1112, EFDEN-001-002, 001

FD CONTROLLER
INSTRUCTION MANUAL
CONTROLLER MAINTENANCE

2nd edition

・Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text.
・The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course.
・When using this robot, observe the low related with industrial robot and with
safety issues in each country.
・This operating manual must be given without fail to the individual who will be actually
operating the robot.
・Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to any
of the service centers listed on the back cover.
 Table of Contents

Table of Contents

Chapter 1 Point on Safety

1.1 For safe use of the robot system......................................................................................... 1-1
1.1.1 Symbols used in all the instruction manuals .................................................................. 1-1
1.1.2 General precautions for safe use of the robot system.................................................... 1-2

Chapter 2 Configuration
2.1 Function of each part and unit............................................................................................. 2-1
2.1.1 Multi power supply unit ................................................................................................... 2-3
2.1.2 Raiser board ................................................................................................................... 2-4
2.1.3 CPU board ...................................................................................................................... 2-5
2.1.4 System CF ...................................................................................................................... 2-7
2.1.5 Sequence board ............................................................................................................. 2-8
2.1.6 Power unit ..................................................................................................................... 2-13
2.1.7 IPM drive unit ................................................................................................................ 2-14
2.1.8 Teach pendant .............................................................................................................. 2-16
2.2 Optional parts .................................................................................................................... 2-17
2.2.1 USB memory (option) ................................................................................................... 2-17
2.2.2 I/O board (option).......................................................................................................... 2-18
2.2.3 Relay unit / Extended relay unit .................................................................................... 2-19
2.2.4 Brake release switch (option) ....................................................................................... 2-20

Chapter 3 Parts replacement procedures

3.1 Parts replacement procedure .................................................................................................... 3-1
3.1.1 Replacement of board ....................................................................................................... 3-2
3.1.2 Replacement of IPM drive unit .......................................................................................... 3-3
3.1.3 Replacement of power unit................................................................................................ 3-6
3.1.4 Replacement of battery for CPU board ............................................................................. 3-7
3.1.5 Replacement of cooling fan (for heat sink and regenerative resistance).......................... 3-8
3.1.6 Replacement of cooling fan (for rack unit) ........................................................................ 3-9

Chapter 4 Periodic inspection / Parts list

4.1 Regular inspection schedule ..................................................................................................... 4-1
4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair............................. 4-1
4.1.2 Inspection items ............................................................................................................... 4-3
4.1.3 Inspection before the long vacation................................................................................... 4-5
4.1.4 Cleaning the heat sink ....................................................................................................... 4-5
4.1.5 Inspection of enable switch ............................................................................................... 4-6
4.1.6 Inspection of Emergency stop button ................................................................................ 4-6
4.2 Maintenance parts ..................................................................................................................... 4-7
4.2.1 List of maintenance parts .................................................................................................. 4-7

Chapter 5 Parts layouts and electric circuit diagram

5.1 External view ....................................................................................................................... 5-1

1
Table of Contents

5.2 Parts layout ......................................................................................................................... 5-2

5.3 Electrical connection diagram (overview) ........................................................................... 5-3

5.4 Electrical connection diagram (Teach pendant).................................................................. 5-4

5.5 Electrical connection diagram (Operation panel) ................................................................ 5-5

2
Chapter 1 Point on Safety

This chapter explains the safety precautions to be observed when handling the robot
system. This section describes general precautions and procedures on safety but
does not show all of the safety measures. Therefore, it is necessary for customers to
prepare yourself a safety control standard including your own operational regulations
in accordance with the actual working environment and to conduct safety control in
order to secure the operators' safety.

1.1 For safe use of the robot system ................................................................... 1-1

1.1.1 Symbols used in all the instruction manuals ......................................... 1-1
1.1.2 General precautions for safe use of the robot system........................... 1-2
ぺージあわせのため白文字（白文字のため印刷されないなので気にしないでください。削除しないでください。）
 1.1 For safe use of the robot system

1.1 For safe use of the robot system

Before using a robot system, read this manual and all other attached documents carefully, and make sure you
understand the correct information on the equipment and safety precautions.

1.1.1 Symbols used in all the instruction manuals

Safety information to prevent the injury to personnel and/or damage to equipment is classified
by the following symbols.

Cases where a mistake made in handling is likely to cause the user to be exposed
to the danger of death or serious injury and where the degree of the urgency
(imminence) of the warning given for the danger to occur is at the high end of the scale
DANGER (including high-level danger).

Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury.
WARNING

Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of minor injuries or of property damage only.
CAUTION

The following symbol is also used for important checkpoints:。

A particularly important checkpoint is shown.

IMPORTANT

INFO.
Useful information is shown.

POINT Info for deeper understanding for the main text is shown.

1-1
1.1 For safe use of the robot system

1.1.2 General precautions for safe use of the robot system

This section describes general precautions to prevent the injury to personnel and/or damage to
equipment.

Conditions when a disaster struck while a robot system was used are shown in Table 1.1.1.

Table 1.1.1 Conditions when a disaster struck

Auto operation started without confirming there were no people inside the
Example 1
manipulator’s work area.
A person entered the manipulator’s work area which was in auto operation
Example 2
mode and the manipulator started unexpectedly.
A person paid attention to one manipulator forgetting another one was
Example 3
operating within reach of them.

Example 4 Sudden change of movement from low speed to high speed

Example 5 Manipulation by another operator without permission

The manipulator is operated by different program because of program

Example 6
mistakes or faulty peripheral equipment.
Work at a stop of a manipulator waiting for interlocking is released
Example 7
suddenly, and then the manipulator started to move unexpectedly.

Thus, a disaster by the robot system is caused by unsafe acts and unsafe conditions of an
operator. Therefore, it is important to remove unsafe acts and unsafe conditions by an operator
in order to prevent a disaster.

The followings are general precautions to prevent a disaster.

Be sure to obey the following precautions when you use a robot system,

Do not get near the manipulator.

Fatal or serious injury may result if a person is hit or caught by a manipulator due to
unexpected motion.
DANGER

Only perform work within the manipulator‘s work area after turning off the primary power
supply and circuit breaker on the robot controller.
DANGER

Make sure no one exists in the manipulator’s work area when the power is turned on.
DANGER

Operators must wear helmet, safety shoes and overalls.

DANGER

In case that inspection or maintenance work has to be done with a robot controller’s
power on, a watcher (third person) must be present outside the guarding fence and
watch the work at any time while being ready to press an emergency stop button
DANGER immediately.

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 1.1 For safe use of the robot system

In case that inspection or maintenance work has to be done with a robot controller’s
power on, allocate, confirm and know an escape route prior to beginning work.
DANGER

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.

While robot controller is power ON, do not touch any parts in the robot controller.
Because protection against electric shock due to live part, wait 5 minutes after turning
off the mains power before working inside the controller.
DANGER

Precautions to follow above terms are described in the section 1.1.3 or later in the instruction
manual “SETUP MANUAL”. Understand and observe them precisely.

If the operators are pinched in the manipulator, a brake can be released to move the arm
manually. For details, refer to the section 2.2.4 "Brake release switch" in the chapter 2.
IMPORTANT

1-3
1.1 For safe use of the robot system

NOTE

1-4
Chapter 2 Configuration

2.1 Function of each part and unit .............................................................. 2-1

2.1.1 Multi power supply unit .................................................................... 2-3
2.1.2 Raiser board .................................................................................... 2-4
2.1.3 CPU board ....................................................................................... 2-5
2.1.4 System CF ....................................................................................... 2-7
2.1.5 Sequence board .............................................................................. 2-8
2.1.6 Power unit...................................................................................... 2-13
2.1.7 IPM drive unit................................................................................. 2-14
2.1.8 Teach pendant............................................................................... 2-16
2.2 Optional parts ..................................................................................... 2-17
2.2.1 USB memory (option) .................................................................... 2-17
2.2.2 I/O board (option)........................................................................... 2-18
2.2.3 Relay unit / Extended relay unit ..................................................... 2-19
2.2.4 Brake release switch (option)......................................................... 2-20
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2.1 Function of each part and unit

Here explains the function of each unit and part.
The person in charge of maintenance should understand the each unit in the robot controller, allocation of
parts and its function before implementing the operation.

INFO. To confirm the model numbers of the boards, parts and units described in this chapter, refer
to “4.2 Parts List”.

Parts layout of robot controller

The layout of parts of robot controller is shown in Fig. 2.1.1.

Fig. 2.1.1 Layout of parts of robot controller

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Outline of each part

The outline of each part is shown in Table 2.1.1.

Table 2.1.1 Outline of each part

No. Name of part and unit Function
- DC+5V power supply
- DC+12V power supply
1 Multi power supply unit
- DC+24V power supply
- Primary power supply monitoring circuit
2 Raiser board - Bus connection between each board, electric supply
- Microprocessor and its peripheral circuit
- LCD I/F
- RS232C
- Ethernet
3 CPU board
(For servo, teach pendant and user)
- PCI bus I/F
- Compact flash card I/F (for system)
- USB memory I/F (for backing up the user data)
- I/O circuit for inside of robot controller
- Sequence circuit for inside of robot controller
4 Sequence board
- Emergency stop safety circuit
- Arc I/F extend function
- Motor power supply electromagnetic contactor control
5 Power unit
- Primary side power supply branch
- Servo control CPU
- Encoder I/F
- Power supply for driving motor
6 IPM drive unit
- Motor power control circuit
- Power supply for brake control
- Brake control circuit
- Operation switch circuit
(emergency stop, enable switch and TP selector switch)
7 Teach pendant - Keyboard, jog dial, liquid-crystal display and touch panel circuit for
teaching, various settings
- USB memory connector

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire, failure or malfunction
caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.

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2.1.1 Multi power supply unit

The Multi power supply unit supplies the DC+5V, DC+12V and DC+24V power used in the
robot controller. And it is equipped with primary power supply monitoring circuit to notice the
power failure to the CPU board.

CNPW

CNPW
CNPW

CNFAN

CNFAN
CNFAN
CNSWO

CNSWO
CNRC
CNSWO

CNP24V
CNRC

CNU24V
CNP24V

CNU24V
F21(2A)
F21
F21(2A) 250V 2A
CNP5V
CNP5V

LED 4 LED 4 +3.3V

LED 3 LED 3 +5V

LED 2 LED 2 +12V

LED 1 LED 1 +24V

Fig. 2.1.2 External view of Multi power supply unit

Table 2.1.2 Connectors of Multi power supply unit

Connector Functions Connected to

CNPW AC200V power input Power unit
CNFAN AC200V power output Rack fan
CNSWO AC200V power output Optional equipment and additional axes kit
CNP5V DC+5V power output Disconnected
CNP24V DC+24V power output IPM drive unit
CNU24V DC+24V power output Disconnected (For external connection)
CNRC Power ON/OFF control Disconnected (Optional)
CNPS Power supply to the raiser board Raiser board

Table 2.1.3 Status indication LED of Multi power supply unit

LED Functions
LED1 Lit while DC 24 V of Multi power supply unit works properly.
LED2 Lit while DC 12 V of Multi power supply unit works properly.
LED3 Lit while DC 5 V of Multi power supply unit works properly.
LED4 Lit while DC 3.3 V (optional) of Multi power supply unit works properly.

Table 2.1.4 Fuses of Multi power supply unit

Fuse Specifications Installed positions
F21 250V T2.0AH Front panel

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2.1.2 Raiser board

The Raiser board is a backplane board to mount CPU board, the Sequence board, the Multi
power supply unit, PCI card and other components so that bus communication among the boards
and power to each board are realized.

CPU board

Multi power board

Sequence board

LED4 [+24V]
LED3 [+12V]
LED2 [+5V]
LED1 [+3.3V]

PCI slot (I/O board,etc)

Fig. 2.1.3 External view of Raiser board

Table 2.1.5 Status indication LED of Raiser board

LED Function
LED1 Lit while DC 3.3 V (optional) of Multi power supply unit works properly.
LED2 Lit while DC 5 V of Multi power supply unit works properly.
LED3 Lit while DC 12 V of Multi power supply unit works properly.
LED4 Lit while DC 24 V of Multi power supply unit works properly.

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2.1.3 CPU board

CPU board has following functions; control robots, communicates with the user I/F and
peripheral equipment, and controls them.

Function
- Microprocessor and its peripheral circuit
- RS232C
- Ethernet
(For servo, teach pendant and user)
- PCI bus I/F
- Compact flash card I/F (for system)
- USB memory I/F (for backing up the user data)

CN19.LiBAT HX
CN.LiBAT
CN7(CRT)
CN2(COMA)
CNCF
LiBAT (System CF)
CNLAN3(SERVO)
CN9(FAN) CNLAN2(TP)

CNSATA
CN12(LAN)

CNUSB3
CNUSB2
CNEXTBUS
CN6,11(KBM)

CN4(USB)

CNSODIMM1

CNSODIMM2

Fig. 2.1.4 External view of CPU board

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Block diagram
The standard cable connection is shown in Fig. 2.1.5.

Fig. 2.1.5 CPU board peripheral connection

Connectors
Connectors on CPU board are shown in Table 2.1.6.

Table 2.1.6 Connectors on CPU board

Connectors Functions Connected to
CNNLX Card-edge Raiser board
CN6,CN11 Keyboard and mouse Not used
CN2 RS232C Not used
CN7 CRT Not used
CN12LAN LAN For Ethernet connection (FTP etc.)
CNLAN2 LAN Teach pendant
CNLAN3 LAN IPM drive unit
CNUSB2 USB
Mount USB memory (backup data)
CNUSB3 USB
CNCF(CFIDE) System CF Mount System CF (system data)
CN19LiBAT Internal battery Lithium battery
CN9 CPU fan Not used

Jumper settings
Standard jumper setting is shown in Table 2.1.7.
(The factory default setting should not be changed.)
Table 2.1.7 Jumper settings of CPU board
Connectors Settings
CN22 (RESET) Open (no socket)
CN20 (FTMODE) Open (no socket)
CN21 (RTC RESET) Short 1 – 2

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2.1.4 System CF
Windows OS and system software are stored in this CF.
The system software is displayed as "Internal memory" for this CF.

The task programs made by a user and various condition files are also stored.

SystemCF
(CNCF)

CPU Board

Fig. 2.1.6 System CF card connector

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2.1.5 Sequence board

The Sequence board controls the sequence in the control panel by the digital I/O signal of the
robot controller and peripheral equipments. The emergency stop circuit is the redundant circuit.

Function
- I/O circuit for inside of robot controller
- Sequence circuit for inside of robot controller
- Emergency stop safety circuit
- Arc I/F Extending function

Fig. 2.1.7 External view of Sequence board

Connectors on sequence board are shown in Table 2.1.8.

Table 2.1.8 Connectors on Sequence board

Connectors Signal names Connected to
CNTP Teach pendant switch signal Teach pendant
CNOP Operation box signal Operation panel (Operation box is optional)
CNOP2 Starting box signal (Optional)
CNSV I/O signals of IPM drive unit IPM drive unit
CNARC Arc I/F signals Arc I/F board (Optional)
TBEX1 User connection signals
TBEX2 User connection signals

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Terminal blocks TBEX1 and TBEX2 (User connections)

For details of each function of terminal and each connection procedure of the terminal blocks,
refer to “3.7 Safety-related signal connections” in the instruction manual “SETUP MANUAL”.
Setting of jumper pins on Sequence board
Jumper settings on sequence board are shown in the following table.
Table 2.1.9 Jumper pin settings of sequence board

Setting position Setting at the shipment Function

Connecting power supply setting
J1 Short 1-2 Short 1-2: internal
Short 2-3: external

List of fixed I/O

"Fixed I/O signals" are the signals that are used for controlling the inside of robot controller
such as servo ON/OFF etc.
When using the Software PLC, it is possible to access the fixed I/O signals using the Relay No.
shown in the following table. For the fixed I/O signal, the input and output can be just referenced
by the software PLC (in another words, it is "READ ONLY"). If you create the program to be
output to the fixed I/O signals, an error is generated at the compiling.

Table 2.1.10 List of fixed input relay numbers（1/2）

Relay Descriptions
Fixed input signal name
No. Light on : ON (Input ON) Light off : OFF(Input OFF)
IN 1 Motors-ON X0032 Lit with Motor ON of the operating box.
Lit off when G-STOP input is OFF.
IN 2 G-STOP X0033 For details of G-STOP signal, refer to the section 3.7 in “SETUP
MANUAL”.
IN 3 Start 1 X0034 Lit when the start 1 button of the operation box 1 is ON.
IN 4 Start 2 X0035 Lit when the start 2 button of the starting box 2 is ON.
IN 5 Start 3 X0036 Lit when the start 3 button of the starting box 3 is ON.
IN 6 Start 4 X0037 Lit when the start 4 button of the starting box 4 is ON.
Normally, this light is ON. It lights off when any stop buttons of
IN 7 Stop X0038 the teach pendant, the operation box or the start box are pressed
ON.
Lit when the selector switch of operation box is in Playback
IN 8 Playback mode X0039 mode with the external mode select input OFF. It lights off when
the selector switch of operation box is in Teach mode.
Lit when the enable switch and MAT switches (TBEX1: 13-14,
IN 9 Mat switch X0040
15-16) are ON.
IN 10 － － (Not used)
IN 11 High-speed Teach X0042 Lit when High-speed Teach is ON.
IN 12 P1 correct X0043 Lit when DC 24 V is supplied properly.
Lit off with the “emergency stop” off or when the external
emergency stop input (TBEX1: 1-2, 3-4) is OFF (on inputting the
IN 13 Ext Emergency stop X0044
emergency stop) is OFF.
Lit by releasing the emergency stop input.
Lit off with the “TP emergency stop” off or when the emergency
stop button of either the operation box or the start box is
IN 14 Emergency stop X0045
depressed (on inputting the emergency stop).
Lit by releasing the entire emergency stop input.
Lit when all the following conditions are met.
IN 15 Safety plug X0046 ･”Playback mode” lights.
･Safety plug input (TBEX1_5-6,7-8) is ON.
IN 16 Confirm motors-ON X0047 Lit with the motor power relays (CRON1 & CRON2) are ON
Lit by releasing the emergency stop input.
IN 17 TP Emergency stop X0048 Lit off with the TP emergency stop button depressed (on
inputting the emergency stop).
Lit when “TEACH mode” is selected by the selector switch of
IN 18 Teach mode X0049
operation box. Light off during “Auto mode”,
IN 19 － － (Not used)
IN 20 TP enable SW X0051 Lit when [ENABLE SWITCH] is ON.

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Table 2.1.11 List of fixed input relay numbers（2/2）

Relay Description
Fixed input signal name
No. Light on : ON (Input ON) Light off : OFF(Input OFF)
IN 21 － － (Not used)
IN 22 CR ON X0053 Lit with the motor power relays (CRON1 and CRON2) are ON.
IN 23 Servo-ON X0054 Lit when the servo ON relay (CRES1) is ON.
IN 24 Servo enable X0055 Lit when Amplifier normal signal is ON.
IN 25 － － (Not used)
IN 26 － － (Not used)
IN 27 － － (Not used)
IN 28 Magnet-ON X0059 Lit when the magnet switches (MS1 and MS2) are ON.
IN 29 － － (Not used)
Normally, it lights on with the motor power OFF.
IN 30 Weld detection X0061 Lit off when contact stick occurs in the magnet switch or the
relay with the motor power OFF.
Normally, it lights off.
IN 31 Inconsistency X0062 Lit when the inconsistency of a redundant safety circuit is
detected.
IN 32 － － (Not used)
Normally, it lights.
IN 33 Inconsist(GSTOP) － Lit off when the inconsistency of a G-STOP redundant safety
circuit is detected.
Normally, it lights.
IN 34 Inconsist(mode) － Lit off when the inconsistency of a mode input redundant safety
circuit is detected.
Normally, it lights.
IN 35 Inconsist(MAT-SW) － Lit off when the inconsistency of a MAT-SW redundant safety
circuit is detected.
Normally, it lights.
IN 36 Inconsist(HI-SP) － Lit off when the inconsistency of a high-speed teaching
redundant safety circuit is detected.
Normally, it lights.
IN 37 Inconsist(Ext ES) － Lit off when the inconsistency of an extension emergency
redundant safety circuit is detected.
Normally, it lights.
IN 38 Inconsist(E.S.) － Lit off when the inconsistency of an emergency redundant
safety circuit is detected.
Normally, it lights.
IN 39 Inconsist(S.plug) － Lit off when the inconsistency of a safety plug redundant safety
circuit is detected.
Normally, it lights.
IN 40 Inconsist(TP-ES) － Lit off when the inconsistency of a TP emergency redundant
safety circuit is detected.
Normally, it lights.
IN 41 Inconsist(ENB-SW) － Lit off when the inconsistency of an enable switch redundant
safety circuit is detected.
Normally, it lights.
IN 42 Inconsist(CRON) － Lit off when the inconsistency of a CRON redundant safety
circuit is detected.
IN 43
- － － (Not used)
IN 48

The status of fixed input signal can be monitored by clicking <Service> – [Monitor * (*: 1 - 4)] –
[Fixed input signal]. The input signal is displayed as "Lighting": signal set to “ON” and
"Extinction": signal set to “OFF”.

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Table 2.1.12 List of fixed output relay numbers

Description
Fixed output signal name Relay No. Light on : Input ON (with output),
Light off : Input OFF (with no output)
Light off：Motor power OFF, Light on：Motor power ON
OUT 1 Motors-ON lamp Y0032 (Light on：The status that the motor power can be turned ON by
turning enable switch ON.)
OUT 2 Motors-ON request Y0033 Lit when the Motors-ON button of the operation box 1 is ON.
With “Multi-station” start method
OUT 3 Start lamp 1 Y0034 Lit with starting the station 1.
Flushes with the station 1 in a queue.
Lit with starting the station 2.
OUT 4 Start lamp 2 Y0035
Flushes with the station 2 in a queue.
Lit with starting the station 3.
OUT 5 Start lamp 3 Y0036
Flushes with the station 3 in a queue.
Lit with starting the station 4.
OUT 6 Start lamp 4 Y0037
Flushes with the station 4 in a queue.
OUT 7 Stop lamp Y0038 Lit during temporary stop.
OUT 8 TP enable release Y0039 Lit when enable switch is released.
Lit when the motor ON has been applied and allowed by
software.
OUT 9 Motors-ON enable Y0040
Lit off if the servo error occurs, when the motor ON has not
been allowed by software or CPU error occurs.
OUT 10 Magnet-ON enable Y0041 Lit with the servo ON allowed by software.
Lit when the start method is specified to “External”.
OUT 11 Internal/External Y0042 Lit off when the start method is specified to “Controller” or
“Multi-station”.
Lit when outputting the software enable signals to the welding
power supply.
OUT 12 WPS E-STOP ctrl Y0043
This is one of the required conditions to output the emergency
stop signals to the welding power supply.
Always lighting off.
OUT 13 CPU failure Y0044 CPU trouble is indicated only by the hardware output.
Check the output status with TBEX2: CPU error output.
Lit when TP selector switch is set to “TEACH”.
OUT 14 TP mode Y0045
Lit off when “AUTO” is selected.
OUT 15 Ext motors-ON Y0046 Lit when external motors-ON is input.
OUT 16
- － － (Not used)
OUT 24

The status of fixed output signal can be monitored by clicking <Service>-[Monitor * (*: 1 - 4)] -
[Fixed output signal]. The output signal is displayed as "Lighting": signal set to "ON" and
"Extinction": signal set to "OFF".

Fuse on the sequence board

Table 2.1.13 Fuse of sequence board

Fuse Specification
F4 250V, 2A

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LED and relays

LEDs and relays on the sequence board are described in the following table.

Table 2.1.14 LEDs and relays on the sequence board

Relay
LED No Function Conditions fo ON/OFF
No.

EMERGENCY STOP 1 NORMAL………………..LED : ON Relay : ON

PD1 CREMG1
OUTPUT EMERGENCY STOP….LED : OFF Relay : OFF

EMERGENCY STOP 2 NORMAL………………..LED : ON Relay : ON

PD2 CREMG2
OUTPUT EMERGENCY STOP….LED : OFF Relay : OFF

CPU : NORMAL………..LED : OFF Relay : OFF

PD3 CRERR CPU ERROR OUTPUT
CPU : ABNORMAL…….LED：ON Relay : ON

SERVO ON 1 : OFF……LED : OFF Relay : OFF

PD4 CRON1 SERVO ON 1
SERVO ON 1 : ON……..LED : ON Relay : ON

SERVO ON 2 : OFF……LED : OFF Relay : OFF

PD5 CRON2 SERVO ON 2
SERVO ON 2 : ON……..LED : ON Relay : ON

EMERGENCY STOP1 : NORMAL

EMERGENCY STOP LED : ON Relay : ON
PD6 CR1
DELAY CONTROL 1 EMERGENCY STOP1 :EMERGENCY STOP
LED : OFF after delay time Relay : OFF after delay time
EMERGENCY STOP2 : NORMAL
LED : ON Relay : ON
EMERGENCY STOP
PD7 CR2 EMERGENCY STOP2 :EMERGENCY STOP
DELAY CONTROL 2
LED turns OFF after delay time
Relay turns OFF after delay time

MAGNETIC SWITCH MAGNETIC SWITCH : OFF………LED : ON Relay : ON

PD8 CR3
OFF CHECK MAGNETIC SWITCH : ON………..LED : OFF Relay : OFF

NORMAL…………………LED : ON Relay : ON
EMERGENCY STOP EMERGENCY STOP……
PD9 CRDL1
DELAY 1 LED turns OFF after delay time setting (software setting)
Relay turns OFF after delay time setting (software setting)
NORMAL…………………LED : ON Relay : ON
EMERGENCY STOP EMERGENCY STOP……
PD10 CRDL2
DELAY 2 LED turns OFF after delay time setting (software setting)
Relay turns OFF after delay time setting (software setting)

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2.1.6 Power unit

The Power unit is configured with the power unit board that has a connector for supplying
AC200V input to each part in the robot controller and the magnet switch that controls the power
to the IPM drive unit with the signal from IPM drive unit.

Fig. 2.1.8 External view of Power unit

Table 2.1.15 Connectors of Power unit

Connectors Figure Functions Connected to
CNRSTIN Front panel connector 3-phase AC 200 V input Secondary side of breaker
CN200P Front panel connector 1-phase AC 200 V output Optional equipment
CNPW Cable drawn 1-phase AC 200 V output Multi power supply unit
CNRST Cable drawn 3-phase AC 200 V output IPM drive unit
CNMS Cable drawn MS control I/F IPM drive unit

Table 2.1.16 Fuse of power unit

Fuse Specification Setting position
F1, F2 250V、8A Front panel

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2.1.7 IPM drive unit

The IPM drive unit is the servo amplifier that servo control CPU is equipped. It is configured
with the encoder I/F, Power supply for driving motor, motor power control circuit, power supply for
brake control, brake control circuit and other items.

CNP4A CNP5A CNP6A

CNP4B CNP5B CNP6B

CNP3B CNP2B CNP1B

CNP3A CNP2A CNP1A
CNRST

CNFAN
CNR

CNPN

< Front view > < Right view >

Fig. 2.1.9 External view of IPM drive unit

Table 2.1.17 Connectors on IPM drive unit (1/2)

Boards included in
Connectors Functions Specifications
IPM drive unit
(Note)
CNP1A / CNP1B Motor I/F Connect to Manipulator motor (Axis 1)
Gate drive board CNP2A / CNP2B(Note) Motor I/F Connect to Manipulator motor (Axis 2)
CNP3A / CNP3B(Note) Motor I/F Connect to Manipulator motor (Axis 3)
CNP4A / CNP4B(Note) Motor I/F Connect to Manipulator motor (Axis 4)
Gate drive board CNP5A / CNP5B(Note) Motor I/F Connect to Manipulator motor (Axis 5)
CNP6A / CNP6B(Note) Motor I/F Connect to Manipulator motor (Axis 6)
CNRST Drive power input Connect to Power unit
CNFAN Fan control I/O Connect to Power unit and Fan
PN board Regenerative
CNR Connect Regenerative resistance
resistance I/F
CNPN Option (Not used)
Connect to Servo board
Brake power board CNPB Brake power output
(internal connection)
(Note) The connector may not be installed according to the type of gate drive board.

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Table 2.1.18 Connectors on IPM drive unit (2/2)

Boards included in
Connectors Functions Specifications
IPM drive unit
Connect to Brake power board (internal
CNBKP Brake power input
connection)
CNBK1 Brake control I/F Connect to Manipulator motors (Axis 1 -3)
CNBK2 Brake control I/F Connect to Manipulator motors (Axis 4 -6)
CNEC1 Encoder I/F Connect to Manipulator encoders (Axis 1 -3)
CNEC2 Encoder I/F Connect to Manipulator encoders (Axis 4 -6)
CN78BK Brake control I/F Connect to external axes motors (Axis 7-8)
CN78E Encoder I/F Connect to external axes encoders (Axis 7-8)
CNCOM CPU communication I/F Connect to CPU board
CNVP Control power input Connect to Multi power supply unit
Servo board CNMS MS control I/F Connect to Power unit
CNSV MS control I/F Connect to Sequence board
For brake positive release
Short-circuiting connector is equipped to this
connector as standard.
CNSW Brake positive release
Only to release brake forcedly, connect the
brake releasing relay cable, and then operate
the specified procedures.
For short-circuiting the shock sensor circuit.
Normally, no connector is equipped.
CNMCH Shock sensor input
In case that shock sensor is not used, the
short-circuiting connector should be equipped.

Table 2.1.19 Status indication LED of IPM drive unit

Boards included
No Lighting condition
in IPM drive unit
LED1 Lit when the servo communication link is established.
LED2 Blinks when the servo communication traffic exists.
Servo board
LED3 Lit DC 24 V input is valid.
LED4 Blinks when the servo main loop works.
Capacitors are fully charged.
LED1
PN board (Lights: Capacitors are fully charged. Light off: Capacitors are discharged.)
LED2 Power output relay for fans is ON.

While LED1 on PN board is lighting, DO NOT touch printed circuit boards.

Touching parts accidentally may cause an electric shock hazard because the capacitor is under
the charged condition while LED1 is lighting.
WARNING The part replacement work must be performed after confirming that the LED1 on the PN board
is OFF after turning OFF the primary power of the robot controller

Table 2.1.20 Fuses on IPM drive unit

Fuses Specifications Installed position
F1 250V 10A Servo board
F3 250V 3.2A Servo board

Table 2.1.21 Jumper pins and rotary switch of IPM drive unit
Setting
Initial settings Remark
positions
Setting of 24 V output of encoder
JP2 Short 1-2
connector
JP3 Short 1-2 Setting of encoder voltage 5.4V
JP4 Open 1-2 Setting of encoder voltage 5.6V DO NOT change the
standard settings.
JP5 Open 1-2 Setting of encoder voltage 6.0V
JP6 Short 1-2 Setting of additional axes thermal
ROTSW1 0 Setting of drive unit number

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2.1.8 Teach pendant

External view of the Teach pendant is shown in Fig. 2.1.10.
(3)
(1)

(4)

(6)
(5)

(7)

(2)

Fig. 2.1.10 External view of Teach pendant (Unit (mm))

(1) [EMERGENCY STOP BUTTON]
Depress this button to urgently stop the robot. The servo power is shut off and the brake
works by pressing this button. To release the emergency stop, then turn this button in the
direction of the arrow. If you wish to bring the robot ready for the operation again, you need to
press “Motors ON” button.
(2) [ENABLE SWITCH]
Enable switch is touched by your left hand when the teach pendant is held by both hands.
Enable switch can be operated only in the teach mode. The servo power is ON while the
enable switch is grasped. If the enable switch is released or grasped tightly, the motor power is
turned off, and the robot stops immediately. For the safety reasons, enable switch cannot be
invalid.
(3) [TP SELECTOR SWITCH]
This switch enables the servo power to be applied from the Teach pendant. This switch is used
in combination with the mode select switch. For details of the operation, refer to the instruction
manual “BASIC OPERATIONS MANUAL”.
(4) [TOUCH PANEL LCD SCREEN]
Touch panel LCD screen displays the details of operation currently being performed, the error
log and others. Touch panel enables you to operate easily. For example, the cursor can be
moved to your desired position directly.
(5) [SHEET KEY]
A variety of keys including Numerical key, Axis key, Command key are allocated to the sheet
keys. Refer to “BASIC OPERATIONS MANUAL” about how to use each key, operation
procedures and so on.
(6) [JOG DIAL]
This dial enables you to move cursors by vertical rotating operations and input “Enter” by
pushing the right of it. Combining with the ENABLE key, SHIFT key, and/or the other key enables
various operations. For details of operations, refer to “BASIC OPERATIONS MANUAL”.
(7) [USB PORT]
Connecting USB memory (Optional) with opening USB cap enables you to use TP external
memory. For details of the precautions for operation or handling, refer to “Chapter 6 file
operations” in “BASIC OPERATIONS MANUAL”.

Attach USB memory to the USB port only during file operations.
After finishing file operations, remove USB memory and close USB cap.
Using with USB memory attached or with USB cap opened may lose dust resistance and
CAUTION waterproof performance so that the teach pendant may be damaged.

2-16
 0

2.2 Optional parts

2.2.1 USB memory (option)

This is a USB memory for "External memory" used to back up user data or upgrade the
version. For details of operating procedures and precautions, refer to “Chapter 6 File operation”
in “BASIC OPERATIONS MANUAL”

CPU board Connectors for USB memory

< Front view (inside) > < Closeup of Rack unit >

Fig. 2.2.1 Installing positions of USB memory

2-17
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2.2.2 I/O board (option)

The I/O board connects the digital I/O signal between inside of robot controller and peripheral
equipment.

Function
- I/O circuit for inside of board
- I/O circuit for external interlock

- For details of installation procedures of I/O board, refer to the section 3.6.3 in “SETUP
INFO. MANUAL”.
- For details of connecting procedures between I/O board and external I/O, refer to the
section 3.9.4 in “SETUP MANUAL”.

CNIN FCIO CNOUT

SW1 and silk indication

Fig. 2.2.2 External view of I/O board

Table 2.2.1 Connectors on I/O board

Connectors Functions Connected to
CNIN Digital input Connect the input signal from external
CNOUT Digital output Connect the output signal to external
I/O circuit
Connected with Relay unit (L21724A00)
FCIO Digital I/O
or Extended relay unit (L21725A00)
CNPCI CPU bus
Connected to Raiser board. (UM344)
CNP24V CPU bus

Table 2.2.2 Setting of Dip switch SW1 of I/O board

Setting position Setting status
Remarks
Board name No. 2 1
OFF OFF I/O board 1 (Initial setting)
OFF ON I/O board 2
I/O board SW1
ON OFF I/O board 3
ON ON Not used

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2.2.3 Relay unit / Extended relay unit

The Relay unit is the unit that can convert the transistor output of the I/O board to the relay
contact output. This board is combined with I/O board as shown in Table 2.2.3. The relay unit can
be used up to two boards at the same time.

- For details of installation procedures of relay unit, refer to the section 3.6.2 in “SETUP
INFO. MANUAL”.
- For details of connecting procedures between relay unit and external I/O, refer to the
section 3.9.3 in “SETUP MANUAL”.

Fig. 2.2.3 External view of Relay unit

Table 2.2.3 Relay unit, Extended relay unit and I/O board

Number of Relay unit Name of Relay unit Combined I/O board Number of signals
IN 32 pts. / Out 32 pts.
1 pcs Relay unit I/O board 1
in total
Relay unit I/O board 1
IN 64 pts. / Out 64 pts.
2 pcs
in total
Extended relay unit I/O board 2

2-19
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2.2.4 Brake release switch (option)

This switch can be used to release the brake in the motor. 1 desired brake can be released by
using this switch. This switch can be used for the situation like shown below:
- The motor power cannot be turned ON because of servo error etc.
- An operator is pinched by a robot arm.

- When releasing a brake, the robot arm may fall down or move fast towards unexpected
direction. Therefore, this releasing operation must be performed after confirming the axis
number to be released and fixing the robot arm securely via cranes etc. Death or serious
injury may result if you make contact with the robot arm or are squeezed between the
robot arm and another part.

DANGER - In case of an axis that falls down because of the gravity, please release the brake after
taking steps to hold or support the robot arm and any other parts. The longer the brake
release switch is pressed, the larger the shock of falling down may get. Therefore, the
pressing time should be short.

Normally, opening the front door of this controller with the "Power ON" condition is
prohibited because there are some portions that have high-voltage. However, if it is
necessary to open the front door for an emergency purpose, please follow the precautions
shown as below without fail.

(1) When trying to turn ON the power of this controller keeping the front door open, DO
NOT TOUCH the parts except for the brake release unit. If you touch the parts that
have high-voltage, electrocution may result.
DANGER (2) Around the breaker switch of this controller, there are some portions that keep
high-voltage even if the power is OFF. Please pay special attention not to touch those
portions carelessly in spite of the power ON/OFF condition. If the controller has a
transformer (option), please pay attention to the high-voltage portions around the part
also.

The input side of the

breaker switch
keeps high-voltage
even if the power is
OFF.

Main power switch

(Breaker) and its
surrounding parts

Power unit
and its surrounding wirings
(black wires)

Fig. 2.2.4 High voltage portions

2-20
 0

In case of FD11-OP90-A (internal type), the brake release switch is in the robot controller.

Brae releasing procedure (FD11-OP90-A)

(1) Turn OFF the power of this controller.

(2) Open the front door of the controller and remove the CNSW from the CNMOD and then insert the
RELEASE instead. (CNSW and RELEASE are tighten with a plastic cable tie)

(3) Pull out an axis selection connector from the CNSEL bottom side and then insert it to the desired position
(axis number).

(4) Turn ON the power of this controller keeping the front door open.

(5) Only while pressing the SW1, the brake of the selected axis number will be released.
(At this time, the robot arm may fall down or move fast. Please do not forget to take a preventive measure
before pressing the SW1.)

(6) After finishing the brake release operation, insert the connectors to their original positions.

FD11-OP90-A

Fig. 2.2.5 FD11-OP90-A

2-21
0

In case of FD11-OP90-B (portable type), it is possible to release the brake by inserting the cable to the CNSW
connector on the IPM drive unit. Because this unit is portable type unit, you can use this unit for plural controllers.

Brake releasing procedure (FD11-OP90-B)

(1) Turn OFF the power of this controller.

(2) Open the front door and then remove the jumper plug that is in the CNSW on the IPM drive unit and insert
the CNSW of this option's cable instead.
(Please keep the jumper plug until finishing this brake releasing operation because this plug is necessary)

Because electrocution may result, it is necessary to turn OFF the primary power of this
controller temporally before removing the CNSW connector on the IPM drive unit.
DANGER

(3) Pull out an axis selection connector from the CNSEL bottom side and then insert it to the desired position
(axis number).

(4) Turn ON the power of this controller keeping the front door open.

(5) Only while pressing the SW1, the brake of the selected axis number will be released.
(At this time, the robot arm may fall down or move fast. Please do not forget to take a preventive measure
before pressing the SW1.)

(6) After finishing the brake release operation, insert the connectors to their original positions.

FD11-OP90-B

CNSW

Fig. 2.2.6 FD11-OP90-B

2-22
 0

In case of FD11-OP90-C, a brake release switch is installed in the cover on the front door of this controller.
This switch can be used without opening the front door. And it is not necessary to turn OFF the power of this
controller.

Brake releasing procedure (FD11-OP90-B)

(1) Turn OFF the power of this controller.

(2) Open the cover and remove the CNSW from the CNMOD and then insert the RELEASE instead.
(CNSW and RELEASE are tighten with a plastic cable tie)

(3) Pull out an axis selection connector from the CNSEL and then insert it to the desired position (axis
number).

(4) Only while pressing the SW1, the brake of the selected axis number will be released.
(At this time, the robot arm may fall down or move fast. Please do not forget to take a preventive measure
before pressing the SW1.)

(5) After finishing the brake release operation, insert the connectors to their original positions and close the
cover securely.

FD11-OP90-C

Fig. 2.2.7 FD11-OP90-C

2-23
0

NOTE

2-24
Chapter 3 Parts replacement procedures

This chapter describes the parts replacement procedures.

3.1 Parts replacement procedure......................................................................3-1

3.1.1 Replacement of board...........................................................................3-2
3.1.2 Replacement of IPM drive unit ..............................................................3-3
3.1.3 Replacement of power unit ...................................................................3-6
3.1.4 Replacement of battery for CPU board .................................................3-7
3.1.5 Replacement of cooling fan (for heat sink and regenerative resistance)3-8
3.1.6 Replacement of cooling fan (for rack unit).............................................3-9
ぺージあわせのため白文字（白文字のため印刷されないなので気にしないでください。削除しないでください。）
 3.1 Parts replacement procedure

3.1 Parts replacement procedure

When you replace the parts of robot controller, implement the operation safely observing the precautions
shown below.

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire, failure or malfunction
caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.

Electric shock may cause serious injury or death.

Wiring work should be done after turning off the primary power supply and the circuit
breaker on the robot controller.
WARNING

When you replace the parts, be sure to implement the operation in 5 minutes after turning
OFF the power supply on primary side. Otherwise, you may get electric shock due to the
remaining electric charge of board and electrolysis capacitor.
WARNING Do not implement the operation with wet hands.
If you get electric shock, it will cause heavy injury or fatal accident.

The replacement work should not be implemented by person other than the person who
attended the class of robot school (maintenance course) implemented by our company.
Otherwise, you may get electric shock or may be clipped by unexpectedly operated robot
WARNING and it may cause heavy injury or fatal accident.

A lot of connectors are connected to each printed circuit board. Promote the replacement
carefully not to cause mistake or omission.
The heavy injury or fatal accident may be caused by electric shock or flare.
WARNING

Do not damage the wiring at the replacement.

Do not touch the electronic parts or pattern of printed circuit board or the contact part of
connector at the replacement. Always hold the periphery of printed circuit board.
WARNING If you touch it, the heavy injury or fatal accident may be caused.

Be absolutely sure NOT to expose the controller inside to direct sunlight, a searchlight or
other strong lights before turning on the primary power supply while the controller door is
left open to enable maintenance or other work to be performed.
WARNING Failure to adhere to the precautions may cause the robot and/or controller to fail or operate
in error.

Prior to work, discharge static electricity charged on a worker.

Antistatic wrist band is effective.
To touch electric parts without countermeasures may cause breakdown.
CAUTION

After finishing the work, close the door completely, and lock the door key.. If the door is not
completely closed, dirt, dust and other foreign matter may enter inside the controller,
possibly causing malfunctions.
CAUTION

3-1
3.1 Parts replacement procedure

3.1.1 Replacement of board

How to remove

1 Turn off the primary power supply and circuit breaker on the controller.

2 Remove all the connectors connected to the replaced board.

3 Remove the fixing screws that fix the board fixing plates, and then pull out the replaced
board.

Fig. 3.1.1 Replacement of board

There are some PCBs that require the dismount of the fixing plate from the original PCB
and re-mount to the new PCB.
IMPORTANT

How to mount
1 Insert the new board along the guide projections, push the board till the connector is fit
to the Raiser board completely, and then fix the board fixing plates by the fixing screws
(M4).
2 Reconnect all the removed cables to the original connectors on the board.

3-2
 3.1 Parts replacement procedure

3.1.2 Replacement of IPM drive unit

Wait 5 minutes after turning off the mains power before replacing IPM drive unit.
WARNING

・ When you replace the IPM drive unit with new one, check that the new one is same type
before replacement. If the IPM drive unit is replaced with the different type, it will cause a
failure or malfunction.
CAUTION ・ Take care not to strike the heat sink at the side face.
・ Take care not to fall it on your foot.

How to remove
1 Turn off the primary power supply and circuit breaker on the controller.

2 Remove the connectors that are connected to the IPM drive unit.

Table 3.1.1 Connectors connected on the front panel

Connector Destination
CNCOM CPU board
CNSV Sequence board
CNVP Multi power supply unit
CNMS, CNRST Power unit
CNFAN Cooling fan (Heat sink)
CNR Regenerative resistance

3 Remove the two fixing screws from the IPM drive unit.
4 Pull the IPM drive unit out 200 mm from the front side.

Fixing screws IPM drive unit

"A"

Pull out

"A"

< Front view (inside) > < View "A"-"A" (Right inside view) >
Fig. 3.1.2 Replace of IPM drive unit (Pull the unit)
5 Remove the connectors connected to the right side of IPM drive unit as shown in
Table 3.1.2.

3-3
3.1 Parts replacement procedure

Table 3.1.2 Connectors connected to the right side of IPM drive unit
Connectors Connected to
If there are connectors that have the same name in the control
CNP1A - CNP6A,
cables (wire-harnesses), please be sure to connect those
CNP1B - CNP6B
connectors without fail.
CNP7A,CNP7B, If these connectors are on the IPM drive unit, please be sure to
CNP8A connect those connectors without fail.
If there are connectors that have the same name in the control
CNBK1, CNBK2 cables (wire-harnesses), please be sure to connect those
connectors without fail.
If there are connectors that have the same name in the control
CNEC1,CNEC2 cables (wire-harnesses), please be sure to connect those
connectors without fail.
When using a brake release cable (option) or a brake release
CNSW
switch (option), please be sure to connect those to this connector.
If there is a cable that is connected to this connector, please be
CN78BK
sure to connect it to this connector.

[FRONT VIEW (7axes spec.)] [RIGHT SIDE VIEW (7axes spec.)]

[FRONT VIEW (8axes spec.)] [RIGHT SIDE VIEW (8axes spec.)]

Fig. 3.1.3 Replacement of IPM drive unit (Releasing connectors)

3-4
 3.1 Parts replacement procedure

6 Pull out the IPM drive unit at the front of controller not to hooking the removed
connectors. At this time, hold the plate working part not to contact with the board and
electrolysis capacitor.

How to mount
1 Insert the IPM drive unit from the front face of the controller to the position pulled out
200 mm bearing away the surrounding connectors.
2 Reconnect the all removed cables on the right side of the IPM drive unit to the original
connectors. When connecting those, please confirm their connector names and their
positions on the IPM drive unit carefully. And, after completing the connection work,
please confirm that those connectors are inserted securely to their respective positions
by pulling the cable with small power.

Again, please check that the all connectors are connected

to their proper positions securely.

3 Insert the IPM drive unit to the original position.

4 Fix the IPM drive unit by the two fixing screws.

5 Reconnect the removed cables on the front panel of the IPM drive unit to the original
connectors.

3-5
3.1 Parts replacement procedure

3.1.3 Replacement of power unit

Take care not to fall power unit on your foot.

CAUTION

How to remove
1 Turn off the primary power supply and circuit breaker on the controller.

2 Remove all the connectors connected to the Power unit and wired from the one. The
connectors are as shown in Table 3.1.3.

Table 3.1.3 Connectors on power unit

Connectors Releasing position Connected to

The secondary side of no fuse
CNRSTIN Remove from the Power unit.
breaker.
CN200P Remove from the Power unit. Optional equipment
CNPW Remove from the Multi power supply unit.
CNRST
Remove from the IPM drive unit.
CNMS

3 Remove two fixing screws that fix the Power unit as shown in Fig. 3.1.4.

4 Pull out the Power unit at the front of controller not to hooking the removed connectors.

How to mount
1 Insert the Power unit from the front face of controller bearing away the surrounding
connectors.
2 Fix the IPM drive unit by the two fixing screws.

3 Reconnect the removed cables on the front panel of the IPM drive unit to the original
connectors.

Fixing screws Power unit

Fig. 3.1.4 Replacement of power unit

3-6
 3.1 Parts replacement procedure

3.1.4 Replacement of battery for CPU board

1. The replacement of the batteries should be done in principle by a trained technician.
2. Do not use the batteries except the specified use.
3. DO NOT recharge the battery.
CAUTION 4.
5.
Do not heat, disassemble, deform, solder and dispose the battery in fire.
Do not drop, hit, throw, or give any shock to the battery.
6. Do not put either plus terminal and the minus one oppositely.
7. Do not connect (+) and (-) of the battery.
8. Keep batteries out of reach of babies and little children. If battery is swallowed,
immediately consult a doctor.
9. A leaking or badly smelling battery should be discarded immediately. The leaking
electrolyte may corrode metal parts.
10. If the liquid of the batteries touches the eyes, the eyes may be injured. Do not rub the
eyes but flush the eyes amply with clean water such as city water and then receive
medical treatment without delay.
11. Remove the used batteries immediately.
12. At disposal of the batteries, insulate the terminal parts with tape or the like.
13. Dispose of the used battery according to your domestic regulations.

How to remove
1 Remove CPU board following the section 3.1.1 .

2 Pull out the connector CN19LiBAT for battery.

3 Loosen the battery fixing screw to remove the battery.

How to mount
1 Attach the new battery on the CPU board by the battery fixing screw.

2 Insert the battery connector to the connector CN19LiBAT.

3 Attach the CPU board following the section 3.1.1 .

When the battery is replaced with new one, set the date and time newly.
CAUTION

Battery connector
(CN19LiBAT)

Battery fixing screw

Battery

CPU Board

Fig. 3.1.5 Replacement of battery for CPU board

3-7
3.1 Parts replacement procedure

3.1.5 Replacement of cooling fan (for heat sink and regenerative resistance)
How to remove
1 Turn off the primary power supply and circuit breaker on the controller.

2 Remove the fixing screws of the replaced fan panel, and then remove the panel.

3 Pull out the fan power cable from the fan power connector.

4 Remove the fan grounding fixing screw of fan.

5 Remove the fan fixing screws to remove the fan.

How to mount
1 Attach the fan to the original panel by the fan fixing screws.

2 Insert the fan power cable to the fan power connector.

3 Attach the panel with the fan to the robot controller by the panel fixing screws.

・ The type of the cooling fan for heat sink and regenerative resistance is different from the
one for the rack unit. Be sure to replace it to the proper type after confirming the model by
CAUTION parts list. To mount the different type of fan may cause breakdown.
・ The fan has an attachment direction. Attach it so that the direction of the wind is set to the
direction indicated by an arrow shown in figure below.

Fig. 3.1.6 Replacement of cooling fans (heat sink / regenerative registance )

3-8
 3.1 Parts replacement procedure

3.1.6 Replacement of cooling fan (for rack unit)

How to remove
1 Turn off the primary power supply and circuit breaker on the controller.

2 Pull out the fan cable from the connector CNFAN of multi power supply unit.

3 Remove the fan unit fixing screw on the top of the rack unit.

4 Pull out the fan unit with it lifting.

5 Remove the fan fixing screws to remove the fan from the fan unit.

How to mount
1 Attach the fan to the fan unit by fan fixing screws.

2 Insert the click of the fan unit to the recess hole, and then locate it on the rack unit.

3 Fix the fan unit to the rack unit by fan unit fixing screw.

4 Connect the fan cable to the connector CNFAN of multi power supply unit.

・ The type of the cooling fan for heat sink and regenerative resistance is different from the
one of rack unit. Be sure to replace it to the proper type after confirming the model by
CAUTION parts list. To mount the different type of fan may cause breakdown.
・ The fan has an attachment direction. Attach it so that the direction of the wind is set to the
direction indicated by an arrow shown in figure below.

Fig. 3.1.7 Replacement of cooling fan (for rack unit)

3-9
3.1 Parts replacement procedure

NOTE

3-10
Chapter 4 Periodic inspection / Parts
list

This chapter describes the periodical inspection.

4.1 Regular inspection schedule.......................................................................4-1

4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair .4-1
4.1.2 Inspection items ..................................................................................4-3
4.1.3 Inspection before the long vacation ......................................................4-5
4.1.4 Cleaning the heat sink ..........................................................................4-5
4.1.5 Inspection of enable switch ...................................................................4-6
4.1.6 Inspection of Emergency stop button ....................................................4-6
4.2 Maintenance parts ......................................................................................4-7
4.2.1 List of maintenance parts ......................................................................4-7
ぺージあわせのため白文字（白文字のため印刷されないなので気にしないでください。削除しないでください。）
 4.1 Regular inspection schedule

4.1 Regular inspection schedule

Perform the daily and periodic inspection to prevent troubles, ensure the safety and maintain the performance.
This section describes the notes and details on periodic inspection operation.

4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair

To perform the inspection, maintenance, adjustment and repair of robot controller, you may be
required to enter the robot work area or to operate with the primary/ servo power ON.
Be sure to follow the notes below in all cases.

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.

Do not enter the robot work area while the power is ON.
Do not approach the robot while it is moving.
Approaching the moving robot may cause a fatal accident resulting in a serious injury
WARNING or death.

Do not touch any live electrical parts.

If you touch them, you may receive a fatal electric shock hazard or a burn.
WARNING

Keep your hands, fingers, hair, clothes and other belongings away from the revolving
part. If you bring them to the parts such as the feed roll of wire feeder or the revolving
WARNING part of the fan, you may be caught in a revolving part and get injured

(1) To ensure your safety, perform the inspection, maintenance, adjustment and repair with
wearing proper clothes specified by laws and regulations such as a protective hard hat, a pair
of safety shoes, a pair of gloves and so on.

(2) Before operation, be sure to check that the robot can certainly stop when needed by testing
the emergency stop or temporary stop. Also, check that the fail-safe devices such as the
safety plug or enable SW, if equipped, properly work. If errors occur, stop the operation and
immediately shut off the power supply. Then, inspect the cause of trouble to take remedies
appropriate to the situation.

(3) Inexpert operators must not approach the robot safety fence.

(4) Before operation, hang out a noticeable sign INSPECTION IN

“INSPECTION IN PROGRESS” as shown on the right to notify
the operators of that the inspection is going.
PROGRESS

(5) Do not use any devices to possibly cause electromagnetic noises in and around the area
where the inspection is going on.

(6) Operations including the inspection must be performed by 2 or more persons; one for the
practical operation and the other as a monitor.

(7) Only the operators who have been trained for the function, operation and maintenance of
robots can perform the work such as inspection, maintenance, adjustment, repairs and so on.
Also, if the special equipment is provided, be fully acquainted with the equipment in details.

(8) Operators, even if qualified, must not perform the operation of the particular equipment without
thorough knowledge.

4-1
4.1 Regular inspection schedule

(9) The signals and gestures used for the inspection operator, monitor and other operators of
related devices must be carried out based on the safety management standards of each user.

(10) Monitors must follow the notes below.

(A) Be in a position to overlook the entire robot work area to pay full attention for monitoring.

(B) Always carry the emergency stop button with you so that you can immediately press it when
the error occurs.

(C) Do not allow anybody else to approach the robot work area unless they are engaged in the
operation such as inspection.

(11) Operators to perform the inspection and other works must follow the notes below.

(A) Be sure to check if it is possible to perform some operations outside the robot work area. If
it is the case, perform all the operations outside that area.

(B) Normally, turn off the robot before performing the inspection etc. If you have no choice but
to operate while the robot is working, be sure to report to the safety manager to ask for
permission. After you obtain permission, then perform the operation outside the robot
work area.

(C) If you are required to perform the operation with the robot stand-by, check the procedures
beforehand to safely carry them out. If not specially required, shut off the input power
supply of robot controller, welding power supply etc. before operation. Besides, shut off
the input power supply of jigs and peripheral equipment, or make it invalid unless the
special procedure is needed.

(D) When entering the robot work area, prepare for the malfunction of robot so that you can
immediately press the emergency stop button.

(E) Be sure to check the safety around your feet before operation. Do not work in an insecure
or elevated (2m or higher) scaffold.

(F) When working in the robot work area, be sure that you could see the entire robot motion.
Never turn your back to the robot.

(G) When replacing the print board inside the robot controller or the teach pendant, take the
antistatic measures such as using a static protective sheet and so on.

(12) Follow the notes below when an error occurs during the operation.

(A) If you find any abnormal motions of robot, press the emergency stop button immediately.

(B) Inform a monitor of the abnormality and turn off the

robot controller. Then, hang out the sign ”Do not
turn ON.” as shown on the left. DO NOT TURN ON
(C) Check that the peripheral equipment has also been turned off.

(D) If you are required to enter the safety fence, be sure to remove the safety plug and keep it
by yourself during operation.

(E) Even if the robot automatically stops by the abnormalities in such as the voltage supply to
robot, oil pressure in the peripheral equipment, air pressure or other factors, be sure to
make it completely stop. Then, inspect the cause of trouble to take the measures against it.

(F) If the fail-safe function of the emergency stop button does not work, shut off the main power
immediately and inspect the cause of trouble to take the measures against it.

(G) When restarting after the emergency stop, inspect the cause of trouble and take the
remedies first. Then, insert the safety plug again and restart from the outside the fence.

(13) When you finish the work, be sure to always check that the required connectors, covers and
panel are properly fixed and connected. And then, be sure to close the door and lock the door
key.

4-2
 4.1 Regular inspection schedule

4.1.2 Inspection items

When you implement the maintenance and inspection, implement the following items
Table 4.1.1 Inspection items ( ●: Replace ◎: Replace when damaged ○: Inspect)
Frequency
of Mainte
periodical nance
ID number

inspection
Inspected point Content of inspection Inspection / treatment method
Annually
Every 3
months

3 years

6 years
Daily

Check the servo power supply is

Teach pendant • Check operation of enable switch
surely turned off at the operation
1 ○ Operation box • Check operation of emergency
of every emergency stop button
Starting box stop button
and enable switch.
Teach pendant • Check indicating lamp and
Operation box operation switch
2 ○ Visual check
Starting box • Check operation of push-button
Other operation switch switch etc.
Visual check and cleaning
If the dust is remarkably attached
3 ○ Indicating plate • Peeling, damage
or the indicating plate is removed,
affix it again.
External surface of • Adhesion of spatter and dust etc.
4 ○ Visual check and cleaning
controller • Locking the door key
• Stain of fin of heat sink
Inside or external air
5 ○ • Stain damage of regenerative Visual check and cleaning
room
resistance
• Existence or nonexistence of
6 ○ Inside of controller Visual check and cleaning
dust and dirt
Visual check and cleaning(Note 1)
• Existence or nonexistence of If the dust is remarkably adhered
7 ○ ● ● Cooling fan
adhesion of oil, fumes or dust or the operation status is
defective, replace it with new one.
Control cable
Visual check
Teach pendant cable
• Check of damage, crashing Additional tightening
8 ○ ◎ ◎ Operation box cable
• Looseness of connector If the cable is remarkably
Starting box cable
damaged, replace it with new one
Other external wiring
(Note 1)
Visual check and cleaning
• Existence or nonexistence of
9 ○ Heat sink of CPU board For details, refer to the section
adhesion of oil, fumes or dust
4.1.5 .
Packing of door • Gap, deformation of packing
10 ○ Visual check
Door key • How the key is locked
• Looseness of screws etc.
Inside of controller Visual check and additional
11 ○ • Looseness of connectors and
Printed circuit board tightening
terminal blocks
• Check damage Visual check and cleaning
If the display of liquid-crystal
• Cleaning of seat key
module is remarkably deteriorated
12 ○ ◎ Teach pendant • Check liquid-crystal display
or malfunction of touch panel
• Check operation of touch panel occurs, replace it with new one
• Check USB cap. respectively.
• Check heat generation, Checked by visual check and
13 ○ Transformer (Optional) abnormal sound or abnormal sound
odor
Visual check and additional
14 ○ Grounding terminals • Check looseness and deficit
tightening
15 ○ IPM drive unit • Looseness of connectors Additional tightening
Electromagnetic Visual check
contactor • Check stain and status of main If the contact is remarkably
16 ○ ● ●
contact / auxiliary contact deteriorated, replace it with new
one.
17 ○ ● ● Battery for CPU • Check battery voltage 3.0 V or more

4-3
4.1 Regular inspection schedule

board(Note 2) (Check with a voltmeter)

• Primary power supply voltage
(Measure the primary side voltage of Specification voltage +10%, -15 %
breaker)
• Main circuit power supply of IPM
18 ○ Voltage measurement drive unit
(measure the input voltage of
3-phase AC 200 V +/- 10 %
connector CNRSTIN on the IPM
drive unit while the servo power
supply is activated)
19 ◎ Overhaul

(Note 1) In cleaning, wipe the dusts and the particles with the soft cloth. Don’t use air blow for the cleaning of the fan. The dust and
particles invade in the fan. Failure and life of the fan may be had a bad influence, because the wing of the fan turns with rotational
speed over capacity. If you use a vacuum cleaner, use it only wing. Be careful absorbing between the rotation part and the body.
(Note 2) For details of the inspection for encoder batteries, refer to the instruction manual “MANIPULATOR MANUAL” you use.

4-4
 4.1 Regular inspection schedule

4.1.3 Inspection before the long vacation

If the long vacation continues, be sure to check the following items before turning OFF the
power supply of robot controller.

- Check whether "A1016 encoder battery voltage reduction" is displayed on the error history and
replace it with new one if an error is displayed. For details of the replacement procedures, refer
to the instruction manual "Manipulator”.

- Check the door is closed and the door keys are locked certainly.

4.1.4 Cleaning the heat sink

CNCF
LiBAT (System CF)

CN9(FAN)

CNSATA

Heat sink
CNEXTBUS

CNSODIMM1

CNSODIMM2

Fig. 4.1.1 Layout of heat sink or CPU board

After reversing the CPU board so that the heat sink becomes lower side, and then remove the
dusts and the particles on the heat sink using a brush etc. At this time, pay attention not to let the
dust and particles stick the surface of the CPU board.

Do not use air blow for the cleaning of the heat sink
Using air flow may cause the adhesion of the dust and particles on the surface of CPU board
CAUTION so that the damage due to short-circuits occurs.

4-5
4.1 Regular inspection schedule

4.1.5 Inspection of enable switch

Teach pendant has the three-positional enable switch.
According to the operation as follow, confirm to work enable switch.

1 Select teach mode.

2 Push [MOTOR ON] of operation box.

3 Grasp the enable switch.

>> While you grasp the enable switch, the servo power for the manipulator is turned ON.

4 You grasp the enable switch more, or release enable switch.

>> The manipulator is servo OFF.

4.1.6 Inspection of Emergency stop button

A teach pendant, operation box and starting box have an emergency stop button respectively.
According to operation as follow, confirm to work each emergency stop button.
教示 再生
TEACH PLAYBACK 1 Select teach mode.

運転準備
MOTOR ON 2 Push [MOTOR ON] of operation box.

3 Grasp the enable switch.

>> While you grasp the enable switch, the servo power for the manipulator is turned
ON.

4 Push the emergency stop button on the Teach pendant.

>> Servo power is turned OFF and “Emergency Stop” is displayed on the Teach
pendant.
Please check the ［EMERGENCY STOP BUTTON] on the operation panel in the
same way.

4-6
 4.2 Maintenance parts

4.2 Maintenance parts

4.2.1 List of maintenance parts

Recommended spare parts are broadly divided into two categories A and B according to the service life and
frequency in use of the parts.

Maintenance parts A Major maintenance parts to be provided for daily maintenance and inspection
A-1 Important backup parts
A-2 Periodical replacement parts

Maintenance parts B Maintenance parts to be provided if two or more robots are purchased
B-1 Parts recommended purchasing from NACHI

Parts including in A-1 and A-2 categories are essential to maintain the normal operation of the robot. Therefore, it
is recommended to provide a complete set of these parts. Furthermore, printed circuit boards have high-reliability
parts. Pay careful attention to the following points for the maintenance of the boards.

• Storage temperature: -10 to +50°C

If the parts are needed to store for an extended period of time, it is recommended to store them at a
temperature of 25°C±10°C in order to maintain reliability. Furthermore, do not store them in places with
sharp changes in temperature (e.g. 10°C/hour).

• Storage humidity: 20 to 85%RH

If the parts are needed to store for an extended period of time, it is recommended to store them at
humidity of 45 to 65% in order to maintain reliability. Furthermore, do not store them under conditions
that tend to cause dew condensation or molds.

• Antistatic measures
If the parts are stored under extremely dry conditions, they will be apt to take charge. Consequently,
shocks caused by discharge may result in the destruction of semiconductors. To avoid that, put the
parts in antistatic bags for storage.

• Other ambient conditions

Store the parts in atmosphere with no toxic gas generation and minimal dirt and dust. Furthermore, do
not store the parts under conditions causing loads to be applied.

4-7
4.2 Maintenance parts

Table 4.2.1 A-1 Important backup parts

Recommended
No. Part name Type Manufacture 備考
quantity
SRA series, MC35/50/70
ROX2200
(Without additional axis) etc.
SRA series, MC35/50/70
(With 1 additional axis)
ROX2220
MR35/50 (Without additional axis)
etc.
MC10L,MC20
ROX2500
IPM drive unit (Without additional axis) etc.
1 (Note 1)
NACHI 1
MR20 (Without additional axis)
ROX2520 MC10L,MC20
(With 1 additional axis) etc.
SRA series, MC35/50/70
ROX2222
(With 2 additional axes(50A)
MC10L, MC20
ROX2522
(With 2 additional axes(50A)
RPX0002 1 additional axis
2 Multi power supply unit JH01G NACHI 1
Printed circuit board
3 L21700R00 NACHI 1
(Raiser board)
Printed circuit board
4 FDCPU10-10 NACHI 1
(CPU board)
Printed circuit board
5 UM352-10 NACHI 1 Not including a fixing plate
(Sequence board)
Printed circuit board
6 UM356 ASSY NACHI 1 Including a fixing plate
(I/O board)
7 Power unit FDPW10-10 NACHI 1
FDTPFSJN-2L08 8m cable
8 Teach pendant FDTPFSJN-2L15 NACHI 1 15m cable
FDTPFSJN-2L25 25m cable
FUJI TERMINAL
9 Fuse FGMB-250V-2A-PBF 1 F4, for sequence board
INDUSTRY
FUJI TERMINAL
10 Fuse FGBO-250V-8A-PBF 2 F1,F2 for power unit
INDUSTRY
Daito Communication
11 Fuse GP100 1 F1,IPM drive unit
Apparatus
Daito Communication
12 Fuse HM32 1 F3,IPM drive unit
Apparatus
13 Fuse SG5013002-R Skygate 1 F21 Multi power supply unit
14 CF card CF-02-A1 NACHI 1 System CF card (JP/EN)

Note1 The type of the drive unit varies with the robot model, number of axes to use, and with or without
additional axis and its motor capacity.
Check for the IPM drive unit type to use, and then check for the number of axes to use and the
additional axis motor specifications. In this manual, just typical examples are described.

4-8
 4.2 Maintenance parts

Table 4.2.2 Parts list of Robot controller (Standard parts)

Recommended
No. Part name Type Manufacturer Remark
quantity
Battery SANYO electric (Note 2)(Note 3)
15 CR14250SE-CN16 1
(Note 2)(Note 3) (NACHI) For CPU board
16 Fan motor (Note4) 4715MS-22T-B50-B00 Minebea 1 For rack (FM3-1)
For heat sink(FM1-1, FM1-2)
17 Fan motor (Note4) 4715HS-22T-B50-BM0 Minebea 3
For regenerative resistance (FM2)
MITSUBISHI
18 Breaker NF63-CV3P40A 1 Recommended spare part
electric
Regenerative
19 FD11-00-C08-001 NACHI 1 Recommended spare part
resistance

Note2 Regardless of operating time, replace the battery once every 5 years.
Note3 On January 1, 2009, for revision of the UN Recommendations on the Transport of Dangerous Goods, Model
Regulations-15th edition, Transportation regulation of Lithium battery is partially revised.
When you transport the Lithium battery by air, transport it according to providing items of the newest ICAO-TI and IMDG
Code of IMO
Note4 Regardless of operating time, replace the battery once every 4 years.

Table 4.2.3 Parts list of Robot controller (Optional parts) (1/2)

Recommended
No. Part name Type Manufacturer Remark
quantity
*= 5,10,15,20,25
5m, 10m, 15m, 20m, 25m spec.
A000F-J1-*-A (3 cables)

Wire-harness SRA series, MC35/50/70, MR35,50 etc.

20 NACHI 1
(Control cable) *= 5,10,15,20,25
5m, 10m, 15m, 20m, 25m spec.
A000F-J1-*-B (2 cables)

MC10L, MC20, MR20 etc.

21 USB memory FD11-OP93-A NACHI 1 1GB

4-9
4.2 Maintenance parts

NOTE

4-10
Chapter 5 Parts layouts and electric circuit
diagram

This Chapter shows the parts layouts and electric circuit diagrams.

5.1 External view ............................................................................................5-1

5.2 Parts layout ..............................................................................................5-2
5.3 Electrical connection diagram (overview) .................................................5-3
5.4 Electrical connection diagram (Teach pendant)........................................5-4
5.5 Electrical connection diagram (Operation panel)......................................5-5
 5.1

TOP VIEW
External view

LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW BACK SIDE VIEW

5-1
5.1External view
5-2
5.2
5.2Parts layout

LEFT SIDE VIEW

TOP VIEW
Parts layout

HEATSINK FAN

DSR FAN

IPM DRIVE UNIT RACK UNIT

COOLING FAN
FRONT VIEW RIGHT SIDE VIEW BACK SIDE VIEW
LEFT SIDE VIEW
(WITHOUT COVER)

BREAKER

SERGE
PROTECTOR

RACK UNIT

REGENERATIVE
DISCHARGE
RESISTOR (DSR) POWER UNIT
 5.3Electrical connection diagram (overview)

5.3 Electrical connection diagram (overview)

HEAT SINK FAN PANEL

DSR FAN PANEL

DOOR
CONTROLLER

5-3
5.4 Electrical connection diagram (Teach pendant)

5.4 Electrical connection diagram (Teach pendant)

5-4
 5.5

PLAYBACK
PLAYBACK
TEACH
TEACH

START 2
START 3
START 4

EMG STOP

CONNECTED BY
CUSTOMER

SFP
PLAYBACK
SFP
PLAYBACK
ENABLE SW
ENABLE SW

CONNECTED BY
CUSTOMER
Electrical connection diagram (Operation panel)

5-5
5.5 Electrical connection diagram (Operation panel)
5.5 Electrical connection diagram (Operation panel)

NOTE

5-6
 http://www.nachi-fujikoshi.co.jp/

Shiodome Sumitomo Bldg. 17F,

Phone: Fax:
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Nachi Europe GmbH Phone: Fax:
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Copyright NACHI-FUJIKOSHI CORP.

Robot Division
1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511
Phone +81-76-423-5137
Fax +81-76-493-5252
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