ס¡¡ → 7 ¡¡×× →C
×ס¡ →3 ¡××× →8 ¡¡×¡ → D
ס×× →4 ¡×ס → 8 ¡¡¡× → E ¡⋅⋅⋅ON
¡¡¡¡ → F ×⋅⋅⋅⋅OFF

The following figure shows an example of error number output when

ERROR6174 (overload error with the fourth axis) occurs.
Thousands of error Hundreds of error No. Tens of error No. Units of error No.
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
× ¡ ¡ × × × × ¡ × ¡ ¡ ¡ × ¡ × ×
Terminal No.
(Connector CN10)

ERROR 6 1 7 4

Example of Error Number Output

(4) Description
If a command is executed when a robot failure or the robot warning signal
is output, the error number, which caused the robot failure or robot
warning signal to be output, will be output to the status area.
If no error exists after an error has been cleared, 0 will be output to the
status area. Also, when there is an error that does not output any robot
failure or robot warning signal, 0 will be outputted.

57
3.5.3.5 Type I Variable Write (0101)
(1) Function
This command substitutes the value specified in data area 2 for the Type I
(integer type) global variable of the number specified in data area 1.

(2) Format
Command area (4 bits, input)
0101

Data area 1 (8 bits, input)

The number of the Type I variable for which a value will be substituted.
Any number between I[0] and I[255] can be specified. When the input data
in data area 1 is nn, the value specified in data area 2 will be substituted
for the Type I variable I [nn].

Data area 2 (16 bits, input)

The value to be substituted for the Type I variable specified in data area 1.
Any value between -32768 and 32767 can be set.

Status area (16 bits, output)

Nothing will be output.

(3) Description
The value specified in data area 2 is substituted for the Type I variable
specified in data area 1.
Although the type I variable has a storage area of 32 bits, the 16-bit data
in data area 2 will be substituted for the lower 16 bits. Zero will be
substituted for the upper 16 bits of the Type I variable.

58
3.5.3.6 Type I Variable Read (0110)
(1) Function
This command outputs to the status area the value of the Type Ι (integer
type) global variable of the number specified in data area 1.

(2) Format
Command area (4 bits, input)
0110

Data area 1 (8 bits, input)

The number of the Type I variable for which a value will be substituted.
Any number between I [0] and I [255] can be specified. When the input
data in data area 1 is nn, the value specified in data area 2 will be
substituted for the Type I variable I [nn].

Data area 2 (16 bits, input)

Nothing will be input.

Status area (16 bits, output)

The lower 16 bit value of the Type I variable specified in data area 1 will
be output.

(3) Description
The value of the Type I variable specified in data area 1 is output to the
status area.
Although the Type I variable has a storage area of 32 bits, the lower 16
bits will be output to the status area.
Therefore, any value between -32768 and 32767 can be output properly.
However, if the value is out of this range, only the lower 16 bits of the data
will be output.

59
3.5.3.7 Mode Switching (0111)
(1) Function
This command switches the robot mode from the external device to
prepare the robot for operation.
This command is executable only in auto mode. An error will occur in
other modes. Before executing this command, select auto mode on the
operating panel or the teach pendant.

(2) Format
Command area (4 bits, input)
0111

Data area 1 (8 bits, input)

Bit 0 (00000001): Motor ON, CAL execution
Bit 1 (00000010): External speed 100
Bit 7 (10000000): External mode switching
These bits can be set together to execute commands. When two or more
bits are set, commands will be executed one after another.

For example, when bits 0, 1 and 7 are set, motor ON, CAL execution,
external speed 100 and external mode will be executed in this order.
If bits other than the above are set, an error will result.

Data area 2 (16 bits, input)

Nothing will be input.

Status area (16 bits, output)

Nothing will be output.

(3) Description
This command is used for equipment using the robot to switch the
operation mode of the robot to external mode from the external device
The processing operations to be executed are specified by the bits set in
data area 1 and will be executed from bit 0 to bit 7.

 Motor ON, CAL execution (bit 0)

When this bit is set, the power to the Robot Controller motor will be
turned ON and CAL will be executed. If CAL is executed once after the
power is turned ON, no processing will take place.

60
‚ External speed 100 (bit 1)
When this bit is set, the external speed, external acceleration and
external deceleration of the Robot Controller will be set to 100.

ƒ External mode switching (bit 7)

When this bit is set, the mode of the Robot Controller will be switched
from automatic to external.

61
3.5.3.8 Clear Robot Failure (1000)
(1) Function
This command clears a robot failure that has been caused.

(2) Format
Command area (4 bits, input)
1000

Data area 1 (8 bits, input)

Nothing will be input.

Data area 2 (16 bits, input)

Nothing will be input.

Status area (16 bits, output)

Nothing will be output.

(3) Description
If a robot failure occurs, this command clears it. When there is no failure,
no processing will take place
When an error is displayed, the same processing as when the OK or
Cancel key of the operating panel or the teach pendant is operated will be
performed.

62
3.5.3.9 I/O Write (1001)
(1) Function
This command substitutes the status specified in data area 1 for the 8-bit
internal I/O area starting from the number specified in data area 2.

(2) Format
Command area (4 bits, input)
1001

Data area 1 (8 bits, input)

The status to be set will be specified in the internal I/O area starting from
the number specified in data area 2.

Data area 2 (16 bits, input)

This is first number of the internal I/O (8-bit) area for which the status will
be substituted. The number can be set between 128 and 504. If the
number is out of this range, an error (ERROR2034) will occur.

Status area (16 bits, output)

Nothing will be output.

(3) Description
This command substitutes the status specified in data area 1 for the 8-bit
internal I/O area starting from the number specified in data area 2.

63
3.5.3.10 I/O Read (1010)
(1) Function
This command outputs to the lower 8 bits of the status area the status of
the 8-bit internal I/O area starting from the number specified in data area
2.

(2) Format
Command area (4 bits, input)
1010

Data area 1 (8 bits, input)

Nothing will be input.

Data area 2 (16 bits, input)

This is the first number of the internal I/O (8-bit) area whose status will be
output. The number can be set between 128 and 504. If the number is out
of this range, an error (ERROR2034) will occur.

Status area (16 bits, output)

The status of the 8-bit internal I/O area starting from the number specified
in data area 2 will be output to the lower 8 bits of this area.

(3) Description
This command outputs to the lower 8 bits of the status area the status of
the 8-bit internal I/O area starting from the number specified in data area
2. Zero will be output to the upper 8 bits.

64
3.6 Example of Using System I/O Signals in Standard Mode
This section illustrates an example of starting and stopping the robot using
system I/O signals.

(1) Equipment setup example

This example shown below assumes an equipment setup which allows you to
run the robot by operating an external equipment’s operation panel connected
via the PLC to the robot controller. It is assumed that the operation panel has
a display, lamps and switches listed on the next page.

Robot

Robot
controller

PLC
Other equipment
(e.g. conveyor)

Operating panel

Example of Equipment Setup Using a Robot

65
 Function Example of Equipment Operating Panel

Classificati
Part Application
on

Displays messages, such as ROBOT PREPARATION

Display Display OK.
⋅ Lights during automatic operation.
Q Automatic operation
indicator lamp ⋅ Turned OFF when the robot is not in automatic
operation.

Lamp R Robot external mode ⋅ Lights when the robot is in external mode.
indicator lamp ⋅ Turned OFF when the robot is not in external mode.

S Operation OK indicator ⋅ Lights when the Enable Auto signal is ON.

lamp ⋅ Turned OFF when the Enable Auto signal is OFF.

Q Robot preparation button Starts the preparation of the robot.

R Automatic start button Starts the operation of the equipment.

Switch
Stops the equipment after a cycle of operations is
S Cycle stop button completed.
Automatic operation of the robot possible when
T Operation/Adjustment OPERATION is selected.
selector switch Manual operation or teach check of the robot possible
when ADJUSTMENT is selected.
Caution: Actual equipment requires emergency stop, interlock and other functions; however,
described here are the necessary functions.

(2) Outline of procedure

Described below is the outline of the procedure when using the equipment
taken as an example shown on the previous page.
Follow steps  to ƒ.
 Operation preparation start
After setting the MOTOR ON, CAL EXECUTION, EXTERNAL SPEED
100 and EXTERNAL MODE SWITCHING bits, execute the mode
switching command to bring the robot into external automatic operation
mode. This operation will be completed when the EXTERNAL MODE
output signal is turned ON.
‚ Automatic operation
Start the program by which the robot starts from the operation origin,
performs operations, and returns to the operation origin.
ƒ Operation end
Terminate the day’s operations with a cycle stop, and turn OFF the
power.

(3) Start and stop procedure, and system I/O signals

The following pages show the relationship between the system I/O signals
for start and stop, worker’s operation, display on the equipment operation
panel, PLC proceeding, and robot motion.

66
 Worker’s operation and display on
Step equipment’s operation panel
PLC processing Robot operation

Equipment power ON

Setting
operation/adjustment
Enable Auto ON (Internal processing)
selector switch to
operation

Operation OK indicator
lamp ON

Setting Mode selector

Q Operation preparation start

switch of the operating

panel or the teach
pendant to AUTO
(Note )
Robot preparation Data area 1 input ON
button ON

Executing mode
Motor power ON
switching command

Executing CAL

Setting SP 100

Switching mode to
external mode

Robot external mode External mode ON

indicator lamp ON (Internal processing)

Moving robot arm close

R Operation start area check

to operation origin,
when external mode
indicator lamp is ON
and operation position
1 indicator lamp is OFF.

Robot operation origin Operation position 1

indicator lamp ON (Internal processing)
ON

Robot preparation OK When both are ON

display (Internal processing)

Start and Stop Procedure and System I/O Signals-1

(Continued on following page)

67
(Continued from preceding page)
Worker’s operation and display on
Step equipment’s operation panel
PLC processing Robot operation

Equipment’s Automatic Program No. Select ON

Start Button ON
Regular operation
program is selected
and output to data
area 2.
S Automatic operation

Automatic Operation Executing Program Program start

indicator lamp ON Operation Command
(Program start)

END

Program No. select ON Robot-in-operation

signal OFF
Regular operation
program is selected
and output to data
area 2.
Repeated
Program start ON

Equipment’s Cycle Cycle Stop ON Executing 1-cycle

Stop button ON

END
T Operation end

Automatic operation (Internal processing)

indicator lamp OFF Robot-in-operation
signal OFF

Equipment power OFF

Note S In data area 1, the bit to each of "motor ON, CAL execution," "external speed 100" and
"External Mode switching" will be turned ON. Refer to Chapter 5, Subsection 5.3.7
"Mode Switching (0111)".
T in the above figure indicates a system I/O signal, and ←represents the flow of
signals.

Start and Stop Procedure and System I/O Signals-2

68
 Chapter 4
System I/O Signals Compatible Mode
4.1 Types and Functions of System Output Signals (Compatible
Mode)
The table below lists the system output signals used in the compatible mode.

Types and Functions of System Output Signals to be Used in Compatible Mode

Application Signal name Function

Robot power ON Outputs when preparations for operation are ready
complete to start.

Auto mode Outputs when the robot is in auto mode.

Start-up Servo ON Outputs when the power to the motor is turned ON.

CAL complete Outputs when calibration is completed.

External mode Outputs when the robot is in external mode.

Program Outputs when the robot is in manual or teach check

Teaching
pre-execution check mode.
Outputs when execution of the program starts in
Program start reset
response to the program start signal received.
Outputs when the robot is in operation (the program
Program execution Robot-in-operation
is being executed).
Continue start
Outputs when the continue start is permitted.
permitted

Program end Single cycle end Outputs when the program completes a cycle.

Outputs when the CPU (hardware) of the Robot

Normal CPU
Controller is normal.
Outputs when a failure (such as a servo failure and
Robot failure
program error) occurs in the robot.

Error/warning Robot warning Outputs when a slight error occurs.

Outputs when the voltage of the encoder backup

Dead battery warning
battery or memory backup battery lowers.
An error number will be outputted in BCD code if an
Error No.
error occurs.

Continue start Continue start permitted Outputs when Continue Start is enabled.

Outputs when the robot is in SS mode. Refer to the

Safe start function SS mode SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6
"SS (Safe Start) Function."
Outputs from a contact exclusively designed for an
Emergency stop Emergency stop
emergency stop circuitry.

69
4.2 Usage of System Output Signals in the Compatible Mode
The usage of each system output signal in the compatible mode is described
below.

4.2.1 Robot Power ON Complete

(1) Function
The signal outputs to the external device that OPERATION
PREPARATION START is possible.
(2) Terminal number
No.9 of connector CN10.

(3) Usage
OPERATION PREPARATION START will be executed after this signal and
the auto mode signal are turned ON after the power was turned ON.

(4) ON conditions
 The signal will be turned ON when the Robot Controller system
program properly starts. Preparations for operation can be started after
the power was turned ON.
‚ The signal will be turned ON when the robot failure is cleared by the
OK or Cancel key of the operating panel or the teach pendant or by
CLEAR ROBOT FAILURE and OPERATION PREPARATION START
signals, after the power was turned OFF.
(5) OFF conditions
The signal will be turned OFF when a robot failure or robot warning signal
is turned ON.

⋅ A robot error is cleared by the OK or Cancel

key of the operating panel or teach pendant.
⋅ When a robot error was cleared with CLEAR
⋅ The system properly ROBOT FAILURE and OPERATION PRE-
starts to operate after PARATION START signals from the external
the power is turned device.
ON.

ROBOT POWER ON
COMPLETE output

⋅ Robot error

Robot Power ON Complete Output

70
4.2.2 Auto Mode (Output)
(1) Function
The signal outputs to the external device that the robot is in the auto
mode.

(2) Terminal number

No.4 of connector CN10.
(3) Usage
Starting the program from the external device requires an SWITCH EXT
MODE input, a PROGRAM NO. SELECT input and a PROGRAM START
input. The signal is used to confirm that the robot is in the auto mode.
(4) ON conditions
The signal will be output when the robot enters the auto mode under the
following conditions.
 The mode selector switch of the operating panel or the teach pendant
is set to AUTO.
(5) OFF conditions
The signal will be turned OFF under the following conditions.
 When the mode selector switch of the operating panel is set to
MANUAL or the teach pendant is set to MANUAL or TEACH CHECK.
‚ When Enable Auto OFF is input.
(Caution: The signal will not be turned OFF in the pendantless state
described in the OPTIONS MANUAL, Chapter 1, Subsection 1.3.3.)

Caution: The signal will not be turned OFF with INSTANTANEOUS

STOP, STEP STOP or CYCLE STOP.

⋅ The Mode selector switch of the operating panel or the teach pendant is
set to AUTO.
⋅ SWITCH AUTO MODE and OPERATION PREPARATION START are
input from the external device.

Auto mode output

⋅ The mode selector switch of the operating panel is set to

MANUAL or that of the teach pendant is set to MANUAL or
TEACH CHECK.
⋅ Enable Auto OFF is input.

Auto Mode Output

71
4.2.3 Servo ON (Output)
(1) Function
The signal outputs to the external device that the power to the robot motor
is turned ON.

(2) Terminal number

No. 10 of connector CN10.
(3) Usage
Executing CAL from the external device or starting the program requires
the power to the motor to be turned ON. This signal is used to confirm that
the power to the motor is turned ON and to light the motor power ON
indicator lamp on an external operating panel.
(4) ON conditions
The signal will be turned ON when the power to the motor is turned ON
under the following conditions.
 The MOTOR switch on the operating panel or the teach pendant is
activated.
‚ MOTOR POWER ON + OPERATION PREPARATION START signals
are input from the external device.

(5) OFF conditions

The signal will be turned OFF when the power to the motor is turned OFF
under the following conditions.
 The MOTOR switch of the operating panel or the teach pendant is
deactivated and the ROBOT STOP button is operated.
‚ ROBOT STOP is input from the external device.
ƒ ROBOT FAILURE is outputted. If any of errors 0 × 6071 to 607B, 0 ×
6671 to 667B, 0 × 607F occurs, the servo ON signal will be turned OFF
in External Auto mode but will not be turned OFF in manual or teach
check mode.

⋅ When the MOTOR button of the operating panel or the teach pendant is
turned
MOTOR
u ON.vON ‘ € ì
⋅ When MOTOR POWER ON and OPERATION PREPARATION START
signals are input from the external device.

Servo ON output

⋅ When the MOTOR button of the operating panel or the teach pendant is
turned OFF and the ROBOT STOP button is operated.
MOTOR v
u OFF
⋅ When a ROBOT STOP signal is input from an external device.
⋅ When a ROBOT FAILURE occurs.

Servo ON Output

72
4.2.4 CAL Complete (Output)
(1) Function
The signal outputs to the external device that CAL is completed.

(2) Terminal number

No. 11 of connector CN10.
(3) Usage
This signal is used to determine whether to execute CAL.
Once CAL is completed, it does not need to be executed again as long as
the power to the Robot Controller is turned ON.
(4) ON conditions
The signal will be turned ON upon proper completion of CAL under the
following conditions.
 When CAL is performed by the operating panel or teach pendant.
‚ When CAL EXECUTION and OPERATION PREPARATION START
signals are input from the external device.

(5) OFF conditions

The signal will be turned OFF when CAL is not properly completed as
shown below.
It will remain OFF until CAL is performed again and properly completed.

⋅ CAL is performed by the teach pendant.

⋅ CAL EXECUTION and OPERATION
PREPARATION START commands are
input from the external device.
(Prerequisite: MOTOR POWER ON) ⋅ CAL is executed again.

When CAL has properly ended

CAL complete
⋅ Normal CAL end When a CAL error occurs.

CAL Complete Output

73
4.2.5 External Mode (Output)
(1) Function
The signal outputs to the external device that the robot is in the external
mode.

(2) Terminal number

No. 5 of connector CN10.
(3) Usage
Starting the program from the external device requires an SWITCH EXT
MODE input, PROGRAM NO. SELECT input and a PROGRAM START
input. The signal is used to confirm to the external device that the robot is
in external mode.
(4) ON conditions
The signal will be turned ON under the following conditions.
 When INTERNAL/EXTERNAL is input on the teach pendant and the
external mode is selected.
‚ When EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL ON state.
ƒ When SWITCH EXT MODE and OPERATION PREPARATION START
signals are input from the external device.

(5) OFF conditions

The signal will be turned OFF under the following conditions.
 When the mode selector switch of the teach pendant is set to MANUAL
or TEACH CHECK in external mode.
‚ When EXTERNAL/INTERNAL is input on the teach pendant and
external mode is selected.
ƒ When EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTERNAL CONTROL OFF state.
„ When ROBOT STOP is input.
When ROBOT FAILURE is outputted.

Caution: The signal will not be turned OFF with STEP STOP.

† When an Enable Auto input is turned OFF.

⋅ When INTERNAL/EXTERNAL is input on the teach pendant and external mode is selected.
⋅ When INTERNAL/EXTERNAL is input on the operating panel in AUTO MODE and in the
INTERNAL CONTROL ON state.
⋅ When EXTERNAL MODE SWITCHING and OPERATION PREPARATION START signals are
input from the external device.

ON
External mode output OFF

⋅ When internal mode is selected on the teach pendant.

⋅ When INTERNAL/EXTERNAL is input on the teach pendant
and external mode is selected.
⋅ When INTERNAL/EXTERNAL is input on the operating panel in
AUTO MODE and in the INTERNAL CONTROL ON state.
⋅ When ROBOT STOP is input.
⋅ When ROBOT ERROR is output.
⋅ When an Enable Auto input is turned OFF.

External Mode Output

74
4.2.6 Teaching (Output)
(1) Function
The signal outputs to the external device that the robot is in the manual
mode or teaches check mode.

(2) Terminal number

No. 12 of connector CN10.
(3) Usage
This signal is used to inform an external operating panel that the robot is
teaching when they are installed separately from each other.

(4) ON conditions
The signal will be turned ON when the mode selector switch of the
operating panel or the teach pendant is set to MANUAL or TEACH
CHECK, as shown below.

(5) OFF conditions

The signal will be turned OFF when the mode selector switch of the
operating panel or teach pendant is set to AUTO and the Enable Auto
input is turned ON.

E
ƒƒIy
ƒ Œ [
ƒeƒB
ƒ “
ƒOƒp
ƒ l
ƒ‹‚Åu
Manual v
‘€ì
⋅ When
E ƒ the
ƒ e B [mode
ƒ “selector
ƒ̀ ƒ ƒ y
O ƒ ƒ“switch
ƒ “
_ ƒ ofg
‚ the
Å operating
MANUAL vpanel
u Eu is set to
Teach
MANUAL.
Check v ‘€ ì
⋅ When the mode selector switch of the teach pendant is set to
MANUAL or TEACH CHECK.

Teaching

⋅ When the mode

ƒ I
E ƒ y Œselector
ƒ ƒ e
[ ƒ B ƒ switch
ƒ O
“ ƒ pƒofl
ƒthe operating
‚ Ü
‹ ‚ ‚ Í
½ ƒ eƒ panel
ƒ ƒ̀or“
B [ ƒthe
teach pendant
ƒ y
ƒ “ƒ is_
ƒ set
ƒ g
“ ‚to Å
AUTO
Autoandv
u ‘the Enable
€ ì ‚ Auto
‚ ©
A Š O
 input
• ”
‚ æ
‚ èŽis
turned ON from the external device.
“®
‰^“]
ƒ C
ƒl [
ƒ u
ƒ‹“ü
— Í
‚ ª
ON

Teaching Output

75
4.2.7 Program Start Reset (Output)
(1) Function
This signal is output to the external device when the robot receives a start
signal from the external device and starts to operate.

(2) Terminal number

No. 6 of connector CN10.

(3) Usage
 The signal is used to prompt the external device to receive information
that the robot program has started to run, and to process subsequent
sequence programs.
‚ The signal is used as a condition to turn OFF the PROGRAM START
signal sent from the external device to the robot.
(4) ON conditions
The signal will be turned ON immediately after the robot program starts to
run, as shown below.

(5) OFF conditions

The signal will be turned OFF automatically when the PROGRAM START
signal sent to the robot is turned OFF.

Robot status
Single-cycle operation Single-cycle operation

Program start signal (input) ON (shorted)

OFF (open)

Program start
Reset (output)

Program Start Reset Output ON Condition

76
4.2.8 Robot-in-operation (Output)
(1) Function
The signal outputs to the external device that the robot is in operation
(executing more than one task ).

(2) Terminal number

No. 2 of connector CN10.
(3) Usage
The signal is used to light the robot operating indicator lamp of the
external operating panel.
Since the signal is turned OFF with STOP ALL PROGRAMS, it outputs to
the external device that all programs are stopped.
(4) ON conditions
The signal will be turned ON while executing the program and also in the
Wait State with a condition branch or timer command.

(5) OFF conditions

The program will be turned OFF with STOP ALL PROGRAMS.

Caution: STOP ALL PROGRAMS means the operation of the ROBOT

STOP or STOP button of the operating panel or the teach
pendant and INSTANTANEOUS TOP (ALL TASKS), STEP STOP
(ALL TASKS) and ROBOT STOP inputs.

77
4.2.9 Single-Cycle End (Output)
(1) Function
The signal outputs to the external device that a single-cycle of the
program is completed.

Caution Q The single-cycle end signal will be output upon reading

END of the program. However, it will be output earlier than
the end of the actual robot operation because the Robot
Controller pre-reads the program.
R The single-cycle end signal will be output on the premise
that only one program is executed at a time. If two or more
programs are executed simultaneously (multi-tasks), the
single-cycle end signal will be turned ON immediately after
any of the programs reads an END command.

(2) Terminal number

No. 13 of connector CN10.

(3) Usage
The signal is used to operate another equipment in synchronization with a
single-cycle end of the program.

(4) ON conditions
The signal will be turned ON when the program is read to the end.

(5) OFF conditions

The signal will be turned OFF immediately after the program starts to run.

Robot status Single-cycle Single-cycle

operation Wait for start operation

PROGRAM START input

1-CYCLE END

Single-Cycle End Output

78
4.2.10 Normal CPU (Output)
(1) Function
The signal outputs to the external device that the CPU (hardware) of the
Robot Controller is normal.

(2) Terminal number

No. 1 of connector CN10.
(3) Usage
 The signal is used to light the Robot Controller error indicator lamp of
an external operating panel.
‚ The signal is used when the NORMAL CPU signal is turned OFF
because of an error and the PLC corrects it.
(4) ON conditions
The signal will be turned ON by the hardware when the CPU of the Robot
Controller operates normally with the power turned ON.

(5) OFF conditions

The signal will be turned OFF by the hardware when the CPU does not
operate normally.

Caution: The OFF state of this signal indicates that the internal
arithmetic circuit of the Robot Controller may be damaged and
ROBOT ERROR, ERROR NUMBER and other outputs may not
be correct.

⋅ Power ON (CPU operates properly)

Normal CPU output

⋅ CPU error (hardware error)

Normal CPU Output

79
4.2.11 Robot Failure (Output)
(1) Function
The signal outputs to the external device that a problem, such as a servo
error and a program error, occurs with the robot.

(2) Terminal number

No. 3 of connector CN10.
(3) Usage
 The signal is used to light the robot failure indicator lamp of an external
operating panel.
‚ The signal is used to help the PLC clear an error in response to a
ROBOT FAILURE signal.
(4) ON conditions
As shown below, the signal will be turned ON under the following
conditions.
 When an error, such as a servo error, a program error and undefined
program, occurs at the start of the program and during execution of the
program.
‚ When an error occurs during execution of the program in internal
operation by the operating panel or the teach pendant or in external
operation by the PLC.
ƒ When an error, such as undefined program, occurs at the start of the
program only in external operation.

Caution: The signal will not be output when an error, such as a

program input error occurs in manual operation, except when
a servo error occurs in manual operation. For further
information, see "ERROR CODE TABLES."

(5) OFF conditions

As shown below, the signal will be turned OFF under the following
conditions.
 When a CLEAR ROBOT FAILURE command is input from the external
device and the existing error is cleared.
‚ When the existing error is cleared by operating the Cancel key of the
operating panel or the teach pendant.

⋅ Program number, parity error, or an undefined program number at

external start. ƒo ƒŠ ƒeƒ B [ ƒGƒ ‰ [A
⋅ The robot errors during automatic operation (both internal operation and
external operation).

Robot failure

⋅ When CLEAR ROBOT FAILURE and OPERATION PREPARATION

START signals are input.
⋅ When the Cancel key of v
Cancel
u ƒtheL operating
‘ € ì panel or the teach pendant is
[
operated.

Robot Failure Output

80
4.2.12 Robot Warning (Output)
(1) Function
The signal outputs to the external device that a minor error has occurred
with an I/O command or during servo processing.

Caution: The signal will not be output in case of a minor error, such as
a program selection error, caused by the operation of the
teach pendant or operating panel.

(2) Terminal number

No. 15 of connector CN10.

(3) Usage
 The signal is used to light the robot warning indicator lamp of an
external operating panel.
‚ The signal is used to help the PLC clear an error in response to a
ROBOT WARNING signal.

(4) ON conditions
As shown below, the signal will be turned ON when a minor error occurs
during I/O processing, execution of the program or servo processing,
irrespective of the operation mode.

(5) OFF conditions

As shown below, the robot-warning signal will be turned OFF under the
following conditions.
 When CLEAR ROBOT FAILURE and OPERATION PREPARATION
START signals are input from the external device and the existing error
is cleared.
‚ When the existing error is cleared by operating the OK or Cancel key
of the operating panel or the teach pendant.

⋅ When a slight error occurs during I/O processing, execution of the

program or servo processing.

Robot warning

⋅ When a CLEAR ROBOT FAILURE command is inputted from the

external device and the existing error is cleared.
⋅ When the existing error is cleared by operating the OK or Cancel key
of the operating panel or teach pendant.

Robot Warning Output

81
4.2.13 Dead Battery Warning (Output)
(1) Function
The signal will be output when the voltage of the encoder back-up battery
or memory back-up battery becomes dangerously low.

(2) Terminal number

No. 14 of connector CN10.
(3) Usage
The signal is used to check the timing of battery replacement (lowering of
the battery voltage).

(4) ON conditions
The signal will be turned ON when the voltage of the encoder back-up
battery or memory backup battery becomes dangerously low.

Caution: Any error of ERROR64A1 to 64A6 indicating the dead encoder

back-up battery or ERROR6103 informing the dead memory
back-up battery will be displayed on the operating panel and
the teach pendant.

(5) OFF conditions

The signal will be turned OFF when the power is turned ON after the dead
battery was replaced.

Power ON Power OFF Power ON Power OFF Power ON

Robot power ON state

⋅ The voltage of the encoder backup

battery or memory back-up battery
becomes dangerously low.

Dead battery
warning output

⋅ Battery replaced

Dead Battery Warning Output

82
4.2.14 Error No. (Output)
(1) Function
When an error occurs, the signal outputs the error number in a 3-digit (12-
bit) hexadecimal code.

(2) Terminal numbers

No.17 to No.28 of connector CN10.
(3) Usage
The signal is used to display an error number on the external device.

(4) Output conditions

The signal will be output when an error occurs.
(5) Clear conditions
The signal will be cleared when CLEAR ROBOT FAILURE and
OPERATION PREPARATION START signals are inputted or by operating
the Cancel key of the operating panel or the teach pendant. When this
signal is cleared, all states will become OFF (0).
(6) Hexadecimal codes
See the following figure.

×××× →0 סס →5 ¡×¡× → A

××ס →1 ס¡× →6 ¡×¡¡ → B
××¡× →2 ס¡¡ →7 ¡¡×× → C
×ס¡ →3 ¡××× →8 ¡¡×¡ → D
ס×× →4 ¡×ס →9 ¡¡¡× → E ¡⋅⋅⋅ON
¡¡¡¡ → F ×⋅⋅⋅⋅OFF

Hexadecimal Codes

The figure below shows an example of error number output, when

ERROR174 (overload error with the fourth axis) occurs.

Hundreds of error No. Tens of error No. Units of error No.

Terminal No. 28 27 26 25 24 23 22 21 20 19 18 17
(connector CN10)

Example of Error Number Output

83
4.2.15 Continue Start Permitted (Output)
(1) Function
The controller will output this signal when the continue start is permitted.

(2) Terminal number

No.16 of connector CN10.
(3) Usage
Use this signal when you want to know whether the continue start is
permitted.

(4) ON condition
This signal comes on when the continue start is permitted. For details,
refer to the SETTING-UP MANUAL.

(5) OFF condition

This signal goes off by carrying out the "Task Status Change Operation."

4.2.16 SS mode (Output)

(1) Function
The controller will output this signal during the SS mode.
This mode is effective when the slow mode is selected.
(2) Terminal number
No. 29 of connector CN10

(3) Usage
This signal is used to warn workers that the robot is in the SS mode by
beeping or lighting the lamp.
(4) ON condition
This signal comes on when the SS mode is selected.
(5) OFF condition
The signal goes off when the TS time passes so as to cancel SS mode.
This function is effective when the slow mode is selected.
Note: If the TS time passes, this signal goes off even when the robot is
operation in the slow mode. After this signal goes off, the robot runs at the
original speed.

84
4.2.17 Emergency Stop (Output from a contact)
(1) Function
This signal outputs from a contact exclusively designed for an emergency
stop circuitry you may configure. It allows red mushroom buttons provided
on the front panel of the robot controller, on the teach pendant, and on the
operating panel to be used as emergency stop buttons of the facilities.
A 0.3A fuse is built in the contact.
(2) Terminal number
No. 10 of connector CN10: Emergency stop (+)
No. 10 of connector CN10: Emergency stop (-)

(3) Usage
This signal is used to stop the facilities or robot in an emergency. (Refer
to Subsection 5.2.4 "Emergency Stop Circuit.")
(4) Contact
This contact is a normal close one (b contact). If any of the emergency
stop buttons is pressed, then the contact turns off to output an emergency
stop signal.

85
4.3 Types and Functions of System Input Signals
(Compatible Mode)
The table below lists the system input signals to be used in compatible mode.

Types and Functions of System Input Signals to be Used in Compatible Mode

Application Signal name Function

Enable Auto Enables switching to Auto mode.

Motor power ON
Turns ON the power to the motor.
+ operation preparation start

CAL execution
Executes calibration.
+ operation preparation start

SP100
Start-up Sets the speed to 100%.
+ operation preparation start

Switch Ext Mode

Switches the mode to external mode.
+ operation preparation start

Initializes all programs on halt. Starting a

Program reset
program after initialization will execute the
+ operation preparation start
program from the beginning.

Program No. select

Executes a specified program.
+ program start

Program reset Cancels the current program and starts

Program + program No. select executing a specified program from the
execution + program start beginning.
Robot stop Stops the robot by opening signals.
Robot stop Stops the robot by canceling signals.
Step stop Step-stops all programs by opening signals.
Stop
Instantaneously stops all programs by
Instantaneous stop
opening signals.

Clear robot failure

Error clear Clears an error.
+ operation preparation start

Interrupts the execution of the current step

Program interrupt Interrupt skip
and starts the next step.

Continue start
Continue start Executes continue start.
+ program start

Caution: Two or more signal names listed in the signal name field
indicate that they should be used in combination.

86
4.4 Usage of System Input Signals in Compatible Mode
The usage of each system input signal in compatible mode is described below:

4.4.1 Enable Auto (Input)

(1) Function
 The signal enables switching of the robot mode to the Auto mode
(shorted state).
‚ The signal enables switching of the robot mode to the manual mode or
the teach check mode (open state).
(2) Terminal number
No.4 of connector CN8.
(3) Usage
The signal is used for the AUTO/TEACHING selector switch of the external
operating panel and can be combined with the safety fence switch.
(4) Input conditions and operation
 As shown below, the selectable operation mode depends on whether
this input is shorted or open.
‚ If the input becomes open during automatic operation, the mode will be
switched to manual mode and ERROR21FC will be displayed.
ƒ If manual operation or a teach check is conducted with this input
shorted, ERROR21F2 will be displayed.
„ If the mode selector switch of the teach pendant or the operating panel is
set to AUTO with this input open, ERROR21F3 will be displayed.
Since this state is × in the table below, this error will remain displayed
until the robot leaves this state.
Although ERROR21FD or ERROR21FC will be displayed when the state
is changed from ¡ to ∆ or × shown in the table below, they will not be
displayed when the state is changed from ∆ or × to ¡.
† When the input is turned OFF (open) in external mode, the external
mode output will also be turned OFF.
Relationship Between Enable Auto Input and Selectable Mode
Enable Auto
Operation Mode Application ON OFF
(shorted) (open)
Manual operation with the operating panel or teach ¡
Manual mode ∆
pendant
Teach check mode Program check with the teach pendant ∆ ¡
Automatic operation with the operating panel or teach ¡
Internal Auto mode ×
pendant
External Auto mode Automatic operation with the external device ¡ ×
Note:¡ = Mode selectable × = Mode not selectable
∆ = Mode selectable, but manual operation and program execution impossible

Caution: In the pendantless state, auto mode is valid even if the Enable Auto input
is open (external mode cannot be switched and the program cannot start
to run).
Perform the following when operating the robot in the pendantless state:
 Set the robot not to start to operate when the Enable Auto input is
open.
‚ Enable Auto input open state and auto mode output (See
Subsections 4.2.2 and 6.2.2 "Auto Mode ".)
Set the equipment to make an emergency stop in an AND state.
Add  and ‚ with the external sequence circuit.

87
4.4.2 Operation Preparation Start (Input)
(1) Function
⋅ By turning ON (short) this signal, input signals  to „ described in (3),
input conditions and operation will be detected and the robot will
automatically start to operate. Input these signals with the system output
ROBOT POWER ON COMPLETE turned ON.
⋅ By turning ON (short) CLEAR ROBOT FAILURE, an error that has
occurred will be cleared.

(2) Terminal number

No.8 of connector CN8.
(3) Input conditions and operation
Before inputting an operation preparation start signal, turn ON (short)
inputs  to „ below:

Q Motor power ON (input)

⋅ Terminal number: No.19 of connector CN8
⋅ By turning ON (short) the operation preparation start signal with this
signal turned ON (shorted), the power to the motor will be turned ON.
However, this signal can be used only in the Auto mode.
R CAL execution (input)
⋅ Terminal number: No.20 of connector CN8
⋅ By turning ON (short) the operation preparation start signal with this
signal turned ON (shorted), calibration takes place. However, this
signal cannot be used when the power to the motor is turned OFF (
not executed).
S SP100 (input)
⋅ Terminal number: No.22 of connector CN8
⋅ By turning ON (short) the operation preparation start signal with this
signal turned ON (shorted), SP100% will be set.
T Switch Ext Mode (input)
⋅ Terminal number: No.23 of connector CN8
⋅ By turning ON (short) the operation preparation start signal with this
signal turned ON (shorted), the mode will be set to the external
mode. However, this signal cannot be used when the power to the
motor is turned OFF and CAL is not completed.
U Program reset (input)
⋅ Terminal number: No.24 of connector CN8
⋅ By turning ON (short) the operation preparation start signal with this
signal turned ON (shorted), all programs will be initialized.

NOTE: By turning ON (short) the operation preparation start signal with

all inputs Q to U turned ON (shorted), Q to U will be executed
one by one. Input R cannot be executed until input Q is
completed. Inputs Q to U will also become valid when part of
them are executed by the operating panel or teach pendant.

88
 For the input timing of the operation preparation start signal and  to „, see
the figure given below.

Caution: The operation preparation start signal and each input signal,
except the Enable Auto signal, will be turned OFF (falling)
upon turning ON of the external mode output is turned ON.
Although the robot is made to execute all items at start-up,
execute only necessary items at the time of recovery from
suspension during operation to reduce recovery time.
The required time to execute all items may be about 5
seconds depending on CAL time. The time is about 1.3
seconds without CAL. (Once CAL is completed, it does not
need to be executed again as long as the power to the Robot
Controller is turned ON.) Determine whether to execute CAL
according to the CAL complete output.

Automatic ON (shorted)
operation enable OFF (open)
1 ms. or more
Operation ON (shorted)
preparation start OFF (open)

The power to the motor is turned ON.

 Motor power ON ON (shorted)
OFF (open)
Input

CAL starts CAL ends

‚ CAL execution ON (shorted)
OFF (open)
SP is set to 100.
ƒ SP100 ON (shorted)
OFF (open)
The mode is switched to
external mode.
„ External ON (shorted)
mode switching OFF (open)

Automatic ON (shorted)
mode output OFF (open)

Servo ON ON (shorted) Approx.2.0s

OFF (open)
Output

Approx. 2.5s CAL time

CAL complete ON (shorted)
OFF (open)

Approx. 0.5s
External ON (shorted)
mode output OFF (open)

Note indicates the input or output of the signal, and indicates robot operation.

Example of Operation Preparation Start Signal Timing Chart

89
4.4.3 Program No. Select (Input)
(1) Function
The program number to be executed can be specified from the external
device by inputting this signal.

(2) Terminal numbers

No.11 to No.18 of connector CN8.
(3) Input conditions and operation
 This signal is executable only in the external mode. In other modes, an
error (ERROR21E2, 21E4, 21E6) will be displayed, and the terminal
motor power will be turned OFF.
‚ As shown in the table given on the next page, the program No. select
signal is made up of eight bits of 20 to 26 and the parity bit.
ƒ Input a decimal program number by converting it into binary 20 to 26 and
parity bit.
„ "Short" represents the bit value = 1, "open" represents the bit value = 0,
and the parity bit is odd parity.
As shown below, input the program No. select signal before the
program start signal (1 msec. or more), and hold the state until the
robot starts to operate. If this condition is not met, ERROR2031 or
ERROR2033 will be displayed, the power to the motor will be turned
OFF, and the mode will be switched to the Auto mode.

Wait for start

Robot status or preceding cycle Single-cycle operation

Program ON (shorted)
start (input) OFF (open)

1 ms. or more required

Program No. select signal

20 to 26 ON (shorted)
Parity OFF (open)

Program No. Select Signal

† Input 1 or 0 as the parity bit so that the total of 1’s existing in the eight
bits of 20 to 26 and the parity bit will be odd.
Example: When the program number is 15, the bit status of 20 to 26 is
(001111), and the total number of 1s is four, an even number.
Set 1 as the parity bit to make the total number of 1s five, an
odd number.

Caution Q The bit value =1 represents short, and the bit value =0
represents open.
R The program numbers executable from the external device
are limited to Pro0 to Pro127.

90
 Example of Program No. Select Signals

Program No. (decimal)

Input signal
1 15 26 65
2 0
= 1 1 1 0 1
2 1
= 2 0 1 1 0
2 2
= 4 0 1 0 0
2 3
= 8 0 1 1 0
2 4
= 16 0 0 1 0
2 5
= 32 0 0 0 0
2 6
= 64 0 0 0 1
Parity 0 1 0 1

The figure below shows an example of a program No. select signal sequence
circuit considering parity.

Lower 4-bit, odd

Upper 3-bit, odd

Program No. select

Example of Program No. Select Signal Sequence Circuit

91
4.4.4 Program Start (Input)
(1) Function
This signal starts the program specified with the program No. select signal
from the external device.

(2) Terminal number

No.10 of connector CN8.
(3) Input conditions and operation
By switching the status of this signal from ON (open) to ON (shorted) in
external mode, operations , ‚ and ƒ described below will take place.
(The status of the signal must be switched from OFF to ON.)
 If the program start signal is input (switched from OFF to ON) when the
robot has not yet completed the program or is at rest after it has
completed a cycle of the program, the program No. select signal will be
read, the program will execute a cycle, and the robot will come to a
stop.

Single-cycle Single-cycle
1-cycle Operation Wait for start operation Wait for start operation
Robot status

Program ON (shorted)
start signal OFF (open)

50 ms. or more required

Program Start Operation-1

Caution: The program start signal requires program start preparation

time (50 msec. or more) before input from OFF (open) to ON
(shorted).
The program start signal must remain OFF (open) during the
program start preparation time. If it is turned ON (shorted)
during that time, the next cycle will not start to run.
To start a new cycle, the status of the external start signal
must be switched from OFF to ON before each cycle.

92
 ‚ When the status of the program start signal is switched from OFF to
ON with the program step-stopped, the program will resume from the
step following the suspended step and stop at the cycle end.

Single-cycle operation
Robot status
Performing
remaining
Operating halfway At step-stop operation

Program start ON (shorted)

signal (input) OFF (open)

Step-stop ON (shorted)
signal (input) OFF (open)

Program Start Operation-2

Caution: To cancel the execution of the remaining steps of a step-

stopped program and start it from the beginning, input a
program reset signal, a program No. select signal and a
program start signal at the same time. For further information,
refer to Subsection 6.4.5 "Program Reset (Input)".

93
 ƒ When the status of the program start signal is switched from OFF to ON
with the program immediately stopped, the program will resume from
the suspended step and stop at the cycle end.

Robot status Single-cycle operation

Performing
Operating On halt remaining
halfway operation

Program start ON (shorted)

signal (input) OFF (open)

Instantaneous stop ON (shorted)

signal (input) OFF (open)

Program Start Operation-3

Caution: To cancel the execution of the remaining steps of an

instantaneously stopped program and start it from the
beginning, input a program reset signal, a program No. select
signal and a program start signal at the same time. For further
information, refer to Subsection 6.4.5 "Program Reset (Input)".

94
 (4) Example of program start signal (rise) ON and (fall) OFF timing
Q Example of program start signal rise (ON) timing
The figure below shows how to make the program start signal rise with
robot system outputs (external mode output and single-cycle end
output).

Wait for start Single-cycle Next cycle

Robot status operation operation

External mode ON
(output) OFF

1-cycle end ON
(output) OFF
200 ms. or
more required
Program start ON (shorted)
signal (input) OFF (open)

Example of Program Start Signal Rise Timing

Caution: The program start signal for the first cycle rises as soon as
the external mode becomes valid and the conditions of the
peripheral devices are met. The program start signal for
subsequent cycles rises after output of a single-cycle end
signal.

95
 R Example of program start signal fall (OFF) timing
a) The following figure shows how to make the program start signal fall
with a robot system output (program start reset output).
When the robot program starts to run, a program start reset signal is
output. The external device receives it and makes the program start
signal fall (OFF).

Robot status Wait for start

or preceding cycle Single-cycle operation

Program start ON
reset (output) OFF
Program start ON (shorted)
signal (input) OFF (open)

Example of Program Start Signal Fall Timing-1

b) The figure below shows how to make the program start signal fall
with the simplified method (1 shot method using a timer).

Robot status Wait for start Single-cycle operation

50 ms. or more required

Program start ON (shorted)
signal (input) OFF (open)

Example of Program Start Signal Fall Timing-2

Caution Q Although the 1 shot method is easy, the timer setting for
falling to raise the program start signal in the middle of the
preceding cycle is difficult.
Use this method only to raise the program start signal after
the robot stops at the end of each cycle.
R The status of the robot-in-operation, program start reset
and single cycle end output signals changes in sequence
after the program start signal is input (T1→T2→T3 in the
figure given on the next page).
The change of the status of these signals takes place within
100 msec. after the program start signal rises (ON). See the
next page.

96
 T1, T2, T3: within 100 ms.

Program start ON (shorted)

signal (input) OFF (open)

Robot in operation
(output)

Program start reset

(output)

Single-cycle end
(output)

Program Start Signal Rise Output Signal Timing

97
4.4.5 Program Reset (Input)
(1) Function
By turning ON (short) this signal, any program can be forcibly executed
from the beginning in a step-stopped state and a suspended state.

Caution: Generally, a step-stopped or suspended program resumes

from where it stopped.

(2) Terminal number

No.24 of connector CN8.

(3) Input conditions and operation

When issued with the Program Start
 The figure below shows the input conditions and an operation timing
chart.
‚ Use the program reset signal together with a program No. select signal,
and input it before the program start signal (1 msec. or more).
ƒ Turn OFF the program reset signal after the robot starts to operate
(after a program start reset signal is output).
„ A program No. select signal is required to execute the same program
number as the suspended one from the beginning.

Input Conditions and Operation of Program Reset Signal

98
 When issued with the Operation Preparation Start
 The figure below shows the input conditions and an operation timing
chart.
‚ Input Program Reset before Operation Preparation Start (1 msec. or
more).
ƒ After turned ON, this signal may take a maximum of one second for
initializing all programs. During the period, do not input signals to the
robot.

Input Conditions and Operation of Program Reset Signal

99
4.4.6 Robot Stop (Input)
(2) Function
 The signal stops the robot with the external device by opening the robot
stop input
‚ The signal readies the power to the robot motor to be turned ON by
shorting the robot stop input.

(2) Terminal number

No.2 of connector CN8.

(3) Input conditions and operation

 The robot stops with this signal OFF (open).
‚ The power to the robot motor is ready to be turned ON with this signal
ON (shorted).
ƒ Irrespective of whether internal mode (operation with the teach
pendant) or external mode (remote operation by the external device) is
selected, the power to the robot motor cannot be turned ON with this
signal OFF (open). Neither manual nor automatic operation can be
performed until this signal is turned ON (shorted). (ERROR2008 will be
displayed.)
„ By turning OFF (open) this signal under the following conditions.
1) The power to the motor will be turned OFF, irrespective of whether
Manual, Internal Auto, or External Auto mode is selected.
2) During execution of the program (Robot-in-operation signal ON), the
power to the motor will be turned OFF and the mode will be
switched to internal mode after the robot decelerates to a stop.
3) When the program is at a stop in the Manual and the Auto mode the
power to the motor will be turned OFF. The suspended operation
can be resumed by turning ON the power to the motor and shorting
the ROBOT STOP signal.
Opening the ROBOT STOP signal and pressing the ROBOT STOP
button of the operating panel or the teach pendant function the same.

(4) Input timing

This signal will be processed prior to all commands and input signals.

100
4.4.7 Step Stop (All Tasks) (Input)
(1) Function
Input this signal to step-stop the program being executed from the
external device. All tasks will be step-stopped.

(2) Terminal number

No.5 of connector CN8.
(3) Input conditions and operation
 If the status of this signal is changed from ON (shorted) to OFF (open),
the robot will stop all tasks immediately after the ongoing step is
completed, and the Robot-in-operation signal will be turned OFF.
However, External Auto mode will remain valid, and the suspended
program will be resumed by inputting a program start signal. See the
figure given below.
‚ Turning OFF (open) this signal when inputting a program start signal
makes the robot stop step by step.
ƒ Internal operation with the teach pendant is valid only when the status
of this signal is changed from ON (shorted) to OFF (open).
„ For resuming the program after a step stop, refer to Subsection 4.4.4
"Program Start (Input)".

Robot status Single-cycle operation

Performing
remaining
Operating halfway Step-stop operation

Program start ON (shorted)

signal (input) OFF (open)

Step-stop ON (shorted)
signal (input) OFF (open)

Robot-in-operation ON
(output) OFF

Step Stop Signal

101
4.4.8 Instantaneous Stop (All Tasks) (Input)
(1) Function
Input this signal to instantaneously stop the program being executed from
the external device. All tasks will instantaneously stop.

(2) Terminal number

No.7 of connector CN8.
(3) Input conditions and operation
 If the status of this signal is changed from ON (shorted) to OFF (open),
the robot will instantaneously stop in the middle of the ongoing step,
and the Robot-in-operation signal will be turned OFF. However, Auto
mode or external mode will remain valid, and the suspended program
will be resumed by inputting a program start signal.
‚ Internal operation by the teach pendant is valid only when the status of
this signal is changed from ON (shorted) to OFF (open).
ƒ For resuming the program after an instantaneous stop, refer to
Subsection 4.4.4 "Program Start (Input)".
„ The minimum required pulse width is 50 msec. or more.

ON (shorted)

Instantaneous
stop OFF (open)
50 ms. or more required

Minimum Instantaneous Stop Pulse Width

102
4.4.9 Clear Robot Failure (Input)
(1) Function
The robot can recover from a stopped state, resulting from a robot failure
by turning ON (shorted) the operation preparation start signal with this
signal ON (shorted).

(2) Terminal number

No.25 of connector CN8.

NOTE: Operation preparation start signal is inputted through No. 8 of

connector CN8.

(3) Usage
The signal is used to clear an error that brought the robot to a stop.
(4) Input conditions and operation
 When a robot failure occurs, clear the error display on the teach
pendant and the external output ERROR NUMBER to ready the robot
to operate.
‚ When the Clear robot failure signal is turned ON (shorted), other input
signals (MOTOR POWER ON, CAL EXECUTION, SP100 and SWITCH
EXT MODE), which are to be used in combination with the operation
preparation start signal, will be ignored.
To turn ON the power to the motor after a robot failure is cleared, turn
OFF (open) the Clear robot failure signal after turning OFF the Robot
failure signal (output) as shown below.
ƒ Input the Clear robot failure signal before (1 msec. or more) the
operation preparation start signal.

Stop due to
Robot status a robot failure Clear robot failure Motor power ON

Operation preparation ON
start (input) OFF
50 ms. or more required
1 ms.
Clear robot ON or more
required
failure (input) OFF

Motor power ON
ON (input) OFF

Robot failure ON
(output) OFF

Servo ON ON
(output) OFF

Input Conditions and Operation of Clear Robot Failure Signal

103
4.4.10 Interrupt Skip (Input)
(1) Function
If this signal is turned ON (shorted) during execution of the robot operation
command within the range between INTERRUPT ON and INTERRUPT
OFF in the program, the operation of the ongoing step will stop and the
next step will start.

Note: For further information about the INTERRUPT ON and OFF

commands, refer to the PROGRAMMER'S MANUAL (I), Chapter
12 "12.3 INTERRUPT ON/OFF (Statement)."
For further information about robot motion commands, refer to
the PROGRAMMER'S MANUAL (I), Chapter 12, "Robot Control
Statements."

(2) Terminal number

No.9 of connector CN8.

(3) Usage
Refer to the PROGRAMMER'S MANUAL (I), Chapter 12 "12.3
INTERRUPT ON/OFF."
(4) Input conditions and operation
If this signal is turned ON (shorted), the robot will immediately stop the
ongoing operation and start executing the next step.

INTERRUPT ON
command Operating halfway Next operation
Robot status

50 ms. or
more required

Interrupt skip ON (shorted)

signal (input) OFF (open)

Input Conditions and Operation of Interrupt Skip

104
 Caution: When turning ON (shorted) the interrupt skip signal, at
least either the program reset signal or the program start
signal must be turned OFF (open).
If the interrupt skip signal is turned ON, the robot interprets
the program start signal as instantaneously turned OFF
(open). Consequently, the program selected with the
program No. select signal will be executed from the
beginning. (See the figure given below.)

Executing cycle
Robot status Executing cycle halfway from beginning

Interrupt skip ON (shorted)

signal (input) OFF (open)

Program start ON (shorted)

signal (input) OFF (open)

Program reset ON (shorted)

WRONG
signal (input) OFF (open)

Program No. select ON (shorted)

signal (input) OFF (open)

Example of Operation When an Interrupt Skip Signal is Input

4.4.11 Continue Start (Input)

(1) Function
Turning the program start signal ON when this continue start signal is ON
will resume the current program being on halt.

(2) Terminal number

No.6 of connector CN8.
(3) Input conditions and operation
This signal is executable only in external mode. If this signal is on,
program numbers will be ignored at execution of Program start and the
current program being on halt will be resumed. If Continue Start Permitted
signal is not ON, the controller will issue ERROR27A8.

105
4.5 Example of Using System I/O Signals in Compatible Mode
This section describes an example of starting and stopping the robot using
system I/O signals.

(1) Equipment setup example

The example shown below assumes an equipment setup which allows you
to run the robot by operating an external equipment’s operation panel
connected via the PLC to the robot controller. It is assumed that the
operation panel has a display, lamps and switches listed on the next page.

Robot

Robot
controller

PLC
Other equipment
(e.g., conveyor)

External equipment’s
operation panel

Example of Equipment Setup Using a Robot

106
 Function Example of Equipment Operating Panel

Classification Part Application

Displays messages, such as ROBOT PREPARATION

Display Display OK.
⋅ Lights during automatic operation.
Q Automatic operation
indicator lamp ⋅ Not illuminated when the robot is not in automatic
operation.

Lamp R Robot external mode ⋅ Lights when the robot is in external mode.
indicator lamp ⋅ Turned OFF when the robot is not in external mode.

S Operation OK indicator ⋅ Lights when the Enable Auto signal is ON.

lamp ⋅ Turned OFF when the Enable Auto signal is OFF.

Q Robot operation button Starts the robot preparation.

R Automatic start button Starts the operation of the equipment.

Switch
S Cycle stop button Stops the equipment after a cycle of operations is
completed.
Automatic operation of the robot possible when
T Operation/Adjustment OPERATION is selected.
selector switch Manual operation or teach check of the robot possible
when ADJUSTMENT is selected.
Note: Actual equipment requires emergency stop, interlock and other functions. However,
described here are only necessary functions and others are omitted.

(2) Outline of procedure

Described below is the outline of the procedure when using the equipment,
as shown on the previous page.
Follow steps  to ƒ.
 Operation preparation start
Setting the MOTOR POWER ON, CAL EXECUTION, SP100 and
SWITCH EXT MODE bits, brings the robot into the External Auto mode.
This operation will be completed when the EXTERNAL MODE output
signal is turned ON.
‚ Automatic operation
Start the program by which the robot starts from the operation origin,
performs operations, and returns to the operation origin.
ƒ Operation end
Terminate the day’s operations with a cycle stop, and turn OFF the
power.

(3) Start and stop procedure and system I/O signals

The following pages show the relationship between the system I/O signals
for start and stop, worker’s operation, display on the equipment operation
panel, PLC proceeding, and robot motion.

107
 Worker’s operation and display on
Step equipment’s operation panel
PLC processing Robot operation

Equipment power ON

Setting
operation/adjustment
Enable Auto ON (Internal processing)
selector switch to
operation

Operation OK indicator
lamp ON
Q Operation preparation start

(Note )
Robot preparation System input
button ON
for start-up ON

Operation Motor power ON

Preparation Start ON

Executing CAL

Setting SP 100

Switching mode to
external mode

Robot external mode (Internal processing) Motor power ON

indicator lamp ON

Moving robot arm close

R Operation start area check

to operation origin,
when external mode
indicator lamp is ON
and operation position
1 indicator lamp is OFF.

Robot operation origin (Internal processing) Operation position 1

indicator lamp ON
ON

Robot preparation OK When both are ON

display (Internal processing)

Start and Stop Procedure and System I/O Signals-1

(Continued on the next page)

108
(Continued from preceding page)
Worker’s operation and display on
Step equipment’s operation panel
PLC processing Robot operation

Equipment’s Program No. Select ON

Automatic Start

Regular Operation
Program is
selected.
S Automatic operation

Automatic Operation Program start ON Program start

indicator lamp ON

END

Program No. select ON Single-cycle End ON

Regular Operation
Program is
selected.
Repeated
Program start ON

Equipment’s Cycle Cycle Stop ON Executing single-cycle

Stop button ON

END
T Operation end

Automatic operation (Internal processing) Single-cycle End ON

indicator lamp OFF

Equipment power OFF

Note Q The system inputs for startup here are four types of system inputs – "motor power ON,"
"CAL execution," "SP100" and "External Mode switching." Refer to Subsection 6.4.2
"Operation Preparation Start (Input)".
R: in the above figure indicates a system I/O signal, and ← represents the flow of the
signal.

Start and Stop Procedure and System I/O Signals-2

109
 Chapter 5
Connector Pin Assignment and I/O Circuits
(NPN type)
This chapter explains the connector pin assignment and circuits of NPN type (source
input and sink output) on an I/O board. I/O boards designed for the use in Japan are
of an NPN type.
For a PNP type (sink input and source output), refer to Chapter 6, "Connector Pin
Assignment and I/O Circuits (PNP type)."

5.1 Connector Pin Assignment (NPN type)

This section describes the pin assignment of connectors on the robot controller. The
signals and pin assignments of output connector CN10 and input connector CN8 are
differently defined in standard mode and compatible mode. As for other connectors,
the definitions of pins are common to standard mode and compatible mode.

5.1.1 Connector Pin Assignment Common to Both Modes (NPN type)

(1) HAND I/O CN9: Connector for end-effector I/O (common to both
modes)
CN9 Pin Assignment, common to both modes (NPN type)

View from the cable side

Wire color Wire color

Terminal Port Terminal Port
Name Name
No. number High No. number High
Standard Standard
strength strength

1 Hand output 64 Black Blue 11 Hand Input 50 Pink White

2 Hand output 65 Brown Yellow 12 Hand Input 51 Pink White

3 Hand output 66 Black Green 13 Hand Input 52 White White

4 Hand output 67 Brown Red 14 Hand Input 53 White White

5 Hand output 68 Red Violet 15 Hand Input 54 White White

6 Hand output 69 Orange Blue 16 Hand Input 55 White Brown

7 Hand output 70 Yellow Yellow 17 Power E24V for Hand  White Brown

8 Hand output 71 Green Green 18 Power E0V for Hand  White Brown

9 Hand input 48 Blue Red 19 Not connected  White Brown

10 Hand input 49 Violet Violet 20 Not connected  White Brown

NOTE: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #11, #2
and #12,…#10 and #20.

110
(2) I/O POWER CN7: Power connector for I/O (common to both modes)

CN7 Pin Assignment, common to both modes (NPN type)

View from the cable side

Terminal No. Name

1 Internal power source output +24V
2 Internal power source output +24V
3 Internal power source output 0V
4 Internal power source output 0V
5 FG
6 Power input E24V
7 Power input E24V
8 Power input E0V
9 Power input E0V

Caution: When using the internal power source, keep the total
current capacity below 1.3 A. To use the internal power source of the
robot controller, connect the wiring so that the internal power source
will be separated from the external power source. Improper wiring may
damage the internal circuit.

(3) RS232C CN1: RS232C connector

CN1 Pin Assignment

Terminal No. Name Terminal No. Name

1  6 DSR
2 RXD 7 RTS
3 TXD 8 CTS
4 DTR 9 

5 SG

111
5.1.2 Connector Pin Assignment in Standard Mode
(1) OUTPUT CN10: User-/System-output connector (standard mode)
CN10 Pin Assignment, in standard mode (NPN type)

View from the cable side

Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color
1 Normal CPU 72 Black 35 User output 106 Pink
2 Robot in operation 73 Brown 36 User output 107 Pink
3 Robot failure 74 Red 37 User output 108 Pink
4 Servo ON 75 Orange 38 User output 109 Pink
5 Robot initialization complete 76 Yellow 39 User output 110 Pink
6 Automatic mode 77 Black 40 User output 111 White
7 External mode 78 Brown 41 User output 112 White
8 Dead battery warning 79 Red 42 User output 113 White
9 Robot warning 80 Orange 43 User output 114 White
10 Continue start permitted 81 Yellow 44 User output 115 White
11 SS mode 82 Green 45 User output 116 White
12 Reserved 83 Blue 46 User output 117 White
13 Reserved 84 Violet 47 User output 118 White
14 Reserved 85 Gray 48 User output 119 White
15 Command processing complete 86 Pink 49 User output 120 White
16 Status area odd parity 87 Black 50 User output 121 Gray
17 Status area bit 0 88 Black 51 User output 122 Violet
18 Status area bit 1 89 Brown 52 User output 123 Violet
19 Status area bit 2 90 Red 53 User output 124 Violet
20 Status area bit 3 91 Orange 54 User output 125 Violet
21 Status area bit 4 92 Yellow 55 User output 126 Violet
22 Status area bit 5 93 Green 56 User output 127 Violet
23 Status area bit 6 94 Blue 57 Not used.  Violet
24 Status area bit 7 95 Gray 58 Not used.  Violet
[ Power supply for Robot
25 Status area bit 8 96 Pink *59  Violet
stop 1 (Internal +24V) ]
26 Status area bit 9 97 Brown *60 [ Robot stop 1 ]  Gray
[ Power supply for Robot
27 Status area bit 10 98 Red *61  Gray
stop 2 (Internal +24V) ]
28 Status area bit 11 99 Orange *62 [ Robot stop 2 ]  Gray
29 Status area bit 12 100 Yellow *63 [ Emergency stop (+) ]  Gray
30 Status area bit 13 101 Green *64 [ Emergency stop (-) ]  Gray
31 Status area bit 14 102 Blue 65 Emergency stop 2 (+)  Gray
32 Status area bit 15 103 Pink 66 Emergency stop 2 (-)  Gray
33 User output 104 Black *67 [ Deadman switch (+) ]  Blue
34 User output 105 Brown *68 [ Deadman switch (-) ]  Blue

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35,
#2 and #36, #34 and #68.
NOTE 2: The terminal number marked with ( * ) is used only for “Dual emergency stop type”.

112
 (2) INPUT CN8: User-/System-input connector (standard mode)
CN8 Pin Assignment, in standard mode (NPN type)

View from the cable side

Terminal Port Wire Terminal Port Wire

number
Name number color number
Name
number color

Power for robot stop

*1  Black 26 Data area 2 bit 7 21 Pink
(internal +24V)

*2 Robot stop  Brown 27 Data area 2 bit 8 22 Pink

Power for Enable Auto

3  Red 28 Data area 2 bit 9 23 Pink
(internal +24V)

4 Enable Auto  Black 29 Data area 2 bit 10 24 White

5 Step-stop (all tasks) 0 Brown 30 Data area 2 bit 11 25 White

6 Not used. 1 Red 31 Data area 2 bit 12 26 White

Instantaneous stop
7 2 Orange 32 Data area 2 bit 13 27 White
(all tasks)

8 Strobe signal 3 Yellow 33 Data area 2 bit 14 28 White

9 Interrupt skip 4 Green 34 Data area 2 bit 15 29 White

10 Command and data odd parity 5 Blue 35 Command area 0 bit 0 30 White

11 Data area 1 bit 0 6 Violet 36 Command area 0 bit 1 31 White

12 Data area 1 bit 1 7 Black 37 Command area 0 bit 2 32 Gray

13 Data area 1 bit 2 8 Brown 38 Command area 0 bit 3 33 Gray

14 Data area 1 bit 3 9 Red 39 User input 34 Gray

15 Data area 1 bit 4 10 Orange 40 User input 35 Gray

16 Data area 1 bit 5 11 Yellow 41 User input 36 Gray

17 Data area 1 bit 6 12 Green 42 User input 37 Gray

18 Data area 1 bit 7 13 Blue 43 User input 38 Gray

19 Data area 2 bit 0 14 Violet 44 User input 39 Gray

20 Data area 2 bit 1 15 White 45 User input 40 Gray

21 Data area 2 bit 2 16 Pink 46 User input 41 Gray

22 Data area 2 bit 3 17 Black 47 User input 42 Violet

23 Data area 2 bit 4 18 Brown 48 User input 43 Violet

24 Data area 2 bit 5 19 Red 49 User input 44 Violet

25 Data area 2 bit 6 20 Orange 50 User input 45 Violet

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #26,
#2 and #27,…#25 and #50.
NOTE 2: The terminal number marked with ( * ) is not used for “Dual emergency stop type”.

113
5.1.3 Connector Pin Assignment in Compatible Mode
(1) OUTPUT CN10: User-/System-output connector (compatible mode)
CN10 Pin Assignment, in compatible mode (NPN type)

View from the cable side

Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color
1 Normal CPU 72 Black 35 User output 106 Pink
2 Robot-in-operation 73 Brown 36 User output 107 Pink
3 Robot failure 74 Red 37 User output 108 Pink
4 Auto mode 75 Orange 38 User output 109 Pink
5 External mode 76 Yellow 39 User output 110 Pink
6 Program start reset 77 Black 40 User output 111 White
7 Not used. 78 Brown 41 User output 112 White
8 Not used. 79 Red 42 User output 113 White
9 Robot power ON complete 80 Orange 43 User output 114 White
10 Servo ON 81 Yellow 44 User output 115 White
11 CAL complete 82 Green 45 User output 116 White
12 Teaching 83 Blue 46 User output 117 White
13 Single-cycle complete 84 Violet 47 User output 118 White
14 Dead battery warning 85 Gray 48 User output 119 White
15 Robot warning 86 Pink 49 User output 120 White
16 Continue start permitted 87 Black 50 User output 121 Gray
17 Error units bit 0 88 Black 51 User output 122 Violet
18 Error units bit 1 89 Brown 52 User output 123 Violet
19 Error units bit 2 90 Red 53 User output 124 Violet
20 Error units bit 3 91 Orange 54 User output 125 Violet
21 Error tens bit 0 92 Yellow 55 User output 126 Violet
22 Error tens bit 1 93 Green 56 User output 127 Violet
23 Error tens bit 2 94 Blue 57 Not connected  Violet
24 Error tens bit 3 95 Gray 58 Not connected  Violet
[ Power supply for Robot
25 Error hundreds bit 0 96 Pink *59  Violet
stop 1 (Internal +24V) ]
26 Error hundreds bit 1 97 Brown *60 [ Robot stop 1 ]  Gray
[ Power supply for Robot
27 Error hundreds bit 2 98 Red *61  Gray
stop 2 (Internal +24V) ]
28 Error hundreds bit 3 99 Orange *62 [ Robot stop 2 ]  Gray
29 SS mode 100 Yellow *63 [ Emergency stop (+) ]  Gray
30 Not used. 101 Green *64 [ Emergency stop (-) ]  Gray
31 Not used. 102 Blue 65 Emergency stop 2 (+)  Gray
32 Not used. 103 Pink 66 Emergency stop 2 (-)  Gray
33 User output 104 Black *67 [ Deadman switch (+) ]  Blue
34 User output 105 Brown *68 [ Deadman switch (-) ]  Blue

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35,
#2 and #36, #34 and #68.
NOTE 2: The terminal number marked with ( * ) is used only for “Dual emergency stop type”.

114
 (2) INPUT CN8: User-/System-input connector (compatible mode)
CN8 Pin Assignment, in compatible mode (NPN type)

View from the cable side

Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color

*1 Power for robot stop (internal +24V) - Black 26 User input 21 Pink

*2 Robot stop - Brown 27 User input 22 Pink

3 Power for Enable Auto (internal +24V) - Red 28 User input 23 Pink

4 Enable Auto - Black 29 User input 24 White

5 Step-stop (all tasks) 0 Brown 30 User input 25 White

6 Continue start 1 Red 31 User input 26 White

7 Instantaneous stop (all tasks) 2 Orange 32 User input 27 White

8 Operation preparation start 3 Yellow 33 User input 28 White

9 Interrupt skip 4 Green 34 User input 29 White

10 Program start 5 Blue 35 User input 30 White

11 Program No. select bit 0 6 Violet 36 User input 31 White

12 Program No. select bit 1 7 Black 37 User input 32 Gray

13 Program No. select bit 2 8 Brown 38 User input 33 Gray

14 Program No. select bit 3 9 Red 39 User input 34 Gray

15 Program No. select bit 4 10 Orange 40 User input 35 Gray

16 Program No. select bit 5 11 Yellow 41 User input 36 Gray

17 Program No. select bit 6 12 Green 42 User input 37 Gray

18 Program No. select odd parity bit 13 Blue 43 User input 38 Gray

19 Motor power ON 14 Violet 44 User input 39 Gray

20 CAL execution 15 White 45 User input 40 Gray

21 Reserved 16 Pink 46 User input 41 Gray

22 SP100 17 Black 47 User input 42 Violet

23 Switch Ext Mode 18 Brown 48 User input 43 Violet

24 Program reset 19 Red 49 User input 44 Violet

25 Clear robot failure 20 Orange 50 User input 45 Violet

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #26,
#2 and #27,…#25 and #50.
NOTE 2: The terminal number marked with ( * ) is not used for “Dual emergency stop type”.

115
5.2 Robot Controller I/O Circuits (NPN type)

5.2.1 User-Input, System-Input and Hand-Input Circuits (NPN type)

The following two pages show examples of the user-input, system-input, and hand-
input circuit configurations and connections of the robot controller.
The maximum allowable capacity of the robot controller's internal power source is 1.3
A. Use the internal power source within this range.

Caution Q Either an external power supply type or built-in power type

Output card is available for the PLC. However, an external
power supply type requires an additional power source (24V)
to be installed. The power capacity is 15W or more.
R When controlling two or more robots with a single PLC using
the internal power source of the Robot Controller, set a PLC
Output card for each robot.
S Other than a PLC, a proximity switch, or a relay contact may
be connected directly to the input terminal of the Robot
Controller. In such a case, use the power input to pins 6 to 9 of
the I/O power connector. A two-wire photoelectric switch or
proximity switch can be connected if its leakage current is 1
mA or less.
T Use a multi-core shielding cable for the purpose of protecting
the Robot Controller from noise. Ground it to the Robot
Controller.

116
 (When the internal power source is used)

(When an external power source is used)

User-Input and System-Input Circuits (NPN type)

117
(When the internal power source is used)

(When an external power source is used)

Hand-Input Circuits (NPN type)

118
5.2.2 Robot Stop and Enable Auto Input Circuits
The Robot Stop and Enable Auto signals are important for safety. The input circuit for
these signals must have contacts as shown below.
Use the INPUT CN8 (pins 1 and 3) of the robot controller for the power source,
irrespective of whether the power source to be used for other I/O signals is the
internal power source or an external power source.
(Note: For the “Dual emergency stop type”, refer to Subsection 5.2.4.2.)

Robot Stop and Enable Auto Input Circuits

TIP: For the configuration sample of an emergency stop output circuitry, refer to
Subsection 5.2.4 "Emergency Stop Circuit."

119
5.2.3 User-Output, System-Output, and Hand-Output Circuits (NPN
type)
The following two pages show an example of the configuration and connection of the
Robot Controller's user-input output, system-output and hand-output circuit.
Since the initial resistance of a lamp is small, the output circuit may be damaged by
rush current that flows when the lamp lights.
When directly turning ON and OFF a lamp, use a lamp whose rating is 0.5W or less.
To reduce rush current, select and connect a resistor R that allows dark current 1/3 or
less of the rated current to flow when the lamp goes OFF.
An example of connecting a lamp is shown on page 121.

(1) The User-Output, System-Output and Hand-Output Circuit are open

collector output circuits.

(2) The maximum allowable source current is 70 mA.

Keep the current consumption of a device to be connected to the Robot

Controller, such as a PLC and a relay coil, below the allowable current.

(3) Select an induction load, such as a relay coil, which has a built-in diode
(for absorbing inverse electromotive force).

To use an induction load without a built-in diode, add a diode equivalent to

the 1S1888 (Toshiba) in close vicinity to the coil.

Caution: When externally attaching a diode, connect it with correct

polarity. Incorrect polarity may damage the Output circuit.

(4) Connecting a lamp requires a circuit through which dark current flows.

Caution: Since the initial resistance of a lamp is small, the output

circuit may be damaged by rush current that flows when
the lamp lights.
Refer to page 121.

(5) When using the internal power source, prepare a PLC input circuit unit that
does not contain a power source.

Caution: Keep the total current capacity of the internal power source
below 1.3A.

(6) Use a multi-core shielding cable for the purpose of protecting the devices
from external noise. Ground it to the robot controller.

(7) +24V internal power source of the robot controller must not be grounded.

Caution: If the output terminal +24V of internal power source is

grounded, there may be a case where the controller is
damaged.

120
 (When the internal power source is used)

(When an external power source is used)

User-Output and System-Output Circuits (NPN type)

121
(When the internal power source is used)

(When an external power source is used)

Hand-Output Circuits (NPN type)

122
 Supplied from the I/O power connector
when the internal power source is used

Lamp

Transistor array

Controller

Example of Circuit with Lamp (NPN type)

123
5.2.4 Emergency Stop Circuit
The following figures show the examples of configuration and connection of
emergency stop circuit for the robot controller.
The red mushroom-shaped switch provided on the robot controller front panel, on the
teach pendant, or on the operating panel can be used as a switch for stopping the
equipment in case of emergency.

5.2.4.1 Standard type

Robot controller
F1 CN7
Internal 24V Fuse (1.3A)

Fuse (1.3A) Emergency stop circuit

Internal 0V F2 (prepared by customers)
F9 Emergency CN10
Fuse (0.3A) Stop +

Emergency
Stop + Output

Internal
24V F8 CN8
Fuse (1.3A) Robot stop switch circuit
(prepared by customers)
Emergency stop switch
on the front panel of the Input
controller

CN5 Teach pendant

Emergency stop switch
on teach pendant

Internal 0V

(When the internal power source is used)

Robot controller
Emergency stop circuit
(prepared by customers)
F9 Emergency CN10
Stop + External 24V
Fuse (0.3A)

Emergency
Stop - Output

External 0V
Internal
24V F8 CN8
Fuse (1.3A)
Robot stop switch circuit
(prepared by customers)
Emergency stop switch
on the front panel of the Input
controller

Teach pendant
CN5
Emergency stop switch
on teach pendant

Internal 0V

(When an external power source is used)

Emergency Stop Circuit (Standard type)

124
5.2.4.2 Dual emergency stop type

Emergency Stop Circuit (Dual emergency stop type)

125
5.2.5 I/O Power Connector (NPN type)
For the power source to communicate signals between the robot controller and the
external device, the internal power source of the robot controller or an external power
source is used.
The figure below shows an example of connecting I/O power connectors when the
internal power source is used, and the figure on the next page shows an example of
connecting I/O power connectors when an external power source is used.

I/O Power Connection Sample (When the internal power source is used) (NPN type)

Caution: To use the internal power source of the robot controller,

connect the wiring so that the internal power source will be
separate from the external power source. Improper wiring may
damage the internal circuit.

126
I/O Power Connection Sample (When an external power source is used) (NPN type)

Caution: Use a cable of 0.5 mm2 or more in size for the wiring between
the external power source and the I/O power input connectors
of the robot controller.

127
5.3 Wiring Notes for Robot Controller I/O Connectors (NPN
type)
After the wiring of the controller's I/O connectors is completed, check the following
before turning ON the power:
Check point (1)
Using a circuit tester, check across the "+24V terminal" and "0V terminal" of each
connector and across the "E24V terminal" and the "E0V terminal" to see that there is
no continuity. See the figure below and the table given on the next page.

Caution: If the connector wiring between the Robot Controller's "+24V

terminal" and "0V terminal" and between the "E24V terminal"
and the "E0V terminal" is shorted, damage to the power circuit
of the Robot Controller will result.

Check point (2)

Using a tester, check across "each signal Output terminal" and "+24V terminal" or
"E24V terminal" of each connector to see that there is no continuity. See the figure
below and the table given on the next page.

Caution: If the wiring between "each signal Output terminal" and "+24V
terminal" or "E24V terminal" of each connector is shorted,
damage to the Output circuit and power circuit of the Robot
Controller will result.

Caution: Wind adhesive vinyl tape around all ends of the unconnected
wiring of each connector to prevent them from contacting other
wiring and parts, which results in shorting.

Circuit tester

Robot
controller External
“+24V terminal” and
“E24V terminal” of the device
controller

“0V terminal” and

“E0V terminal” of
the controller

Checking Example

128
 Connector Terminals and Check Points (NPN type)
Connector for hand I/O Connector for user/system input

View from cable side engaging face View from cable side engaging face
Terminal Check Terminal Check
Name Meaning Name Meaning
Number point Number point
+24V internal
+24V internal
Hand output 0V (GND) at power
1 to 8 (2) 1, 3 power source (1)
terminal output source
output
terminal

Power
24V power
17 terminal for (1)
output
hand (E24V)

Power
Power (GND)
18 terminal for (1)
output
hand (E0V)

Connector for user/system output Connector for I/O power source

View from cable side engaging face

View from cable side engaging face

Terminal Check Terminal Check

Name Meaning Name Meaning
number point number point
+24V internal +24V internal
Signal output 0V (GND)
1 to 56 (2) 1, 2 power source power source (1)
terminal at output
terminal output

0V internal 0V internal
3, 4 power source power source (1)
terminal output

E24V input 24V power

6, 7 (1)
terminal input

E0V (GND) Power (GND)

8, 9 (1)
input terminal input

129
 Chapter 6
Connector Pin Assignment and I/O Circuits
(PNP type)
This chapter explains the connector pin assignment and circuits of PNP type (sink
input and source output) on an I/O board.
For an NPN type (source input and sink output), refer to Chapter 5, "Connector Pin
Assignment and I/O Circuits (NPN type)."

6.1 Connector Pin Assignment (PNP type)

This section describes the pin assignment of connectors on the robot controller. The
signals and pin assignments of output connector CN10 and input connector CN8 are
differently defined in standard mode and compatible mode. As for other connectors,
the definitions of pins are common to standard mode and compatible mode.

6.1.1 Connector Pin Assignment Common to Both Modes (PNP type)

(1) HAND I/O CN9: Connector for end-effector I/O (common to both
modes)
CN9 Pin Assignment, common to both modes (PNP type)

View from the cable side

Wire color Wire color

Terminal Port Terminal Port
Name Name
No. number High No. number High
Standard Standard
strength strength

1 Hand output 64 Black Blue 11 Hand Input 50 Pink White

2 Hand output 65 Brown Yellow 12 Hand Input 51 Pink White

3 Hand output 66 Black Green 13 Hand Input 52 White White

4 Hand output 67 Brown Red 14 Hand Input 53 White White

5 Hand output 68 Red Violet 15 Hand Input 54 White White

6 Hand output 69 Orange Blue 16 Hand Input 55 White Brown

7 Hand output 70 Yellow Yellow 17 Power E0V for Hand  White Brown

8 Hand output 71 Green Green 18 Power E24V for Hand  White Brown

9 Hand input 48 Blue Red 19 Not connected  White Brown

10 Hand input 49 Violet Violet 20 Not connected  White Brown

NOTE: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #11, #2
and #12,…#10 and #20.

130
(2) I/O POWER CN7: Power connector for I/O (common to both modes)
CN7 Pin Assignment, common to both modes (PNP type)

View from the cable side

Terminal No. Name

1 Internal power source output +24V
2 Internal power source output +24V
3 Internal power source output 0V
4 Internal power source output 0V
5 FG
6 Power input E0V
7 Power input E0V
8 Power input E24V
9 Power input E24V

Caution: When using the internal power source, keep the total
current capacity below 1.3 A. To use the internal power source of the
robot controller, connect the wiring so that the internal power source
will be separated from the external power source. Improper wiring may
damage the internal circuit.

(3) RS232C CN1: RS232C connector

CN1 Pin Assignment

Terminal No. Name Terminal No. Name

1  6 DSR
2 RXD 7 RTS
3 TXD 8 CTS
4 DTR 9 

5 SG

131
6.1.2 Connector Pin Assignment in Standard Mode
(1) OUTPUT CN10: User-/System-output connector (standard mode)

CN10 Pin Assignment, in standard mode (PNP type)

View from the cable side

Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color
1 Normal CPU 72 Black 35 User output 106 Pink
2 Robot in operation 73 Brown 36 User output 107 Pink
3 Robot failure 74 Red 37 User output 108 Pink
4 Servo ON 75 Orange 38 User output 109 Pink
5 Robot initialization complete 76 Yellow 39 User output 110 Pink
6 Automatic mode 77 Black 40 User output 111 White
7 External mode 78 Brown 41 User output 112 White
8 Dead battery warning 79 Red 42 User output 113 White
9 Robot warning 80 Orange 43 User output 114 White
10 Continue start permitted 81 Yellow 44 User output 115 White
11 SS mode 82 Green 45 User output 116 White
12 Reserved 83 Blue 46 User output 117 White
13 Reserved 84 Violet 47 User output 118 White
14 Reserved 85 Gray 48 User output 119 White
15 Command processing complete 86 Pink 49 User output 120 White
16 Status area odd parity 87 Black 50 User output 121 Gray
17 Status area bit 0 88 Black 51 User output 122 Violet
18 Status area bit 1 89 Brown 52 User output 123 Violet
19 Status area bit 2 90 Red 53 User output 124 Violet
20 Status area bit 3 91 Orange 54 User output 125 Violet
21 Status area bit 4 92 Yellow 55 User output 126 Violet
22 Status area bit 5 93 Green 56 User output 127 Violet
23 Status area bit 6 94 Blue 57 Not used.  Violet
24 Status area bit 7 95 Gray 58 Not used.  Violet
[ Power supply for Robot
25 Status area bit 8 96 Pink *59  Violet
stop 1 (Internal +24V) ]
26 Status area bit 9 97 Brown *60 [ Robot stop 1 ]  Gray
[ Power supply for Robot
27 Status area bit 10 98 Red *61  Gray
stop 2 (Internal +24V) ]
28 Status area bit 11 99 Orange *62 [ Robot stop 2 ]  Gray
29 Status area bit 12 100 Yellow *63 [ Emergency stop (+) ]  Gray
30 Status area bit 13 101 Green *64 [ Emergency stop (-) ]  Gray
31 Status area bit 14 102 Blue 65 Emergency stop 2 (+)  Gray
32 Status area bit 15 103 Pink 66 Emergency stop 2 (-)  Gray
33 User output 104 Black *67 [ Deadman switch (+) ]  Blue
34 User output 105 Brown *68 [ Deadman switch (-) ]  Blue

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35,
#2 and #36, #34 and #68.
NOTE 2: The terminal number marked with ( * ) is used only for “Dual emergency stop type”.

132
 (2) INPUT CN8: User-/System-input connector (standard mode)

CN8 Pin Assignment, in standard mode (PNP type)

View from the cable side

Terminal Port Wire Terminal Port Wire

number Name number color number
Name
number color

Power for robot stop

*1  Black 26 Data area 2 bit 7 21 Pink
(internal +24V)

*2 Robot stop  Brown 27 Data area 2 bit 8 22 Pink

Power for Enable Auto

3  Red 28 Data area 2 bit 9 23 Pink
(internal +24V)

4 Enable Auto  Black 29 Data area 2 bit 10 24 White

5 Step-stop (all tasks) 0 Brown 30 Data area 2 bit 11 25 White

6 Not used. 1 Red 31 Data area 2 bit 12 26 White

Instantaneous stop
7 2 Orange 32 Data area 2 bit 13 27 White
(all tasks)

8 Strobe signal 3 Yellow 33 Data area 2 bit 14 28 White

9 Interrupt skip 4 Green 34 Data area 2 bit 15 29 White

10 Command and data odd parity 5 Blue 35 Command area 0 bit 0 30 White

11 Data area 1 bit 0 6 Violet 36 Command area 0 bit 1 31 White

12 Data area 1 bit 1 7 Black 37 Command area 0 bit 2 32 Gray

13 Data area 1 bit 2 8 Brown 38 Command area 0 bit 3 33 Gray

14 Data area 1 bit 3 9 Red 39 User input 34 Gray

15 Data area 1 bit 4 10 Orange 40 User input 35 Gray

16 Data area 1 bit 5 11 Yellow 41 User input 36 Gray

17 Data area 1 bit 6 12 Green 42 User input 37 Gray

18 Data area 1 bit 7 13 Blue 43 User input 38 Gray

19 Data area 2 bit 0 14 Violet 44 User input 39 Gray

20 Data area 2 bit 1 15 White 45 User input 40 Gray

21 Data area 2 bit 2 16 Pink 46 User input 41 Gray

22 Data area 2 bit 3 17 Black 47 User input 42 Violet

23 Data area 2 bit 4 18 Brown 48 User input 43 Violet

24 Data area 2 bit 5 19 Red 49 User input 44 Violet

25 Data area 2 bit 6 20 Orange 50 User input 45 Violet

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #26,
#2 and #27,…#25 and #50.
NOTE 2: The terminal number marked with ( * ) is not used for “Dual emergency stop type”.

133
6.1.3 Connector Pin Assignment in Compatible Mode
(1) OUTPUT CN10: User-/System-output connector (compatible mode)
CN10 Pin Assignment, in compatible mode (PNP type)

View from the cable side

Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color
1 Normal CPU 72 Black 35 User output 106 Pink
2 Robot-in-operation 73 Brown 36 User output 107 Pink
3 Robot failure 74 Red 37 User output 108 Pink
4 Auto mode 75 Orange 38 User output 109 Pink
5 External mode 76 Yellow 39 User output 110 Pink
6 Program start reset 77 Black 40 User output 111 White
7 Not used. 78 Brown 41 User output 112 White
8 Not used. 79 Red 42 User output 113 White
9 Robot power ON complete 80 Orange 43 User output 114 White
10 Servo ON 81 Yellow 44 User output 115 White
11 CAL complete 82 Green 45 User output 116 White
12 Teaching 83 Blue 46 User output 117 White
13 Single-cycle complete 84 Violet 47 User output 118 White
14 Dead battery warning 85 Gray 48 User output 119 White
15 Robot warning 86 Pink 49 User output 120 White
16 Continue start permitted 87 Black 50 User output 121 Gray
17 Error units bit 0 88 Black 51 User output 122 Violet
18 Error units bit 1 89 Brown 52 User output 123 Violet
19 Error units bit 2 90 Red 53 User output 124 Violet
20 Error units bit 3 91 Orange 54 User output 125 Violet
21 Error tens bit 0 92 Yellow 55 User output 126 Violet
22 Error tens bit 1 93 Green 56 User output 127 Violet
23 Error tens bit 2 94 Blue 57 Not connected  Violet
24 Error tens bit 3 95 Gray 58 Not connected  Violet
[ Power supply for Robot
25 Error hundreds bit 0 96 Pink *59  Violet
stop 1 (Internal +24V) ]
26 Error hundreds bit 1 97 Brown *60 [ Robot stop 1 ]  Gray
[ Power supply for Robot
27 Error hundreds bit 2 98 Red *61  Gray
stop 2 (Internal +24V) ]
28 Error hundreds bit 3 99 Orange *62 [ Robot stop 2 ]  Gray
29 SS mode 100 Yellow *63 [ Emergency stop (+) ]  Gray
30 Not used. 101 Green *64 [ Emergency stop (-) ]  Gray
31 Not used. 102 Blue 65 Emergency stop 2 (+)  Gray
32 Not used. 103 Pink 66 Emergency stop 2 (-)  Gray
33 User output 104 Black *67 [ Deadman switch (+) ]  Blue
34 User output 105 Brown *68 [ Deadman switch (-) ]  Blue

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and #35,
#2 and #36, #34 and #68.
NOTE 2: The terminal number marked with ( * ) is used only for “Dual emergency stop type”.

134
 (2) INPUT CN8: User-/System-input connector (compatible mode)
CN8 Pin Assignment, in compatible mode (PNP type)

View from the cable side

Terminal Port Wire Terminal Port Wire

Name Name
number number color number number color

*1 Power for robot stop (internal +24V) - Black 26 User input 21 Pink

*2 Robot stop - Brown 27 User input 22 Pink

3 Power for Enable Auto (internal +24V) - Red 28 User input 23 Pink

4 Enable Auto - Black 29 User input 24 White

5 Step-stop (all tasks) 0 Brown 30 User input 25 White

6 Continue start 1 Red 31 User input 26 White

7 Instantaneous stop (all tasks) 2 Orange 32 User input 27 White

8 Operation preparation start 3 Yellow 33 User input 28 White

9 Interrupt skip 4 Green 34 User input 29 White

10 Program start 5 Blue 35 User input 30 White

11 Program No. select bit 0 6 Violet 36 User input 31 White

12 Program No. select bit 1 7 Black 37 User input 32 Gray

13 Program No. select bit 2 8 Brown 38 User input 33 Gray

14 Program No. select bit 3 9 Red 39 User input 34 Gray

15 Program No. select bit 4 10 Orange 40 User input 35 Gray

16 Program No. select bit 5 11 Yellow 41 User input 36 Gray

17 Program No. select bit 6 12 Green 42 User input 37 Gray

18 Program No. select odd parity bit 13 Blue 43 User input 38 Gray

19 Motor power ON 14 Violet 44 User input 39 Gray

20 CAL execution 15 White 45 User input 40 Gray

21 Reserved 16 Pink 46 User input 41 Gray

22 SP100 17 Black 47 User input 42 Violet

23 Switch Ext Mode 18 Brown 48 User input 43 Violet

24 Program reset 19 Red 49 User input 44 Violet

25 Clear robot failure 20 Orange 50 User input 45 Violet

NOTE 1: The optional I/O cable for the above connector consists of twisted pair wires--pairs of #1 and
#26, #2 and #27,…#25 and #50.
NOTE 2: The terminal number marked with ( * ) is not used for “Dual emergency stop type”.

135
6.2 Robot Controller I/O Circuits (PNP type)

6.2.1 User-Input, System-Input and Hand-Input Circuits (PNP type)

The following two pages show examples of the user-input, system-input and hand-
input circuit configurations and connections of the robot controller.
The maximum allowable capacity of the robot controller's internal power source is 1.3
A. Use the internal power source within this allowable range.

Caution Q Either an external power supply type or built-in power type

Output card is available for the PLC. However, an external power
supply type requires an additional power source (24V) to be
installed. The power capacity is 15W or more.
R When controlling two or more robots with a single PLC using the
internal power source of the robot controller, set a PLC Output
card for each robot.
S Other than a PLC, a proximity switch, or a relay contact may be
connected directly to the input terminal of the Robot Controller.
In such a case, use the power input to pins 6 to 9 of the I/O power
connector. A two-wire photoelectric switch or proximity switch
can be connected if its leakage current is 1 mA or less.
T Use a multi-core shielding cable for the purpose of protecting the
robot controller from noise. Ground it to the robot controller.

136
 (When the internal power source is used)

(When an external power source is used)

User-Input and System-Input Circuits (PNP type)

137
(When the internal power source is used)

(When an external power source is used)

Hand-Input Circuits (PNP type)

138
6.2.2 Robot Stop and Enable Auto Input Circuits
The Robot Stop and Enable Auto signals are important for safety. The input circuit for
these signals must have contacts as shown below.
Use the INPUT CN8 (pins 1 and 3) of the robot controller for the power source,
irrespective of whether the power source to be used for other I/O signals is the
internal power source or an external power source.
(Note: For the “Dual emergency stop type”, refer to Subsection 6.2.4.2.)

Robot Stop and Enable Auto Input Circuits

TIP: The configuration sample of an emergency stop output circuitry is shown

in Subsection 6.2.4 "Emergency Stop Circuit."

139
6.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP type)
The following two pages show an example of the configuration and connection of the
Robot Controller's user-input output, system-output and hand-output circuit.
Since the initial resistance of a lamp is small, the output circuit may be damaged by
rush current that flows when the lamp lights.
When directly turning a lamp ON or OFF, use a lamp whose rating is 0.5W or less.
To reduce rush current, connect a resistor R that allows dark current 1/3 or less of the
rated current to flow when the lamp goes OFF.
An example of connecting a lamp is shown on page 140.
(1) The User-Output, System-Output and Hand-Output Circuit are open
collector output circuits.
(2) The maximum allowable sink current is 70 mA.
Keep the current consumption of a device to be connected to the Robot
Controller, such as a PLC and a relay coil, below the allowable current.
(3) Select an induction load, such as a relay coil, which has a built-in diode
(for absorbing inverse electromotive force).
To use an induction load without a built-in diode, add a diode equivalent to
the 1S1888 (Toshiba) in close vicinity to the coil.

Caution: When externally attaching a diode, connect it with correct

polarity. Incorrect polarity may damage the Output circuit.

(4) Connecting a lamp requires a circuit through which dark current flows.

Caution: Since the initial resistance of a lamp is small, the output

circuit may be damaged by rush current that flows when the
lamp lights.
Refer to page 140.

(5) When using the internal power source, prepare a PLC input circuit unit
that does not contain a power source.

Caution: Keep the total current capacity of the internal power source
below 1.3A.

(6) Use a multi-core shielding cable for the purpose of protecting the devices
from external noise. Ground it to the robot controller.
(7) 24V internal power source of the robot controller must not be grounded.

Caution: If the output terminal +24V of internal power source is

grounded, there may be a case where the controller is
damaged.

140
 (When the internal power source is used)

(When an external power source is used)

User-Output and System-Output Circuits (PNP type)

141
(When the internal power source is used)

(When an external power source is used)

Hand-Output Circuits (PNP type)

142
 Supplied from the II/O power connector
when the internal power source is used

Lamp

Transistor array

Controller

Example of Circuit with Lamp (PNP type)

143
6.2.4 Emergency Stop Circuit
The following figures show the examples of configuration and connection of
emergency stop circuit for the robot controller.
The red mushroom-shaped switch provided on the robot controller front panel, on the
teach pendant, or on the operating panel can be used as a switch for stopping the
equipment in case of emergency.

6.2.4.1 Standard type

Robot controller
F1 CN7
Internal 24V Fuse (1.3A)

Fuse (1.3A) Emergency stop circuit

Internal 0V F2 (prepared by customers)
F9 Emergency CN10
Fuse (0.3A) Stop +

Emergency
Stop + Output

Internal
24V F8 CN8
Fuse (1.3A) Robot stop switch circuit
(prepared by customers)
Emergency stop switch
on the front panel of the Input
controller

CN5 Teach pendant

Emergency stop switch
on teach pendant

Internal 0V

(When the internal power source is used)

Robot controller
Emergency stop circuit
(prepared by customers)
F9 Emergency CN10
Stop + External 24V
Fuse (0.3A)

Emergency
Stop - Output

External 0V
Internal
24V F8 CN8
Fuse (1.3A)
Robot stop switch circuit
(prepared by customers)
Emergency stop switch
on the front panel of the Input
controller

Teach pendant
CN5
Emergency stop switch
on teach pendant

Internal 0V

(When an external power source is used)

Emergency Stop Circuit (Standard type)

144
6.2.4.2 Dual emergency stop type

Emergency Stop Circuit (Dual emergency stop type)

145
6.2.5 I/O Power Connector (PNP type)
For the power source to communicate signals between the robot controller and the
external device, the internal power source of the robot controller or an external power
source is used.
The figure below shows an example of connecting I/O power connectors when the
internal power source is used, and the figure on the next page shows an example of
connecting I/O power connectors when an external power source is used.

I/O Power Connection Sample (When the internal power source is used) (PNP type)

Caution: To use the internal power source of the robot controller, connect
the wiring so that the internal power source will be separate from
the external power source. Improper wiring may damage the
internal circuit.
The +24V
+ internal power source of the robot controller must not
be grounded.

146
I/O Power Connection Sample (When an external power source is used) (PNP type)

Caution: Use a cable of 0.5 mm2 or more in size for the wiring between the
external power source and the I/O power input connectors of the
robot controller.

147
6.3 Wiring Notes for Robot Controller I/O Connectors (PNP
type)
After the wiring of the controller's I/O connectors is completed, check the following
before turning ON the power:
Check point (1)
Using a circuit tester, check across the "+24V terminal" and "0V terminal" of each
connector and across the "E24V terminal" and the "E0V terminal" to see that there
is no continuity. See the figure below and the table given on the next page.

Caution: If the connector wiring between the robot controller's "+24V

terminal" and "0V terminal" and between the "E24V terminal" and
the "E0V terminal" is shorted, damage to the power circuit of the
Robot Controller will result.

Check point (2)

Using a circuit tester, check across "each signal Output terminal" and "+24V terminal"
or "E24V terminal" of each connector to see that there is no continuity. See the figure
below and the table given on the next page.

Caution: If the wiring between "each signal Output terminal" and "+24V
terminal" or "E24V terminal" of each connector is shorted,
damage to the Output circuit and power circuit of the robot
controller will result.

Caution: Wind adhesive vinyl tape around all ends of the unconnected
wiring of each connector to prevent them from contacting other
wiring and parts, which results in shorting.

Circuit tester

Robot
controller External
“+24V terminal” and
“E24V terminal” of the device
controller

“0V terminal” and

“E0V terminal” of the
controller

Checking Example

148
 Connector Terminals and Check Points (PNP type)
Connector for hand I/O Connector for user/system input

View from cable side engaging face

View from cable side engaging face
Terminal Check Terminal Check
Name Meaning Name Meaning
Number point Number point
+24V internal
+24V internal
Hand output power
1 to 8 24V at output (2) 1, 3 power source (1)
terminal source
output
terminal

Power
Power (GND)
17 terminal for (1)
output
hand (E0V)

Power
24V power
18 terminal for (1)
output
hand (E24V)

Connector for user/system output Connector for I/O power source

View from cable side engaging face

View from cable side engaging face

Terminal Check Terminal Check

Name Meaning Name Meaning
number point number point
+24V internal +24V internal
Signal output 24V at
1 to 56 (2) 1, 2 power source power source (1)
terminal output
terminal output

0V internal 0V internal
3, 4 power source power source (1)
terminal output

E0V (GND) Power (GND)

6, 7 (1)
input terminal input

E24V input 24V power

8, 9 (1)
terminal input

149
 Chapter 7 I/O Wiring
7.1 Multi-core Cables with Connectors
Multi-core cables with connectors to be used for the I/O wiring of the Robot Controller
are options. Select an appropriate cable from the table given below if necessary.

I/O Cables (Optional items)

Classification No. Name Remarks Part Number

1 I/O Cable Set (8m) (3-cable set of Nos. 1-1 to 1-3) 410149-0330

1-1 Input Cable (8m) 410141-1630

1-2 Output Cable (8m) 410141-1650

1-3 Hand I/O Cable (8m) 410141-1740

I/O Cable I/O Cable Set
2 (8m) (3-cable set of Nos. 2-1 to 2-3) 410149-0350
(hand I/O cable: high strength type)

2-1 Input Cable (8m) 410141-1630

2-2 Output Cable (8m) 410141-1650

2-3 Hand I/O Cable (high strength type) (8m) 410141-1670

3 I/O Cable Set (15m) (3-cable set of Nos. 3-1 to 3-3) 410149-0340

3-1 Input Cable (15m) 410141-1640

3-2 Output Cable (15m) 410141-1660

3-3 Hand I/O Cable (15m) 410141-1750

I/O Cable I/O Cable Set
4 (15m) (3-cable set of Nos. 4-1 to 4-3) 410149-0360
(hand I/O cable: high strength type)

4-1 Input Cable (15m) 410141-1640

4-2 Output Cable (15m) 410141-1660

4-3 Hand I/O Cable (high strength type) (15m) 410141-1680

150
 If you do not use optional cables listed on the previous page, use the recommended
connectors and cables listed below.

Recommended Connectors for I/O Cables and Cable Standards

Connector Connector
Cable Standards Remarks
name model/manufacturer
PCR-E68FS connector UL2789 - With shield Caution: Be sure to modify the
PCS-E68LA cover Equivalent to AWG28-68P shielding wire at the end of the
OUTPUT cable to be used, as shown
Honda Communications below. Without this modification,
Industry Co., Ltd. the robot may malfunction due to
PCR-E20FS connector UL2789 - With shield noise.
PCS-E20LA cover Equivalent to AWG28-20P
HAND I/O
Honda Communications
Industry Co., Ltd.
PCR-E50FS connector UL2789 - With shield
PCS-E50LA cover Equivalent to AWG28-50P
INPUT
Honda Communications
Industry Co., Ltd.
DE-9P connector UL2405 - With shield
I/O DE-C4-J6 cover Equivalent to AWG20-2P
POWER Japan Aviation
Electronics Industry, Ltd.

Crimp terminal

Vinyl tube
The connector shell
Braided should be made of
shielding wire Shielding wire conductive metal.
I/O cable

Fasten to the connector

I/O power
connector Vinyl tube

Modifying the Shielding Wire (Example)

151
7.2 Wiring of Primary Power Source
Observe the following precautions when wiring the primary power source of the robot
controller:
(1) Connect the robot power cable to a power source separate from the welder
power source.
(2) Ground the grounding wire (green) of the robot power cable.
(3) Ground the grounding terminal of the robot controller using a wire of 1.25 mm2 or
more in size.
(4) For the robot power supply, use a grounding wire with grounding resistance of
100 Ω or less.
(5) If the supply power source for the robot controller requires a leakage breaker, use
a high frequency-proof leakage breaker for inverters.
(6) Prepare wires of an appropriate capacity for the 200 VAC main line and other
cables according to the tables given below.

Robot Controller Power Supply Specifications

Pin assignment on power connector (CN11)
Item Specifications (View from the pin face of cable)

A: 200 VAC, phase R

3-phase power supply 3-phase, 200 VAC -15% to B: 200 VAC, phase S
230 VAC + 10%, 50/60 Hz C: 200 VAC, phase T
(RC5 all models) D: Ground

Single-phase power supply

Singe-phase, 230 VAC -10%
(RC5 for VS-D/-E, H∗-D, to 230 VAC + 10%, 50/60 Hz A: 230 VAC, phase R
HS-E, XYC-D) B: 230 VAC, phase S
C: Not used.
Single-phase power supply D: Ground
Singe-phase, 200 VAC -10%
(RC5 for VC-E) to 230 VAC + 10%, 50/60 Hz

Max. rush current when

the power is turned ON 50 A (for 1/50 or 1/60 second)

3.3 kVA (VM-D/HM-E)

2.0 kVA (H∗-D)
Power consumption of 1.9 kVA (VS-E)
robot 1.8 kVA (HS-E)
1.5 kVA (VS-D, XYC-D)
0.6 kVA (VC-E)

Caution: If ERROR6102 (power voltage drop) occurs when the robot is in

operation, then it may be due to an insufficient capacity of the primary
power source.

(7) Do not bundle the teach pendant cables, I/O cables or motor cables together with
high power lines such as 200 VAC lines and peripheral device cables, or route
the motor cables near high power devices (motor, welder, parts feeder, etc.).
(8) Do not route any additional cables or air tubes of end-effectors through the robot
unit. Doing so will result in broken cables or tubes.

152
 Index

Auto Mode (Output) ............................................ 28, 71 I/O Write .................................................................... 63

INPUT CN8: User-/System-input connector
(compatible mode) ........................................... 115, 135
INPUT CN8: User-/System-input connector
CAL Complete (Output) ............................................ 73
(standard mode) .............................................. 113, 133
Clear Robot Failure (Input) ..................................... 103
Instantaneous Stop (All Tasks) (Input) .............. 42, 102
Command and Data Areas ......................................... 48
Interface ..................................................................... 14
Command Execution I/O Signals Dedicated to Standard
Mode.......................................................................... 45 Interrupt Skip (Input) ......................................... 43, 104
Command Processing Complete (Output) ................. 50
Compatible Mode .......................................... 14, 23, 69
Connector Pin Assignment and I/O Circuits (PNP type) Mode Switching......................................................... 60
................................................................................. 130
Connector Pin Assignment I/O Circuits (NPN type) .....
................................................................................. 110 Normal CPU (Output).......................................... 32, 79
Continue Start (Input) .............................................. 105
NPN type ................................................................. 110
Continue Start Permitted (Output)....................... 36, 84
Control System Configuration ................................... 12
Controller I/O Circuits..................................... 116, 136
Operation Preparation Start (Input)............................ 88
Controller I/O Connectors ............................... 128, 148
OUTPUT CN10: User-/System-output connector
Controller Specifications ............................................. 7 (compatible mode) ........................................... 114, 134
OUTPUT CN10: User-/System-output connector
(standard mode) ............................................... 112, 132
Dead Battery Warning (Output)........................... 35, 82

PNP type .................................................................. 130

Emergency Stop (Output from a contact) ............ 37, 85 Processing I/O Commands......................................... 46
Emergency Stop Output Circuit....................... 124, 144 Program No. Select (Input) ........................................ 90
Enable Auto (Input) ............................................. 39, 87 Program Operation Command ................................... 53
Error No. (Output) ..................................................... 83 Program Reset (Input)................................................ 98
Error Read ................................................................. 57 Program Start (Input) ................................................. 92
External Mode (Output)....................................... 29, 74 Program Start Reset (Output)..................................... 76
External Speed and Acceleration Setting................... 56

Robot Controller Components ..................................... 4

HAND I/O CN9: Connector for end-effector I/O Robot Controller I/O Connectors............................. 148
(common to both modes) ................................. 110, 130 Robot Failure (Output)......................................... 33, 80
Hand-Input Circuits ......................................... 118, 138 Robot Initialization Complete (Output) ..................... 27
Hand-Output Circuits....................................... 122, 142 Robot Power ON Complete ....................................... 70
Robot Stop (Input) ..................................................... 40
Robot Stop and Enable Auto Input Circuits..... 119, 139
I/O Commands........................................................... 52 Robot Warning (Output) ...................................... 34, 81
I/O POWER CN7: Power connector for I/O Robot-in-operation (Output) ................................ 31, 77
(common to both modes) .................................111, 131 RS232C.................................................................... 111
I/O Power Connector ....................................... 126, 146 RS232C CN1: RS232C connector ........................... 131
I/O Read..................................................................... 64
I/O Signals ................................................................. 22
I/O Type Variable....................................................... 24
I/O Wiring................................................................ 150
Servo ON (Output) .............................................. 30, 72
Single-Cycle End (Output) ........................................ 78
SS mode (Output) ................................................ 36, 84
Standard Mode............................................... 14, 22, 26
Status Area................................................................. 51
Step Stop (All Tasks) (Input) ............................. 41, 101
Strobe Signal (Input).................................................. 49
System I/O Signals Compatible Mode....................... 69
System I/O Signals Standard Mode ........................... 26
System Input Signals (Compatible Mode)................. 86
System Input Signals (Standard Mode) ..................... 38

Teaching (Output)...................................................... 75
Type I Variable Read ................................................. 59
Type I Variable Write................................................. 58

User I/O Signals......................................................... 24

User Input Commands ............................................... 24
User Output Commands ............................................ 25
User-Input and System-Input Circuits ............. 117, 137
User-Output and System-Output Circuits........ 121, 141

Wiring ...................................................................... 152

Wiring Notes for Robot Controller I/O Connectors.......
......................................................................... 128, 148
 RC5 CONTROLLER

INTERFACE MANUAL
First Edition February 2002
Second Edition June 2002
DENSO WAVE INCORPORATED 6D20C
Factory Automation Division

The purpose of this manual is to provide accurate information in the handling and operating
of the robot. Please feel free to send your comments regarding any errors or omissions you
may have found, or any suggestions you may have for generally improving the manual.
In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages
resulting from the application of the information in this manual.