MITSUBISHI ELECTRIC

MELFA

Industrial Robots

Instruction Manual

Controller
CR1

Art. no.: 133799

18 03 2002 MITSUBISHI ELECTRIC INDUSTRIAL AUTOMATION
BFP-A8054-F
 Safety Precautions
Always read the following precautions and the separate "Safety
Manual" before starting use of the robot to learn the required
measures to be taken.

CAUTION All teaching work must be carried out by an operator who has received special training.
(This also applies to maintenance work with the power source turned ON.)
→ Enforcement of safety training

CAUTION For teaching work, prepare a work plan related to the methods and procedures of oper-
ating the robot, and to the measures to be taken when an error occurs or when restart-
ing. Carry out work following this plan. (This also applies to maintenance work with the
power source turned ON.)
→ Preparation of work plan

WARNING Prepare a device that allows operation to be stopped immediately during teaching work.
(This also applies to maintenance work with the power source turned ON.)
→ Setting of emergency stop switch

CAUTION During teaching work, place a sign indicating that teaching work is in progress on the
start switch, etc. (This also applies to maintenance work with the power source turned
ON.)
→ Indication of teaching work in progress

WARNING Provide a fence or enclosure during operation to prevent contact of the operator and
robot.
→ Installation of safety fence

CAUTION Establish a set signaling method to the related operators for starting work, and follow
this method.
→ Signaling of operation start

CAUTION As a principle turn the power OFF during maintenance work. Place a sign indicating that
maintenance work is in progress on the start switch, etc.
→ Indication of maintenance work in progress

CAUTION Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
→ Inspection before starting work
The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.

CAUTION Use the robot within the environment given in the specifications. Failure to do so could
lead to a drop or reliability or faults. (Temperature, humidity, atmosphere, noise environ-
ment, etc.)

CAUTION Transport the robot with the designated transportation posture. Transporting the robot
in a non-designated posture could lead to personal injuries or faults from dropping.

CAUTION Always use the robot installed on a secure table. Use in an instable posture could lead
to positional deviation and vibration.

CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise source,
positional deviation or malfunction could occur.

CAUTION Do not apply excessive force on the connector or excessively bend the cable. Failure to
observe this could lead to contact defects or wire breakage.

CAUTION Make sure that the workpiece weight, including the hand, does not exceed the rated load
or tolerable torque. Exceeding these values could lead to alarms or faults.

WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to observe
this could lead to personal injuries or damage if the object comes off or flies off during
operation.

WARNING Securely ground the robot and controller. Failure to observe this could lead to malfunc-
tioning by noise or to electric shock accidents.

CAUTION Indicate the operation state during robot operation. Failure to indicate the state could
lead to operators approaching the robot or to incorrect operation.

WARNING When carrying out teaching work in the robot's movement range, always secure the pri-
ority right for the robot control. Failure to observe this could lead to personal injuries or
damage if the robot is started with external commands.

CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do so
could lead to interference with the workpiece or peripheral devices.

CAUTION After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with peripheral
devices because of programming mistakes, etc.

CAUTION Make sure that if the safety fence entrance door is opened during automatic operation,
the door is locked or that the robot will automatically stop. Failure to do so could lead to
personal injuries.

CAUTION Never carry out modifications based on personal judgments, or use non-designated
maintenance parts.
Failure to observe this could lead to faults or failures.

WARNING When the robot arm has to be moved by hand from an external area, do not place hands
or fingers in the openings. Failure to observe this could lead to hands or fingers catching
depending on the posture.

CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's main
power OFF.
If the robot controller main power is turned OFF during automatic operation, the robot
accuracy could be adversely affected.
C.Precautions for the basic configuration are shown below.(When CR1-571 is used for the controller.)

CAUTION Provide an earth leakage breaker that packed together on the primary power
supply of the controller as protection against electric leakage. Confirm the set-
ting connector of the input power supply voltage of the controller, if the type
which more than one power supply voltage can be used. Then connect the
power supply.
Failure to do so could lead to electric shock accidents.

Power supply *RV-1A/2AJ series and RP-1AH/3AH/5AH series: Single phase 90-132VAC, 180-253VAC.
*Except the above: Single phase 180-253VAC.

Rear side of controller

Earth leakage
breaker
(NV)

Cover

Terminal

Cover

Terminal cover

Protective earth
terminal
(PE)
 Revision history
Date of print Specifications No. Details of revisions

2000-02-17 BFP-A8054Z-* ・ First print

2000-03-24 BFP-A8054 ・ The earth leakage breaker packaged is added.

・ Writing error correction.

2000-04-11 BFP-A8054-A ・ RP-1AH/3AH/5AH series was added.

2000-06-09 BFP-A8054-B ・ The power supply voltage of CR1 controller was corrected.

2000-12-18 BFP-A8054-C ・ Writing error correction.

2001-03-21 BFP-A8054-D ・ Writing error correction.

2001-09-06 BFP-A8054-E ・ RV-2A/3AJ series was added.

・ The power supply voltage of CR1 controller was corrected.
・ Writing error correction.

2002-03-18 BFP-A8054-F ・ CR1-MB (controller protection box) was added.

・ Writing error correction.
■ Introduction

Thank you for purchasing the Mitsubishi industrial robot.

This instruction manual explains the unpacking methods, installation, basic operation, maintenance and
inspection of the controller.
The optional equipments and power supply voltage are different according to connecting robot type.
Refer to separate "Standard Specifications Manual" for detail.
Always read through this manual before starting use to ensure correct usage of the robot.
The information contained in this document has been written to be accurate as much as possible. Please
interpret that items not described in this document "cannot be performed."

・ No part of this manual may be reproduced by any means or in any form, without prior consent from
Mitsubishi.
・ The details of this manual are subject to change without notice.
・ An effort has been made to make full descriptions in this manual. However, if any discrepancies or
unclear points are found, please contact your dealer.
・ Please contact your nearest dealer if you find any doubtful, wrong or skipped point.

Copyright(C) 2000 MITSUBISHI ELECTRIC CORPORATION

 Contents
Page
1 Before starting use ......................................................................................................................................................................... 1-1
1.1 Using the instruction manuals ............................................................................................................................................ 1-1
1.1.1 The details of each instruction manuals ................................................................................................................ 1-1
1.1.2 Symbols used in instruction manual ........................................................................................................................ 1-2
1.2 Safety Precautions ................................................................................................................................................................. 1-3
1.2.1 Precautions given in the separate Safety Manual ............................................................................................. 1-4

2 Unpacking to installation .............................................................................................................................................................. 2-5

2.1 Confirming the products ....................................................................................................................................................... 2-5
2.2 Installation .................................................................................................................................................................................. 2-6
2.2.1 Unpacking procedures ................................................................................................................................................... 2-6
2.2.2 Transportation procedures .......................................................................................................................................... 2-6
2.2.3 Installation procedures .................................................................................................................................................. 2-7
2.2.4 Connecting the power cable and grounding cable ............................................................................................. 2-8
(1) Setting the power specifications .......................................................................................................................... 2-8
(2) Connecting the power and grounding cable ..................................................................................................... 2-9
2.2.5 Connecting the external emergency stop ........................................................................................................... 2-10
2.2.6 Connecting to the robot arm .................................................................................................................................... 2-10
2.3 Setting the origin ................................................................................................................................................................... 2-10
2.4 Confirming the operation .................................................................................................................................................... 2-10

3 Installing the option devices ..................................................................................................................................................... 3-11

3.1 Installing the pneumatic hand interface and motorized hand interface .......................................................... 3-11
3.2 Installing the expansion option box ................................................................................................................................ 3-14
3.3 Installation of the controller protection box (CR1-MB) ........................................................................................ 3-16
3.3.1 Name of each part ......................................................................................................................................................... 3-16
3.3.2 Confirmation before installation .............................................................................................................................. 3-17
3.3.3 Unpacking procedures ................................................................................................................................................. 3-17
3.3.4 Transportation procedures ........................................................................................................................................ 3-17
3.3.5 Installation procedures ................................................................................................................................................ 3-18
3.3.6 Handling the protection box ...................................................................................................................................... 3-24

4 Basic operations ............................................................................................................................................................................ 4-25

4.1 Handling the controller ........................................................................................................................................................ 4-26
4.1.1 Functions of each key ................................................................................................................................................. 4-26
4.2 Handling the T/B ................................................................................................................................................................... 4-28
4.2.1 Installing and removing the T/B .............................................................................................................................. 4-28
(1) Installing with the control power OFF .............................................................................................................. 4-28
(2) Removing with the control power ON ............................................................................................................... 4-28
(3) Installing with the control power ON ................................................................................................................ 4-28
4.2.2 Functions of each key ................................................................................................................................................. 4-29
4.3 Turning the power ON and OFF ...................................................................................................................................... 4-31
4.3.1 Turning the control power ON ................................................................................................................................. 4-31
4.3.2 Shutting OFF the control power ............................................................................................................................. 4-31
4.4 Turning the servo power ON/OFF ................................................................................................................................. 4-32
4.4.1 Turning the servo power ON (servo ON) ............................................................................................................. 4-32
4.4.2 Shutting OFF the servo power (servo OFF) ...................................................................................................... 4-32
4.5 Jog operation .......................................................................................................................................................................... 4-33
4.6 Opening and closing the hand .......................................................................................................................................... 4-33
4.7 Programming ............................................................................................................................................................................ 4-34
(1) Creation procedures ................................................................................................................................................ 4-34
(2) Robot work ................................................................................................................................................................... 4-34
4.7.1 Creating the program ................................................................................................................................................... 4-35
(1) Deciding the operation order ................................................................................................................................ 4-35
(2) Deciding the operation position name .............................................................................................................. 4-36

i
 Page
(3) Describing and creating the program ................................................................................................................ 4-37
(4) Confirming the program .......................................................................................................................................... 4-42
(5) Correcting the program .......................................................................................................................................... 4-43
(6) Start automatic operation. .................................................................................................................................... 4-47

5 Maintenance and Inspection ..................................................................................................................................................... 5-49

5.1 Maintenance and inspection interval ............................................................................................................................. 5-49
5.2 Inspection items ..................................................................................................................................................................... 5-50
5.2.1 Daily inspection items .................................................................................................................................................. 5-50
5.2.2 Periodic inspections ..................................................................................................................................................... 5-50
5.3 Maintenance and inspection procedures ..................................................................................................................... 5-51
5.3.1 Replacing the battery ................................................................................................................................................... 5-51
5.4 Maintenance parts ................................................................................................................................................................. 5-52

ii
 1Before starting use

1 Before starting use

This chapter explains the details and usage methods of the instruction manuals, the basic terminology and the
safety precautions.

1.1 Using the instruction manuals

1.1.1 The details of each instruction manuals
The contents and purposes of the documents enclosed with this product are shown below. Use these documents
according to the application.
For special specifications, a separate instruction manual describing the special section may be enclosed.

Safety Manual Explains the common precautions and safety measures to be taken for robot handling,
system design and manufacture to ensure safety of the operators involved with the
robot.

Standard Explains the product's standard specifications, factory-set special specifications, option
Specifications configuration and maintenance parts, etc. Precautions for safety and technology, when
incorporating the robot, are also explained.

Robot Arm
Setup &
Explains the procedures required to operate the robot arm (unpacking, transportation,
Maintenance
installation, confirmation of operation), and the maintenance and inspection procedures.

Controller
Setup, Basic
Operation and Explains the procedures required to operate the controller (unpacking, transportation,
Maintenance installation, confirmation of operation), basic operation from creating the program to
automatic operation, and the maintenance and inspection procedures.

Detailed
Explanation of
Functions and Explains details on the functions and operations such as each function and operation,
Operations commands used in the program, connection with the external input/output device, and
parameters, etc.

Explanations of Explains details on the MOVEMASTER commands used in the program.

MOVEMASTER (For RV-1A/2AJ and RV-2A/3AJ series)
COMMANDS

Troubleshooting Explains the causes and remedies to be taken when an error occurs. Explanations are
given for each error No.

Using the instruction manuals 1-1

1Before starting use

1.1.2 Symbols used in instruction manual

The symbols and expressions shown in Table 1-1 are used throughout this User's Manual. Learn the meaning of
these symbols before reading this instruction manual.

Table 1-1 ： Symbols in instruction manual

Symbol Meaning

Precaution indicating cases where there is a risk of operator fatality or seri-

DANGER ous injury if handling is mistaken. Always observe these precautions to safely
use the robot.

Precaution indicating cases where the operator could be subject to fatalities

WARNING or serious injuries if handling is mistaken. Always observe these precautions to

safely use the robot.

Precaution indicating cases where operator could be subject to injury or

CAUTION physical damage could occur if handling is mistaken. Always observe these
precautions to safely use the robot.

If a word is enclosed in brackets or a box in the text, this refers to a key on

［ JOINT ］
the teaching pendant.

This indicates to press the (B) key while holding down the (A) key.
［＋／ Ｆ Ｏ Ｒ Ｗ Ｄ ］ ＋ ［＋ Ｘ ］
In this example, the [+/Forward] key is pressed while holding down the [+X/
（Ａ） （Ｂ）
+Y] key.

This indicates to hold down the (A) key, press and release the (B) key, and
［ Ｓ Ｔ Ｅ Ｐ ／ Ｍ Ｏ Ｖ Ｅ ］ ＋ ([ Ｃ Ｏ Ｎ Ｄ ] → [ Ｒ Ｐ Ｌ ↓ ]）
then press the (C) key. In this example, the [Step/Move] key is held down, the
（Ａ） （Ｂ） （Ｃ）
[Condition] key is pressed and released, and the [Replace ↓ key is pressed.

Ｔ ／Ｂ This indicates the teaching pendant.

1-2 Using the instruction manuals

 1Before starting use

1.2 Safety Precautions

Always read the following precautions and the separate "Safety Manual" before starting use of the robot to learn
the required measures to be taken.

CAUTION All teaching work must be carried out by an operator who has received special training.
(This also applies to maintenance work with the power source turned ON.)
→ Enforcement of safety training

CAUTION For teaching work, prepare a work plan related to the methods and procedures of oper-
ating the robot, and to the measures to be taken when an error occurs or when restart-
ing. Carry out work following this plan. (This also applies to maintenance work with the
power source turned ON.)
→ Preparation of work plan

WARNING Prepare a device that allows operation to be stopped immediately during teaching work.
(This also applies to maintenance work with the power source turned ON.)
→ Setting of emergency stop switch

CAUTION During teaching work, place a sign indicating that teaching work is in progress on the
start switch, etc. (This also applies to maintenance work with the power source turned
ON.)
→ Indication of teaching work in progress

DANGER Provide a fence or enclosure during operation to prevent contact of the operator and
robot.
→ Installation of safety fence

CAUTION Establish a set signaling method to the related operators for starting work, and follow
this method.
→ Signaling of operation start

CAUTION As a principle turn the power OFF during maintenance work. Place a sign indicating that
maintenance work is in progress on the start switch, etc.
→ Indication of maintenance work in progress

CAUTION Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
→ Inspection before starting work

Safety Precautions 1-3

1Before starting use

1.2.1 Precautions given in the separate Safety Manual

The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.

CAUTION Use the robot within the environment given in the specifications. Failure to do so could
lead to a drop or reliability or faults. (Temperature, humidity, atmosphere, noise envi-
ronment, etc.)

CAUTION Transport the robot with the designated transportation posture. Transporting the
robot in a non-designated posture could lead to personal injuries or faults from drop-
ping.

CAUTION Always use the robot installed on a secure table. Use in an instable posture could lead
to positional deviation and vibration.

CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.

CAUTION Do not apply excessive force on the connector or excessively bend the cable. Failure
to observe this could lead to contact defects or wire breakage.

CAUTION Make sure that the workpiece weight, including the hand, does not exceed the rated
load or tolerable torque. Exceeding these values could lead to alarms or faults.

WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or flies
off during operation.

WARNING Securely ground the robot and controller. Failure to observe this could lead to mal-
functioning by noise or to electric shock accidents.

CAUTION Indicate the operation state during robot operation. Failure to indicate the state could
lead to operators approaching the robot or to incorrect operation.

WARNING When carrying out teaching work in the robot's movement range, always secure the
priority right for the robot control. Failure to observe this could lead to personal inju-
ries or damage if the robot is started with 　 external commands.

CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do so
could lead to interference with the workpiece or peripheral devices.

CAUTION After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with periph-
eral devices because of programming mistakes, etc.

CAUTION Make sure that if the safety fence entrance door is opened during automatic opera-
tion, the door is locked or that the robot will automatically stop. Failure to do so could
lead to personal injuries.

CAUTION Never carry out modifications based on personal judgments, or use non-designated
maintenance parts.
Failure to observe this could lead to faults or failures.

WARNING When the robot arm has to be moved by hand from an external area, do not place
hands or fingers in the openings. Failure to observe this could lead to hands or fingers
catching depending on the posture.

CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's main
power OFF.
If the robot controller main power is turned OFF during automatic operation, the robot
accuracy could be adversely affected.

1-4 Safety Precautions

 2Unpacking to installation

2 Unpacking to installation
2.1 Confirming the products
Confirm that the parts shown in the standard configuration of the controller shown in Table 2-1 are enclosed with
the purchased product.
Users who have purchased options should refer to the separate "Standard Specifications". The primary power
supply cable and grounding cable must be prepared by the customer.

Table 2-1 ： Standard configuration

No. Part name Type Qty. Remarks

1 Controller CR1-571 1 unit With machine cable

2 Earth leakage breaker(NV) 1 pc.

3 Safety Manual BFP-A8006 1 copy

4 Standard Specifications BFP-A8050 RV-1A/2AJ series type.

5 BFP-A8182 1 of RV-2A/3AJ series type.

these
6 BFP-A8104 copy RP-1AH/3AH/5AH series type.

7 BFP-A8176 RH-15UHC series type.

8 Instruction Manual BFP-A8052 RV-1A/2AJ series type.

(Robot arm setup and maintenance)
9 BFP-A8183 1 of RV-2A/3AJ series type.
these
10 BFP-A8111 copy RP-1AH/3AH/5AH series type.

11 BFP-A8177 RH-15UHC series type.

12 Instruction Manual
BFP-A8054 1 copy This book
(Controller setup, basic operation and maintenance)

13 Instruction Manual
BFP-A5992 1 copy
(Detailed explanations of functions and operations)

14 Instruction Manual
BFP-A8056 1 copy For RV-1A/2AJ and RV-2A/3AJ series type.
（Explanations of MOVEMASTER COMMANDS）

15 Instruction Manual
BFP-A5993 1 copy
(Troubleshooting)

16 Guarantee Card 1 copy

Confirming the products 2-5

2Unpacking to installation

2.2 Installation
2.2.1 Unpacking procedures

1. Open the top of the cardboard box,

and remove the instruction manual.
Manuals, etc

3. Remove the inner case 2,

Packaging and remove the controller.
material

2. Remove the inner case, and Controller

remove the machine cable.

Inner case-２
Machine cable

Inner case-１

Note)The packaging material is required when transporting the controller again, so keep it in safekeeping.
Fig.2-1 ： Unpacking the controller

2.2.2 Transportation procedures

!!

Fig.2-2 ： Transporting the controller

(1) Transport the controller by placing hands between the lower clearance created with the rubber foot on the
front and back sides, and lifting up the controller. Do not hold the switches or connectors.

2-6 Installation
 2Unpacking to installation

2.2.3 Installation procedures

50 STATUS NUMBER
EMG.STOP
50
CHANG DISP
UP

DOWN

MODE SVO ON START RESET

TEACH
AUTO AUTO
(Op.) (Ext.) REMOVE T/B
SVO OFF STOP END

170 or more

Fig.2-3 ： Installation dimensions

[Caution] A fan is installed on the bottom of the controller, so do not remove the rubber foot and install the
controller flat on a surface.

Installation 2-7
2Unpacking to installation

2.2.4 Connecting the power cable and grounding cable

The power supply voltage is classified as follows by the use robot type. The connection of the cable is to proceed
in each explanation clause, and do it.
*RV-1A/2AJ series
Power supply voltage : Choose 1-phase AC100V or 1-phase AC200V. (Default setting is 1-phase AC100V.)
Explanation clause : Do it from the following "(1)Setting the power specifications".
*RP-1AH/3AH/5AH series
Power supply voltage : Choose 1-phase AC100V or 1-phase AC200V. (Default setting is 1-phase AC200V.)
Explanation clause : Do it from the following "(1)Setting the power specifications".
*Except the above
Power supply voltage : 1-phase AC200V fixation. (Default setting is 1-phase AC200V.)
Explanation clause : Proceed to "(2) Connecting the power and grounding cable" on page 9.

CAUTION Use an earth leakage breaker in the package on the primary power
supply of the controller to protect against leakage currents.
Failure to observe this could lead to electric shock accidents.
Input power voltage setting connector

AC200V
AC100V Power card(RZ802A)

Earth leakage
breaker
(NV)
Power supply connection
terminal

L1

L2
Protective earth Power and grounding cable
terminal FG (Prepared by user)
Power supply connection
(PE) terminal(M4)
(With cover)

Fig.2-4 ： Connecting the power cable and grounding cable

(1) Setting the power specifications

1) Remove the controller cabinet cover.
2) Set the input power voltage setting connector on the power card (RZ802A: refer to Fig. 2-4) in the controller
as follows.
<When using as single-phase 200VAC>
Insert the "input power voltage setting connector" into the connector indicated as 200VAC (CON200V:
refer to Fig. 2-4) on the power card (RZ802A).
<When using as single-phase 100VAC>
Insert the "input power voltage setting connector" into the connector indicated as 100VAC (CON100V:
refer to Fig. 2-4) on the power card (RZ802A).
3) Install the controller cabinet cover.

CAUTION If the voltage set with "input power voltage setting connector" and the actual input
voltage differ (ex. When input voltage is 200VAC even though 100VAC is set), the
error "input Power Voltage Setting Incorrect" (error No.850) will occur.
Error No. 850 will also occur if the robot arm designed for 200 VAC is set to 100
VAC.

2-8 Installation
 2Unpacking to installation

(2) Connecting the power and grounding cable

1) Prepare the 2 power cables and 1 grounding cable (both A.W.G#14(2mm2) or more).
2) Remove the two M4 screws for the power supply terminal block cover on the rear of the controller.
3) Confirm that the primary power is set to the power specifications set in "(1)Setting the power specifications"
above.
4) Confirm that the primary power is OFF, and that the power switch on the front of the controller is OFF.
5) Connect the 1 power cable to the power supply terminal on the back of the controller. (L1 and L2 from the
top.) Connect the opposition side to the secondary terminal of the earth leakage breaker packaged. (Terminal
of the bottom side.)
6) Connect the grounding cable to the grounding terminal on the power supply terminal block. (Lowest terminal.)
7) Connect the one rest of the power cable with the primary terminal of the earth leakage breaker. (Terminal of
the upside)
8) Install the power supply terminal block cover removed in step "2)".
This completes the connection of the power and grounding cables.
Note:Do the installation of the earth leakage breaker packaged by the customer. The length of the power cable
varies according to the distance between the installation place and the controller.

Installation 2-9
2Unpacking to installation

2.2.5 Connecting the external emergency stop

24V
1
Short piece 1
2
RA1 Emergency stop input
3
Short piece 2
4
RA2 Door switch input
5
RA3
6
RG (24G)
Note1)
Emergency stop output
Composition of external emergency stop and door switch

DOOR EMG.
Switch STOP
1
2
3
4 Wire insert
24V
5 Controller rear side
1)
System emergency 6 2) Wire fixing screw
stop line RA2
(Prepared by user) 3)
4)
5)
RG (24G) 6)
Example of wiring for external emergency stop and door switch
Terminal block array of
external emergency stop
Note1) Output the system emergency stop output when either following the switch or the signal is turned on.
・Emergency stop switch of the controller
・Emergency stop switch or deadman sw itch of the T/B
・External emergency stop input
・External door input

Fig.2-5 ： Connecting the external emergency stop

For safety purposes, install the External emergency stop switch at an easy-to-operate place.
The external emergency stop input and door switch input terminal block are short-circuited with a short bar (short
piece) as shown in Fig. 2-5.
Connect the external emergency stop switch and door switch with the following procedures.
Refer to the standard specifications for details on the door switch functions.

1) Prepare the emergency stop switch and door switch.

2) Loosen the wire fixing screw on the terminal block, and remove the short bars 1 and 2.
3) Securely connect the external emergency stop contact across "1-2" on the terminal block, and connect the
door switch contact across "3-4" on the terminal block. The connection method is indicated below.
a) Loosen the wire fixing screw on the terminal block, and open the wire insertion port.
b) Peel 5 to 7mm of the sheath off the wire (A.W.G#24 to 16 recommended).
c) Insert the wire into the wire insertion port.
d) Securely tighten the wire fixing screw to fix the wire.

2.2.6 Connecting to the robot arm

Refer to the separate manual "Robot arm setup and maintenance", and connect the controller and robot arm with
machine cables.

2.3 Setting the origin

Refer to the separate manual "Robot arm setup and maintenance", and set the origin.

2.4 Confirming the operation

Refer to the separate manual "Robot arm setup and maintenance", and confirm the robot operation with jog
operation.

2-10 Setting the origin

 3Installing the option devices

3 Installing the option devices

The T/B can be installed in the power OFF state as described in the separate manual "Robot arm setup and main-
tenance", or can be installed/removed in the power ON state as described in "4.2.1 Installing and removing the T/
B" on page 28 of this manual. Refer to the respective explanations.
Refer to the separate "Standard Specifications" for the optional devices other than those described in this man-
ual.

3.1 Installing the pneumatic hand interface and motorized hand interface
The method for installing the pneumatic hand interface and motorized hand interface is explained below.

CAUTION Always turn the controller supply base power and controller power switch OFF
before starting this work.

(1) Removing the controller cover

1) Remove the cabinet cover installation screws from the side of the controller, and remove the cabinet cover.
2) Remove the operation panel installation screws from the side of the controller, and remove the operation panel.

One cabinet cover

Cabinet cover installation screw
(Rear side) CAUTION
Wait at least three minutes
after turning OFF the supply
base power before removing
Four operation panel the cabinet cover (top plate).
installation screws
(Two each on left/right) Do not supply the power until
the top plate is installed.
Failure to observe this could
Operation panel lead to electric shocks.

RZ386 or RZ387 card

Connection cable A
CAUTION
The operation panel is con-
nected with cables. Take care
not to pull the cables with
force.

Fig.3-1 ： Removing the controller cover

Installing the pneumatic hand interface and motorized hand interface 3-11
3Installing the option devices

(2) Removing the RZ386 or RZ387 card

1) Remove the connection cable A connector.

RZ386 or RZ387 card

Spread the connector

fixing latches outward

Connection cable A connector

Fig.3-2 ： Removing the connection cable A

2) Remove the three installation screws from the RZ386 or RZ387 card, and pull out the card to a height where
the hand interface can be installed.

Two RZ386 or RZ387 card installation screws

RZ386 or RZ387 card

Battery cable

Push up the bottom of the

connector and pull out.
［Caution］Pull out while taking
care to the connector
fixing fittings.

One RZ386 or RZ387 card installation screw

Fig.3-3 ： Pulling out the RZ386 or RZ387 card

3-12 Installing the pneumatic hand interface and motorized hand interface
 3Installing the option devices

(3) Installing the pneumatic hand interface or motorized hand interface

Install the pneumatic hand interface or motorized hand interface.

CNHNDOUT connector Connect both connectors

RZ386 or RZ387 card CNHND connector together. Push in securely.

Pneumatic hand interface

or motorized hand interface

Fig.3-4 ： Installing the hand interface

(4) Assembling the controller

1) Install the RZ386 or RZ387 card at the original position, removed in step "(2)" "2)", and securely fix with the
three installation screws. Return the battery cable to the original position.
2) Install the connection cable A connector, removed in step "(2)" "1)" on the original position of the RZ386 or
RZ387 card. Fix by pressing the connector fixing latches inward until a "click" is heard.
3) Install the operation panel, removed in step "(1)" "2)" at the original position. Take care not to catch the cable
at this time. The cable could be damaged if forcibly bent and pressed in.
4) Install the cabinet cover, removed in step "(1)" "1)" at the original position.
Take care not to catch the battery cable at this time.

This completes the installation of the pneumatic hand interface or motorized hand interface.

Installing the pneumatic hand interface and motorized hand interface 3-13
3Installing the option devices

3.2 Installing the expansion option box

The procedures for installing the expansion option box are indicated below.

Installation screw 1) Loosen the four screws from the side of

（Four positions） the controller, and remove the side
plate.

Side plate

2) Remove the four screws from the

expansion option box and remove the
upper cover.
Upper cover

Installation screw
（Four positions）

Expansion option
box

3) Connect the connectors from the side

of the controller with the connectors
from the expansion option box.
At this time, insert and position the
Connector
positioning latches on the expansion
option box into the groove on the side
of the controller.

Installation screw 4) Securely fix both pieces with the

Groove （Four positions）
（Two positions） screws removed in step 1).
Positioning latches
（Two positions）

3-14 Installing the expansion option box

 3Installing the option devices

Installation screw
（Four positions） 5) Insert the option card to be mounted
into the corresponding slot, and fix with
Rail plate
(2 PCS.) the rail plate. Lead any required cables
from the cable lead-out port on the rear
side.

Option card Note) The No. of the slot for inserting

each option is determined. Refer to
the instruction manual provided with
Cable lead-out port each option for the corresponding
Option slot 1（RT-BUS1） slot Nos.
･Ethernet interface
･Extended serial interface
･Additional axis interface
Option slot 2（RT-BUS2）
･Extended serial interface
･CC-Link interface
･Additional axis interface
Option slot 3（RT-BUS3）
･Additional axis interface
Installation screw 6) Install the upper cover removed in step
（Four positions） "2)".

Upper cover

7) This completes the installation of the

expansion option box.

Installing the expansion option box 3-15

3Installing the option devices

3.3 Installation of the controller protection box (CR1-MB)

Shows the installation method of using the controller protection box (hereinafter referred to as the protection box)
to protect the CR1-571 controller from using environment such as oil-mist in the following.
For outside dimensions, refer to separate manual "Standard specifications manual".

3.3.1 Name of each part

Fig. 3-5 shows the names of each part of the protection box. Put the CR1-571 controller in this box, and use it.

<Front> <Rear>

Chassis cover (Top board) Cable cover

(Machine cable for power)
Rear panel Heat exchanger

Window
Front panel
Cable cover
Corner type catch clip
(Machine cable for signal)

Name of each part of CR1-MB

CR1-571 controller

CR1-MB

Teaching pendant（option）

The installation state of the controller

Fig.3-5 ： Name of each part of protection box (CR1-MB)

3-16 Installation of the controller protection box (CR1-MB)

 3Installing the option devices

3.3.2 Confirmation before installation

(1) Confirming the products

The configuration part of the protection box is shown in Table 3-1. Confirm the parts.

Table 3-1 ： Configuration device

Part name Type Qty. Remarks
Controller protection box CR1-MB 1 unit
Serial number posting label 1
Protection seal transparent 1 Protection for the serial number posting label
Cable tie 2
Power supply wiring cable 1 For connecting the power relay terminal and the controller inside the box.
Grounding cable 1 For connecting the FG terminal and the controller inside the box.
External emergency stop box HW1X-BV401R 1 unit Single emergency line. Install at a location outside the protection box where
(Controll box) operation can be performed easily. The outside dimensions is shown in Fig.
3-10.

(2) Customer preparation parts

Prepare the cable etc. which show in the following by the customer.
・ Power cable(AWG#14(2mm2)) ................................................................................. 2 cables
・ Grounding cable(AWG#14(2mm2)).......................................................................... 1 cables
・ External emergency stop box cables(AWG#24 ～ 16 recommendation) 2 cables
・ External emergency stop box cable clamp ........................................................ 1 piece
Fit the size to the use external emergency stop box cable, and make preparation.
Table 3-2 shows the recommendation cable clamp as a reference.

Table 3-2 ： Cable clamp for external emergency stop box (recommendation)
Type JIS wiring tube Adaptation cable outside diameter Manufacturer

OA-W1606 4 ～ 6φ
OA-W1608 6 ～ 8φ
OA-W1609 G1/2 7 ～ 9φ OHM electric Corp
OA-W1611 9 ～ 11φ
OA-W1613 11 ～ 13φ

(3) Copy of the manufacture number of the controller.

Write the manufacture number (serial number) printed on the rear of CR1-571 controller to the attached serial
number copy seal by immortality ink.

3.3.3 Unpacking procedures

The protection box is shipped from the factory packaged in cardboard.
Unpack the cardboard packing, and take out the protection box and accessories.

3.3.4 Transportation procedures

Transport the protection box by placing hands between the lower clearance created with the rubber foot on the
front and back sides, and lifting up. (Mass of the protection box: 10kg.）

Installation of the controller protection box (CR1-MB) 3-17

3Installing the option devices

3.3.5 Installation procedures

(1) Installation dimensions
Secure and install the space shown in the Fig. 3-6.

Note)
150mm or more Note) 150mm or more Note) Keep the space of
150mm or more for
opening and closing
the corner type catch clip.

150mm or more

Fig.3-6 ： Installation dimensions

CAUTION The fan installed at the back inside of the protection box for heat exchange.
Take care to not obstruct the rotation of air.

3-18 Installation of the controller protection box (CR1-MB)

 3Installing the option devices

(2) Installation of CR1-571 controller

CR1-571 controller

Chassis cover (Top board)

CR1-MB

Corner type catch ckip

*Set the rubber foot of CR1-571 controller on

he positioning groove (two place).

Front cover

Fig.3-7 ： Installation of CR1-571 controller

1) Remove the catch clip (two places of the right and left.) fixing the front cover of protection box, and remove
the front cover.
2) Remove the top cover of protection box by removing the ten installation screws.
3) Install the CR1-571 controller into the protection box. Turn the front of the controller into front of the pro-
tection box, set the rubber foot on the positioning groove to fix the controller.
If you use the expansion option box (CR1-EB3), install it first. （Refer to "3.2 Installing the expansion option
box" on page 14.）

CAUTION If the protection box is carried with CR1-571 controller installed, lift it horizontally surely.
Lifting the protection box obliquely or vertically could lead to personal injuries or damage
from dropping the controller inside the box.

Installation of the controller protection box (CR1-MB) 3-19

3Installing the option devices

(3) Installation of earth leakage breaker

Fig. 3-8 shows the installation method of earth leakage breaker.

M4 x 50 screw (2pcs.）
*Attachments of
CR1-571 controller
Earth leakage breaker
*Attachments of
CR1-571 controller

CR1-MB
CR1-571 controller

Front view

Fig.3-8 ： Installation of earth leakage breaker

1) Install the earth leakage breaker securely with attached installation screw (M4x20-2) as shown in the Fig.
3-8. The upside is ON in the installation direction.

3-20 Installation of the controller protection box (CR1-MB)

 3Installing the option devices

(4) Connecting the power cable, grounding cable, fan power cable
Fig. 3-9 shows wiring configuration and wiring system diagram of power, grounding, fan power cable.

Cable outlet

Power supply wiring cable

(for controller)

Grounding cable
(for controller)

Grounding terminal (PE) Earth leakage breaker

(for grounding)
Grounding terminal (PE)
(Grounding for primary power supply)
Fan grounding cable Fan power cable Primary terminal (upside)
Secondary terminal (downside)
Grounding terminal (PE)
Grounding for fan Primary power supply cable/grounding cable
(Prepared by customer)
Appearance diagram
Controller protection box

Power supply wiring cable

Earth leakage (Attachment)
breaker Rear side of controller
（L1） （L1） (Power supply
terminal)
Primary power supply cable/ ACIN
grounding cable
（L2） （L2）
(Prepared by customer)
（L2） （L1） （FG）
FG

AC fan Grounding cable Grounding terminal of

(for controller) protection box
（FG） （FG）
（FG） Grounding terminal
(PE)
（FG）

External emergency stop box

(Attachment) Rear side of controller
Connecton of external (The customer needs the preparation and wiring) (External emergency
emergency stop stop terminal block)
(Prepared by customer)
Wiring system diagram
Fig.3-9 ： Connecting the power cable, grounding cable
1) Confirm the setting of input power voltage setting connector of CR1-571 controller. The power supply volt-
age is different by the use robot type. Refer to the separate "Manual/Standard Specifications" for confirm
the power voltage which can be used. Set the input power voltage referring to "2.2.4 Connecting the power
cable and grounding cable" on page 8.
2) Connecting the power cable and grounding cable
Prepare the 2 primary power cables and 1 grounding cable (both AWG#14(2mm2 ) or more).
At inside of the protection box, use the attached power supply wiring cable for the connection of earth
leakage breaker and controller, and use the attached grounding cable for the grounding of controller.
Connect the both power cable and grounding cable referring to Fig. 3-9 and "2.2.4 Connecting the power
cable and grounding cable" on page 8.
Connect the grounding cable prepared by customer to grounding terminal (PE), connect the attached
grounding cable for controller grounding to another grounding terminal (PE).
Pull out the primary power supply cable and grounding cable from the cable outlet of the protection box,
and then fix them with a cable tie together with the machine cable.
3) Connect the power cable of fan on the protection box to secondary terminal of earth leakage breaker, and
connect the grounding cable of fan to the grounding terminal on the protection box.

Installation of the controller protection box (CR1-MB) 3-21

3Installing the option devices

(5) Connection of the external emergency stop

CAUTION Install the attached external emergency stop box to the place easy to operate for
safety surely.
Because the CR1-571 controller is enclosed in the protection box, the emergency stop
switch located on the front side of the controller cannot be operated.

Install the attached external emergency stop box to the place easy to operate.
The outside and installation dimensions of the external emergency stop box are shown in Fig. 3-10 for your
reference.
For the cable connection method, refer to "2.2.5 Connecting the external emergency stop" on page 10.
Please prepare a cable clamp that is fit for the external emergency stop box cable.
For details of the external emergency stop box, refer to the Instruction Manual attached to the product.
Also, pull out the external emergency stop cable from the cable outlet of the protection box, and then fix them
with a cable tie together with the machine cable.

Operation switch BOX cover BOX base

□ 70.0

TOP

32.0 58.0 φ23.0 conduit

BOX cover installation screw
(Knockout)

TOP
42.4

2-φ4.6
(Two M4 installation *The M4 screw prepared by customer
screw holes)

58.0

Panel installation dimension

Fig.3-10 ： The outside dimensions and installation dimensions of emergency stop box

(6) Connecting to the robot arm

Refer to the separate manual "Robot arm setup and maintenance", and connect the controller and robot arm with
machine cables.
Lead the machine cable from the cable outlet on the rear of the protection box.

3-22 Installation of the controller protection box (CR1-MB)

 3Installing the option devices

(7) Block the cable outlet

Cable cover Cable tie

CR1-MB
Fig.3-11 ： Block the cable outlet

The cable cover is attached to the cable outlet.(two places of top and bottom.)
Fix the cable taken out from cable outlet by using the cable tie from the top of the cable cover, and block the
cable outlet so that the oil-mist etc. not come in.

(8) Sticking the serial number posting label

Stick the serial number posting label written down in "3.3.2 Confirmation before installation" on page 17 to front
panel as shown in Fig. 3-12. And stick the protection seal transparent last.

Front panel

Serial number posting label

Protection seal transparent
Fig.3-12 ： Sticking the serial number posting label

Installation of the controller protection box (CR1-MB) 3-23

3Installing the option devices

(9) Installation of top board and front panel

Remove the sheet on the surface of packing stuck on the top board contact part at the up side of the protection
box. Reinstall the top board and securely fix with tentwelve screws. Reinstall the front panel, and close the catch
clip (two places of the right and left) for fixing the panel.

Packing Remove the seet CR1-MB

Fig.3-13 ： Installation of top board, front panel

This completes the installation of the protection box.

3.3.6 Handling the protection box

(1) Operation with removing the panel
The power supply ON/OFF of the controller, the operation of the front panel, the operation under the condition
that T/B is connected are carried out under the condition that the front panel of protection box is removed.

(2) Installation of the expansion option box(CR1-EB3) later

When the expansion option box installed later, take out the CR1-571 controller once. The method of installation of
the expansion option box is shown in the "3.2 Installing the expansion option box" on page 14.

(3) Installation of optional equipment

Any other equipments aren't installed inside the protection box except for the expansion option box.
Install the necessary equipment such as parallel I/O unit to outside of the protection box.

3-24 Installation of the controller protection box (CR1-MB)

 4Basic operations

4 Basic operations
In this chapter, the following items will be explained regarding the basic operations for handling the robot.

Handling the controller The functions of the various keys on the controller are
explained.

Handling the teaching pendant The methods of installing/removing the T/B, and the
functions of the various keys are explained.

Turning the power ON/OFF The items to confirm before turning on the controller
power, and the methods of turning the power ON and
OFF are explained.
Operating the robot with jog operation The methods for manually operating the robot arm using
the teaching pendant are explained. This is mainly used
for teaching work.
Opening and closing the hand The methods of opening and closing the hand using the
teaching pendant are explained.

Program creation to automatic operation The procedures of creating the program are explained in
order.

4-25
4Basic operations

4.1 Handling the controller

4.1.1 Functions of each key

<Front> <Front side of operation panel>

9) 2) 7) 4) 15) 5)

EMG.STOP
STATUS NUMBER CHANG DISP
UP
11) DOWN

MODE SVO ON START RESET

TEACH
AUTO AUTO
(Op.) (Ext.) REMOVE T/B
SVO OFF STOP END
14) 6)

1)

Front operation panel 12) 10) 13) 3) 8)

Fig.4-1 ： Names of controller parts

1) POWER switch ..................................... This turns the control power ON/OFF.

2) START button...................................... This executes the program and operates the robot. The program is run continuously.
3) STOP button......................................... This stops the robot immediately. The servo does not turn OFF.
4) RESET button ...................................... This resets the error. This also resets the program's halted state and resets the program.
5) Emergency stop switch .................... This stops the robot in an emergency state. The servo turns OFF.
6) T/B remove switch ............................ This is used to connect/disconnect the T/B without turning OFF the controller's control
power.
7) CHNGDISP button.............................. This changes the details displayed on the display panel in the order of "Override" → "Pro-
gram No." → "Line No.".
8) END button............................................ This stops the program being executed at the last line or END statement.
9) SVO.ON button.................................... This turns ON the servo power. (The servo turns ON.)
10) SVO.OFF button............................... This turns OFF the servo power. (The servo turns OFF.)
11) STATUS NUMBER
　 (display panel)...................................... The alarm No., program No., override value (%), etc., are displayed.
12) T/B connection connector ......... This is a dedicated connector for connecting the T/B.
13) Personal computer
　 connection connector...................... This is an RS-232C specification connector for connecting the personal computer.
14) MODE changeover switch ............ This changes the robot's operation mode. Note)
AUTO (Op.).................................. Only operations from the controller are valid. Operations for which the operation mode
must be at the external device or T/B are not possible.
TEACH .......................................... When the T/B is valid, only operations from the T/B are valid. Operations for which the
operation mode must be at the external device or controller are not possible.
AUTO (Ext.)................................. Only operations from the external device are valid. Operations for which the operation
mode must be at the T/B or controller are not possible.
15) UP/DOWN button ............................ This scrolls up or down the details displayed on the "STATUS. NUMBER" display panel.

4-26 Handling the controller

 4Basic operations

CAUTION Note) The servo will turn OFF when the controller's [MODE] switch is changed.
Note that axes not provided with brakes could drop with their own weight.

Carry out the following operations to prevent the servo from turning OFF when
the [MODE] switch is changed.

The servo on status can be maintained by changing the mode with keeping pressing
lightly the deadman switch of T/B. The operating method is shown below.

(1) When the mode is changed from TEACH to AUTO.

1) While holding down the deadman switch on the T/B, set the [ENABLE/
DISABLE] switch to "DISABLE".
2) While holding down the deadman switch on the T/B, set the controller [MODE]
switch to "AUTO".
3) Release the T/B deadman switch.

(2) When the mode is changed from AUTO to TEACH.

1) While the [ENABLE/DISABLE] switch on the T/B is "DISABLE", hold down the
deadman switch.
2) While holding down the deadman switch on the T/B, set the controller [MODE]
switch to "TEACH".
3) While holding down the deadman switch on the T/B, set the [ENABLE/
DISABLE] switch to "ENABLE", then do the operation of T/B that you wish.

◇◆◇ What are the operation rights? ◇◆◇

Even when multiple devices, such as a T/B and personal computer, are connected to the controller, the
operation at one time is limited to one device. This limited device (has the operation rights)
◇◆◇ What operations require the operation rights? ◇◆◇
Operations that start the robot, such as program start and alarm reset, and operations that can cause starting
require the operation rights.
Conversely, operation that stop the robot, such as stopping and servo OFF, can be used without the operation
rights for safety purposes.
Refer to the separate manual "Explanation of functions and operations" for details on the functions related to
operation rights.

Handling the controller 4-27

4Basic operations

4.2 Handling the T/B

4.2.1 Installing and removing the T/B
By using the "REMOVE T/B" switch, the T/B can be installed and removed while the controller's control power is
ON.

(1) Installing with the control power OFF

Refer to the separate manual "From robot arm setup to maintenance" for details on installing the T/B with the
power OFF.

(2) Removing with the control power ON

DISABLE ENABLE
1) Set the T/B [ENABLE/DISABLE] switch to "DISABLE".

DISABLE    ENABLE
P8T B-TE

EMG.STOP

2) Press the [REMOVE T/B] switch on the controller. (Indented

Connector REMOVE T/B switch
state) The switch's LED will start flickering.
3) Securely hold the T/B connector, and turn it to the left to
remove it.
4) Remove the T/B connector within 5 seconds after the LED
starts flickering. The switch's LED will turn OFF when the
work is completed.
Teaching pendant
(T/B)

(3) Installing with the control power ON

DISABLE ENABLE
1) Set the T/B [ENABLE/DISABLE] switch to "DISABLE".

DISABLE    ENABLE
P8T B-TE

EMG.STOP

Connector REMOVE T/B switch

2) Connect the T/B connector. The switch's LED will start

flickering.
3) Press the [REMOVE T/B] switch on the side of the controller
within 5 seconds after installing the T/B. (Projected state)
The switch's LED will light when the work is completed.
Teaching pendant
(T/B)

WARNING The T/B emergency stop is invalid while the [REMOVE T/B] switch is pressed
(indented state) even after the T/B is connected. This state will cause an emergency
stop within 5 seconds, but as the T/B is invalid, starting operations from devices
other than the T/B will be valid.

◇◆◇ When an emergency stop state occurs ◇◆◇

If the emergency stop state occurs during the above operations, cancel it with the following procedures.
(1) Press the [REMOVE T/B] switch on the side of the controller, and light the switch's LED.
(Projected state)
(2) Set the T/B [ENABLE/DISABLE] switch to "ENABLE".
(3) Press the T/B [ERROR RESET] key.

4-28 Handling the T/B

 4Basic operations

4.2.2 Functions of each key

1) [EMG. STOP] switch

This is a push-button switch with
lock function for emergency stop.
DISABLE ENABLE
When this switch is pressed, the
3) R28TB 2)
servo will turn OFF and the robot
will stop immediately regardless of
5) the T/B enable/disable state. To
4) 1) cancel this state, turn the switch
clockwise.
6) 2) [ENABLE/DISABLE] switch
19) TOOL JOINT XYZ MENU
STOP This changeover switch is used to
Back = ＊/ ( )？ $" : #%!

SVO ON enable or disable the T/B key

EMG.STOP
7) STEP －X ＋X operations. To carry out operations
MOVE (J1) (J1)
using the T/B, always set this
8)
ADD
13)
＋ －Y ＋Y ↑ switch to "ENABLE" (valid).
FORWD (J2) (J2)
14) Operations with the T/B will be
9) － －Z ＋Z
RPL
↓ enabled, and operations from the
BACKWD (J3) (J3)
15) controller and external sources will
10) －A ＋A
DEL
← be disabled. The T/B will have the
COND
18)
(J4) (J4)
HAND
16) operation rights. To operate with
POS －B ＋B → the controller or external source,
11) 　 CHAR
　 (J5) (J5) set this switch to "DISABLE"
－C ＋C
INP 17) (invalid).
ERROR
RESET (J6) (J6) EXE
3) Display LCD
12) The program contents and robot
state are displayed with the T/B
key operations.
Fig.4-2 ： Teaching pendant (Front side of R28TB)

4) [TOOL] key
This selects the TOOL JOG mode.
4) [JOINT] key
This selects the JOINT JOG mode.
4) [XYZ] key
This selects the XYZ JOG, 3-AXIS XYZ or CYLINDER JOG mode.
5) [MENU] key
This returns the display screen to the "menu screen"
6) [STOP] key
This stops the program and decelerates the robot to a stop. This is the same function as the [STOP] switch on
the front of the controller, and can be used even when the T/B [ENABLE/DISABLE] switch is set to DISABLE.
7) [STEP/MOVE] key
Jog operations are possible when this key is pressed simultaneously with the 12) jog operation key. Step jump
is carried out when pressed simultaneously with the [INP/EXE] key. This also turns the servo ON.
8) [+/FORWD] key
Step feed is carried out when this key is pressed simultaneously with the [INP/EXE] key. On the edit screen,
the next program line is displayed. When pressed simultaneously with the [STEP/MOVE] key, the override will
increase.
9) [-/BACKWD] key
On the edit screen, the previous program line is displayed. When pressed simultaneously with the [INP/EXE]
key, the axis will return along the robot's operation path. When pressed simultaneously with the [STEP/MOVE]
key, the override (speed) will decrease.
10) [COND] key
This is used to edit the program.
11) [ERROR RESET] key
This key resets an error state that has occurred. When pressed simultaneously with the [INP/EXE] key, the
program will be reset.

Handling the T/B 4-29

4Basic operations

12) [Jog operation] key (12 keys from [-X

(J1)] to [+C (J6)]
In this manual, these keys are generically
called the "jog operation" keys. When
JOINT JOG is selected, each axis will
rotate, and when XYZ JOG is selected, the
robot will move along each coordinate
20) system. These keys are also used to input
numeric values such as when selecting a
menu or inputting a step No.
13) [ADD/ ↑ ] key
This additionally registers the position
19)
data. It also moves the cursor upward.
14) [RPL/ ↓ ] key
This corrects the position data. It also
moves the cursor downward .
15) [DEL/ ← ] key
This deletes the position data. It also
moves the cursor to the left .
16) [HAND/ → ] key
When pressed simultaneously with the [+C
(J6)] or [-C (J6)] key, hand 1 will open or
close. In the same manner, hand 2 will
open/close when pressed simultaneously
with the [+B (J5)] or [-B (J5)] key, hand 3
with the [+A (J4)] or [-A (J4)] key, and
hand 4 with the [+Z (J3)] or [-Z (J3)] key.
This key also moves the cursor to the
right .

Fig.4-3 ： Teaching pendant (Rear and side of R28TB)

17) [INP/EXE] key

This inputs the program, and carries out step feed/return.
18) [POS CHAR] key This changes between numbers and alphabetic characters when editing the position data,
etc.
19) Deadman switch
When the [ENABLE/DISABLE] switch 2) is set to "ENABLE", and this key is released or pressed with force,
the servo will turn OFF. Press this switch lightly when carrying out functions with the servo ON, such as jog
operations. If emergency stop or servo OFF operation have been applied, and the servo is OFF, the servo will
not turn ON even when this switch is pressed. In this case, carry out the servo ON operation again.
20) Contrast setting switch (Top: Dark, bottom: light)
This sets the display LCD brightness.

4-30 Handling the T/B

 4Basic operations

4.3 Turning the power ON and OFF

4.3.1 Turning the control power ON

CAUTION Always confirm the following items before turning the controller power ON.
1) Make sure that there are no operators in the robot operation range.
2) Make sure that the controller and robot arm are securely connected with the
machine cable.
3) Make sure that the external emergency stop switch is connected to the controller.
4) Make sure that the controller's power cable and grounding cable are correctly
connected.
5) Make sure that the grounding cable is connected to the robot arm.
6) Make sure that there are no obstacles, such as tools, in the robot operation range.

STATUS NUMBER

POWER
OFF ON

Turn the controller [POWER] switch ON.

" □ . 100" will appear on the STATUS NUMBER display.
This completes the turning ON of the control power.

◇◆◇ What is the main power, control power and servo power? ◇◆◇
Main power ------ This supplies power to the controller. (Primary power)
Control power --- This supplies power to the control sections (PCB, etc.) in the controller.
Servo power ----- This supplies power to the motor that drives the robot.
When energized, this is called servo ON, and when shut off, this is called servo OFF.

4.3.2 Shutting OFF the control power

STOP
1) If the robot is operating, press the controller [STOP] switch, and stop
the robot.
Stop the program

SVO OFF
2) After the robot has stopped, press the controller [SVO OFF] switch,
and turn the servo OFF.
Shut OFF the motor powe

3) Turn the controller [POWER] switch OFF.

The control power will be shut OFF.

Turning the power ON and OFF 4-31

4Basic operations

4.4 Turning the servo power ON/OFF

4.4.1 Turning the servo power ON (servo ON)
DISABLE ENABLE
1) Confirm that the T/B [ENABLE/DISABLE] switch is
set to "DISABLE".

T/B disable
MODE
TEACH
2) Confirm that the [MODE] switch on the front of the
AUTO AUTO controller is set to "TEACH" or "Auto (Op.)".
(Op.) (Ext.)

Controller enable

SVO ON
3) Press the [SVO ON] switch on the front of the
controller.
Turn ON the servo power The switch's lamp will light indicating that the servo is
ON.

CAUTION Make sure that there are not operators in the robot operation range before turning ON
the servo.

4.4.2 Shutting OFF the servo power (servo OFF)

STOP
1) If the robot is operating, press the controller [STOP]
switch on the front of the controller, and stop the
Stop the program robot.

SVO OFF

2) After the robot has stopped, press the controller

Shut OFF the servo [SVO OFF] switch on the front of the controller, and
turn the servo OFF. The switch's lamp will light
indicating that the servo is OFF.

◇◆◇ Operation rights not required ◇◆◇

This operation does not require the operation rights, so the servo can be turned OFF at any time by pressing
the [SVO OFF] switch.

4-32 Turning the servo power ON/OFF

 4Basic operations

4.5 Jog operation

Refer to the separate manual "Robot arm setup and maintenance" when carrying out jog operation.
The following jog operation modes are available. Use these according to the purpose.
Table 4-1 ： Jog modes
Jog mode Main application Explanation

JOINT JOG ・ Moves each joint.

・ Moves the robot arm largely.
・ Changes the robot posture.

XYZ JOG ・ Accurately sets the teaching position.

・ Moves the axis straight along the XYZ coordinate system.
・ Moves the axis straight while maintaining the robot posture.
・ Changes the posture while maintaining the hand position.
Separate manual "Robot arm
TOOL JOG ・ Accurately sets the teaching position.
setup and maintenance"
・ Moves the axis straight along the hand direction.
・ Changes the posture while maintaining the hand position.
・ Rotates the hand while maintaining the hand position.

3-AXIS XYZ JOG ・ When the axis cannot be moved with XYZ JOG that maintains the posture.
・ When the tip is to be moved linearly but the posture is to be changed.

CYLINDER JOG ・ Moves in a cylindrical shape centering on the Z axis while maintaining the posture.
・ Moves linearly in a radial shape centering on the Z axis while maintaining the posture.

4.6 Opening and closing the hand

Hands 1 to 4 can be opened and closed with the T/B.

HAND -C
＋ (J6)
→
0 Opening and closing hand 1
Open: Press [HAND] + [+C (J6)] key
Close: Press [HAND] + [-C (J6)] key
Opening and closing hand 2
HAND +C Open: Press [HAND] + [+B (J5)] key
→ ＋ (J6)
Close: Press [HAND] + [-B (J5)] key
5
Open Close Opening and closing hand 3
Open: Press [HAND] + [+A (J4)] key
Close: Press [HAND] + [-A (J4)] key
Opening and closing hand 4
Open: Press [HAND] + [+Z (J3)] key
Close: Press [HAND] + [-Z (J3)] key

Jog operation 4-33

4Basic operations

4.7 Programming
The procedures from creating the program to automatic operation are explained in order using a simple procedure
as an example.

(1) Creation procedures

Start

Decide the robot operation order, operation path

Deciding the operation order
(necessity of linear movement), and the work at each
operation position (hand open/close, etc).

Teach the robot operation position in the position

Deciding the operation position name
variables.
Decide the position variable name.

Based on the decided operation order and operation

Describing and creating the program
position name, convert the robot operations and work
into commands. Describe the commands in the program
and save in the controller.

Move the robot to each operation position with jog

Teaching the operation position
operation, and teach each position in the position
variables.

Execute the program saved in the controller line by line,

Confirmation of program and operation position
and confirm that the program and operation positions
are correctly saved.

Yes
Judgment: OK?
No

If any mistakes were found in the robot operation or

Correcting the program
work during the program confirmation, correct the
program.

If any mistakes were found in the robot operation

Correcting the position position during the program confirmation, correct the
taught position.

Automatically execute the completed program.

Automatic operation

End

Fig.4-4 ： Program creation procedures

(2) Robot work

Assume that the robot is going to carry the workpiece from the left to the right.
Workpiece Carry the workpiece

Fig.4-5 ： Example of work

4-34 Programming
 4Basic operations

4.7.1 Creating the program

(1) Deciding the operation order

(1) ：Joint movement

Wait position
：Linear movement
：Teaching position
(10
(2) )
Upward position to (6) Upward position to
grasping workpiece release workpiece

(3) (7)
20mm

(4) Hand close (8) Hand open

(5) (9) Position to release workpiece
Position to grasp workpiece

Start
(1) Move to wait position (joint movement).
(2) Move to 20mm upward workpiece (joint movement).
(3) Move to position to grasp workpiece (linear movement).
(4) Grasp workpiece (hand close).
(5) Move 20mm upward (linear movement).
(6) Move to 20mm upward position to place workpiece
(joint movement).
(7) Move to position to place workpiece (linear movement).
(8) Release workpiece (hand open).
(9) Move 20mm upward (linear movement).
(10) Move to wait position (joint movement).
End

Fig.4-6 ： Deciding the operation order

◇◆◇ Joint movement and linear movement ◇◆◇

The operation for which the robot movement path is not designated in particular is the "joint movement". The
operation for which the movement path is designated as linear is "linear movement".
If the robot could interfere with the peripheral devices, such as the workpiece, when moving to grasp or release
the workpiece, designate "linear movement" to prevent any interference.

Programming 4-35
4Basic operations

(2) Deciding the operation position name

Wait position
(ＰＷＡＩＴ)

Upward position to Upward position to

grasping workpiece release workpiece

Position to release
20mm

Position to grasp workpiece workpiece

(ＰＧＥＴ) (ＰＰＵＴ)

Position
Name Teaching Remarks
variable name

Wait position PWAIT Required

Upward position to grasping － Not required Designate with commands.

workpiece

Position to grasp workpiece PGET Required

Upward position to release workpiece － Not required Designate with commands.

Position to release workpiece PPUT Required

Position variable name ････ Designate a random character string starting with "P".
Up to eight characters can be designated.

Fig.4-7 ： Deciding the operation position name

◇◆◇ Teaching the operation position ◇◆◇

The operation position does not necessarily need to be taught.
The positions shown with white circles in Fig. 4-7 can be designated with commands as "position 20mm away
from target position". Refer to "(3) Describing and creating the program" on page 37.

CAUTION The designation of the direction separated from the target position differs according to the
robot type.
The position is along the Z axis of the TOOL coordinate system, and the direction is
designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Instruction Manual/
Robot arm setup and maintenance", and confirm the Z axis direction of the TOOL
coordinate system. Then, designate the correct sign (direction) that matches the robot
being used.
Designating the reverse direction could lead to interference with the peripheral devices and
damage.
Generally (in the default state), the hand retract direction is the "-" sign with the vertical
articulate type robot, and the "+" sign is the robot's upward direction with the other robots.

4-36 Programming
 4Basic operations

(3) Describing and creating the program

■ Convert the target robot operations and work into commands.
Refer to the separate manual "Instruction Manual: Detailed explanations of functions and operations" for details
on the commands.
Table 4-2 ： Commands used
Target operation and work Command Example of designation
Joint movement MOV Move to position variable PWAIT MOV PWAIT
Move to 20mm upward position variable PGET MOV PGET,+20 Note)
Linear movement MVS Move to position variable PGET MVS PWAIT
Move to 20mm upward position variable PGET MVS PGET,+20 Note)
Hand open HOPEN Open hand 1 HOPEN 1
Hand close HCLOSE Close hand 1 HCLOSE 1
Wait DLY Wait 1 second DLY 1.0
End END End the program END

■ Program the converted commands

Wait position
(ＰＷＡＩＴ)

Upward position to Upward position to

grasping workpiece release workpiece

Position to release
20mm

Position to grasp workpiece workpiece

(ＰＧＥＴ) (ＰＰＵＴ)

Start
(1) Move to wait position (joint movement) ...................................................................10 MOV PWAIT
Note)
(2) Move to 20mm upward workpiece (joint movement) ...........................................20 MOV PGET,+20
(3) Move to position to grasp workpiece (linear movement)...................................30 MVS PGET
(4) Grasp workpiece (hand close).......................................................................................40 HCLOSE 1
.......................................................................................50 DLY 1.0
Note)
(5) Move 20mm upward (linear movement).....................................................................60 MVS PGET,+20
Note)
(6) Move to 20mm upward position to place workpiece (joint movement) .......70 MOV PPUT,+20
(7) Move to position to place workpiece (linear movement) ...................................80 MVS PPUT
(8) Release workpiece (hand open)....................................................................................90 HOPEN 1
....................................................................................100 DLY 1.0
Note)
(9) Move 20mm upward (linear movement).....................................................................110 MVS PPUT,+20
(10) Move to wait position (joint movement) .................................................................120 MOV PWAIT
End...................................................................................................................................................130 END

Hand ････ Up to four hands can be installed. However, in the above program, the 1st hand connected to
hand 1 is the target.
Fig.4-8 ： Describing the program

CAUTION Note) Upward movement is designated at a position along the Z axis of the TOOL coor-
dinate system, and the direction is designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Installation
Manual/ Robot arm setup and maintenance", and confirm the Z axis direction of
the TOOL coordinate system. Then, designate the correct sign (direction) that
matches the robot being used.
Designating the reverse direction could lead to interference with the peripheral
devices and damage.
Generally (in the default state), the hand retract direction is the "-" sign with the
vertical articulate type robot, and the "+" sign is the robot's upward direction with
the other robots.
Programming 4-37
4Basic operations

◇◆◇ Program format ◇◆◇

The program format is configured of the "line No. command parameter affixed to command" as shown in Fig. 4-8.
Example) １ ０ Ｍ Ｏ Ｖ ＰＷＡ Ｉ Ｔ
Line No. Command Parameter affixed to command
The program is executed in order from the line No. with the smallest number.

■ Input the described program into the controller.

The T/B is used for this operation.

Preparing the T/B

MODE ENABLE
TEACH
DISABLE 1) Set the controller [MODE] switch to
"TEACH".
AUTO AUTO
(Op.) (Ext.)
2) Set the T/B [ENABLE/DISABLE] switch to
"ENABLE".

Opening the program editing screen

3) In the <MENU> screen, press the arrow keys
<TEACH> (" ↑ ", " ↓ ", " ← ", " → ") and move the
<MENU>
( ) cursor to "1. TEACH", and then press the
1.TEACH 2.RUN
[INP] key. The <TEACH> screen will appear.
3.FILE 4.MONI
5.MAINT 6.SET SELECT PROGRAM

ADD RPL DEL HAND INP

↑ ↓ ← → → EXE
Move the cursor → set

<TEACH> PR:1 4) Press the [1] → [INP] keys.

(1 ) The program No. 1 editing screen will appear.
--NO DATA--
SELECT PROGRAM
-B INP
(J5)
1 DEF → EXE
Set the program number 1 　

DEL
POS
CHAR
＋ ←
Delete an input character

◇◆◇ Using the T/B ◇◆◇

Set the controller [MODE] switch to "TEACH" and the T/B [ENABLE/DISABLE] switch to "ENABLE".
Operations from the T/B are not possible unless the controller [MODE] switch is set to "TEACH".

◇◆◇ Inputting numbers and spaces ◇◆◇

To input a number, press the key having a number on the lower left.
To input a space, press the key having "SPACE" on the lower left.

◇◆◇ Correcting incorrect numbers ◇◆◇

Press the [DEL] key while holding down the [CHAR] key to delete the character, and then input it again.
If the cursor is returned by pressing the [ ← ] key, and a character is input, it will be inserted.

4-38 Programming
 4Basic operations

Input the program 10 MOV PWAIT

PR:1 ST:1 PR:1 ST:1 5) Press the [ ↓ ] key three times.

LN:0 LN:0 The cursor will move to the command editing
--NO DATA-- line.
CODE EDIT
RPL
↓
Using the cursor

PR:1 ST:1 PR:1 ST:1

LN:0 LN:0 6) Press the [1], [0] and [SPACE] keys.
10 The line No. "10" will be input.
CODE EDIT CODE EDIT
-B -C -X
(J5) → (J6) → (J1)
Input "1","0" 1 DEF 0 ABC SPACE PQR

PR:1 ST:1 PR:1 ST:1

LN:0 LN:0 7) Press the [M] key while holding down the
10 10 M [POS CHAR] key. "M" will appear.
CODE EDIT CODE EDIT
-Y
POS
CHAR ＋
(J2)
Input "M" 4 MNO

PR:1 ST:1 1.MOV 2.MVS

LN:0 3.MVC 4.MVR 8) Hold down the [CHAR] key. The four
10 M 10 M commands assigned to "M" will appear.
CODE EDIT CODE EDIT
POS
CHAR
Input "M"

1.MOV 2.MVS PR:1 ST:1

3.MVC 4.MVR LN:0 9) Press the [1] key while holding down the
10 M 10 MOV [CHAR] key.
CODE EDIT CODE EDIT The "MOV" command will be input.
-B
POS
CHAR
＋ (J5)
1 DEF
Input "MOV"

◇◆◇ Inputting characters ◇◆◇

The characters that can be input are indicated, three in a group, on the lower right of each key.
To input a character, hold down the [CHAR] key and press the key having the character to be input. Each time
the corresponding character key is pressed while the [CHAR] key is pressed, the three characters will appear
alternately.
Release the [CHAR] key when the target character appears, and set the character.

◇◆◇ Inputting commands ◇◆◇

The commands can be input one character at a time (ex., for "M" → "O" → "V" for the MOV command), but if
the head character of the command is input, the command can be selected as a number from the list of
commands that appears.
After inputting the head character of the command, press the [CHAR] key. The list of commands will appear.
While holding down the [CHAR] key, press the numeral key for the target command No., and select the command
If the target command is not found in the list, press the [CHAR] key again to update the list.

Programming 4-39
4Basic operations

PR:1 ST:1 PR:1 ST:1 10) Press the [P] key while holding down the
LN:0 LN:0 [CHAR] key, and then release the [CHAR]
10 MOV 10 MOV P key.
CODE EDIT CODE EDIT "P" will be input.
-X
POS
CHAR ＋ (J1)
SPACE PQR
Input "P"

PR:1 ST:1 PR:1 ST:1 11) Press the [W] key twice while holding down
LN:0 LN:0 the [CHAR] key, and then release the
10 MOV P 10 MOV PW [CHAR] key.
CODE EDIT CODE EDIT "W" will be input.
+B
POS
CHAR ＋ (J5)
Input "W" 6 VWX

PR:1 ST:1 PR:1 ST:1

12) Input "A", "I" and "T" in the same manner.
LN:0 LN:0
10 MOV PW 10 MOV PWAIT
CODE EDIT CODE EDIT
POS -C -A +C
CHAR ＋ (J6) ・ (J4) ・ (J6)
Input "A","I","T" 0 ABC 2 GHI 5 STU

PR:1 ST:1 PR:1 ST:2

LN:0 LN:0 13) Press the [INP] key.
10 MOV PWAIT "10 MOV PWAIT" will be set.
CODE EDIT CODE EDIT
INP
EXE
Set

PR:1 ST:2 PR:1 ST:13

14) Input the program from line 20 to line 130 in
LN:0 LN:0
the same manner.
20 MOV PGET,+2 130 END
CODE EDIT CODE EDIT

This completes the inputting of the program.

◇◆◇ Displaying the previous and next command line ◇◆◇

To display the previous line, press the [BACKWD] key, and to display the next line, press the [FORWD] key.

◇◆◇ Displaying a specific line ◇◆◇

Press the [ ↑ ] and move the cursor to LN:. Input the No. of the line to be displayed in the parentheses, and then
press the [INP] key. The designated line will appear.

4-40 Programming
 4Basic operations

■ Teach the robot operation position.

Set the position with jog operation (Teaching PGET)
1) Move the robot with jog operation, and set
Hand the end of the hand to the position for
grasping the workpiece. When the position
has been set, open and close the hand to
confirm that the workpiece can be grasped.
Refer to "4.5 Jog operation" on page 33 for
Work
details on the jog operation, and section "4.6
Opening and closing the hand" on page 33 for
detains on opening and closing the hand.

◇◆◇ Effective use of jog mode ◇◆◇

When the robot's current position is greatly separate from the target position, move the robot in axis units with
the "JOINT JOG mode", to approach the position.
If the target position is nearby, move linearly with the "XYZ JOG mode", and finely adjust the position. The
position can be set accurately by delaying the override (operation speed) at this time.

Registering the position (Teaching PGET)

2) On the command editing screen, press the
PR:1 ST:13 [ADD] key while holding down the [POS] key.
MO.POS( )
LN:130 The position editing screen will appear.
X: +0.00
130 END Y: +0.00
CODE EDIT Z: +0.00
ADD
POS
CHAR ＋ ↑
Change to the position screen
3) Input "PGET" in the parentheses at
MO.POS(PGET ) MO.POS(PGET ) MO.POS, and then press the [INP] key.
X: +0.00 X: +0.00 The position variable name PGET will be
Y: +0.00 Y: +0.00 called, and the currently registered
Z: +0.00 Z: +0.00 coordinate value will appear.
-X -A -B +C
POS
＋ (J1) ・ (J4) ・ (J5) ・ (J6)
CHAR
SPACE PQR 2 GHI 1 DEF 5 STU Refer to " ◇◆◇ Inputting characters ◇◆
Input "P","G","E","T"
◇ " on page 39 for details on inputting
INP characters.
EXE

MO.POS(PGET ) MO.POS(PGET ) 4) Press the [ADD] key while holding down the
X: +0.00 [STEP] key, and release only the [ADD] key.
Y: +0.00 The buzzer will sound a "beep", and a
Z: +0.00 ADDITION ? confirmation message will appear.
While holding down the [STEP] key, press the
MO.POS(PGET ) MO.POS(PGET ) [ADD] key again.
X: +0.00 X: +132.30 The buzzer will sound a "beep", and the
Y: +0.00 Y: +254.10 message "ADDING" will appear. Then, the
ADDITION ? Z: +32.00 current position will be registered.

◇◆◇ Changing between the command editing screen and position editing screen. ◇◆◇
The commands are edited on the command editing screen, and the positions are edited on the position editing
screen.
To change from the command editing screen to the position editing screen, press the [POS] + [ADD] keys.
To change from the position editing screen to the command editing screen, press the [COND] key.

Programming 4-41
4Basic operations

MO.POS(PPUT ) MO.POS(PPUT ) 5) Teach PPUT (position to place workpiece)

X: +0.00 X: +132.30 and PWAIT (wait position) in the same
Y: +0.00 Y: +554.10 manner.
Z: +0.00 Z: +32.00

MO.POS(PWAIT ) MO.POS(PWAIT )
X: +0.00 X: +132.30
Y: +0.00 Y: +354.10
Z: +0.00 Z: +132.00

This completes teaching of the robot operation positions.

(4) Confirming the program

Using the T/B execute the program line by line (step operation), and confirm the operation.
The following operations are carried out while lightly pressing the deadman switch on the T/B.

MO.POS(PWAIT ) PR:1 ST:1 1) Press the [COND] key, and display the
X: +132.30 LN:10 command editing screen.
Y: +354.10 10 MOV PWAIT
Z: +132.00 CODE EDIT

COND
Change to the command screen
2) While holding down the [FORWD] key, hold
PR:1 ST:1 PR:1 ST:2 down the [EXE] key.
LN:10 LN:20 The robot will start moving.
10 MOV PWAIT 20 MOV PGET
CODE EDIT CODE EDIT When the execution of one line is completed,
the robot will stop, and the next line will
＋ INP appear on the screen.
FORWD
＋ EXE If [EXE] is released during this step, the
Start of step execution
robot will stop.

CAUTION Take special care to the robot movements during operation. If any abnormality occurs,
such as interference with the peripheral devices, release the [EXE] key and stop the
robot.

◇◆◇ Step operation ◇◆◇

"Step operation" executes the program line by line. The operation speed is slow, and the robot stops after each
line, so the program and operation position can be confirmed.
During execution, the lamp on the controller's [START] switch will light.

◇◆◇ Immediately stopping the robot during operation ◇◆◇

・ Press the [EMG. STOP] (emergency stop) switch.
The servo will turn OFF, and the moving robot will immediately stop.
To resume operation, reset the alarm, turn the servo ON, and start step operation.
・ Release or forcibly press the "deadman" switch.
The servo will turn OFF, and the moving robot will immediately stop.
To resume operation, lightly press the "deadman" switch, and start step operation.
・ Release the [EXE] key.
The step execution will be stopped. The servo will not turn OFF.
To resume operation, press the [EXE] key.

4-42 Programming
 4Basic operations

PR:1 ST:2 PR:1 ST:13 3) Carry out step operation up to the END
LN:20 LN:130 command at line No. 130, and confirm the
20 MOV PGET 130 END operation in the same manner.
CODE EDIT CODE EDIT If the robot operation or position is incorrect,
refer to the following operations and make
＋ INP
＋ corrections.
FORWD EXE
Start of step execution

(5) Correcting the program

■ Correcting the commands
As an example, the joint movement at line No. 70 will be changed to linear movement.
(Change 70 MOV PPUT, +20 to 70 MVS PPUT, +20) Note)

Call the line No.

1) Press the [ ↑ ] key to move the cursor to
PR:1 ST:1 PR:1 ST:1 LN: ( ).
LN:10 LN:(10)
10 MOV PWAIT 10 MOV PWAIT
CODE EDIT LINE NUMBER
ADD
↑
Using the cursor

PR:1 ST:1 PR:1 ST:7 2) Press the [7], [0] and [INP] keys. Line No. 70
LN:(70) LN:70 will appear.
10 MOV PWAIT 70 MOV PPUT,+20
CODE EDIT CODE EDIT

+A -C INP
(J4) (J6)
EXE
7 YZ_ 0 ABC
Input the line number

CAUTION Note) Upward movement is designated at a position along the Z axis of the TOOL coor-
dinate system, and the direction is designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Installation
Manual/ Robot arm setup and maintenance", and confirm the Z axis direction of
the TOOL coordinate system. Then, designate the correct sign (direction) that
matches the robot being used.
Designating the reverse direction could lead to interference with the peripheral
devices and damage.
Generally (in the default state), the hand retract direction is the "-" sign with the
vertical articulate type robot, and the "+" sign is the robot's upward direction
with the other robots.

◇◆◇ Cursor movement ◇◆◇

When the cursor is at a command line display, the command can be edited. When at a line No. display (LN:), the
line No. is designated.
The cursor is moved with the [ ↑ ], [ ↓ ], [ ← ] and [ → ] keys.

◇◆◇ Calling out a line No. ◇◆◇

When designating and calling out a line No., move the cursor to the line No. display (LN:), input the line No., and
then press the [INP] key.
The displayed line can be scrolled up or down by pressing the [FORWD] or [BACKWD] key.

Programming 4-43
4Basic operations

Change to the command

3) Press the [ ↓ ] key and move the cursor to
PR:1 ST:7 PR:1 ST:7 the command line.
LN:(70 ) LN:70 Press the [ → ] key six times, and move the
70 MOV PPUT,+20 70 MOV PPUT,+20 cursor to the right of "V".
LINE NUMBER CODE EDIT
RPL HAND
↓ →
Using the cursor

PR:1 ST:7 PR:1 ST:7 4) Press the [DEL] key, and delete "OV". "M"
LN:70 LN:70 will remain displayed.
70 MOV PPUT,+20 70 M PPUT,+20
CODE EDIT CODE EDIT
DEL
←
Deleting a character
5) Hold down the [CHAR] key.
PR:1 ST:7 1.MOV 2.MVS The four commands assigned to "M" will
LN:70 3.MVC 4.MVR appear.
70 M PPUT,+20 70 M PPUT,+20
CODE EDIT CODE EDIT

POS
CHAR
Display the command list
6) Press the [2] key while holding down the
1.MOV 2.MVS 1.MOV 2.MVS
[CHAR] key, and select "MVS".
3.MVC 4.MVR 3.MVC 4.MVR
70 M PPUT,+20 70 MVS PPUT,+20
CODE EDIT CODE EDIT
-A
POS (J4)
CHAR ＋ 2 GHI 7) Press the [INP] key, and set line No. 70. The
Select the "MVS" command
next line will appear on the screen.
PR:1 ST:7 PR:1 ST:8
LN:70 LN:80
70 MVS PPUT,+20 80 MVS PPUT
CODE EDIT CODE EDIT

INP
EXE
Set line 70

Line No. 70 has been changed to linear movement with the above operation.

◇◆◇ Correcting a character ◇◆◇

Move the cursor to the right of the incorrect character, and press the [DEL] key to delete in the left direction.
Then, input the correct character. The input character will be inserted at the cursor position.
If the cursor is returned by pressing the [ ← ] key, and a character is input, it will be inserted.

◇◆◇ After correcting a program ◇◆◇

After correcting the program, carry out step operation, and confirm that the program has been corrected.

4-44 Programming
 4Basic operations

■ Correcting the taught position

As an example, the wait position (PWAIT) will be corrected.

New wait position

(ＰＷＡＩＴ)
Change

Change the movement position

PR:1 ST:8 MO.POS( )
1) On the command editing screen, press the
LN:(80 ) X: +0.00
[ADD] key while holding down the [CHAR]
80 MVS PPUT Y: +0.00
key.
CODE EDIT Z: +0.00
The position editing screen will appear.
ADD
POS
CHAR ＋ ↑
Change to the position screen

MO.POS(PWAIT ) MO.POS(PWAIT ) 2) Input "PWAIT" in the parentheses at

X: +0.00 X: +132.30 MO.POS, and then press the [INP] key.
Y: +0.00 Y: +354.10 The position variable name PWAIT will be
Z: +0.00 Z: +132.00 called out, and the currently registered
-X +B -C coordinate value will appear.
POS
CHAR ＋ (J1) ・ (J5) ・ (J6) ・
SPACE PQR
6 VWX 0 ABC
Input "P","W","A","I","T"

-A +C INP
(J4) ・ (J6)
EXE
2 GHI 5 STU
　　

◇◆◇ Calling out a position variable ◇◆◇

Input the name of the variable to be called out in the parentheses at MO. POS on the position editing screen.
Then, press the [INP] key.
The displayed position variable can be scrolled up or down by pressing the [FORWD] or [BACKWD] key.

Programming 4-45
4Basic operations

JOINT LOW 3) Move the robot to the new wait position with
J1 +34.50 jog operation.
J2 +20.00
J3 +80.00

MO.POS(PWAIT ) MO.POS(PWAIT )
X: +132.30 X: +132.30 4) Press the [RPL] key while holding down the
Y: +354.10 Y: -284.10 [STEP] key, and release only the [RPL] key.
Z: +132.00 Z: +132.00 The buzzer will sound a "beep", and a
confirmation message will appear.
RPL RPL
STEP
＋ ↓ ・ ↓
While holding down the [STEP] key, press the
MOVE [RPL] key again.
Correct the position
The buzzer will sound a "beep", and the
message "Replacing" will appear. Then, the
current position will be registered.

This completes correction of the wait position.

◇◆◇ After correcting a program ◇◆◇

After correcting the program, carry out step operation, and confirm that the program has been corrected.

4-46 Programming
 4Basic operations

(6) Start automatic operation.

CAUTION Before starting automatic operation, always confirm the following item. Starting
automatic operation without confirming these items could lead to property damage or
physical injury.
・ Make sure that there are no operators near the robot.
・ Make sure that the safety fence is locked, and operators cannot enter
unintentionally.
・ Make sure that there are no unnecessary items, such as tools, inside the robot
operation range.
・ Make sure that the workpiece is correctly placed at the designated position.
・ Confirm that the program operates correctly with step operation.

In the following explanation, automatic operation will be carried out with the controller.
Prepare the controller
DISABLE ENABLE 1) Set the T/B [ENABLE/DISABLE] switch to
"DISABLE".

T/B disable

MODE
TEACH
2) Set the controller [MODE] switch to "AUTO
(Op.)".
AUTO AUTO
(Op.) (Ext.)

Controller enable

Set the operation speed

CHNG DISP STATUS NUMBER
3) Press the controller [CHNG DISP] switch
twice, and display the "OVERRIDE" on the
Display the override STATUS NUMBER display panel. (A "(" will
appear at the lower left.)
Press the [DOWN] key several times, and
UP display "10".
STATUS NUMBER The operation speed will be set to 10%.
DOWN

Set the override

CAUTION The servo will turn OFF when the controller's [MODE] switch is changed.
Note that axes not provided with brakes could drop with their own weight.
Carry out the following operations to prevent the servo from turning OFF when the
[MODE] switch is changed.

◇◆◇ Operations to change [MODE] switch without turning servo OFF ◇◆◇
(Only CR2A-572 controller)
(1) While holding down the deadman switch on the T/B, set the [ENABLE/DISABLE] switch to "DISABLE".
(2) While holding down the deadman switch on the T/B, set the controller [MODE] switch to "AUTO (Op.)".
(3) Release the T/B deadman switch.

Programming 4-47
4Basic operations

Select the program number

4) Press the [CHNG DISP] switch, and display
CHNG DISP STATUS NUMBER the "program No." on the STATUS NUMBER
display panel. (A "P" will appear at the head.)

Display the program number Confirm that the program No. targeted for
automatic operation is displayed.
With the previous operation, the program was
UP created in program No. 1, so "P. 0001" will
STATUS NUMBER
appear.
DOWN
If the correct program No. is not displayed,
Select the program number press the [UP] and [DOWN] keys to display
the correct program No.
Start automatic operation
START END
5) After pressing the controller [START] switch,
press the [END] switch.
Start End with one cycle
The robot operation will start and will stop
after one cycle.

CAUTION When executing the work example given in "Fig. 4-5Example of work" on page 34,
always press the [END] switch and end the program after one cycle. If the [END]
switch is not pressed, the hand will interfere with the existing workpiece when it goes
to pale the workpiece in the second cycle.

CAUTION Before starting automatic operation, always confirm that the target program No. is
selected.

CAUTION Take special care to the robot movements during automatic operation. If any
abnormality occurs, press the [EMG. STOP] switch and immediately stop the robot.

◇◆◇ Operating from the controller ◇◆◇

Set the T/B [ENABLE/DISABLE] switch to "DISABLE" and the controller [MODE] switch to "AUTO (Op.)".
Operations from the controller are not possible unless the controller [MODE] switch is set to "AUTO (Op.)".

◇◆◇ Operation speed ◇◆◇

The operation speed for automatic operation with the controller can be set.
When the override is displayed on the STATUS NUMBER display panel (with a " □ " displayed on the lower left)
the override display will increment or decrement each time the [UP] or [DOWN] key is pressed. The max. speed
is 100%.
Initially set a low speed, and gradually increase it.

4-48 Programming
 5Maintenance and Inspection

5 Maintenance and Inspection

The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are
described in this chapter. The types and replacement methods of consumable parts are also explained.

5.1 Maintenance and inspection interval

Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carry
out at set intervals. Always carry these out to prevent unforeseen trouble, to maintain the product for a long time,
and to secure safety.

(1) Inspection schedule

０ Hr

Monthly inspection

Monthly inspection

５ ０ ０ Hr Monthly inspection

Monthly inspection

Monthly inspection
Daily inspection

１ ０ ０ ０ Hr Monthly inspection

Monthly inspection

Monthly inspection

１ ５ ０ ０ Hr Monthly inspection

Monthly inspection

Monthly inspection

２ ０ ０ ０ Hr Monthly inspection Yearly inspection

Operating time

<Guideline for inspection period>

For one shift
8 Hr/day x 20 days/month x 12 months = approx. 1800 Hr
10 Hr/day x 20 days/month x 12 months = approx. 2400 Hr
For two shifts
15 Hr/day x 20 days/month x 12 months = approx. 3600 Hr

[Caution] According to the schedule on the above, when using the double shift, you should
make the inspections at half the regular intervals.

Fig.5-1 ： Inspection schedule

Maintenance and inspection interval 5-49

5Maintenance and Inspection

5.2 Inspection items

The controller inspection items are shown below.
Refer to section "Maintenance and Inspection" in the separate manual "Robot arm setup and maintenance", and
inspect the robot arm at the same time.

5.2.1 Daily inspection items

Carry out daily inspections following the procedures given in Table 5-1.

Table 5-1 ： Daily inspection items (details)

Procedure Inspection items (details) Remedies

Before turning the power ON (Check the following inspection items before turning the power ON.)

1 Is the power cable securely connected? Securely connect.

(Visual)

2 Are the machine cables between the robot arm and controller securely Securely connect.
connected?
(Visual)

3 Is the controller cover cracked, has any foreign matter adhered, or is Replace with a new part, or take remedial measures.
there any interference?

4 Is the controller filter dirty? Clean or replace with a new part.

After turning the power ON (Turn the power ON while monitoring the robot.)

1 Is there any abnormal movement or noise when the power was turned Refer to the Troubleshooting section and remedy.
ON?

During operation (Try moving with an original program.)

1 Check that the operation point is not deviated. If deviated, check the Refer to the Troubleshooting section and remedy.
following items.
1) Are any of the installation bolts loose?
2) Are the bolts at the hand installation section loose?
3) Is the position of the jigs, other than the robot, deviated?
4) If the positional deviation cannot be eliminated, refer to
"Troubleshooting", and remedy.

2 Is there any abnormal movement or noise? Refer to the Troubleshooting section and remedy.
(Visual)

5.2.2 Periodic inspections

Carry out periodic inspections following the procedures given in Table 5-2.

Table 5-2 ： Periodic inspection items (details)

Procedure Inspection items (details) Remedies

Monthly inspection items

1 Are any of the connector fixing screws or terminal block terminal Securely tighten the screws.
screws loose?

Yearly inspection items

1 Replace the backup battery in the controller.

5-50 Inspection items

 5Maintenance and Inspection

5.3 Maintenance and inspection procedures

The procedures for carrying out periodic maintenance and inspection are described below. Thoroughly compre-
hend the procedures, and follow the instructions. This work can be commissioned to the Mitsubishi Service Dept.
for a fee. (Never disassemble, etc., any of the parts not described in this section.)
The maintenance parts required for the maintenance and inspection are shown in section "5.4 Maintenance parts"
on page 40. Contact your dealer for these parts when required.

5.3.1 Replacing the battery

CAUTION The procedures for replacing the battery are described below.
If the system is used after the battery cumulative time over error (Error No. 7520)
occurs, the backup fault alarm will occur. If the backup fault alarm occurs, the con-
tents of the memory cannot be guaranteed, so save important program and position
data on a floppy disk using personal computer support software, etc.

CAUTION Replace the batteries for the controller and robot arm at the same time. Replace
the controller battery within 15 minutes after removing the old battery.

Screw-Ａ
Cabinet cover 1) Turn the controller power ON once. (For approx. one minute.)

2) Turn the controller power and base power OFF, and wait for
at least three minutes. Then, loosen the cabinet cover fixing
screw A, and remove the cover.

Battery 3) Remove the old battery installed in the battery holder on the
battery fixing plate. (Hold the connector and pull the battery
upward.)

4) Fix the new battery into the battery holder.

5) Hold both ends of the new battery's cable connector and

insert into the connectors on the relay card. Complete the
work within 15 minutes after removing the old battery.
Battery fixing plate
Battery holder Connecta
Battery
6) Refer to the separate manual "Detailed Explanation of Func-
tions and Operations", and reset the battery cumulative time
over alarm.

Relay card

Details of battery section

This completes the replacement of the controller battery.

Maintenance and inspection procedures 5-51

5Maintenance and Inspection

5.4 Maintenance parts

The consumable parts that must be replaced periodically are shown in Table 5-3, and spare parts that may be
required during repairs are shown in Table 5-4. Purchase these parts from the dealer when required. Some Mit-
subishi-designated parts differ from the maker's standard parts. Thus, confirm the part name, robot arm and con-
troller serial No. and purchase the parts from the dealer.

Table 5-3 ： Controller consumable part list

No. Part name Type Qty. Usage section Maker

1 Lithium battery ER6 BKO-NC2157H01 1 Control unit Mitsubishi Electric

Table 5-4 ： Controller spare part list

No. Part name Type Qty. Usage section Maker

1 Fuse LM16 1
RZ386 or RZ387 board
2 LM32 1

3 LM32 1
RZ802A board Mitsubishi Electric
4 HM32 1

5 MF60NR5A05 2 Rear side of the controller

6 Filter FLM6 1 Bottom of the controller

5-52 Maintenance parts

 MITSUBISHI ELECTRIC

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