95578F808E64976C8F91312E626F6F6B Mitsubishi Industrial Robot RV 6S 6Sspecs

User Manual: Mitsubishi Industrial Robot RV-6S

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Mitsubishi Industrial Robot

RV-6S Series
Standard Specifications Manual
(CR3-535M/CR2B-574 Controller)

BFP-A8322-E

Supplemental Instruction
Thank you for purchasing the Mitsubishi Industrial Robot MELFA Series.
This supplemental instruction manual provides additional explanations for some of the specifications
of the Mitsubishi industrial robot controller option “Expansion Serial Interface.” Therefore, check the
content, and use it together with your standard specifications.
1. Supplemental details
It is now possible to install up to three expansion serial interface cards per controller from Version B.
In addition, a tracking function has been added.
(The software version of the robot controller is K8 edition or later)
Accordingly, we have some supplemental details to add to the configuration and specifications. Please
refer to the following to make the best use of this option card.
■Configuration
Table 1: Configuration device
No.

Part name

Type

Qty.

<1>
<2>
<3>

Instruction manual (this document)
Tracking Function Manual
Expansion serial interface card

BFP-A8106
BFP-A8524
RZ581?

1
1
1

<4>

Ferrite core

E04SR301334

Remarks

The “?” show the version
of card.
Be sure to install this for
noise countermeasure.

Note) The numbers in the table correspond to the figure shown below.

<1>

<2>

<3>

<4>

■Specifications
Three cards can be installed on one controller.
(The communication line of maximum 6 channels cable connected.)
Type

Supporting software version
From the version
Version Ｋ7 or later
E1 to version K6

RZ581A or earlier
△
RZ581B or later
△

(*1)

△

○

Remarks
Unrelated to the software version,
up to two boards can be used.
(Option slot 1(OPT1)/ 2(OPT2))
Up to three boards can be used,
by using with version K7 or later.
(Option slot 1(OPT1)/ 2(OPT2)/ 3(OPT3))

△: The option slot 1(OPT1) or 2(OPT2) is available. (Up to two boards can be used.)

○: Every option slot is available. (Up to three boards can be used.)
(*1) Operation is compatible with RZ581A.

BFP-A8227-08

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
CAUTION

WARNING
CAUTION

WARNING
CAUTION
CAUTION
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
For teaching work, prepare a work plan related to the methods and procedures of
operating the robot, and to the measures to be taken when an error occurs or when
restarting. Carry out work following this plan. (This also applies to maintenance
work with the power source turned ON.)
Preparation of work plan
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
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
Provide a fence or enclosure during operation to prevent contact of the operator
and robot.
Installation of safety fence
Establish a set signaling method to the related operators for starting work, and follow this method.
Signaling of operation start
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
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
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
WARNING
CAUTION
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
WARNING

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 environment, etc.)
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.
Always use the robot installed on a secure table. Use in an instable posture could
lead to positional deviation and vibration.
Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
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.
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.
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.
Securely ground the robot and controller. Failure to observe this could lead to malfunctioning by noise or to electric shock accidents.
Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
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 injuries or damage if the robot is started with external commands.
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.
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.
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.
Never carry out modifications based on personal judgments, or use non-designated
maintenance parts.
Failure to observe this could lead to faults or failures.
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.Moreover, it may interfere with the peripheral device by drop or
move by inertia of the arm.
Do not turn off the main power to the robot controller while rewriting the
internal information of the robot controller such as the program or parameters.
If the main power to the robot controller is turned off while in automatic
operation or rewriting the program or parameters, the internal information of
the robot controller may be damaged.

■ Revision history
Date of print

Specifications No.

Details of revisions

2003-10-10

BFP-A8322

First print.

2004-03-02

BFP-A8322-A

Error in writing correction.

2006-01-16

BFP-A8322-B

Error in writing correction.

2006-06-05

BFP-A8322-C

Error in writing correction.

2006-07-12

BFP-A8322-D

Error in writing correction.

2007-07-10

BFP-A8322-E

Error in writing correction.

2006-06-05

BFP-A8322-C

Error in writing correction.

■ Introduction
This series is a full-scale industrial vertical multi-joint type robot that is designed for use in machining processes
and assembling. This series supports the oil mist environment as standard, offering a variety of specifications
including clean specification and long-arm specification.
However, to comply with the target application, a work system having a well-balanced robot arm, peripheral
devices or robot and hand section must be structured.
When creating these standard specifications, we have edited them so that the Mitsubishi robot's characteristics
and specifications can be easily understood by users considering the implementation of robots. However, if there
are any unclear points, please contact your nearest Mitsubishi branch or dealer.
Mitsubishi hopes that you will consider these standard specifications and use our robots.
Note that in this specification document the specifications related to the robot arm is described "2 Robot arm" on
page 6 , the specifications related to the controller "3 Controller" on page 38 , and software functions and a command list "4 Software" on page 99 separately.
The contents of this manual correspond to the following robot types.

・ RV-6S
・ RV-6SC
・ RV-6SL
・ RV-6SLC

・ No part of this manual may be reproduced by any means or in any form, without prior consent
from Mitsubishi.
・ The contents of this manual are subject to change without notice.
・ The specifications values are based on Mitsubishi standard testing methods.
・ 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.".
Please contact your nearest dealer if you find any doubtful, wrong or skipped point.
・ Microsoft, Windows, Microsoft Windows NT are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries.
Copyright(C) 2005 MITSUBISHI ELECTRIC CORPORATION

Contents
Page
1 General configuration ....................................................................................................................................................................
1.1 Structural equipment .............................................................................................................................................................
1.1.1 Standard structural equipment ..................................................................................................................................
1.1.2 Shipping special specifications ...................................................................................................................................
1.1.3 Options .................................................................................................................................................................................
1.1.4 Maintenance parts ...........................................................................................................................................................
1.2 Model type combination of robot ......................................................................................................................................
1.2.1 Combinations of robot arms and controllers ........................................................................................................
1.2.2 How to identify the robot model ................................................................................................................................
1.3 CE marking specifications ....................................................................................................................................................
1.4 Indirect export ..........................................................................................................................................................................
1.5 Instruction manuals ................................................................................................................................................................
1.6 Contents of the structural equipment ............................................................................................................................
1.6.1 Robot arm ...........................................................................................................................................................................
1.6.2 Controller ............................................................................................................................................................................
1.6.3 CR1B-571 controller ......................................................................................................................................................
1.6.4 CR2B-574 controller ......................................................................................................................................................
1.7 Contents of the Option equipment and special specification ..............................................................................

1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-3
1-4
1-4
1-5
1-5
1-6
1-7

2 Robot arm ........................................................................................................................................................................................... 2-9
2.1 Standard specifications ........................................................................................................................................................ 2-9
2.2 Definition of specifications ................................................................................................................................................ 2-10
2.2.1 Pose repeatability .......................................................................................................................................................... 2-10
2.2.2 Rated load (mass capacity) ....................................................................................................................................... 2-11
2.2.3 Relationships Among Mass Capacity, Speed, and Acceleration/Deceleration Speed ...................... 2-12
(1) Setting Load Capacity and Size (Hand Conditions) .................................................................................... 2-12
2.2.4 Vibrations at the Tip of the Arm during Low-Speed Operation of the Robot ..................................... 2-12
2.2.5 Protection specifications and working environment ....................................................................................... 2-13
(1) Types of protection specifications .................................................................................................................... 2-13
(2) About the use with the bad environment ........................................................................................................ 2-14
2.2.6 Clean specifications ...................................................................................................................................................... 2-15
(1) Types of clean specifications ............................................................................................................................... 2-15
2.3 Names of each part of the robot .................................................................................................................................... 2-16
2.4 Outside dimensions ・ Operating range diagram ........................................................................................................ 2-17
(1) RV-3SB/3SBC (6-axis type) ............................................................................................................................... 2-17
(2) RV-3SJB/3SJBC (5-axis type) .......................................................................................................................... 2-19
2.5 Tooling ........................................................................................................................................................................................ 2-21
2.5.1 Wiring and piping for hand .......................................................................................................................................... 2-21
2.5.2 Internal air piping ............................................................................................................................................................ 2-22
(1) General-purpose envi-ronment/Oil mist specifications ........................................................................... 2-22
(2) Clean type .................................................................................................................................................................... 2-22
2.5.3 Internal wiring for the pneumatic hand output cable ...................................................................................... 2-22
2.5.4 Internal wiring for the hand check input cable .................................................................................................. 2-22
2.5.5 Spare Wiring ..................................................................................................................................................................... 2-22
2.5.6 Wiring and piping system diagram for hand ......................................................................................................... 2-23
2.5.7 Electrical specifications of hand input/output .................................................................................................. 2-25
2.5.8 Air supply circuit example .......................................................................................................................................... 2-26
2.6 Shipping special specifications, options, and maintenance parts ...................................................................... 2-27
2.6.1 Shipping special specifications ................................................................................................................................. 2-27
(1) Machine cable ............................................................................................................................................................. 2-28
2.7 Options ....................................................................................................................................................................................... 2-29
(1) Machine cable extension ........................................................................................................................................ 2-30
(2) Changing the operating range .............................................................................................................................. 2-33
(3) Solenoid valve set ..................................................................................................................................................... 2-34
(4) Hand input cable ........................................................................................................................................................ 2-36
(5) Hand output cable ..................................................................................................................................................... 2-37
(6) Hand curl tube ............................................................................................................................................................ 2-38
2.8 Maintenance parts ................................................................................................................................................................. 2-39
i

Page
3 Controller .........................................................................................................................................................................................
3.1 Standard specifications ......................................................................................................................................................
3.1.1 Standard specifications ..............................................................................................................................................
3.1.2 Protection specifications and operating supply ...............................................................................................
3.2 Names of each part .............................................................................................................................................................
3.3 Outside dimensions/Installation dimensions .............................................................................................................
3.3.1 Outside dimensions ......................................................................................................................................................
3.3.2 Installation dimensions ................................................................................................................................................
3.4 External input/output .........................................................................................................................................................
3.4.1 Types ..................................................................................................................................................................................
3.4.2 Explanation .......................................................................................................................................................................
3.5 Dedicated input/output ......................................................................................................................................................
3.6 Emergency stop input/output .........................................................................................................................................
3.6.1 Connection of the external emergency stop .....................................................................................................
3.6.2 Door switch function ...................................................................................................................................................
3.7 Parallel input/output unit ..................................................................................................................................................
3.8 Options ......................................................................................................................................................................................
(1) Teaching pendant (T/B) ........................................................................................................................................
(2) Pneumatic hand interface .....................................................................................................................................
(3) Controller protection box ......................................................................................................................................
(4) Expansion option box ..............................................................................................................................................
(5) Parallel I/O unit .........................................................................................................................................................
(6) External I/O cable ....................................................................................................................................................
(7) Personal computer cable .......................................................................................................................................
(8) Extended serial interface .......................................................................................................................................
(9) CC-Link interface .....................................................................................................................................................
(10) Ethernet interface ..................................................................................................................................................
(11) Additional axis interface ......................................................................................................................................
(12) Extension memory cassette ..............................................................................................................................
(13) Personal computer support software/Personal computer support software mini .....................
(14) Instruction Manual(bound edition) ...................................................................................................................
3.9 Maintenance parts ................................................................................................................................................................
4 Software .........................................................................................................................................................................................
4.1 List of commands ...............................................................................................................................................................
(1) The procedure of robot language selection .................................................................................................
(2) MELFA-BASIC Ⅳ commands ...........................................................................................................................
4.2 List of parameters ..............................................................................................................................................................
(1) List of parameters ..................................................................................................................................................
(2) Change the display language / 表示言語の切 り 替え ............................................................................

3-40
3-40
3-40
3-42
3-43
3-46
3-46
3-48
3-49
3-49
3-49
3-50
3-52
3-52
3-54
3-55
3-60
3-61
3-64
3-67
3-70
3-72
3-82
3-84
3-86
3-88
3-90
3-92
3-94
3-96
3-98
3-99

4-100
4-100
4-100
4-101
4-103
4-103
4-105

5 Instruction Manual ...................................................................................................................................................................... 5-106
5.1 The details of each instruction manuals ................................................................................................................... 5-106
6 Safety .............................................................................................................................................................................................. 6-108
6.1 Safety ...................................................................................................................................................................................... 6-108
6.1.1 Self-diagnosis stop functions ................................................................................................................................ 6-108
6.1.2 External input/output signals that can be used for safety protection measures ........................... 6-108
6.1.3 Precautions for using robot .................................................................................................................................... 6-109
6.1.4 Safety measures for automatic operation ........................................................................................................ 6-109
6.1.5 Safety measures for teaching ................................................................................................................................ 6-109
6.1.6 Safety measures for maintenance and inspections, etc. ........................................................................... 6-109
6.1.7 Examples of safety measures ................................................................................................................................ 6-110
6.2 Working environment ......................................................................................................................................................... 6-112
6.3 Precautions for handling .................................................................................................................................................. 6-113
7Appendix ........................................................................................................................................................................... Appendix-114
Appendix 1 ： Specifications discussion material ......................................................................................... Appendix-114
ii

1General configuration

1 General configuration
1.1 Structural equipment
Structural equipment consists of the following types.

1.1.1 Standard structural equipment
The following items are enclosed as a standard.
(1) Robot arm
(2) Controller
(3) Machine cable
･ In the case of the CR3-535M, it is connected to the controller.
･ In the case of the CR2B-574, it is disconnected from the controller.
(4) Robot arm installation bolts
(5) Safety manual, CD-ROM (Instruction manual)
(6) Guarantee card

1.1.2 Shipping special specifications
Part of the standard structural equipment is changed at the time of factory shipment. Consequently, kindly confirm the delivery date.
To make changes to the specifications after shipment, service work must be performed at the work site or the
robot must be returned for service.

1.1.3 Options
Installation is possible after shipment. Customer needs to perform the installation work.

1.1.4 Maintenance parts
Consumable parts and spare parts for maintenance use.
For items not listed, contact the dealer where you made your purchase.

Structural equipment 1-1

1General configuration

1.2 Contents of the structural equipment
1.2.1 Robot arm
The list of structural equipment is shown in Fig. 1-1.

Vertical six-axis
multiple-jointed type

Machine cable
(Standard product: 7m(CR3-535M) accessory,
5m(CR2B-574) attachment)

Machine cable: CR2B-574 only
(Fixed type: 2m)
・ 1S-02CBL-01
Machine cable extension
・ Fixed type: 1S- □□ CBL-01
・ Flexed type: 1S- □□ LCBL-01

RV-6S/6SL/6SC/6SLC
*Refer to Page 6, "2.1.1 Standard
specifications" for ditails on the
specifications.

Note1) □□ refer the length.
Refer to Table 1-1 for datails.
Note2) Extend by adding to the arm side of the
standard accessory cable (for fastening).

Solenoid valve set
(Hand output cable is attached)

・ 1 set: 1S-VD01-02/1S-VD01-02E
・ 2 set: 1S-VD02-02/1S-VD02-02E
・ 3 set: 1S-VD03-02/1S-VD03-02E
・ 4 set: 1S-VD04-02/1S-VD04-02E

・ 1S-GR35S-01 (4sets)

Hand input cable

・ 1S-HC25C-01

Hand curl tube

・1
・2
・3
・4

set:
set:
set:
set:

1E-ST0402C
1E-ST0404C
1E-ST0406C
1E-ST0408C

Pneumatic hand customer-manufactured parts

Hand output cable

Stopper for changing the operating range
of the J1 axis
・ Stopper part: 1S-DH-02
*This must be installed by the customer.

［Caution］

Standard configuration
equipment
Special shipping
specifications
Option
Prepared by customer

Fig.1-1 ： Structural equipment (Robot arm)
1-2 Contents of the structural equipment

1General configuration

1.2.2 Controller
The devices shown below can be installed on the controller.

Controller
・ CR3-535M

Controller
・ CR2B-574

Caster type controller

Teaching pendant (T/B)
・ R28TB

*1)

Pneumatic hand interface
・ 2A-RZ365 (Sink)
・ 2A-RZ375 (Source)

Parallel I/O unit
・ 2A-RZ361 (Sink)
・ 2A-RZ371 (Source)

External I/O cable

*1) Choose either a CR3 or
CR2B controller that is
suited to your application.

・ 2A-CBL05 (5m)
・ 2A-CBL15 (15m)

PLC(Programmable
Logic Controller)
External device
Prepared by customer

*2)
Extended serial
interface

*2)
CC-Link interface
・ 2A-HR575-E

*2)
Ethernet interface
・ 2A-HR533-E
2A-HR533

・ 2A-RZ581-E

Personal computer
cable
・ RS-MAXY-CBL

Personal computer
Prepared by customer

Instruction Manual
(bound edition)
・ 4S-MAP-102(for CR2B-574)
・ 4S-MAP-105(for CR3-535M)

*2) *3）
Additional axis
interface

Extension memory
cassette

・ 2A-RZ541-E

・ 2A-HR432

Personal computer support software
･ 3A-01C-WINE(CD-ROM)
(MS-Windows95/98/2000/NT4.0/Me/XP)
Personal computer support software mini
･ 3A-02C-WINE(CD-ROM)
(MS-Windows95/98/2000/NT4.0/Me/XP)

*2) There are some restrictions on the
number of optional interfaces and
their combinations.
Refer to the separate "Controller
setup, basic operation, and maintenance" for details.
*3) As the CR3-535M controller is
equipped with the additional axis
function as standard, it is not necessary to use this option.

［Caution］

Standard configuration
equipment
Special shipping
specifications
Option
Prepared by customer

Fig.1-2 ： Structural equipment(Controller)

Contents of the structural equipment 1-3

1General configuration

1.3 Contents of the Option equipment and special specification
A list of all Optional equipments and special specifications are shown below.
Table 1-1 ： The list of Option equipment and special specification
Item

Type

Stopper for changing the
operating range of the J1
axis

1S-DH-02

Machine cable(Replaced
with shorter cable)
Extended machine cable
(Extension type)

1S-02CBL-1
1S- □□ CBL-01
1S- □□ LCBL-01

Solenoid valve set

Specifications
Stopper part
+ side: +135, +90, or +45 deg.
- side: -135, -90, or -45 deg.
One each of the following can be
selected: ± 170 deg. are used for
the standard specification.
For fixing
(Two sets for power and signal)

Classificati
on Note1)
○

○・□

Descripsion

This must be installed by the customer.

2m(A 2 m cable is supplied instead of the 5 m
cable that is supplied as standard)

For fixing
(Two sets for power and signal)
For bending
(Two sets for power and signal)
1 set (Sink type)
2 set (Sink type)
3 set (Sink type)
4 set (Sink type)
1 set (Source type)
2 set (Source type)
3 set (Source type)
4 set (Source type)
Length 350mm with robot side connector. One terminal is not treated.

○

5, 10, 15ｍ

○
○
○
○
○
○
○
○
○

5, 10, 15ｍ

○

The cable is connected to the hand output connector by the customer.
The cable is connected to the sensor by the customer.

Hand output cable

1S-VD01-02
1S-VD02-02
1S-VD03-02
1S-VD04-02
1S-VD01E-02
1S-VD02E-02
1S-VD03E-02
1S-VD04E-02
1S-GR35S-01

Hand input cable

1S-HC25C-01

One terminal is not treated.

○

Hand curl tube

1E-ST0402C

For solenoid valve 1set.:Φ4x2

○

1E-ST0404C

For solenoid valve 2set.:Φ4x4

○

1E-ST0406C

For solenoid valve 3set.:Φ4x6

○

1E-ST0408C

For solenoid valve 4set.:Φ4x8

○

R28TB

Cable length 7m

○

R28TB-15

○

2A-RZ365

Cable length 15m
(special specification)
DO: 8 point (Sink type)

2A-RZ375

DO: 8 point (Source type)

○

2A-RZ361

DO: 32 point (Sink type)/
DI : 32 point (Sink type)

○

2A-RZ371

DO: 32 point (Source type)/
DI : 32 point (Source type)

○

2A-CBL05

○

2A-CBL15

15m

○

Personal computer cable

RS-MAXY-CBL

RS-232C cable 3m for PC-AT compatible model

○

Personal computer
Support software

3A-01C-WINE

CD-ROM

○

MS-Windows98/2000/NT4.0/Me/XP
(With the simulation function)

Personal computer
Support software mini

3A-02C-WINE

CD-ROM

○

MS-Windows98/2000/NT4.0/Me/XP

Extended serial interface

2A-RZ581-E

RS-232C x 1
RS-232C or RS-422 x 1

○

CC-Link interface

2A-HR575-E

Local station (The local station alone
is supported.)

○

Ethernet interface

2A-HR533-E

ETHERNET x 1

○

2A-RZ541-E

SSC x 1
Up to 8 axises can be added

○

2A-HR432

Teaching point number: 25,400
Steps number: 50,800
Program number: 100

○

CR3-535M

Self-contained floor type, Closed
type (IP54)

□

Specifications with casters

□

Teaching pendant

Pneumatic hand interface
Parallel I/O interface

External I/O cable

Additional
axis interface
Note3）
Extended memory cassette
Controller specification
with countermeasure
against oil mist Note4）
Caster specifications
controller Note5）

A solenoid valve set for the pneumatic hand

Curl type air tube

With 3-position deadman switch/ IP 65

○
The unit for expansion the external input/output.
Electrical isolated Type
(100mA/Point)
Use to connect the external peripheral device to
the parallel input/output unit

for MELSEC PLC with CC-Link connection.
MR-J2 servoAmplifer Unit connection. CR-EB3 is
need.
The battery backup function is provided.
Together with 2,500 points of standard teaching
positions, the total number of teaching positions is
27,900 points.

The controller height
will be h =615.

Note1) In the classification column, ○ refers to an option,and □ to a Shipping special specifications.
Note2) This option only applies to the CR2B-574 controller.
Note3) The CR3-535M controller is installed with the additional axis function as standard. This optional function is
applicable to the CR2B-574 controller only.
Note4) Be sure to select the CR3-535M controller (-SM specification) if you intend to use the controller in environments where oil mist is present.
Note5) This option only applies to the CR3-535M controller (-SM specification).
1-4 Contents of the Option equipment and special specification

1General configuration

Table 1-1 ： The list of Option equipment and special specification (Continued)
Item

Type

Instruction Manual
(CR2B-574 controller version) 4S-MAP-102
Safety Manual
Standard Specifications

BFP-A8006
BFP-A8322

Robot Arm Setup & Maintenance

BFP-A8323

Controller Setup, Basic
Operation and Maintenance

BFP-A5991

Detailed Explanation of FuncBFP-A5992
tions and Operations
Troubleshooting

BFP-A5993

Instruction Manual
(CR3-535M controller version) 4S-MAP-105
Safety Manual
Standard Specifications

BFP-A8006
BFP-A8322

Robot Arm Setup & Maintenance

BFP-A8323

Controller Setup, Basic
Operation and Maintenance

BFP-A8324

Detailed Explanation of FuncBFP-A5992
tions and Operations
Troubleshooting

BFP-A5993

Additional axis interface

BFP-A8107

Specification
Instruction manual set for the CR2B-574 controller
Items relating to safety in handling the robot
Specification of the robot arm and controller
Installation method of the robot arm, jog operation, and maintenance and inspection procedures
Installation method of the controller, basic
operation, and maintenance and inspection procedures
Functions of the controller and T/B, operation
method, and explanation of MELFA-BASIC Ⅳ
Causes of errors occurred and their countermeasures
Instruction manual set for the CR3-535M controller
Items relating to safety in handling the robot
Specification of the robot arm and controller
Installation method of the robot arm, jog operation, and maintenance and inspection procedures
Installation method of the controller, basic
operation, and maintenance and inspection procedures
Functions of the controller and T/B, operation
method, and explanation of MELFA-BASIC Ⅳ
Causes of errors occurred and their countermeasures
Functions and operation method of the additional axis interface

Classification
Note1)

Descripsion

○
○
○
○

○
○
○
○
○
○
○

○
○
○
○

Note1) In the classification column, ○ refers to an option,and □ to a Sipping special specifications.

Contents of the Option equipment and special specification 1-5

2Robot arm

2 Robot arm
2.1 Standard specifications
2.1.1 Standard specifications
Table 2-1 ： Tab Standard specifications of robot
Item

Unit

Type
Type of robot
Degree of freedom
Installation posture
Structure
Drive system
Position detection method
Upper arm
Arm length
Fore arm
Waist (J1)
Shoulder (J2)
Elbow (J3)
Operating
range
Wrist twist (J4)
Wrist pitch (J5)
Wrist roll (J6)
Waist (J1)
Shoulder (J2)
Elbow (J3)
Speed of
motion
Wrist twist (J4)
Wrist pitch (J5)
Wrist roll (J6)
Maximum resultant velocity Note1)
Load
Maximum Note2)
Rating
Pose repeatability Note3)
Ambient temperature
Mass
Wrist twist (J4)
Allowable
moment load Wrist pitch (J5)
Wrist roll (J6)
Wrist twist (J4)
Allowable
Wrist pitch (J5)
inertia
Wrist roll (J6)
Arm reachable radius froot p-axis
center point
Tool wiring Note5)

Degree

Degree/
s

mm/sec
kg
mm
℃
kg
N･m

kg ･ m2

Specifications
RV-6S
RV-6SC
RV-6SL
RV-6SLC
6-axis standard arm
6-axis long arm
Clean
Clean
Standard
Standard
(Special Specifications)
(Special Specifications)
6
On floor, hanging
On floor
On floor, hanging
On floor
Vertical, multiple-joint type
AC servo motor (brake provided on all axes)
Absolute encoder
280
380
315
425
340(-170 to +170)
227(-92 to +135)
273(-107 to +166)
295(-129 to +166)
320(-160 to +160)
240(-120 to +120)
720(-360 to +360)
401
250
321
267
401
267
352
450
660
Approx. 9,300
Approx. 8,500
6
5
± 0.02
0 to 40
Approx. 58
Approx. 60
12
12
4.5
0.29
0.29
0.046 Note4)

696

902

Hand input 8 point / hand output 8 point
Four spare wires :
Six spare wires :
Four spare wires :
AWG#24(0.2mm2)
AWG#28(0.1mm2)
AWG#24(0.2mm2)
(shielded)
Primary side: Φ6 × 2 (Base to fore arm section)
0.49 ± 10%
J1 to J3 axis : IP54
J1 to J3 axis : IP54
J4 to J6 axis : IP65
J4 to J6 axis : IP65
10(0.3μm)
10(0.3μm)
Internal suction
Internal suction
requirement
requirement
Light gray （Equivalent to Munsell: 0.8GY7.64/0.81)
Six spare wires :
AWG#28(0.1mm2)
(shielded)

Tool pneumatic pipes
Supply pressure
Protection

specificationNote6)

Degree of cleanlinessNote7)
Painting color

MPa

Note1) This is the value on the hand flange surface when all axes are combined.
Note2) The maximum load capacity is the mass with the flange posture facing downword at the ± 10°limit.
Note3) The pose repeatability details are given in Page 7, "2.2.1 Pose repeatability"
Note4) Up to 0.092kg ･ m2 can be supported by performing variable acceleration/deceleration control and also by setting the
load inertia.
Note5) The air hand interface (option) is required when the tool (hand) output is used. Also, if the solenoid set (option) is
used, eight points of hand outputs are used for other options. ｡
Note6) The protection specification details are given in Page 10, "2.2.5 Protection specifications and working environment".
Note7) The clean specification details are given in Page 11, "2.2.6 Clean specifications" .A down flow(0.3m/s or more) in the
clean room is the necessary conditions for the cleanliness.

2-6 Standard specifications

2 Robot arm

2.2 Definition of specifications
The accuracy of pose repeatability mentioned in catalogs and in the specification manual is defined as follows.

2.2.1 Pose repeatability
For this robot, the pose repeatability is given in accordance with JIS 8432 (Pose repeatability). Note that the value
is based on 100 measurements (although 30 measurements are required according to JIS).
［Caution］ The specified "pose repeatability" is not guaranteed to be satisfied under the following conditions.
[1] Operation pattern factors
1) When an operation that approaches from different directions and orientations are included in relation to the teaching position during repeated operations
2) When the speed at teaching and the speed at execution are different
[2] Load fluctuation factor
1) When work is present/absent in repeated operations
[3] Disturbance factor during operation
1) Even if approaching from the same direction and orientation to the teaching position, when the
power is turned OFF or a stop operation is performed halfway
[4] Temperature factors
1) When the operating environment temperature changes
2) When accuracy is required before and after a warm-up operation
[5] Factors due to differences in accuracy definition
1) When accuracy is required between a position set by a numeric value in the robot's internal coordinate system and a position within the actual space
2) When accuracy is required between a position generated by the pallet function Note1) and a position within the actual space

Note1)
The pallet function is a function that teaches only the position of the work used as reference (3 to 4 points) and
obtains the remaining positions by calculations, for an operation that arranges works orderly or for an operation
that unloads orderly arranged works. By using this function, for example, in the case of an operation that arranges
works on grid points of 100 x 100, by teaching only three points of four corners, the remaining grid points are
automatically generated; thus, it is not necessary to teach all 10,000 points. For more information about the pallet
function, refer to the separate volume, "Instruction Manual/Detailed Explanation of Functions and Operations."

Definition of specifications 2-7

２ Robot arm

2.2.2 Rated load (mass capacity)
The robot's mass capacity is expressed solely in terms of mass, but even for tools and works of similar mass,
eccentric loads will have some restrictions. When designing the tooling or when selecting a robot, consider the fol lowing issues.
(1) The tooling should have the value less or equal than the smaller of the tolerable inertia and the tolerable
moment found in Page 6, "Table 2-1 ： Tab Standard specifications of robot"
(2) Fig. 2-1 shows the distribution dimensions for the center of gravity in the case where the volume of the
load is relatively small. Use this figure as a reference when designing the tooling.
(3) When the load is not mass, but force, you should design the tooling so that it does not exceed the value for
allowable moment described in Page 6, "Table 2-1 ： Tab Standard specifications of robot"
[Caution] The mass capacity is greatly influenced by the operating speed of the robot and the motion posture.
Even if you are within the allowable range mentioned previously, an overload or generate an overcurrnt
alarm could occur. In such cases, it will be necessary to change the time setting for acceleration/deceleration, the operating speed, and the motion posture.
[Caution] The overhang amount of the load for the specified moment and inertia in this section is the dynamic
limit value determined by the motor driving each axis and by the capacity of the reduction gears. Consequently, accuracy cannot be guaranteed for the entire tooling area. Since accuracy is based on the
center point of the mechanical interface surface, position accuracy can diminish as you go away from
the flange surface, or vibration can result, with tooling that is not rigid or that is long.
[Caution] Even within the allowable range previously mentioned, an overload alarm may be generated if an ascending operation continues at a micro-low speed. In such a case, it is necessary to increase the ascending
speed.

Unit : mm
200

Rotation center for J5 axis
125

2.5kg

100
90

5.0kg

200

300

400

100

Rotation center for J6 axis

90
100
125

340

245

200

Fig.2-1 ： Position of center of gravity for loads (for loads with comparatively small volume):RV-6S/6SL Series

2-8 Definition of specifications

２ Robot arm

2.2.3 Relationships Among Mass Capacity, Speed, and Acceleration/Deceleration Speed
This robot automatically sets the optimum acceleration and deceleration speeds and maximum speed, according
to the load capacity and size that have been set, and operates using these automatically set speeds.
To achieve that, it is necessary to correctly set the actual load data (mass and size of hand and work) to be used.
However, vibration, overheating and errors such as excessive margin of error and overload may occur,depending
on the robot operation pattern or ambient temperature. In such a case, change the setting value to the +20%
range. If a setting is performed in such a way that it falls below the mounted load, the life span of the mechanism
elements used in the robot may be shortened. In the case of a work requiring a high degree of accuracy, set up the
load correctly and use the robot by lowering the ratios of the acceleration and deceleration speeds.

(1) Setting Load Capacity and Size (Hand Conditions)
Set up the capacity and size of the hand with the "HNDDAT*" parameter (optimum acceleration/deceleration
setting parameter), and set up the capacity and size of the work with the "WRKDAT*" parameter. Numbers 0 to 8
can be used for the asterisk (*) part. Designate the "HNDDAT*" and "WRKDAT*" parameters to be used using
the "LOADSET" command in a program.
For more details, refer to the separate "Instruction Manual/Detailed Explanation of Functions and Operations."
It is the same meaning as "LOADSET 0.0" if not using the "LOADSET".

2.2.4 Vibrations at the Tip of the Arm during Low-Speed Operation of the Robot
Vibrations at the tip of the arm may increase substantially during the low-speed operation of the robot, depending
on the combination of robot operation, hand mass and hand inertia. This problem occurs when the vibration count
specific to the robot arm and the vibration count of the arm driving force are coming close to each other. These
vibrations at the tip of the arm can be reduced by taking the following measures:
1) Lower the robot's operating speed by approximately 5% from high speed using the OVRD instruction.
2) Change and move the teaching points of the robot.
3) Change the hand mass and hand inertia.

Definition of specifications 2-9

２ Robot arm

2.2.5 Protection specifications and working environment
(1) Types of protection specifications
The robot arm has protection specifications that comply with the IEC Standards. The protection specifications
and applicable fields are shown in Table 2-2.
Even oil mist environment can be used in addition to the general environment.
Table 2-2 ： Protection specifications and applicable fields
Type
RV-6S
RV-6SL

Protection
specifications
(IEC Standards value)
IP54
(J1 to J3 axis)
IP65
(J4 to J6 axis)

Classification
General-purpose
environment specifications
Oil mist specifications

Applicable field

Remarks

General assembly
Slightly dusty environment
Machine tool (cutting)
Machine shop with heavy oil mist
Dusty work shop

Note that if the cutting machine
contains abrasive materials, the
machine line will be shortened.

The IEC IP symbols define the degree of protection against solids and fluids, and do not indicate a protective
structure against the entry of oil or water.
The evaluation regarding oil mist specifications has been confirmed with Mitsubishi's standard testing methods
using the cutting oils shown in Table 2-3
Table 2-3 ： Tested cutting oil for oil mist specifications
Name
Emulcut
FA-800

Maker
Kyodo Yushi Co., Ltd

Relevant JIS
Class A1 No. 2

Main characteristics
Water soluble cutting oil
・ Base oil........................................................ 50-60％
・ Surfactant and rust inhibitor.............. 30-40％
・ Additives..................................................... 5％ or less
・ Water .......................................................... The rest

Application
Water soluble cutting oil
Emulcut

【Information】
・ The IEC IP54
The IEC IP54 standard refers to protection structure designed to prevent any harmful effects by fresh water
scattering vertically onto the testing equipment in a radius of 180 degrees from a distance of 300 to 500 mm,
with 10 ± 0.5 liters of water every minute, at a water pressure of 80 to 100kPa , covering the entire area of
the robot with the exception of the installation section at 1 ㎡ per minute, for a total of 5 minutes or more.
・ The IEC IP65
Protection against water infiltration as specified in IP65 indicates a protective structure that is not harmfully
affected when 12.5 ± 5% liters of water is supplied from a test device at a position approx. 3m away in various
directions and a water pressure of 30kPa at the nozzle section. The water is filled one minute per 1m2 of test
device surface area for a total of three minutes.

(2) About the use with the bad environment
This robot has protection methods that conform to IEC'sIP54 (for J1 to J3 axis) and IP65 (for J4 to J6 axis) stan dards (splashproof type). Recommended usage conditions.
1) The robot is designed for use in combination with machining device.
2) Please examine cutting oil referring to Table 2-3 used by a standard examination of our company.
3) Take measures so that the robot will not be exposed to water, oil and/or chips for a long period of time.
The warranty is invalid for any faults that occur when the robot is used under the following conditions.
Also, if the cover and/or other parts are damaged by interferences caused by the peripheral devices and the
robot, the protection specification (seal performance, etc.) may be degraded. Therefore, please pay extra attention
when handling the robot.
Refer to Page 111, "6.2 Working environment".
1) In surroundings that generate inflammable gases or corrosive gasses.
2) Atmosphere used excluding cutting oil shown in Table 2-3
3) Environment where the robot is exposed to water, oil and/or chips for a long period of time.
4) In surroundings where chips fall directly on the robot.In surroundings where the minimum diameter of chips
is less than 0.5mm.
5) Mist atmosphere exceeding the specification.
2-10 Definition of specifications

２ Robot arm

2.2.6 Clean specifications
(1) Types of clean specifications
The robot arm with clean specification is made by order. Please check the delivery schedule.
Table 2-4 ： Clean specifications
Clean specifications
RV-6SC-SA
RV-6SLC-SA

Type

Degree of cleanliness

Internal suction

10(0.3μm)

Concentrated suction with vaccum generating valve.

The use of a vacuum generating valve
is recommended.

Table 2-5 ： Specifications of vacuum generation valve
Type

Maker

Air pressure

MEDT 14

KONEGAI CORPORATION

0.2 to 0.6 MPa

■ Precautions for use
1) When using a device that moves or rotates the robot arm, the down flow may not be secured because of the
air flow. In this case, the degree of cleanliness cannot be ensured.
2) A Φ8 coupling is provided in the base section of the robot arm for suction inside the robot arm. When using
the robot, connect this coupling with the vacuum generating valve and vacuum pump (furnished by the customer).
* Install the vacuum generating valve downstream of the downflow or install a filter in the exhaust air sec tion so that the exhaust air from the vacuum generating valve does not affect cleanness.
Recommended filter: Exhaust filter EF300-02, Koganei Corporation
* If any vacuum pump is prepared by the customer, assure on the vacuum side flow rate 30 liters/min.(ANR)
or more .
3) When using the Mitsubishi standard option solenoid valve set, use the spare piping (Φ6 pneumatic hose) of
the primary piping to exhaust the air.
If the exhaust leaks into the robot arm, the degree of cleanliness could be affected.

Definition of specifications 2-11

２ Robot arm

2.3 Names of each part of the robot

Fore arm

J5 axis

Elbow block

J4 axis

＋
－
＋

Mechanical interface
(Hand installation flange surface)

＋
－

－

J3 axis

＋
J6 axis －

Upper arm
＋
Shoulder
－

－
J2 axis

J1 axis

＋

Base

Fig.2-2 ： Names of each part of the robot

2-12 Names of each part of the robot

２ Robot arm

2.4 Outside dimensions ・ Operating range diagram
(1) RV-6S/6SC

2-φ6 holes
(prepared holes for φ8 positioning pins)

4-φ9 installation hole

φ31.5

6.3a (Installation)

φ20H7 +0.021
depth 7.5
0
0
φ40ｈ8 -0.039
depth 6.5

6.3a (Installation)

122

4-M5 screw, depth 9

160

204

115

45°

96
102.5
205
115

View D bottom view drawing : Detail of installation dimension

View A: Detail of mechanical interface

78 73

φ70

51.5

58.5

110

78 84

340
165

140

200

depth 5
φ5H7 +0.012
0

Screw holes for fixing wiring hookup (M4)
(for customer use)

View C: Detail of screw holes for fixing wiring hookup
140
315

120

90
63

165
90

162

φ53

100 80.5

280

φ1

200
φ158

Machine cable

350

8
R9

B
204

* Dimensions when installing a solenoid valve (optional)

115

140

200
(Maintenance space)

Fig.2-3 ： Outside dimensions : RV-6S/6SC

Outside dimensions ・ Operating range diagram 2-13

２ Robot arm

170°

P-point path: Reverse range
(alternate long and short dash line)

170°

P-point path: Entire range
(solid line)

R2
02

26
R5
R6
96

R2
58

170°
170°

315

Flange downward
limit line(dotted line)

308

Restriction on wide angle
in the rear section Note2)

R280

238

R2
87

R28

Restriction on wide angle
in the front section Note5)

135
°

594

°
17

179

R611

421

294

R173

R331

961

280

100

Restriction on wide angle
in the rear section Note1)
31
R3
92°

350

Restriction on wide angle
in the rear section Note3)

Areas as restricted by Note1) and Note3)
within the operating range

76°

Restriction on wide angle
in the front section Note4)

444
437

258

474

Restriction on wide angle in the rear section
Note1) J2＋Ｊ3×2 ≧ -200 degree when -45 degree≦ J2 ＜ 15 degree.
Note2) J2＋Ｊ3 ≧ 8 degree when ｜J1｜≦ 75 degree, Ｊ2 ＜ -45 degree.
Note3) J2＋Ｊ3 ≧ -40 degree when ｜J1｜＞ 75 degree, Ｊ2 ＜ -45 degree.
Restriction on wide angle in the front section
Note4) J3 ≧ -40 degree when -105 degree≦ J1 ≦ 95 degree, J2 ≧ 123 degree.
Note5) J2 ≧ 110 degree when J1 ＜ -105 degree, J1 ＜ -95 degree.
However, J2 - J3 ≦ 150 degree when 85 degree J2 ≦ 110 degree.

Fig.2-4 ： Operating range diagram : RV-6S/6SC
2-14 Outside dimensions ・ Operating range diagram

２ Robot arm

(2) RV-6SL/6SLC

2-φ6 holes
(prepared holes for φ8 positioning pins)

4-φ9 installation hole

122

φ31.5

204

4-M5 screw, depth 9

160

115

45°

φ5H7 +0.012
depth 5
0

6.3a (Installation)

φ20H7 +0.021
depth 7.5
0
0
φ40ｈ8 -0.039
depth 6.5

View A: Detail of mechanical interface

205
115

140

58.5

Screw holes for fixing wiring hookup (M4)
(for customer use)

View C: Detail of screw holes for fixing wiring hookup
85

425

85
90
63

165
120

162

200

78 73

φ70

51.5

110

78 84

102.5

View D bottom view drawing : Detail of installation dimension

413
165

φ53

100 80.5

380

58
φ1

200
φ158

Machine cable

239

350

8
R9

B
* Dimensions when installing a solenoid valve (optional)
204

115

140

200
(Maintenance space)

Fig.2-5 ： Outside dimensions : RV-6SL/6SLC

Outside dimensions ・ Operating range diagram 2-15

２ Robot arm

P-point path: Reverse range
(alternate long and short dash line)

170°
170°

P-point path: Entire range
(solid line)

R1
85

32
R7
R9
02

R2
85

170°
170°

Flange downward
limit line(dotted line)

425

85
333

403

Restriction on wide angle
in the rear section Note3)

380

R4
37
135
°

476

R437

98
R1

37
R4

39°

100

350

7
R81

70
R2

649

1167

100

R3
80

R38
8

355

76°

Restriction on wide angle
in the rear section Note2)
Restriction on wide angle
in the front section Note5)

617

285

185

Areas as restricted by Note2) and Note4)
within the operating range

547

Restriction on wide angle
in the rear section Note1)
Restriction on wide angle
in the rear section Note4)

Restriction on wide angle in the rear section
Note1) J2＋Ｊ3×2 ≧ -254 degree when -38 degree≦ J2 ＜ 4 degree.
Note2) J2×1.5＋J3 ≧ -165 degree when ｜J1｜≦ 70 degree, -80 dgree ≦ Ｊ2 ＜ -38 degree.
Note3) J2＋Ｊ3 ≧ -47 degree when ｜J1｜≦ 70 degree, Ｊ2 ＜ -80 degree.
Note4) J2＋Ｊ3×2 ≧ -254 degree when ｜J1｜＞ 70 degree, J2 ＜ -38 degree.
Restriction on wide angle in the front section
Note5) J2 ≦ 110 degree when J1 - 120 degree, J1 ＞ 95 degree.

Fig.2-6 ： Operating range diagram : RV-6SL/6SLC
2-16 Outside dimensions ・ Operating range diagram

２ Robot arm

2.5 Tooling
2.5.1 Wiring and piping for hand
Shows the wiring and piping configuration for a standard-equipped hand.
Secondary piping pneumatic hose (φ4)
(customer-prepared)
(1)φ4 quick coupling
Solenoid valve set (option)
* Use by connecting it with the hand
output signal connector.
Primary piping pneumatic hose

(4)Hand output signal connector
(3)Hand input signal connector
Hand input signal cable
CN2

CN1

Hand output signal cable

VACUUM（φ8）

Note1）

AIRIN（φ6）
RETURN（φ6）
SPARE WIRE INLET
Spare wiring

AIRIN
RETURN

(2)φ6 quick coupling
(5)φ8 quick coupling Note1）

Connector and pneumatic coupling
Robot side (Robot arm side)
No

Name

Manufacturer
Connectors, couplings Connector pins

(1)

Coupling

Counter side (customer-prepared)

Qty.
Connector

Connector pins

KJW04-M3

－

KJL04-M3

－

SMC Corporation

(2)

Coupling

UKBL6

Koganei Corporation

(3)

Connector

1-1717834-3

1318108-1

1-1318115-3

1318112-1

Tyco Electronics
AMP K.K.

(4)

Connector

1-1717834-4

1318108-1

1-1318115-4

1318112-1

Tyco Electronics
AMP K.K.

(5)

Coupling

UKBL8

－

Koganei Corporation

Note1)

Note1) For dust suction in the clean specification

Fig.2-7 ： Wiring and piping for hand

Tooling 2-17

２ Robot arm

2.5.2 Internal air piping
(1) Standard type
1) The robot has two φ6 x 4 urethane hoses from the pneumatic entrance on the base section to the shoulder
cover.
2) One hose is the primary piping for the pneumatic equipment. The remaining pipe is used for air exhaust.
3) The optional solenoid is provided with a maximum of eight couplings for the φ4 air hose.
4) The pneumatic inlet in the base section has a φ6 pneumatic coupling bridge.
5) Refer to Page 32, "(3) Solenoid valve set" for details on the electronic valve set (optional).

(2) Clean type
1) The clean type basically includes the same piping as the standard type.
2) With the clean specification, a φ8 coupling is provided in the base section for suction inside the machine.
For use, connect it to the suction port of the vacuum pump or the coupling on the "VACUUM" side of the
vacuum generating valve. Moreover, to clean the exhaust from the vacuum pump or vacuum generator, use
the exhaust filter (prepared by the customer). Table 2-6 shows the specifications of the vacuum generating valve.
3) To use the vacuum pump, assure a flow rate of 30 liters/min. or more.
4) Use clean air as the air supplied to the vacuum generator.
Table 2-6 ： Vacuum generating valve specifications
Type

Maker

MEDT14

KONEGAI CORPORATION

Air pressure
0.2 to 0.6 MPa

2.5.3 Internal wiring for the pneumatic hand output cable(Standard type/Clean type)
1) When the controller uses the optional pneumatic hand interface (2A-RZ365/RZ375), the hand output signal
works as the pneumatic hand cable.
2) The hand output primary cable extends from the connector PCB of the base section to the inside of the
forearm. (AWG#24(0.2mm2)x 2 : 8 cables) The cable terminals have connector bridges for eight hand outputs. The connector names are GR1 and GR2.
To extend the wiring to the outside of the arm, a separate cable (optional "hand output cable 1S-GR35S01" IP65 is recommended) is required.

2.5.4 Internal wiring for the hand check input cable(Standard type/Clean type)
1) The hand output primary cable extends from the connector PCB of the base section to the inside of the
forearm. (AWG#24(0.2mm2)x 2 : 8 cables) The cable terminals have connector bridges for eight hand inputs.
The connector names are HC1 and HC2. The terminal section is connected to the connector in the forearm section.
2) The hand check signal of the pneumatic hand is input by connecting this connector.
To extend the wiring to the outside of the arm, a separate cable (optional "hand input cable 1S-HC25C01" IP65 is recommended) is required.

2.5.5 Spare Wiring
(1) Standard type
As spare wiring, three pairs of AWG#28(0.1mm2) cab tire cables (total of six cores) are preinstalled between the
base section and the forearm side section.
Both ends of the wire terminals are unprocessed. Use them under the following circumstances:
● For folding as the hand output cable when installing the solenoid valve in outside the robot.
● For when installing six or more hand I/O points for the sensor in the hand section
(Connects to the parallel I/O general purpose input.)

(2) Clean type
As spare wiring, four cables of AWG#24(0.2mm2) are preinstalled between the base section and the forearm side
section.

2-18 Tooling

２ Robot arm

2.5.6 Wiring and piping system diagram for hand
Shows the wiring and piping configuration for a standard-equipped hand.

(1) Standard type
Hand signal input connection connector
1-1318115-3

(Tyco Electronics AMP)
Hand signal input connector (HC1 connector)
1-1717834-3

(Tyco Electronics AMP)

Hand
prepared
by customer

Hand input cable
(option)

Hand signal output
connection connector

A1
A2
A3
B1
B2
B3

<+24V>

A1
A2
A3
B1
B2
B3

<24GND>

(Tyco Electronics AMP)

Driving devices,
such as solenoid
and hand, provided
by the customer

Hand output cable
attached to the solenoid set
φ4 quick coupling (1 to 8)

Hand signal input connector (HC2 connector)
White
Black
White
Black
White
Black

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Hand signal output connector (GR1 connector)
1-1717834-4
(Tyco Electronics AMP)

1-1318115-4

Hand output cable
(option)

White
Black
White
Black
White
Black

A1
A2
A3
A4
B1
B2
B3
B4

<+24V(COM)>

A1
A2
A3
A4
B1
B2
B3
B4

<+24V(COM)>

White
Black
White
Black
White
Black

Hand signal output connector (GR2 connector)

Yellow
White
Red
Blue
Green
Orange

White
Black
White
Black
White
Black

Spare wiring AWG#28(0.1mm2)×6 (cab tire cables with the shield)

Primary piping pneumatic hoses

1
2
3
4
5
6
7
8

Solenoid set
(option)
valve mounting
section

φ6 quick coupling

Forearm
Secondary pneumatic hose piping (customer-prepared)
φ4 hose

φ6 hose

AIR IN

φ6 hose

RETURN

φ6 quick coupling

Base

*Refer to Fig. 2-12 for Air
supply circuit example.

Fig.2-8 ： Wiring and piping system diagram for hand and example the solenoid valve installation(Sink type)

Tooling 2-19

２ Robot arm

Hand signal input connection connector
1-1318115-3

(Tyco Electronics AMP)
Hand signal input connector (HC1 connector)
1-1717834-3

(Tyco Electronics AMP)

Hand
prepared
by customer

Hand input cable
(option)

Hand signal output
connection connector

A1
A2
A3
B1
B2
B3

<+24V>

A1
A2
A3
B1
B2
B3

<24GND>

(Tyco Electronics AMP)

Driving devices,
such as solenoid
and hand, provided
by the customer

Hand output cable
attached to the solenoid set
φ4 quick coupling (1 to 8)

Hand signal input connector (HC2 connector)
White
Black
White
Black
White
Black

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a
t
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Hand signal output connector (GR1 connector)
1-1717834-4
(Tyco Electronics AMP)

1-1318115-4

Hand output cable
(option)

White
Black
White
Black
White
Black

A1
A2
A3
A4
B1
B2
B3
B4

<24GND(COM)>

A1
A2
A3
A4
B1
B2
B3
B4

<24GND(COM)>

White
Black
White
Black
White
Black

Hand signal output connector (GR2 connector)

Yellow
White
Red
Blue
Green
Orange

White
Black
White
Black
White
Black

Spare wiring AWG#28(0.1mm2)×6 (cab tire cables with the shield)

Primary piping pneumatic hoses

1
2
3
4
5
6
7
8

Solenoid set
(option)
valve mounting
section

φ6 quick coupling

Forearm
Secondary pneumatic hose piping (customer-prepared)
φ4 hose

φ6 hose

AIR IN

φ6 hose

RETURN

φ6 quick coupling

Base

*Refer to Fig. 2-12 for Air
supply circuit example.

Fig.2-9 ： Wiring and piping system diagram for hand and example the solenoid valve installation(Source type)

2-20 Tooling

２ Robot arm

(2) Clean type
Hand signal input connection connector
1-1318115-3

(Tyco Electronics AMP)
Hand signal input connector (HC1 connector)
1-1717834-3

(Tyco Electronics AMP)

Hand
prepared
by customer

Hand input cable
(option)

Hand signal output
connection connector

A1
A2
A3
B1
B2
B3

<+24V>

A1
A2
A3
B1
B2
B3

<24GND>

(Tyco Electronics AMP)

Hand signal input connector (HC2 connector)

A1
A2
A3
A4
B1
B2
B3
B4

Driving devices,
such as solenoid
and hand, provided
by the customer

Hand output cable
attached to the solenoid set
φ4 quick coupling (1 to 8)

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White
Black
White
Black
White
Black

Hand signal output connector (GR1 connector)
1-1717834-4
(Tyco Electronics AMP)

1-1318115-4

Hand output cable
(option)

White
Black
White
Black
White
Black

A1
A2
A3
A4
B1
B2
B3
B4

White
Black
White
Black
White
Black

<+24V(COM)>

Hand signal output connector (GR2 connector)

White
Black
White
Black
White
Black

<+24V(COM)>

White
Black
White
Black

Spare wiring AWG#24(0.2mm2)×4

Primary piping pneumatic hoses

1
2
3
4
5
6
7
8

Solenoid set
(option)
valve mounting
section

φ6 quick coupling

φ6 hose

AIR IN

φ6 hose

RETURN

φ6 quick coupling
VACUUM
φ8 quick coupling
(Internal suction)

Forearm
Secondary pneumatic hose piping (customer-prepared)
φ4 hose

Base

*Refer to Fig. 2-12 for Air
supply circuit example.

Fig.2-10 ： Wiring and piping system diagram for hand and example the solenoid valve installation(Sink type)

Tooling 2-21

２ Robot arm

Hand signal input connection connector
1-1318115-3

(Tyco Electronics AMP)
Hand signal input connector (HC1 connector)
1-1717834-3

(Tyco Electronics AMP)

Hand
prepared
by customer

Hand input cable
(option)

Hand signal output
connection connector

A1
A2
A3
B1
B2
B3

<+24V>

A1
A2
A3
B1
B2
B3

<24GND>

(Tyco Electronics AMP)

Hand signal input connector (HC2 connector)

A1
A2
A3
A4
B1
B2
B3
B4

Driving devices,
such as solenoid
and hand, provided
by the customer

Hand output cable
attached to the solenoid set
φ4 quick coupling (1 to 8)

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White
Black
White
Black
White
Black

Hand signal output connector (GR1 connector)
1-1717834-4
(Tyco Electronics AMP)

1-1318115-4

Hand output cable
(option)

White
Black
White
Black
White
Black

A1
A2
A3
A4
B1
B2
B3
B4

White
Black
White
Black
White
Black

<24GND(COM)>

Hand signal output connector (GR2 connector)

White
Black
White
Black
White
Black

<24GND(COM)>

White
Black
White
Black

Spare wiring AWG#24(0.2mm2)×4

Primary piping pneumatic hoses

1
2
3
4
5
6
7
8

Solenoid set
(option)
valve mounting
section

φ6 quick coupling

φ6 hose

AIR IN

φ6 hose

RETURN

φ6 quick coupling
VACUUM
φ8 quick coupling
(Internal suction)

Forearm
Secondary pneumatic hose piping (customer-prepared)
φ4 hose

Base

*Refer to Fig. 2-12 for Air
supply circuit example.

Fig.2-11 ： Wiring and piping system diagram for hand and example the solenoid valve installation(Source type)

2-22 Tooling

２ Robot arm

2.5.7 Electrical specifications of hand input/output
Table 2-7 ： Electrical specifications of input circuit
Item

Specifications

Type

DC input

No. of input points

Insulation method

Photo-coupler insulation

Rated input voltage

12VDC/24VDC

Rated input current

Approx. 3mA/approx. 7mA

Working voltage range

DC10.2 to 26.4V(ripple rate within 5%)

ON voltage/ON current

8VDC or more/2mA or more

OFF voltage/OFF current

4VDC or less/1mA or less

Input resistance

Approx. 3.3kΩ

Response time

OFF-ON

10ms or less(DC24V)

ON-OFF

10ms or less(DC24V)

Internal circuit

24V
24V
820

HCn*

3.3K

0V(COM)

+24V
+24V
3.3K

HCn*

820
24GND

* HCn ＝ HC1 ～ HC8

Table 2-8 ： Electrical specifications of output circuit
Item

Specification

Type

Transistor output

No. of output points

Insulation method

Photo coupler insulation

Rated load voltage

DC24V

Rated load voltage range

DC21.6 to 26.4VDC

Max. current load

0.1A/ 1 point (100%)

Current leak with power OFF

0.1mA or less

Maximum voltage drop with power ON

DC0.9V(TYP.)

Response time

OFF-ON

2ms or less (hardware response time)

ON-OFF

2 ms or less (resistance load) (hardware response time)

Fuse rating

Internal circuit

24V
（Internal power supply）

GRn

Fuse
1.6A

1.6A (each one common) Cannot be exchanged

Fuse +24V
1.6A
GRn*

24GND(COM)

* GRn ＝ GR1 ～ GR8

Note) An optional air hand interface (2A-RZ365/RZ375) is required to use hand output.

Tooling 2-23

2 Robot arm

2.5.8 Air supply circuit example for the hand
Fig. 2-12 shows an example of pneumatic supply circuitry for the hand.
(1) Place diodes parallel to the solenoid coil.
(2) When the factory pneumatic pressure drops, as a result of the hand clamp strength weakening, there can be
damage to the work. To prevent it, install a pressure switch to the source of the air as shown in Fig. 2-12 and
use the circuit described so that the robot stops when pressure drops. Use a hand with a spring-pressure
clamp, or a mechanical lock-type hand, that can be used in cases where the pressure switch becomes damaged.
(3) The optional hand and solenoid valve are of an oilless type. If they are used, don't use any lubricator.

Pressure switch

Pneumatic source
0.7MPa less

To the robot's air intake
（0.5MPa
±10%）
Filter

Regurater

Fig.2-12 ： Air supply circuit example for the hand

2-24

２ Robot arm

2.6 Shipping special specifications, options, and maintenance parts
2.6.1 Shipping special specifications
■ What are sipping special specifications?
Shipping special specifications are changed at the time of shipment from the factory. Consequently, customer
need to confirm the delivery date.
To make changes to the specifications after shipment, service work must be performed at the work site or the
robot must be returned for service.
■ How to order
(1) Confirm beforehand when the factory special specifications can be shipped, because they may not be
immediately available.
(2) Order before the factory shipping date.
(3) Specified method …… Specify the part name, model, and robot model type.

Shipping special specifications, options, and maintenance parts 2-25

２ Robot arm

(1) Machine cable
（CR2B-574 contoroller only）
■ Order type:

● Fixed type

1S-02CBL-1 (2m)

■ Outline

This cable is exchanged for the machine cable (5 m for fixed type) that was supplied
as standard to shorten the distance between the controller and the robot arm.

■ Configuration
Table 2-9 ： Configuration equipments and types
Part name
Fixed

Type

Qty.

Set of signal and power cables

1S-02CBL-1

Motor signal cable

BKO-FA0741H02

(1 cable)

1 set

Motor power cable

BKO-FA0768H02

(1 cable)

Remarks
2ｍ

Note) Standard 5 m (for fixed type) is not attached.

[Caution] Orders made after purchasing a robot are treated as purchases of optional equipment. In this case, the
machine cable (5 m for fixed type) that was supplied as standard is not reclaimed.
Please keep it in storage.

2-26 Shipping special specifications, options, and maintenance parts

２ Robot arm

2.7 Options
■ What are options?
There are a variety of options for the robot designed to make the setting up process easier for customer needs.
customer installation is required for the options. Options come in two types: "set options" and "single options".
1. Set options .......................................A combination of single options and parts that together, from a set for serving
some purpose.
2. Single options ..................................That are configured from the fewest number of required units of a part.
Please choose customer's purpose additionally.

Options 2-27

２ Robot arm

(1) Machine cable extension
■ Order type :

● Fixed type
● Flexed type

1S- □□ CBL-01
1S- □□ LCBL-01

Note) The numbers in the boxes □□ refer the length.

■ Outline
This cable is exchanged for the machine cable (5 m) that was supplied as standard to
extend the distance between the controller and the robot arm.
A fixed type and flexible type are available.
Exchanges after shipment will be charged (for packaging, shipping costs).
The fixing and flexible types are both configured of the motor signal cable and motor
power cable.
■ Configuration
Table 2-10 ： Configuration equipments and types
Part name
Fixed

Qty.

Type

Remarks

Fixed

Flexed

Set of signal and power cables

1S- □□ CBL-01

1 set

Motor signal cable

1S- □□ CBL(S)-01

(1 cable)

Motor power cable

1S- □□ CBL(P)-01

(1 cable)

Set of signal and power cables

1S- □□ LCBL-01

1 set

Motor signal cable

1S- □□ LCBL(S)-01

(1 cable)

Motor power cable

1S- □□ LCBL(P)-01

(1 cable)

Nylon clamp

NK-14N

2 pcs.

for motor signal cable

Nylon clamp

NK-18N

2 pcs.

for motor power cable

4 pcs.

Flexed

Silicon rubber

10m, or 15m each

5m, 10m, or 15m each

Note) The numbers in the boxes □□ refer the length.
■ Specifications
The specifications for the fixed type cables are the same as those for standard cables.
Shows usage conditions for flexed type cables in Table 2-11.
Table 2-11 ： Conditions for the flexed type cables
Item

Specifications

Minimum flexed radius

100R or more

Cable bare, etc., occupation rate

50% or less

Maximum movement speed

2000mm/s or less

Guidance of life count

7.5 million times

Environmental proof

Oil-proof specification sheath
(for silicon grease, cable sliding lubricant type)

Cable configuration

Motor signal cable

φ6 x 5, φ8.5 x 1 and φ1.7 x 1

Motor power cable

φ8.9 x 2 and φ6.5 x 8

[Caution] The guidance of life count may greatly differ according to the usage state (items related to Table 2-11
and to the amount of silicon grease applied in the cable conduit.
[Caution] This option can be installed on clean-type, but its cleanliness is not under warranty.

2-28 Options

２ Robot arm

■ Cable configuration
The configuration of the flexible cable is shown in Table 2-12. Refer to this table when selecting the cable bare.
Table 2-12 ： Cable configuration
Motor signal cable
1S- □□ LCBL(S)-01

Item
No. of cores

Motor power cable
1S- □□ LCBL(P)-01

AWG#24(0.2mm2)-4P

AWG#24(0.2mm2)-7P

AWG#18(0.75mm2)

AWG#16(1.25mm2)-4C

AWG#18(0.75mm2)-4C

Finish dimensions

Approx. φ6mm

Approx. φ8.5mm

Approx. φ1.7mm

Approx. φ8.9mm

Approx. φ6.5mm

No.of cables used

5 cables

1 cable

2 cable

8 cable

No. in total

7 cables

10 cables

Note) The square in the cable name indicates the cable length.
■ Fixing the flexible cable
(1) Connect the connector to the robot arm .
(2) Wind the silicon rubber around the cable at a position 300 to 400 mm from the side of robot arm and extension section as shown in Fig. 2-13, and fix with the nylon clamp to protect the cable from external stress.

Options 2-29

２ Robot arm

Robot arm
CR2B-574 controller

Nylon clamp
NK-18N
1S-□□LCBL(P)-01
1S-□□LCBL(S)-01

300～400ｍｍ
300～400ｍｍ
Nylon clamp
NK-18N

Nylon clamp
NK-14N

Extended flexible cable The fixed cable 5m
(option)
(standard attachment)

Nylon clamp

Extension section

Silicon rubber

CR3-535M controller

Robot arm
Robot arm
1S-□□LCBL(S)-01

1S-□□LCBL(P)-01

Nylon clamp
NK-18N

300～400ｍｍ
300～400ｍｍ
Nylon clamp
NK-18N
Nylon clamp
NK-14N

Nylon clamp
NK-14N

Extended flexible cable The fixed cable 7m
(option)
(standard attachment)
Extension section

Fig.2-13 ： Fixing the flexible cable

2-30 Options

２ Robot arm

(2) Changing the operating range
■ Order type: 1S-DH -02
■ Outline
The J1 axis operating range is limited by the robot arm's mechanical stopper and the
controller parameters.
If the axis could interfere with the peripheral devices, etc., and the operating range
need to be limited, use this.

■ Configuration
Table 2-13 ： Configuration devices
Part name

Type

Qty.

Remarks

Stopper for changing the operating range

1S-DH-02

2 pcs.

Hexagon socket bolt: M10 x 20 plating (strength classification 10.9)

■ Specifications
Table 2-14 ： Specifications
Axis
J1

Standard

Changeable angle

+ side

+170 degree

One point from +135°, +90°, +45°

- side

-170 degree

One point from -135°, -90°, -45°

(1) The changeable angle shown in Table 2-14indicates the operation range by the software.
The limit by the mechanical stopper is positioned 1 degrees outward from that angle, so take care when
designing the layout.
(2) The changeable angle can be set independently on the + side and - side.
(3) The operating range is changed with robot arm settings and parameter settings. Refer to the separate
"Instruction Manual/ROBOT ARM SETUP & MAINTENANCE" or "Instruction Manual/Detailed Explanation
of Functions and Operations" for details.

Options 2-31

２ Robot arm

(3) Solenoid valve set
■ Order type: One set:
Two sets:
Three sets:
Four sets:
■ Outline

1S-VD01-02(Sink type)/1S-VD01E-02(Source type)
1S-VD02-02(Sink type)/1S-VD02E-02(Source type)
1S-VD03-02(Sink type)/1S-VD03E-02(Source type)
1S-VD04-02(Sink type)/1S-VD04E-02(Source type)

The solenoid valve set is an option that is used for controlling toolings when various
toolings, such as the hand, are installed at the end of the arm. All have double solenoid specification, and either one or two or three sets can be selected. This solenoid
valve set has a hand output cable attached to the solenoid valve. Also, for easy
installation of this electromaagnetic set onto the robot, it comes equipped with a
manifold, couplings, silencers, among other things.
When using the robot arm's hand output signal, the pneumatic hand interface option
must be installed on the separate controller.
■ Configuration
Table 2-15 ： Configuration equipment
Part name

Type

Solenoid valve set (1 set)

1S-VD01-02/
1S-VD01E-02
1S-VD02-02/
1S-VD02E-02
1S-VD02-02/
1S-VD02E-02
1S-VD02-02/
1S-VD02E-02

Solenoid valve set (2 sets)
Solenoid valve set (3 sets)
Solenoid valve set (4 sets)

Q'ty
One set

Two sets

Three sets

Four sets

1 pc.

－

1 pc.

－

1 pc.

－

1 pc.

Remark

M4x8 four screws (installation screws).
1S-VD01-02/VD02-02/VD03-02/VD04-02 are
the sink type.
1S-VD01E-02/VD02E-02/VD03E-02/VD04E-02
are the source type.

■ Specifications
Table 2-16 ： Valve specifications
Item

Specifications

Number of positions
Port
Valve function
Operating fluid
Operating method
Effective sectional area (CV value)
Oiling
Operating pressure range
Guaranteed proof of pressure
Response time
Max. operating frequency
Ambient temperature

2
5Note1) )
Double solenoid
Clean air Note2)
Internal pilot method
0.64mm
Unnecessary
0.1 to 0.7MPa
1.0MPa or more
22msec or less (at 0.5 MPa)
5c/s
-5 to 50 ℃ (However, there must be no condensation.)

Note1) Couplings of unused solenoid valves must be blocked with plugs. If they are not blocked, supplied
air will blow out from the couplings, lowering the air pressure of the solenoid valves being used
and making them nonfunctional
(recommended plugs: KQ2P-04 plugs made by SMC).

CAUTION

Note2) The air to be provided must be clean, i.e., filtered with a mist separator or air
filter. Failing to do so may lead to malfunctions.

Table 2-17 ： Solenoid specifications
Item
Coil rated voltage
Power consumption
Voltage protection circuit with power surge
protection

2-32 Options

Specifications
DC24V ± 10%
0.55W
Diode

２ Robot arm

81
⑦⑧

GR1

24
⑨

φ4.8

③

100

GR2

108.5

⑥

②

①

⑤

④

4.5

φ4.8

1.6

13.5

Part no.

3.5

54
61

10
Part name

1 sets

Specifications

Solenoid valve

Manifold block

③

Quick coupling

④

Block plate

⑤

Quick coupling

φ6

⑥
⑦

Quick coupling
Connector

1
1

1
2

φ6
1-1318115-4

⑧

Contact

1318112-1

⑨

Installation screw

M4 × 8

+24V (COM) A1
Reserve A2

A3
A4

B1
B2
Reserve B3
Reserve B4

24V (RG) A1
Reserve A2

Black

B1
B2
Reserve B3
Reserve B4
+24V (COM) A1
Reserve A2

Connector name

White

A3
A4

φ4

GR3
GR4

GR7
GR8

4 sets

②

Connector name

GR5
GR6

3 sets

①

GR1
GR2

2 sets

Red
Black

SOL1B

Red
Black

SOL1A

Red
Black

SOL2B

Red

SOL2A

GR1
GR2
GR3
GR4

B1
B2
Reserve B3
Reserve B4
24V (RG) A1
Reserve A2

Black
Red
Black
Red
Black
Red
Black
Red

SOL3B
SOL3A
SOL4B
SOL4A

Red
Black
Red
Black
Red
Black
Red
Black

A3
A4

White

GR5
GR6
GR7
GR8

A3
A4

B1
B2
Reserve B3
Reserve B4

SOL1B
SOL1A
SOL2B
SOL2A

White

Red
Black
Red
Black
Red
Black
Red
Black

SOL3B
SOL3A
SOL4B
SOL4A

Fig.2-14 ： Outline dimensional drawing

Options 2-33

２ Robot arm

(4) Hand input cable
■ Order type: 1S-HC25C-01
■ Outline

The hand input cable is used for customer-designed pneumatic hands.
It is necessary to use this to receive the hand's open/close confirmation signals and
grasping confirmation signals, at the controller.
One end of the cable connects to the connector for hand input signals, which is in
the wrist section of the hand. The other end of the cable connects to the sensor
inside the hand customer designed.
■ Configuration
Table 2-18 ： Configuration equipment
Part name
Hand input cable

Type

Qty.

1S-HC25C-01

Remarks

1 cable

■ Specifications
Table 2-19 ： Specifications
Item

Specifications

Remarks

Size x cable core

AWG#24

Total length

800mm (Including the curl section, which is 300mmlong）

One-sided connector, one-sided cable bridging

× 12

100
HC1

φ25

(0.2mm2)

HC2

15
200

300

200±10

1-1318115-3
(Tyco Electronics AMP)

(Purple)
(Brown)
(Blue)
(Black)

A1 +24V
A2 Reserve
A3 HC1
B1 HC2
B2 HC3
B3 HC4

(Green)
(Red)
(White)
(Gray)
（Pink）

A1 Reserve
A2 24G（RG）
A3 HC5
B1 HC6
B2 HC7
B3 HC8

(Yellow)

Fig.2-15 ： Outside dimensional drawing and pin assignment
[Caution] This option can be installed on clean-type, but its cleanliness is not under warranty.

2-34 Options

２ Robot arm

(5) Hand output cable
■ Order type: Four sets:1S-GR35S-01
■ Outline
The hand output cable (solenoid valve connection cable) is an option that is used
when an solenoid valve other than one of the solenoid valve set options, is used.
One end of the cable has a connector that connects to the input terminal inside the
robot. The other end of the cable is connected.

■ Configuration
Table 2-20 ： Configuration equipment
Part name
Hand output cable

Type

Qty.

1S-GR35S-01

1 cable

Remarks
For four sets

■ Specifications
Table 2-21 ： Specifications
Item

Specifications

Size x Cable core

AWG#24(0.2mm2) x 12 cores

Total length

400mm

Remarks
One side connector and one side cable connection

GR1

100

GR2

1-1318115-4
(Tyco Electronics AMP)

300

(Yellow)
(Purple)
(Brown)
(Blue)
(Black)

(Green)
(Red)
(White)
(Gray)
（Pink）

Sink
type
A1 +24V (COM)
A2 Reserve
A3 GR1
A4 GR2
B1 GR3
B2 GR4
B3 Reserve
B4 Reserve

Source
type
24G (RG)
Reserve
GR1
GR2
GR3
GR4
Reserve
Reserve

A1 +24V（COM）
A2 Reserve
A3 GR5
A4 GR6
B1 GR7
B2 GR8
B3 Reserve
B4 Reserve

24V（RG）
Reserve
GR5
GR6
GR7
GR8
Reserve
Reserve

Fig.2-16 ： Outline dimensional drawing and pin assignment

Options 2-35

２ Robot arm

(6) Hand curl tube
■ Order type: One set
Two sets
Three sets
Four sets

:1E-ST0402C
:1E-ST0404C
:1E-ST0406C
:1E-ST0408C

■ Outline
The hand curl tube is a curl tube for the pneumatic hand.

■ Configuration
Table 2-22 ： Configuration equipment
Part name

Type

Qty.

Remarks

Hans curl tube (One set: 2 pcs.)

1E-ST0402C

1 pc.

Φ4 tube, 2pcs.

Hans curl tube (Two set: 4 pcs.)

1E-ST0404C

1 pc.

Φ4 tube, 4pcs.

Hans curl tube (Three set: 6 pcs.)

1E-ST0406C

1 pc

Φ4 tube, 6pcs.

Hans curl tube (Four set: 8 pcs.)

1E-ST0408C

1 pc.

Φ4 tube, 8pcs.

■ Specifications
This option can be installed on clean-type, but its cleanliness is not under warranty.
Table 2-23 ： Specifications
Item

Specifications

Material

Urethane

Size

Outside diameter: φ4 x Inside diameter: φ2.5

250

(Robot side)

600
300

(Tooling side)

Fig.2-17 ： Outline dimensional drawing
[Caution] This option can be installed on clean-type, but its cleanliness is not under warranty.

2-36 Options

２ Robot arm

2.8 Maintenance parts
The consumable parts used in the robot arm are shown in Table 2-24. Purchase these parts from the designated
maker or dealer when required. Some Mitsubishi-designated parts differ from the maker's standard parts. Thus,
confirm the part name, robot arm and controller serial No. and purchase the parts from the dealer.
Table 2-24 ： Consumable part list
No.

Type Note1)

Part name

Usage place

Grrase

SK-1A

Reduction gears of each axis

Lithium battery

A6BAT

In the battery cover

Qty.

Supplier

As needed

Mitsubishi Electric System &
Service;Co.,Ltd.

5 pcs.

Note1)Confirm the robot arm serial No., and contact the dealer or service branch of Mitsubishi Electric Co., for
the type.

Maintenance parts 2-37

3Controller

3 Controller
3.1 Standard specifications
3.1.1 Standard specifications
Table 3-1 ： Standard specifications of controller
Item
Type
Number of control axis
CPU
Memory
Programmed positions and No.
capacity
of steps
Number of programs
Robot language

Power
source

Specification

Remarks

point

CR3-535M
CR2B-274
Simultaneously 6(Maximum)
64 bit RISC, and DSP
2,500
5,000
88
MELFA-BASIC Ⅳ
or
MOVEMASTER COMMAND
Pose teaching method ,MDI method
32/32

point

Assigned with general-purpose input/output

point

Input 8 point/Output 0 point

Emergency stop input
Door switch input
Emergency stop output
RS-232C

point
point
point
port

1
1
1

RS-422

port

Hand dedicated slot

slot

Expansion slot
Memory expand slot

slot
slot

Teaching method
External
input and output
input and
Dedicated input/output
output
Hand open/close input/output

Interface

Unit

point
step

Robot input/output link

channel

Additional axis interface
Input voltage range
Power capacity

V
KVA

Outline dimensions

3
1
1

1
0
3-phase, AC180 to 253 1-phase, AC180 to 253
2.0
450(Ｗ)x380(D)x625( Ｈ )
Note4)

Mass
Construction

Paint color

deg.
%RH
Ω

460(Ｗ)x400(D)x200( Ｈ )

Approx. 20
Self-contained floor
type, Opened type
(IP20) Note6)
0 to 40
45 to 85
100 or less

Memory option
Used for general-purpose input/
output (Max. 256/256)
SSCNET
Does not include rush current
Note3)

Excluding protrusions

Approx. 60
Self-contained floor
type, Closed type (IP54)
Note5)

Operating temperature range
Ambient humidity
Grounding

Max. 256/256Note1)
"STOP" 1 point is fixed
Up to 8 output points can be added
as an optionNote2)
Dual emergency line
Dual door switch line
Dual emergency line
For expansion such as the personal
cpmputer, Vision sensor
Dedicated for T/B
Dedicated for pneumatic hand
interface

Light gray

Without dew drops
D class grounding earthNote7)
Munsell 0.08GY7.64/0.81

Note1) It is the value when seven maximums expand (224/224) the Parallel I/O unit.
(2A-RZ361 or 2A-RZ371:Input 32 points / Output 32 points.)
Note2) It is when an pneumatic hand interface (2A-RZ365 or 2A-RZ375) is installed.
Note3) The power capacity is the rating value for normal operation. The power capacity does not include the rush
current when the power is turned ON. The power capacity is a guideline and the actual operation is
affected by the input power voltage. The power consumption in the specific operation pattern with the
RV-6S/6SL series is approx. 0.64kW. The peak value at the robot's maximum speed is 2.72 kW.
Note4) Becomes 615(H) at the caster specification (CR3-535M controller only).
Note5) CR3-535M controller exchanges heat using the internal air circulation self-cooling method. Furthermore,
the rear side sucks in the outside air and the top and bottom sections of the rear side discharges the
inside air. This controller can also be used in the oil-mist environment.
Note6) The CR2B-574 controller of this robot is a general environment specification. For use in an oil-mist
environment or in an environment with excess dust, use the CR3-535M controller instead.
Note7) The robot must be grounded by the customer.

3-38 Standard specifications

3Controller

3.1.2 Protection specifications and operating supply
A protection method complying with the IEC Standard CR3-535M: IP54(Closed type), CR2B-574: IP20(Opened
type) is adopted for the controller.
The IEC IP symbols refer only to the degree of protection between the solid and the fluids, and don't indicated
that any special protection has been constructed for the prevention against oil and water.
【Information】

・ The IEC IP20
It indicates the protective structure that prevents an iron ball 12 +0.05
0 mm diameter, which is being pressed with the
power of 3.1 kg ± 10%, from going through the opening in the outer sheath of the supplied equipment.

・ The IEC IP54
The IEC IP54 standard refers to protection structure designed to prevent any harmful effects by fresh water
scattering vertically onto the testing equipment in a radius of 180 degrees from a distance of 300 to 500 mm, with
10 ± 0.5 liters of water every minute, at a water pressure of 80 to 100kPa , covering the entire area of the robot
with the exception of the installation section at 1 ㎡ per minute, for a total of 5 minutes or more.
Refer to the section Page 111, "6.2 Working environment" for details on the working environment.

Standard specifications 3-39

3Controller

3.2 Names of each part
CR3-535M controller

7)
9)
4) 15)
11) 2)
16)

6)
12)
14)10) 3) 8)
13)

Front operation panel

CR2B-574 controller

9) 2)
14)

11)

4)
7)

15)

Front operation panel

1)
10) 3)

13)

12)

Fig.3-1 ： Names of controller parts
1)
2)
3)
4)
5)
6)

POWER switch ..................................... This turns the control power ON/OFF.
START button ...................................... This executes the program and operates the robot. The program is run continuously.
STOP button......................................... This stops the robot immediately. The servo does not turn OFF.
RESET button....................................... This resets the error. This also resets the program's halted state and resets the program.
Emergency stop switch .................... This stops the robot in an emergency state. The servo turns OFF.
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" → "Program 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 key 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.
16) Power cable clamp........................... Fix the primary power cable.

3-40 Names of each part

3Controller

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
whenthe [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.
■ 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.
■ 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.

Names of each part 3-41

3Controller

CR3-535M controller

CN2

CN1

1)
CR2B-574 controller

3) 4)

7)
2)

Fig.3-2 ： Names of each controller part (Rear side)
1) Machine cable connector (for motor power)........... Connects to the robot arm base. (CN1 connector)
2) Machine cable connector (for motor signal)............ Connects to the robot arm base. (CN2 connector)
3) External input/output signal connector.
4) Network cable connector for parallel I/O unit expansion.
5) Emergency stop switch and door switch terminals.
6) Magnet contactor control connector for additional axis (AXMC1)
7) Memory cassette entry
8) Optional cable inlet

3-42 Names of each part

3Controller

1)
2)
3)

Control unit
(R6x2CPU)

Fig.3-3 ： Names of each controller part (interior)(CR3-535M controller)
1)
2)
3)
4)
5)

External input/output signal connector.
Memory cassette entry
Network cable connector for parallel I/O unit expansion.
Emergency stop switch and door switch terminals.
Magnet contactor control connector for additional axis (AXMC1)

Names of each part 3-43

3Controller

3.3 Outside dimensions/Installation dimensions
3.3.1 Outside dimensions

4-M5 screw

Fig.3-4 ： Outside dimensions of controller (CR2B-574 controller)

3-44 Outside dimensions/Installation dimensions

3Controller

340

(55)

450

Eye bolt 2-M10

（50）

380

3.2

(75)

550
625

288

(134)
(45)

(35)

（40.5）
（15）

（65） 550
615

（15）

380
420

2×2-φ15
320
440

（79.5）

←（When specifications with casters）

Fig.3-5 ： Outside dimensions of controller (CR3-535M controller)

Outside dimensions/Installation dimensions 3-45

3Controller

FAN

(625)

FAN

Exhaust

Suction

123

(380)

(7,000)

（Right side drawing）
Fig.3-6 ： Outside dimensions of controller (Supplement)

3-46 Outside dimensions/Installation dimensions

(75)

122

140

Exhaust

CN2 CN1

（Back drawing）

3Controller

3.3.2 Installation dimensions

150

7 or more

250 or more

Horizontal placement

CAUTION

Use the rubber foot (4 positions) at the bottom of the controller as it is, or put the
spacer, and leave the space between the installation side and the controller
installation side more than 7mm when you fix the controller with the installation
screw.In the other case, the air intake hole at the bottom of the controller is
occupied, and temperature rises in the board, and causes the trouble.

Fig.3-7 ： Installation of controller (CR2B-574 controller)
Back
Approx. 500

Note1)

Side
Approx.
200

450

Side
Approx.
300

Front
Approx. 500
450

440

STA

Controller
(upside)

TUS

NUM
BER
CHA
NG DISP

MOD
E

UP
SVO

A UTO

T EAC

DOW

(O p.)

STA
AU TO

SVO

EMG
.STO
N

RT
RES

(E xt.)

OFF
STO

P
END
REM
OVE

T/B

Maintenance area
(View from upside)

The mold cover
for the RS-232C connector
The rubber cover
for the T/B connector

(Anchor bolt installation: 4 places)

Note1) The controller sucks in the outside air and discharges the inside air after cooling (Fig. 3-4).
The space required for cooling is 100 mm minimum. Reserve approximately 500 mm of space
behind the unit as the maintenance work area.
Fig.3-8 ： Installation of controller (CR3-535M controller)

Outside dimensions/Installation dimensions 3-47

3Controller

The controller has the openings (1) to (4) as shown in Fig. 3-9.
67
45

Capcon installing panel

STATUS NUMBER

EMG.STOP

CHANG DISP

UP
DOWN

MODE

199

(1) φ28

SVO ON

START

RESET

SVO OFF

STOP

END

TEACH
AUTO
(Op.)

AUTO
(Ext.)

REMOVE T/B

(4)
(3) φ34

273

(2)

□40×81

Enlarged view of A section

Cable lead in port
(1) Left surface input power supply
lead-in port
(2) Bottom surface input/output signal
lead-in port (with sponge)
(3) Left surface cable outlet
(4) Right surface input/output signal
lead-in port
(no sponge, with cabl fixing plate)
・Use (1) to lead in the input
power cable.
・Use (2) or (4) to lead in the
input/output signal cable.

Right side drawing

Front drawing

（45）

Left side drawing

□40×90

Bottom view

(39)

Fig.3-9 ： Cable lead-in ports and dimensions (CR3-535M controller)

3-48 Outside dimensions/Installation dimensions

3Controller

3.4 External input/output
3.4.1 Types
(1) Dedicated input/output...............................These inputs and outputs carry out the robot remote operation and
status display.
(2) General-purpose input/output.................These are inputs and outputs that the customer can program for
peripheral device control. Moreover, it is possible to use parallel input/
output units and input/output signals via CC-Link.
(3) Hand input/output .........................................These are inputs and outputs related to the hand that the customer
can program. (The hand output is an option. The Page 67, "(2) Pneumatic hand interface" is required.)
No. of input/output points
Class

Connection
format

Name
Input

Output

Standard Emergency stop

Standard Door switch

Standard Parallel input/output

Occupies 32 general-purpose points/(6)
dedicated points in general-purpose

Connector

Occupies 32 general-purpose points/(4)
dedicated points in general-purpose

3.4.2 Explanation
The parallel input/output unit uses connector bridging. Purchase the "External I/O cable" for connection with
external devices.
The hand output is an option. Refer to Page 67, "(2) Pneumatic hand interface" for details
The parallel input/output unit can be expanded outside of the controller.
The expansion parallel input/output unit is connected with the control unit in the controller using a robot I/O link
cable. Parallel input and output units can be expand as an option to seven maximums. With allows up to input 256
points and output 256 points of maximums can be used including 32 points input and 32 points output of standard.
Refer to Page 70, "(3) Parallel I/O unit" for details on the parallel input/output unit.

External input/output 3-49

3Controller

3.5 Dedicated input/output
Show the main function of dedicated input/output in the Table 3-2. Refer to attached instruction manual
"Detailed explanations of functions and operations" in the product for the other functions. Each parameter indicated with the parameter name is used by designated the signal No., assigned in the order of input signal No. and
output signal No. If the number of dedicated inputs and general-purpose input points used exceeds the standard
No. of input/output points, install the parallel input /output unit (1st to 7th station: option).
Table 3-2 ： Dedicated input/output list
Parameter
name

Input
Name

Output

Note1)

Function

Level

Name

Function

TEACHMD

None

Teaching mode output signal

Outputs that the teaching mode is
entered.

ATTOPMD

None

Automatic mode output signal

Outputs that the automatic mode is
entered.

ATEXTMD

None

Remote mode output
signal

Outputs that the remote mode is
entered.

RCREADY

None

Controller power ON
complete signal

Outputs that external input signals can
be received.

Automatic operation
enabled output signal

Outputs the automatic operation
enabled state.

Operating output signal

Outputs that the slot is operating.

Wait output signal

Outputs that the slot is temporarily
stopped.

Program selection
enabled output signal

Outputs that the slot is in the program
selection enabled state.

Error occurring output signal

Outputs that an error has occurred.

In cycle stop operation output signal

Outputs that the cycle stop is operating.

Automatic operation enabled input
signal

Allows automatic operation.

START

Start input signal

Starts all slots.

STOP

Stop input signal

Stops all slots.
The input signal No. is fixed to 0.
Note) Use the emergency stop
input for stop inputs related
to safety.

AUTOENA

SLOTINIT

Program reset input
signal

Ｌ

Resets the wait state.

Ｅ

Ｌ

ERRRESET Error reset input
signal

Resets the error state.

CYCLE

Cycle stop input
signal

Carries out cycle stop.

SRVOFF

Servo ON enabled
input signal

Turns the servo OFF for all mechanisms.

Ｌ

Servo ON enabled
output signal

Outputs servo-on disable status.
(Echo back)

SRVON

Servo ON input
signal

Turns the servo ON for all mechanisms.

Ｅ

In servo ON output
signal

Outputs the servo ON state.

IOENA

Operation rights
input signal

Requests the operation rights for
the external signal control.

Ｌ

Operation rights output signal

Outputs the operation rights valid state
for the external signal control.

MELOCK

Machine lock input
signal

Sets/resets the machine lock
state for all mechanisms.

Ｅ

In machine lock output signal

Outputs the machine lock state.

SAFEPOS

Evasion point
return input signal

Requests the evasion point return
operation.

Ｅ

In evasion point
return output signal

Outputs that the evasion point return
is taking place.

OUTRESET General-purpose
output signal reset

Resets the general-purpose output
signal.

Ｅ

EMGERR

None

None
Emergency stop output signal

Outputs that an emergency stop has
occurred.

S1START
：
S32START

Start input

Starts each slot.

Ｅ

In operation output

Outputs the operating state for each
slot.

S1STOP
：
S32STOP

Stop input

Stops each slot.

Ｌ

In wait output

Outputs that each slot is temporarily
stopped.

Program selection
input signal

Designates the setting value for
the program No. with numeric value
input signals.

Ｅ

None

Override selection
input signal

Designates the setting value for
the override with the numeric value
input signals.

Ｅ

None

PRGSEL

OVRDSEL

3-50 Dedicated input/output

3Controller

Parameter
name
IODATA

Input
Name

Function

Numeric value input
(start No., end No.)

Used to designate the program
name, override value., mechanism
value.

Program No. output request

Requests output of the program
name.

LINEOUT

Line No. output
request

Requests output of the line No.

OVRDOUT

Override value out- Requests the override output.
put request

Note2)

PRGOUT

Output

Note1)

Level

Name

Function

Ｌ

Numeric value output
(start No., end No.)

Ｅ

Program No. output
signal

Outputs that the program name is
being output to the numeric value output signal.

Ｅ

Line No. output signal

Outputs that the line No. is being output to the numeric value output signal.

Ｅ

Override value output signal

Outputs that the override value is being
output to the numeric value output signal.

Ｅ

Error No. output signal

Outputs that the error No. is being output to the numeric value output signal.

Ｅ

Jog valid output signal

Outputs that the jog operation with
external signals is valid.

Ｌ

Jog mode output 2bit

Outputs the current jog mode.

Used to output the program name,
override value., mechanism No.

ERROUT

Error No. output
request

Requests the error No. output.

JOGENA

Jog valid input signal

Validates jog operation with the
external signals

JOGM

Jog mode input 2bit

Designates the jog mode.

JOG+

Jog feed + side for
8-axes

Requests the + side jog operation.

Ｌ

None

JOG-

Jog feed - side for
8-axes

Requests the - side jog operation.

Ｌ

None

HNDCNTL1
：
HNDCNTL3
None

HNDSTS1
：
HNDSTS3

HNDERR1
：
HNDERR3
AIRERR1

：
AIRERR3

None

Mechanism 1 hand
error input signal
：
Mechanism 3 hand
error input signal
Pneumatic pressure
error 1 input signal
：
Pneumatic pressure
error 3 input signal

Requests the hand error occurrence.

Request the pneumatic pressure
error occurrence.

：
M3PTEXC
USERAREANote3)

None

Mechanism 1: Outputs the status of
general-purpose outputs
900 to 907.
Mechanism 2: Outputs the status of
general-purpose outputs
910 to 917.
Mechanism 3: Outputs the status of
general-purpose outputs
920 to 927.

Mechanism 1 hand
input signal status
：
Mechanism 3 hand
input signal status

Mechanism 1: Outputs the status of
hand inputs 900 to 907.
Mechanism 2: Outputs the status of
hand inputs 910 to 917.
Mechanism 3: Outputs the status of
hand inputs 920 to 927.

Ｌ

Mechanism 1 hand
error output signal
：
Mechanism 3 hand
error output signal

Outputs that a hand error is occurring.

Ｌ

Pneumatic pressure
error 1 output signal.
：
Pneumatic pressure
error 3 output signal.

Outputs that a pneumatic pressure
error is occurring.

M1PTEXC
None

Mechanism 1 hand
output signal status
：
Mechanism 3 hand
output signal status

Ｌ

Maintenance parts
replacement time
warning signal

Outputs that the maintenance parts
have reached the replacement time.

User-designated area
8-points

Outputs that the robot is in the userdesignated area.

Note1) The level indicates the signal level.
L: Level signal → The designated function is validated when the signal is ON, and is invalidated when the signal is OFF.
E: Edge signal → The designated function is validated when the signal changes from the OFF to ON state, and
the function maintains the original state even when the signal then turns OFF.
Note2) Four elements are set in the order of input signal start No., end No., output signal start No. and end No.
Note3) Up to eight points can be set successively in order of start output signal No. and end output signal No.

Dedicated input/output 3-51

3Controller

3.6 Emergency stop input/output
Input from the "emergency stop input" terminal, which is located inside the CR3-535M controller, or on the rear
of the CR2B-572 controller.
Table 3-3 ： Dedicated input terminals in controller
Class

Name

Details

Input

Emergency stop

Applies the emergency stop (Dual emergency line.)

Input

Door switch

The servo turns OFF.

Output

Emergency stop

This output indicates that the emergency stop is being input.

3.6.1 Connection of the external emergency stop
The external emergency stop input and door switch input are short-circuited with a short cable at shipment as
shown in Fig. 3-10.
Connect the external emergency stop switch and door switch with the following procedure.
1) Prepare the "emergency stop switch" and "door switch".
2) Remove the two short pieces 1 and 2.
3) Securely connect the external emergency stop's contacts across "1)-2), and the door switch's contacts
across 3)-4)" on the terminal block.
[Caution] When wiring the emergency stop switch (duble emergency line type), wire both contacts to the two terminal blocks on the controller. If both contacts are wired to only one of the terminal blocks, errors cannot be cancelled using the door switch.

EMG. DOOR
STOP SWITCH
24V

EXTEMG1
6
5

Short piece 2
Short piece 1

4
3

RA3:Emergency stop output
24V
RA2

2
1

Note1)

RA1

Short piece 2
Short piece 1

4
3

RA31:Emergency stop output

RA21

5
4
3
2
1

GND (24G)
System emergency
stop line
(Prepared
by cusotmer)
RA Relay

24V

EXTEMG2
6
5
4
3

External door switch input

RA11

External emergency stop input

(Customer-prepared wiring) (Controller side)

Internal circuit composition of
external emergency stop and door switch

Warning

Note1)

24V

External emergency stop input

EXTEMG2
5

EXTEMG1

External door switch input

RG (24G)
6

System emergency
stop line
(Prepared
by cusotmer)
RA Relay

GND (24G)

Example of wiring for
external emergency stop and door switch
(customer-prepared wiring)

Do not check the voltage which withstand insulation.
And, failure will be caused if it connects incorrectly.

Wire fixing screw
EXTEMG1
EXTEMG2

Control unit

Note 1) Emergency stop output opens
6
when either one of the emergency stop switches
Wire insert
5
4
AWG#24 to #12
shown below or an input signal turns on.
3
(0.2 to 2.5mm2)
2
･Emergency stop switch of the controller.
Maker:Phoenix Contact
1
･Emergency stop switch of the T/B (option).
Type:FRONT-MSTB2.5/6-ST-5.08
･External emergency stop input.
EXTEMG connector
･External door input.
(Same for both left and right outputs)
･The T/B mount/dismount switch is OFF
when the T/B is unconnected.
×

Fig.3-10 ： Connection of the external emergency stop (CR3-535M controller)

3-52 Emergency stop input/output

3Controller

Upside terminal block

DOOR
Switch

24V
Short piece 1

Short piece 2

Door switch input

RA2

RA3

Note1)

Emergency stop input

RA11

Door switch input

RA21

RA31

1
2

Note1)

24V

System emergency
stop line
(Prepared by cusotmer)

RG (24G)
Emergency stop output

DOOR
Switch

4
5

6
RA5

EMG.
STOP

24V
1

Short piece 2

RG (24G)

(Customer-prepared wiring) (Controller side)

Bottom side terminal block

24V

System emergency
stop line
(Prepared by cusotmer)

RG (24G)
Emergency stop output

Emergency stop input

RA1

Short piece 1

EMG.
STOP

5
6
RA51

RG (24G)
Example of wiring for external emergency stop and door switch
(customer-prepared wiring)

Internal circuit composition of
external emergency stop and door switch
Note 1) Emergency stop output opens
when either one of the emergency stop switches
shown below or an input signal turns on.
･Emergency stop switch of the controller.
･Emergency stop switch of the T/B (option).
･External emergency stop input.
･External door input.
･The T/B mount/dismount switch is OFF
when the T/B is unconnected.

Wire fixing screw

Controller rear side

①②
Maker:Phoenix Contact
③④
⑤⑥
Type:FRONT-MSTB2.5/6-ST-5.08
EXTEMG connector (Same for both top and bottom outputs)
Wire insert

Fig.3-11 ： Connection of the external emergency stop (CR2B-574 controller)

[Note] Refer to Page 109, "6.1.7 Examples of safety measures" together, and carry out wiring to the emergency stop.

Emergency stop input/output 3-53

3Controller

3.6.2 Door switch function
This function retrieves the status of the switch installed on the door of the safety fence, etc., and stops the robot
when the door is opened. This differs from an emergency stop in that the servo turns OFF when the door is
opened and an error does not occur. Follow the wiring example shown in Fig. 3-10, and wire so that the contact
closes when the door is closed. Details of this function according to the robot status are shown below.
・ During automatic operation .............When the door is opened, the servo turns OFF and the robot stops. An error
occurs.
The process of the restoration : Close the door, reset the alarm, turn on the
servo, and restart
・ During teaching.......................................Even when the door is opened, the servo can be turned ON and the robot
moved using the teaching pendant.
① Auto executing
Safeguard
STOP!!
TEACH
AUTO
(Op.)

AUTO
(Ext.)

Robot arm
(Example)

Open

Turns OFF the servo

② Teaching

Safeguard

TEACH
AUTO
(Op.)

AUTO
(Ext.)

Open

Robot arm
(Example)

Teaching
pendant

The servo can be turned ON/Off
by turning the deadman switch ON/OFF.

Fig.3-12 ： Door switch function

3-54 Emergency stop input/output

3Controller

3.7 Additional Axis Function (CR3-535M controller only)
The CR3-535M controller is equipped with an additional axis interface for controlling an additional axis when a
traveling axis or rotary table is added to the robot. A maximum of eight axes of servo motors can be controlled at
the same time by connecting a general-purpose servo amplifier (MR-J2S-B, MR-J2M series) that supports Mitsubishi's SSC Net.
Refer to the separate "Additional axis interface Instruction Manual" for details on the additional axis function.

3.7.1 Wiring of the Additional Axis Interface
Table 3-4 shows the connectors for additional axes inside the controller and Fig. 3-5 shows a connection example
(configuration example). The magnet contactor control connector for additional axes, AXMC1, is designed to
accommodate circuit connection with improved safety in Mitsubishi's industrial robot systems connecting additional axes. Please implement the appropriate circuit connection by refere to Page 56, "3.8 Magnet contactor
control connector output (AXMC) for addition axes".
Table 3-4 ： Dedicated Connectors inside the Controller
Name

Connector name
Note1)

Connector for additional axes

CN1B

Magnet contactor control connector
for additional axes

AXMC1

Details
This connector is used to connect between general-purpose servo
amplifiers and the controller.
This contact output is used to turn ON/OFF the motor power by
connecting to general-purpose servo amplifiers.

Note1) The CN1A connector has already been in use.
Control unit
(R6x2CPU)

CN1A connector

AXMC1 connector

CN1B connector
Control unit
(R6x2CPU)
Servo amplifier

Bus cable between
controller and amplifier

Servo amplifier

Bus cable between amplifiers

CN1B connector CN1A connector

CN1B connector

CN1A connector

Terminator

CN1B connector

Illegible

Table 3-5 ： Connection Example of Additional Axis Interface Connection (Configuration Example)

Additional Axis Function (CR3-535M controller only) 3-55

3Controller

3.8 Magnet contactor control connector output (AXMC) for addition axes
When an additional axis is used, the servo ON/OFF status of the additional axis can be synchronized with the
servo ON/OFF status of the robot itself by using the output contact (AXMC1) provided on the rear or inside of
the controller and configuring a circuit so that the power to the servo amplifier for the additional axis can be
turned off when this output is open. Fig. 3-14 and Fig. 3-13 shows an example of its circuit, and Fig. 3-16 and Fig.
3-16 show the layout drawings of the output contact (AXMC1). When you are using an additional axis, please per form appropriate circuit connections by referring to these drawings.
Refer to the separate "Additional axis interface Instruction Manual" for details on the additional axis function.

1) Get the power supply for the controller from the secondary erminal
of short circuit breaker (NV) built in the addition axis amplifier box.
2) Get the power supply for the MC synchronization from the secondary
terminal of short circuit breaker (NV) built in the controller.

NV
To the internal circuit
AXMC1

Note)

1
2

Note) This output is opened, if the robot turns off the servo
by occurrence of alarm etc.

AC3 class(AC200 to 220V) 6A
AC2 class(DC24V)12A

AXMC is outputted
from the contact
for internal servo
power supplies.

Fig.3-13 ： Example of circuit for addition axes of Magnet contactor control output (CR2B-574 controller)

NV
To the internal circuit

AXMC1

Note)

1
2
AXMC is outputted
from the contact
for internal servo
power supplies.

Note) This output is opened, if the robot turns off the servo
by occurrence of alarm etc.

AC15 class(AC200V) 5A
AC13 class(DC48V)3A

Fig.3-14 ： Example of circuit for addition axes of Magnet contactor control output (CR3-535M controller)

3-56 Magnet contactor control connector output (AXMC) for addition axes

3Controller

CR2A-572 controller of backside

Plug side (user) : FRONT-MSTB2.5/2-STF-5.08
Socket side (controller) : DFK-MSTB2.5/2-GF-5.08
(Connector maker name : Phoenix Contact)

Fig.3-15 ： Arrangement figure of the AXMC1 connector (CR2B-574 controller)

AXMC1 connector

Enlargement

Fig.3-16 ： Arrangement figure of the AXMC1 connector (CR3-535M controller)

Magnet contactor control connector output (AXMC) for addition axes 3-57

3Controller

3.9 Parallel input/output unit
・ A parallel input/output unit or card is mounted as a standard in the controller's control unit.
・ The external input/output circuit specifications are shown in Table 3-6 and Table 3-7.
・ The correspondence of the external input/output connector pin No. and the colors of the connected "external
input/output cable" wires (separate option) is as shown in Page 61, "Table 3-8"and Table 3-9. Refer to Page
81, "(4) External I/O cable" for details of external I/O cable.
・ Pin Nos. described as both general-purpose signal and dedicated signal can be shared.
・ The other dedicated input/output signals that are not assigned can be assigned to required general-purpose
input/output pins when creating the program.
・If the standard inputs and outputs are insufficient, install the parallel input/output unit connection option outside
the controller.
Table 3-6 ： Electrical specifications of input circuit
Item

Specifications

Type
No. of input points
Insulation method
Rated input voltage
Rated input current
Working voltage range
ON voltage/ON current
OFF voltage/OFF current
Input resistance
OFF-ON
Response time
ON-OFF
Common method
External wire connection
method

DC input
32
Photo-coupler insulation
12VDC/24VDC
Approx. 3mA/approx. 7mA
10.2VDC to 26.4VDC(ripple rate within 5%)
8VDC or more/2mA or more
4VDC or less/1mA or less
Approx. 3.3kΩ
10ms or less(DC24V)
10ms or less(DC24V)
8 points per common

Internal circuit

24V/12V
(COM)
820
3.3K

Input

3.3K

Input

Connector

820
0V(COM)

Table 3-7 ： Electrical specifications of output circuit
Item

Specifications

Type
No. of output points
Insulation method
Rated load voltage
Rated load voltage range
Max. load current
Leakage current at OFF
Max. voltage drop at ON
OFF-ON
Response time
ON-OFF
Fuse rating
Common method
External wire connection
method
External power
supply

Transistor output
32
Photo-coupler insulation
DC12V/DC24V
DC10.2 ～ 30V(peak voltage 30VDC)
0.1A/point (100％)
0.1mA or less
DC0.9V(TYP.)
2ms or less
(hardware response time)
2ms or less
(Resistance load) (hardware response time)
Fuse 3.2A (one per common) Replacement not possible
8 points per common (common terminal: 8 points)

(24/12V)
Outline
Fuse

(0V)

Fuse (24/12V)

Connector

Voltage

DC12/24V(DC10.2 ～ 30V)

Current

60mA (TYP. 24VDC per common)
(base drive current)

3-58 Parallel input/output unit

Internal circuit

Outline
(0V)

3Controller

[Caution] When connecting the phototransistor output to the input circuit, be sure to allocate an input current of
approximately 7 mA at 24 VDC. Especially when using a photo diode and a phototransistor (sensor) away
from each other, it is recommended to verify the current that can be carried in the design stage.

CAUTION

The output circuit protective fuses prevent failure in case of load short-circuit and
improper connections. Please do not connect loads that cause the current to exceed
the maximum rated current. If the maximum rated current is exceeded, the internal
transistors may be damaged.

Parallel input/output unit 3-59

3Controller

AX41C
(Mitsubishi programmable
controller)
＋24V
COM

Parallel I/O interface
（Output）
60mA
(24/12V)
Output
……

Output
Fuse

24V

24G

(0V)
External
power supply

AY51C
(Mitsubishi programmable
controller)
CTL＋
24V

(Input)
(COM)
Input

……

3.3K

Input

24V

COM
CTLG
24G

External
power supply

Fig.3-17 ： Connection with a Mitsubishi PLC (Example of sink type)
*The input/output circuit external power supply (24 VDC) must be prepared by the customer.

(Output)

AX81C

60mA
Fuse (24/12V)

＋24V

……

Output
Output

X
24V

COM
24G

(0V)
External
power supply

CTL ＋
24V

(Input)
3.3K Input
……

Input

(COM)

24V

CTLG
24G
AY81C

External
power supply

Fig.3-18 ： Connection with a Mitsubishi PLC (Example of source type)
*The input/output circuit external power supply (24 VDC) must be prepared by the customer.
3-60 Parallel input/output unit

3Controller

Table 3-8 ： Standard parallel I/O interface CN100pin No. and signal assignment list (2A-CBL □□ )
Function name

Pin
No.

Line color

1
2
3
4
5
6
7
8
9
10

Orange/Red A
Gray/Red A
White/Red A
Yellow/Red A
Pink/Red A
Orange/Red B
Gray/Red B
White/Red B
Yellow/Red B
Pink/Red B

Pin
Dedicated/power supply, common No.

General-purpose

General-purpose output 8

26
27
28
29
30
31
32
33
34
35

11 Orange/Red C General-purpose output 9

Gray/Red C General-purpose output 10

White/Red C General-purpose output 11

General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

0
1
2
3

14 Yellow/Red C
15
16
17
18
19
20
21
22
23
24
25

Pink/Red C
Orange/Red D
Gray/Red D
White/Red D
Yellow/Red D
Pink/Red D
Orange/Red E
Gray/Red E
White/Red E
Yellow/Red E
Pink/Red E

FG
0V:For pins 4-7, 10-13
12V/24V:For pins 4-7
Running
Servo on
Error
Operation rights
0V:For pins 4-7, 10-13
12V/24V:For pins 10-13

COM0:For pins 15-22
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input
input
input
input
input
input
input
input

Stop(All slot) Note2)
Servo off
Error reset
Start
Servo on
Operation rights

0
1
2
3
4
5
6
7

Reserved
Reserved
Reserved

Orange/Blue A
Gray/Blue A
White/Blue A
Yellow/Blue A
Pink/Blue A
Orange/Blue B
Gray/Blue B
White/Blue B
Yellow/Blue B
Pink/Blue B

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 29-32, 35-38
12V/24V:For pins 29-32
General-purpose
General-purpose
General-purpose
General-purpose

output 4
output 5
output 6
output 7
0V:For pins 29-32, 35-38
12V/24V:For pins 35-38
output

General-purpose
12
Orange/Blue C General-purpose
13
Gray/Blue C General-purpose
14
White/Blue C General-purpose
15
Yellow/Blue C

40
41
42
43
44
45
46
47
48
49
50

Pink/Blue C
Orange/Blue D
Gray/Blue D
White/Blue D
Yellow/Blue D
Pink/Blue D
Orange/Blue E
Gray/Blue E
White/Blue E
Yellow/Blue E
Pink/Blue E

input 8
input 9
input 10
input 11
input 12
input 13
input 14
input 15

38
Note1)

Function name
Line color

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
COM1:For pins 40-47

Note1)

Reserved
Reserved
Reserved

Note1)Sink type:24V/12V(COM), Source type:0V(COM)
Note2)The assignment of the dedicated input signal "STOP" is fixed.
Table 3-9 ： Standard parallel I/O interface CN300pin No. and signal assignment list (2A-CBL □□ )
Function name

Pin
No.

Line color

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Orange/Red A
Gray/Red A
White/Red A
Yellow/Red A
Pink/Red A
Orange/Red B
Gray/Red B
White/Red B
Yellow/Red B
Pink/Red B
Orange/Red C
Gray/Red C
White/Red C
Yellow/Red C
Pink/Red C
Orange/Red D
Gray/Red D
White/Red D
Yellow/Red D
Pink/Red D
Orange/Red E
Gray/Red E
White/Red E
Yellow/Red E
Pink/Red E

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 4-7, 10-13
12V/24V:For pins 4-7
General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

16
17
18
19
0V:For pins 4-7, 10-13
12V/24V:For pins 10-13

General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

24
25
26
27

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input 16
input 17
input 18
input 19
input 20
input 21
input 22
input 23

COM0:For pins 15-22

Note1)

Reserved
Reserved
Reserved

Function name

Pin
No.

Line color

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

Orange/Blue A
Gray/Blue A
White/Blue A
Yellow/Blue A
Pink/Blue A
Orange/Blue B
Gray/Blue B
White/Blue B
Yellow/Blue B
Pink/Blue B
Orange/Blue C
Gray/Blue C
White/Blue C
Yellow/Blue C
Pink/Blue C
Orange/Blue D
Gray/Blue D
White/Blue D
Yellow/Blue D
Pink/Blue D
Orange/Blue E
Gray/Blue E
White/Blue E
Yellow/Blue E
Pink/Blue E

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 29-32, 35-38
12V/24V:For pins 29-32
General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

20
21
22
23
0V:For pins 29-32, 35-38
12V/24V:For pins 35-38

General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input
input
input
input
input
input
input
input

28
29
30
31
COM1:For pins 40-47

Note1)

24
25
26
27
28
29
30
31
Reserved
Reserved
Reserved

Note1)Sink type:24V/12V(COM), Source type:0V(COM)

Parallel input/output unit 3-61

3Controller

・The signals assigned as dedicated inputs can be used as general-purpose inputs during program execution. Note
that for safety proposes, these should not be shared with the general-purpose inputs other than for numeric
value inputs. The signals assigned as dedicated outputs cannot be used in the program. An alarm will occur during operation if used.
(Channel No. is set to 0 at shipment) [*1]

＜CN300＞
Input 16 to 31
Output 16 to 31

＜CN100＞
Input 0 to 15
Output 0 to 15

Connection and pin layout

Control unit
*The I/O card in the control unit is equal to the PIO unit of the option.
(Occupies one channel)

Fig.3-19 ： Parallel input/output unit (in the control unit) connection and pin layout (CR3-535M controller)

Connector pin layout

＜CN100＞
Output 0 to 15
Input 0 to 15
＜CN300＞
Output 16 to 31
Input 16 to 31

Controller back side

*The I/O card in the control unit is equal to the PIO unit of the option.
(Input 32/Output 32 points)
Fig.3-20 ： Parallel input/output unit (in the control unit) connection and pin layout (CR2B-574 controller)
3-62 Parallel input/output unit

3Controller

3.10 Options
■ What are options?
There are a variety of options for the robot designed to make the setting up process easier for user needs.
User installation is required for the options.
Options come in two types: "set options" and "single options".
1． Set options......................................A combination of single options and parts that together, form a set for serving
some purpose.
2． Single options.................................That are configured from the fewest number of required units of a part.
Please choose user's purpose additionally.

Options 3-63

3Controller

(1) Teaching pendant (T/B)
■ Order type: R28TB
:Cable length 7m
R28TB-15 :Cable length 15m
Note) There is a cable length 15m as special spcification. Confirm the delivery date.
■ Outline
This is used to create, edit and control the program, teach the operation position and
for jog feed, etc.
For safety proposes, a 3-position deadman switch is mounted.Note1)
If there are several robots, one teaching pendant can be used by connecting it to the
respective robot.
■ Configuration
Table 3-10 ： Configuration device
Part name

Type

Teaching pendant

R28TB
R28TB-15

Qty.
Either one pc.

Remarks
Cable length is 7m. Hand strap is attached.
Cable length is 15m. Hand strap is attached.

■ Specifications
Table 3-11 ： Specifications
Items

Specifications

Outline dimensions

153(W) x 203(H) x 70(D) (refer to outline drawing)

Body color

Light gray (reference Munsell color: 0.08GY7.64/0.81)

Mass

Approx. 0.8kg (only arm, excluding cable)

Connection method

Connection with controller and round connector (30-pin)

Interface

RS-422

Display method

LCD method: 16 characters x 4 lines, LCD illumination: with backlight

Operation section

28 keys

Protection specifications

IP65

Remarks

Note2)

Note2) The manual operation section of the teaching pendant has a protection method that complies with the IEC
Standards IP65 (protection type).
[Reference] IProtection against water infiltration as specified in IP65 indicates a protective structure that is
not harmfully affected when 12.5 ± 5% liters of water is supplied from a test device at a position approx. 3m away in various directions and a water pressure of 30kPa at the nozzle section.
The water is filled one minute per 1m2 of test device surface area for a total of three minutes.
.

Note1) <3-position deadman switch>
In ISO/10218 (1992) and JIS-B8433 (1993), this is defined as an "enable device". These standards specify that the
robot operation using the teaching pendant is enabled only when the "enable device" is at a specified position.
With the Mitsubishi Electric industrial robot, the above "enable device" is configured of an "Enable/Disable switch"
and "Deadman switch".
The 3-position deadman switch has three statuses. The following modes are entered according to the switch state.
"Not pressed"............................... The robot does not operate. *)
"Pressed lightly".......................... The robot can be operated and teaching is possible.
"Pressed with force" ................. The robot does not operate. *)

*) Operations, such as program editing and status display, other than robot operation are possible.
Safety is secured as the servo power is turned OFF simultaneously with the input of the emergency stop.
3-64 Options

3Controller

Hand strap

Contrast adjusting
switch

Enable/Disable switch

Display LCD

DISABLE

ENABLE

R28TB

TOOL

JOINT

XYZ

=＊/

( )？

$" :

#%!

STOP

203

SVO ON
STEP

－X

＋X

MOVE

(J1)

EMG.STOP
ADD

＋

－Y

＋Y

FORWD

(J2)

－

－Z

＋Z

BACKWD

(J3)

↑
RPL
↓

Emergency stop
switch

DEL
COND

－A

＋A

(J4)

←
HAND

POS
CHAR

ERROR
RESET

－B

＋B

(J5)

－C

＋C

(J6)

→

Teaching pendant

INP
EXE

Operation keys
Dead man switch
Cable
(with connection connector)

55
70

153

Hand strap

Fig.3-21 ： Outside dimensions of teaching pendant

■ Installation method
The teaching pendant is connected to the T/B connector on the front of the controller.

Options 3-65

3Controller

■ Key layout and main functions

DISABLE

ENABLE

R28TB

2)
5)

4)
19)

Back

1)
6)
TOOL

JOINT

=＊/

( )？

XYZ
$" :

MENU
#%!

STOP

SVO ON

7)
8)
9)
10)
18)

STEP

－X

＋X

MOVE

(J1)

＋

－Y

＋Y

FORWD

(J2)

－

－Z

＋Z

BACKWD

(J3)

－A

＋A

(J4)

－B

＋B

(J5)

ADD
↑
RPL

COND

ERROR
RESET

－C

＋C

(J6)

14)
15)

←
HAND

CHAR

13)

↓
DEL

POS

11)

EMG.STOP

16)

→

INP

17)

EXE

12)
1) : Emergency stop switch...................The robot servo turns OFF and the operation stops immediately.
2) : T/B enable/disable
changeover switch ............................This switch changes the T/B key operation between enable and disable.
3) : LCD display panel .............................The robot status and various menus are displayed.
4) : key .............This selects the jog mode (JOINT, XYZ, 3-AXIS XYZ, CYLINDER,
TOOL).
5) : key........................................This returns the display screen to the menu screen.
6) : key ........................................This stops the program and decelerates the robot to a stop.
7) : key..........................Jog operation is carried out when this key is pressed simultaneously
with the jog operation key. This also turns the Servo ON and carries
out step jump.
8) : <( ＋ FORWD> key............................This carries out step feed and increases the override.
9) : <( － BACKWD> key.........................This carries out step return (return along operation path) and
decreases the override.
10) : key .....................................This sets the program.
11) : key...................This resets the error, and releases the software limit.
12) : Jog operation key ...........................This operates the robot according to the jog mode. When inputting
numeric values, this inputs each numeric value.
13) : key...............................This additionally registers the position data. It also moves the cursor
upward.
14) : key................................It also moves the cursor downward.
15) : key................................This deletes the position data. It also moves the cursor to the left.
16) : key............................This opens and closes the hand. It also moves the cursor to the right.
17) : key................................This inputs the program, and carries out step feed/return.
18) : key...........................This changes the edit screen, and changes between numbers and
alphabetic characters.
19) : Deadman switch ..............................When the [Enable/Disable] switch "2)" is enabled, and this key is
released or pressed with force, the servo will turn OFF, and the operating robot will stop immediately.
Fig.3-22 ： Teaching pendant key layout and main functions

3-66 Options

3Controller

(2) Pneumatic hand interface
■ Order type: 2A-RZ365(Sink type)
2A-RZ375(Source type)
■ Outline
This interface is required to use the robot arm's hand output signals. This interface is
pre-installed on the controller.
・ Up to eight hand output points can be used with this interface.
・ The eight hand input points can be used without this interface.
・ When using more than eight hand input/output points, install the "Parallel I/O
unit". Refer to Page 70, "Parallel I/O unit" for detail.

■ Configuration
Table 3-12 ： Configuration device
Part name
Pneumatic hand interface

Type

Qty.

2A-RZ365/
2A-RZ375

1pc.

Remarks
Output 8 points expansion. 2A-RZ365 is the sink type.
2A-RZ375 is the source type.

■ Specifications
Table 3-13 ： Specifications
Item

Specification

Type

Transistor output

No. of output points

Insulation method

Photo coupler insulation

Rated load voltage

DC24V

Rated load voltage range

DC21.6 to 26.4VDC

Max. current load

0.1A/ 1 point (100%)

Current leak with power OFF

0.1mA or less

Maximum voltage drop with power ON

DC0.9V(TYP.)

Response time

OFF-ON

2ms or less (hardware response time)

ON-OFF

2 ms or less (resistance load) (hardware response time)

Fuse rating

Fuses 1.6A (each one common)

Common method

8 points, 1 common

Internal circuit

24V
（Internal power supply）

GRn

Fuse
1.6A
0V

Fuse
1.6A

+24V
GRn*

24GND(COM)

* GRn ＝ GR1 ～ GR8

Options 3-67

3Controller

■ Installation method
This is mounted on the control unit (RZ181/RZ326A/RZ327 card) in the controller.
Securely insert the pneumatic hand interface (2A-RZ365/375) into the CNHNDOUT/CNHND connector on the
control unit.

Control unit （RZ181 card）

＜RZ181＞

CNHND
CNHND

CNHNDOUT
2A-RZ365
or
2A-RZ375

CNHNDOUT
Jumper

Fig.3-23 ： Installation of pneumatic hand interface(CR3-535M controller)

3-68 Options

3Controller

Pneumatic hand interface

RZ326A/327 card

CNHNDOUT
CNHND

2A-RZ365/375

＜RZ326A/327＞

CNHNDOUT

CNHND

View A
Fig.3-24 ： Installation of pneumatic hand interface (CR2B-574 controller)

Options 3-69

3Controller

(3) Parallel I/O unit
■ Order type: 2A-RZ361(Sink type)
2A-RZ371(Source type)
■ Outline
This is used to expand the external inputs and outputs. One one equal with this unit
is built into the control unit among controllers the standard.
・ The connection cable is not included. Prepare the optional external input/output
cable (2A-CBL05 or 2A-CBL15).

■ Configuration
Table 3-14 ： Configuration device
Part name
Parallel I/O unit

Robot I/O link connection connector

Type

Qty.

2A-RZ361/
2A-RZ371

1 pc.

Input/output 32 points/32 points
2A-RZ361 is the sink type.
2A-RZ371 is the source type.

NETcable-1

2 sets

Connector with pins.
The cable must be prepared and wired by the customer.

DCcable-2

1 set

Connector with pins.
The cable must be prepared and wired by the customer.

R-TM

1 pc.

100Ω(1/4W)

Power connection connector
Terminator

Remarks

■ Specifications
1) Up to eight stations can be connected to this unit. (One station occupies one unit.)
One unit is built into the controller as a standard, so up to seven units can be installed as expansions.
2) The power supply (24V) must be prepared by the customer and connected with the power connection cable
(DCcable-2)
A separate 24V power supply is required for the input/output circuit wiring.
The detailed specifications of the input/output circuit are the same as the parallel input/output unit mounted as a
standard. Refer to Page 58, "3.9 Parallel input/output unit" for details.
Table 3-15 ： Electrical specifications of input circuits
Item

Specification

Type

DC input

Number of input points

Insulation method

Photo coupler insulation

Rated input voltage

12VDC/24VDC

Rated input current

Approx 3mA/7mA

Working voltage range

10.2 to 26.4VDC(Ripple factor should be less than 5%.)

ON voltage/ON current

8VDC or more/ 2mA or more

OFF voltage/ OFF current

4VDC or less/ 1mA or less

Input resistance

Approx. 3.3kΩ

Response time

OFF-ON

10ms or less (24VDC)

ON-OFF

10ms or less (24VDC)

Common method

8 points per common

External cable connection method

Connector

Internal circuit

24V/12V
(COM)
820
3.3K

Input

3.3K

Input

820
0V(COM)

3-70 Options

3Controller

Table 3-16 ： Electrical specifications for the output circuits
Item

Specification

Type

Transistor output

No. of output points

Insulation method

Photo-coupler insulation

Rated load voltage

12VDC/24VDC

Rated load voltage range

10.2 to 30VDC(peak voltage 30VDC)

Max. load current

0.1A/point (100％)

Leakage current at OFF

0.1mA or less

Max. voltage drop at ON

0.9VDC(TYP.)

OFF-ON

2ms or less
(hardware response time)

ON-OFF

2ms or less
(Resistance load) (hardware response time)

Response time

Fuse rating

Fuse 3.2A (one per common) Replacement not possible

Common method

8 points per common (common terminal: 8 points)

External wire connection
method

Connector

External power
supply

Voltage

12VDC/24VDC(10.2 to 30VDC)

Current

60mA (TYP. 24VDC per common) (base drive current)

CAUTION

Internal circuit

(24/12V)
Outline
Fuse

(0V)

Fuse (24/12V)
Outline
(0V)

Options 3-71

3Controller

NETcable-1 (Network cable)
Pin No.

RIO1/2

Pin No.

１

TXRXH

１

２

TXRXL

２

３

SG(GND)

３

Note 2)

FG
DCcable-2 (Power cable)
Pin No.

DCIN

１

24V

＋

２

24G(RG)

－

３

FG(PE)

Note 1)

24V Power

Connected the frame ground or protect ground
R-TM (Terminator)
Pin No.

RIO1/2

１

TXRXH

２

TXRXL

３

SG(GND)

100Ω

List of parts and manufacturer
Connector type

Contact type

Resistant

NETcable-1

Type

1-178288-3 (2)

175218-3 (6)

－

DCcable-2
R-TM

2-178288-3 (1)
1-178288-3 (1)

175218-3 (3)
175218-3 (2)

－
100Ω(1/4W) (1)

Manufacturer
AMP
AMP
Equivalent to KOA.

Note 1) The 24V power supply is prepared by customer (The power consumption is approx. 0.3A.)
Note 2) The cable for general purpose can be used to the network cable. However, use the twisted shield cable of
AWG#22(0.3mm2) or more.
Fig.3-25 ： Spacifications for the connection cable

3-72 Options

3Controller

■ Installation method
The expansion parallel input/output unit is installed outside of the controller. Connect with the network connection cable (NETcable-1) from the RIO1 connector in the into of the controller.(Terminator is connected at the
time of shipment)

RIO1 connector

Control unit
(R6x2CPU)

(175)
128

100

(40)

Wiring
space

2-Ｍ５ screw

150

<2A-RZ361>
<2A-RZ371>

168

Radiation/wiring space

156

Heat radiation space

upside

54
60

Control panel installation dimensions

downside

Installation dimensions of 2A-RZ361/2A-RZ371 The controller outside installation.
Fig.3-26 ： Installing the parallel input/output unit (CR3-535M controller)

Options 3-73

3Controller

RIO1 connector

(175)
128

100

(40)

Wiring
space

2-Ｍ５ screw

150

<2A-RZ361>
<2A-RZ371>

168

Radiation/wiring space

156

Heat radiation space

upside

54
60

Control panel installation dimensions

downside

Installation dimensions of 2A-RZ361/2A-RZ371
(The controller outside installation.）
Fig.3-27 ： Installing the parallel input/output unit (CR2B-574 controller)

3-74 Options

3Controller

Parallel I/O unit 1 . . . 6

Control unit R6x2CPU

Parallel I/O unit 7

Station No. setting
1...6

Station No. setting
7

RIO1 connector (R6)
＜CN300＞
＜CN100＞

RIO2 connector RIO1 connector

RIO1connector
Note)
NETcable-1
cable

Note)
NETcable-1
cable

DCIN connector
FG

＜CN300＞
＜CN100＞

DCcable-2
cable

DCIN connector
FG

RIO2 connector
R-TM
terminator

DCcable-2
cable
Front
RIO1 connector

RIO2 connector

DCIN connector

I/O unit the bottom
Connecta layout

Connect the NET cable-1 to the RIO1 connector (R6) on the front of the control unit
(R6x2CPU) in the controller. Each unit is connected to from a daisy chain.
Always install a terminator (R-TM) to the last unit.
Note) Use a shield cable for NET cable-1 as a measure against noise.
Always connect the shield to FG.
The unit could malfunction because of noise if the shield cable is not used.

Fig.3-28 ： Connection method of expansion parallel input/output unit (CR3-535M controller)

Options 3-75

3Controller

RIO1 connector
Parallel I/O unit 1 . . . 6

Parallel I/O unit 7

Controller back side
Station No. setting
7

Station No. setting
1...6

Note)
NETcable-1
cable

＜CN300＞

＜CN100＞

RIO1 connector

RIO2 connector RIO1 connector

Note)
NETcable-1
cable

DCIN
connector
DCcable-2
cable

DCIN
connector
FG

RIO2 connector
R-TM
terminator

DCcable-2
cable
Front
RIO1 connector

RIO2 connector

DCIN connector

I/O unit the bottom
Connecta layout

Connect the NET cable-1 to the RIO1 connector on the back of the controller. Each unit is
connected to from a daisy chain.
Always install a terminator (R-TM) to the last unit.
Note) Use a shield cable for NET cable-1 as a measure against noise.
Always connect the shield to FG.
The unit could malfunction because of noise if the shield cable is not used.
Fig.3-29 ： Connection method of expansion parallel input/output unit (CR2B-574 controller)

3-76 Options

3Controller

■ Parallel I/O interface (First expansion unit)
Table 3-17 ： Connector CN100pin No. and signal assignment list (2A-CBL □□ )
Function name
Pin
No.

Line color

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Function name

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 4-7, 10-13
12V/24V:For pins 4-7
General-purpose
General-purpose
General-purpose
General-purpose

output 32
output 33
output 34
output 35
0V:For pins 4-7, 10-13
12V/24V:For pins 10-13

General-purpose
General-purpose
General-purpose
General-purpose

output 40
output 41
output 42
output 43

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input
input
input
input
input
input
input
input

COM0:For pins 15-22

Note1)

32
33
34
35
36
37
38
39
Reserved
Reserved
Reserved

Pin
No.

Line color

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 29-32, 35-38
12V/24V:For pins 29-32
General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

36
37
38
39
0V:For pins 29-32, 35-38
12V/24V:For pins 35-38

General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input
input
input
input
input
input
input
input

44
45
46
47
COM1:For pins 40-47 Note1)

40
41
42
43
44
45
46
47
Reserved
Reserved
Reserved

Note1)Sink type:24V/12V(COM), Source type:0V(COM)
Table 3-18 ： Connector CN300pin No. and signal assignment list (2A-CBL □□ )
Function name
Pin
No.

Line color

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Orange/Red A
Gray/Red A
White/Red A
Yellow/Red A
Pink/Red A
Orange/Red B
Gray/Red B
White/Red B
Yellow/Red B
Pink/Red B
Orange/Red C
Gray/Red C
White/Red C
Yellow/Red C

15
16
17
18
19
20
21
22
23
24
25

Pink/Red C
Orange/Red D
Gray/Red D
White/Red D
Yellow/Red D
Pink/Red D
Orange/Red E
Gray/Red E
White/Red E
Yellow/Red E
Pink/Red E

Function name

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 4-7, 10-13
12V/24V:For pins 4-7
General-purpose
General-purpose
General-purpose
General-purpose

output 48
output 49
output 50
output 51
0V:For pins 4-7, 10-13
12V/24V:For pins 10-13

General-purpose
General-purpose
General-purpose
General-purpose

output 56
output 57
output 58
output 59

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input
input
input
input
input
input
input
input

COM0:For pins 15-22

Note1)

48
49
50
51
52
53
54
55
Reserved
Reserved
Reserved

Pin
No.

Line color

26
27
28
29
30
31
32
33
34
35
36
37
38
39

Orange/Blue A
Gray/Blue A
White/Blue A
Yellow/Blue A
Pink/Blue A
Orange/Blue B
Gray/Blue B
White/Blue B
Yellow/Blue B
Pink/Blue B
Orange/Blue C
Gray/Blue C
White/Blue C
Yellow/Blue C

40
41
42
43
44
45
46
47
48
49
50

Pink/Blue C
Orange/Blue D
Gray/Blue D
White/Blue D
Yellow/Blue D
Pink/Blue D
Orange/Blue E
Gray/Blue E
White/Blue E
Yellow/Blue E
Pink/Blue E

Dedicated/power supply,
common

General-purpose

FG
0V:For pins 29-32, 35-38
12V/24V:For pins 29-32
General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

52
53
54
55
0V:For pins 29-32, 35-38
12V/24V:For pins 35-38

General-purpose
General-purpose
General-purpose
General-purpose

output
output
output
output

General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose
General-purpose

input
input
input
input
input
input
input
input

60
61
62
63
COM1:For pins 40-47 Note1)

56
57
58
59
60
61
62
63
Reserved
Reserved
Reserved

Note1)Sink type:24V/12V(COM), Source type:0V(COM)

Options 3-77

3Controller

Channel No. setting

(Set channel No. to 1.) [*1]

TXD
LED display

＜CN100＞
Input 32 to 47
Output 32 to 47

＜CN300＞
Input 48 to 63
Output 48 to 63

*The 2A-RZ361/2A-RZ371 has 32 input and 32 output points unit
(Occupies one channel)
Fig.3-30 ： Parallel input/output unit <2A-RZ361/2A-RZ371:First expansion> connection and pin layout

CAUTION

3-78 Options

[*1] For the 1st expansion unit, set the channel No. to "1".
The channel No. of 8 to F is used for the maker test. If any value of 8 to F is set, it may
be dangerous since the robot unexpectedly moves. Don't set any value of 8 to F.

3Controller

■ Parallel I/O interface (Second expansion unit)
Table 3-19 ： Connector CN100pin No. and signal assignment list (2A-CBL □□ )
Function name
Pin
No.

Line color

Orange/Red A

Gray/Red A

White/Red A

Yellow/Red A General-purpose output 64

5
6

General-purpose

Pink/Red A

Function name
Pin
No.

Line color

Orange/Blue A

0V:For pins 4-7, 10-13

Gray/Blue A

0V:For pins 29-32, 35-38

12V/24V:For pins 4-7

White/Blue A

12V/24V:For pins 29-32

Yellow/Blue A General-purpose output 68

Dedicated/power supply,
common

General-purpose output 65

Orange/Red B General-purpose output 66

Pink/Blue A

Gray/Red B

Gray/Blue B

White/Red B

0V:For pins 4-7, 10-13

White/Blue B

Yellow/Red B

12V/24V:For pins 10-13

Yellow/Blue B

Pink/Red B

General-purpose output 72

Pink/Blue B

General-purpose output 69

Orange/Red C General-purpose output 73

General-purpose output 71
0V:For pins 29-32, 35-38
12V/24V:For pins 35-38
General-purpose output 76

Orange/Blue C General-purpose output 77

Gray/Red C

General-purpose output 74

Gray/Blue C

White/Red C

General-purpose output 75

White/Blue C General-purpose output 79

Yellow/Red C

Pink/Red C

Note1)

Yellow/Blue C

General-purpose input 64

Pink/Blue C

Orange/Red D General-purpose input 65

COM0:For pins 15-22

General-purpose output 78
COM1:For pins 40-47 Note1)
General-purpose input 72

Orange/Blue D General-purpose input 73

Gray/Red D

General-purpose input 66

Gray/Blue D

General-purpose input 74

White/Red D

General-purpose input 67

White/Blue D

General-purpose input 75

Yellow/Red D General-purpose input 68

Yellow/Blue D General-purpose input 76

20
21

General-purpose input 69

Orange/Red E General-purpose input 70

Pink/Red D

General-purpose input 71

Dedicated/power supply,
common

Orange/Blue B General-purpose output 70

General-purpose output 67

General-purpose

Pink/Blue D

General-purpose input 77

Orange/Blue E General-purpose input 78

Gray/Red E

Gray/Blue E

White/Red E

Reserved

White/Blue E

General-purpose input 79
Reserved

Yellow/Red E

Reserved

Yellow/Blue E

Reserved

Pink/Red E

Reserved

Pink/Blue E

Reserved

Note1)Sink type:24V/12V(COM), Source type:0V(COM)
Table 3-20 ： Connector CN300pin No. and signal assignment list (2A-CBL □□ )
Function name
Pin
No.

Line color

Orange/Red A

Gray/Red A

White/Red A

Yellow/Red A General-purpose output 80

5
6

General-purpose

Pink/Red A

Function name
Pin
No.

Line color

Orange/Blue A

0V:For pins 4-7, 10-13

Gray/Blue A

0V:For pins 29-32, 35-38

12V/24V:For pins 4-7

White/Blue A

12V/24V:For pins 29-32

Yellow/Blue A General-purpose output 84

Dedicated/power supply,
common

General-purpose output 81

Orange/Red B General-purpose output 82

Gray/Red B

White/Red B

9
10
11

General-purpose output 83

General-purpose

Pink/Blue A

General-purpose output 85

Orange/Blue B General-purpose output 86

Gray/Blue B

White/Blue B

Yellow/Red B
12V/24V:For pins 10-13
Pink/Red B General-purpose output 88

34
35

Yellow/Blue B
12V/24V:For pins 35-38
Pink/Blue B General-purpose output 92

Orange/Red C General-purpose output 89

Orange/Blue C General-purpose output 93

0V:For pins 4-7, 10-13

General-purpose output 87
0V:For pins 29-32, 35-38

Gray/Red C

General-purpose output 90

Gray/Blue C

White/Red C

General-purpose output 91

White/Blue C General-purpose output 95

Yellow/Red C

Yellow/Blue C

15
16

Dedicated/power supply,
common

Pink/Red C

COM0:For pins 15-22

Note1)

General-purpose input 80

Orange/Red D General-purpose input 81

Pink/Blue C

General-purpose output 94
COM1:For pins 40-47 Note1)
General-purpose input 88

Orange/Blue D General-purpose input 89

Gray/Red D

General-purpose input 82

Gray/Blue D

General-purpose input 90

White/Red D

General-purpose input 83

White/Blue D

General-purpose input 91

Yellow/Red D General-purpose input 84

Yellow/Blue D General-purpose input 92

20
21

Pink/Red D General-purpose input 85
Orange/Red E General-purpose input 86

45
46

Pink/Blue D General-purpose input 93
Orange/Blue E General-purpose input 94

Gray/Red E

Gray/Blue E

White/Red E

General-purpose input 87
Reserved

White/Blue E

General-purpose input 95
Reserved

Yellow/Red E

Reserved

Yellow/Blue E

Reserved

Pink/Red E

Reserved

Pink/Blue E

Reserved

Note1)Sink type:24V/12V(COM), Source type:0V(COM)

Options 3-79

3Controller

[*1]
Channel No. setting (Set channel No. to 2.)
TXD
LED display

＜CN300＞
Input 80 to 95
Output 80 to 95

＜CN100＞
Input 64 to 79
Output 64 to 79

*The 2A-RZ361/2A-RZ371 has 32 input and 32 output points unit
(Occupies one Channel)

Fig.3-31 ： Parallel input/output unit <2A-RZ361/2A-RZ371:Second expansion unit> connection and pin layout

CAUTION

[*1] For the 2nd expansion unit, set the channel No. to "2".
The channel No. of 8 to F is used for the maker test. If any value of 8 to F is set, it may
be dangerous since the robot unexpectedly moves. Don't set any value of 8 to F.

Table 3-21 lists the correspondence between the station numbers to be set and the I/O signal assignment.
Refer to this table when the third and subsequent units are used.
Table 3-21 ： Station Number Settings and I/O Signal Assignment
Unit No.

Station number setting

1st unit

Input: 32 ～ 47
Output: 32 ～ 47

Input: 48 ～ 63
Output: 48 ～ 63

2nd unit

Input: 64 ～ 79
Output: 64 ～ 79

Input: 80 ～ 95
Output: 80 ～ 95

3rd unit

Input: 96 ～ 111
Output: 96 ～ 111

Input: 112 ～ 127
Output: 112 ～ 127

4th unit

Input: 128 ～ 143
Output: 128 ～ 143

Input: 144 ～ 159
Output: 144 ～ 159

5th unit

Input: 160 ～ 175
Output: 160 ～ 175

Input: 176 ～ 191
Output: 176 ～ 191

6th unit

Input: 192 ～ 207
Output: 192 ～ 207

Input: 208 ～ 223
Output: 208 ～ 223

7th unit

Input: 224 ～ 239
Output: 224 ～ 239

Input: 240 ～ 255
Output: 240 ～ 255

3-80 Options

CN100

CN300

3Controller

(4) External I/O cable
■ Order type: 2A-CBL □□

Note） The numbers in the boxes □□ refer to the length. （05: 5m、 15: 15m）

■ Outline
This is the dedicated cable used to connect an external peripheral device to the connector on the parallel input/output unit.
One end matches the connector on the parallel input/output unit, and the other end
is free. Connect the peripheral device's input/output signal using the free end.
One cable correspond to the input 16 points and output 16 points.
Two cables are needed to connection of (input 32 points and output 32 points) with
built-in standard.
■ Configuration
Table 3-22 ： Configuration device
Part name

Type

External I/O cable

2A-CBL □□

Qty.
1pc.

Remarks
5m or 15m

■ Specifications
Table 3-23 ： Specifications
Items

Specifications

Number of cables x cable size

50 pairs x AWG #28

Total length

5m or 15m

■ Connector pin numbers and cable colors
Table 3-24 ： Connector pin numbers and cable colors
Pin
no.

Cable colors

Pin
no.

Cable colors

Pin
no.

Cable colors

Pin
no.

Cable colors

Pin
no.

Cable colors

Orange/Red A

Orange/Red C

Orange/Red E

Orange/Blue B

Orange/Blue D

Gray/Red A

Gray/Red C

Gray/Red E

Gray/Blue B

Gray/Blue D

White/Red A

White/Red C

White/Red E

White/Blue B

White/Blue D

Yellow/Red A

Yellow/Red C

Yellow/Red E

Yellow/Blue B

Yellow/Blue D

Pink/Red A

Pink/Red C

Pink/Red E

Pink/Blue B

Pink/Blue D

Orange/Red B

Orange/Red D

Orange/Blue A

Orange/Blue C

Orange/Blue E

Gray/Red B

Gray/Red D

Gray/Blue A

Gray/Blue C

Gray/Blue E

White/Red B

White/Red D

White/Blue A

White/Blue C

White/Blue E

Yellow/Red B

Yellow/Red D

Yellow/Blue A

Yellow/Blue C

Yellow/Blue E

Pink/Red B

Pink/Red D

Pink/Blue A

Pink/Blue C

Pink/Blue E

Options 3-81

3Controller

■ Connections and outside dimensions
The sheath of each signal cable (50 lines) is color indicated and marked with dots. Refer to the cable color specifications in "Table 3-24: Connector pin numbers and cable colors" when making the connections.
(Eg.) Pin number: color indication
１
： Orange ／ Red ／ Ａ
Type of dot mark (see figure below)
Color of dot mark
Color of sheath

Type of dot mark

Dot pattern

A type

Dot pattern

F type
18.5

18.5

1.5

B type

G type

18.5

18.5
1.5

C type

H type

18.5

18.5
1.5

7.5

I type

D type

18.5

18.5
1.5

7.5

J type

E type
Continuous

Continuous

5000
1

76.74
64.53
51.816
2.159

13.54
16.2

9.27

35.7

Receptacle type (PCB side)：57AE-40500-21D(D8)
Plug type
（cable side）：57YE-30500-2(D8) Note1)

Maker

……DDK
……DDK

Note1) The type of the plug shows the specification of this cable.
The following connector is recommended when user make the cable.
・Plug type (cable side) : 57E series (Soldering type).....................................................DDK
57FE series (Flat cable pressure connection type)......DDK

Fig.3-32 ： Connections and outside dimensions
3-82 Options

3Controller

(5) Personal computer cable
■ Order type: ● For PC/AT ： RS-MAXY-CBL
■ Outline
This is the RS-232C interface cable used for connecting the controller with a personal
computer. The personal computer on hand may be usable with the above interface cable.
Confirm the connection specifications when placing an order.
Personal computer cables for the PC/AT compatible model is available.
The cable for the NEC PC9821 (half-pitch 14-pin) must be manufactured by the customer.
■ Configuration
Table 3-25 ： Configuration device
Part name
Personal computer cable (for PC/AT)

Type

Qty.

RS-MAXY-CBL

1pc.

Remarks
3m, D-SUB 9 pinNote1)

Note1)The personal computer cable is the same as that for use with "Movemaster M1/M2/E/EN series".
■ Specifications
（1） For PC/AT
RS-MAXY-CBL

Controller side
(Signal name, pin No.)

（2） For PC98

Personal computer side
(Signal name, pin No.)

(FG) 1

1 (CD)

(SD) 2

2 (RD)

(RD) 3

3 (SD)

(RS) 4

4 (DTR)

(CS) 5

6 (DSR)

(DR) 6

8 (CTS)

(ER)20

7 (RTS)

(SG) 7

5 (GND)
Personal computer side
25 pin connector
(Signal name, pin No.)

Controller side
(Signal name, pin No.)
(FG) 1

1 (FG)

(SD) 2

2 (SD)

(RD) 3

3 (RD)

(RS) 4

4 (RS)

(CS) 5

5 (CS)

(DR) 6
(ER)20

6 (DR)
20 (ER)

(SG) 7

7 (SG)

Fig.3-33 ： Personal computer cabe connection
RS-MAXY-CBL
25
13
6

5
1
15

P/C side
15
39

Robot side
Type:17JE-23250-02(D8A6)-CG (DDK)

Fig.3-34 ： Personal computer cabe connector

Options 3-83

3Controller

(6) Extended serial interface
■ Order type: ● 2A-RZ581-E
■ Outline
The extension serial interface is the option to add a serial communication function to
the robot controller. One channel of RS-232C interface is provided in the front of the
controller. By using the extension serial interface, more channels can be added in
order to allow the use of a personal computer, vision sensor and PLC at the same
time. Also, in addition to RS-232C communication, RS-422 communication, which is
superior in noise resistance, is also supported.
Caution) This option can only be used with the robot controller's main unit software
version E1 or later.

■ Configuration
Table 3-26 ： Configuration device
Part name

Type

Qty.

Extended serial interface

2A-RZ581-E

Instruction Manual

BFP-A8106

Ferrite core

E04SR301334

Remarks

Be sure to install this for noise countermeasure.

Table 3-27 ： Procured by the customer
Part name

Type

Personal computer, vision sensor, etc.

Qty.

Remarks

From 1 unit.

Communication cable
(used when the length of the standard RS-232C
cable is too short, or when RS-422
communication is implemented)

RS-232C or RS-422

Two channel per one board.

From 1 cable.

■ Specifications
Table 3-28 ： Specifications
Item

Specifications

Mountable optional slots

Slot 1 or 2

Number of mountable interface cards

Maximum 2

Number of channels
Communication data
Communication baud rate
Parity

2
ASCII data

Channel 1: Dedicated to RS-232C
Channel 2: Either RS-232C or RS-422
Note1)

2400 / 4800 / 9600 / 19200

This has been set to "9600" at shipment.

Notiong / Odd/ Even

This has been set to "even" at shipment.

Stop bit

1/2

End code

CR code/ CR code + LF code

Protocol
Remarks

Remarks

Nonprocedural / Procedural / Data link

This has been set to "2" at shipment.
This has been set to "CR code" at shipment.
Note2)

This has been set to "nonprocedural" at shipment.

Capable of offering the same functions as
provided by the standard RS-232C interface in
the front of the controller

Note1)Binary data communication is not supported.
Note2)Nonprocedural: Nonprocedural protocol with the personal computer support software
Procedural: Procedural protocol with the personal computer support software
Data link: Nonprocedural (ASCII data) protocol for data link between robot programs and a personalcomputer/PLC/vision sensor, etc.

3-84 Options

3Controller

■ Functions
(1) Controller communication function
・ This function allows to update and download programs as well as to monitor various statuses.
・The personal computer support software (sold separately) is available as a robot controller programming support
tool. Refer to (9), Page 95, "(11) Personal computer support software/Personal computer support software mini"
of details.
(2) Data link function
・ The data link function allows to link numerical values and position data between robot programs and a personal
computer using the MELFA-BASIC IV language (OPEN/PRINT/INPUT instruction).
・ Data can be exchanged one to one by specifying the COM number at the communication open destination.
■ Pin assignment
(1) RS-232C pin assignment
Refer to Page 83, "(5) Personal computer cable".
(2) RS-422 pin assignment
13

Fig.3-35 ： D-SUB25 Pin Female Connector (RZ581 Board Side)

Pin no.

Abbreviated signal name

Signal name

Frame ground

7, 9

Signal ground

TXD+(SDA)

Transmission data (+)

TXD-(SDB)

Transmission data (-)

DTR+(RSA)

Terminal ready (+)

DTR-(RSB)

Terminal ready (-)

RXD+(RDA)

Reception data (+)

RXD-(RDB)

Reception data (-)

DSR+(CSA)

Data set ready (+)

DSR-(CSB)

Data set ready (-)

Signal direction
2A-RZ581 ⇔ Device on other end

Options 3-85

3Controller

(7) CC-Link interface
■ Order type: ● 2A-HR575-E
■ Outline
The CC-Link interface is the option to not only add bit data to the robot controller.
but also to add CC-Link field network function that allows cyclic transmission of
word data.
Caution) This option can only be used with the robot controller's main unit software
version E1 or later.

■ Configuration
Table 3-29 ： Configuration deviceon
Part name

Type

Qty.

CC-Link interface

2A-HR575-E

Instruction Manual

BFP-A8105

Ferrite core

E04SR301334

Remarks

Be sure to install this for noise countermeasure.

Table 3-30 ： Procured by the customer
Part name

Type

Qty.

Remarks

QJ61BT11(Q series)
AJ61QBT11(QnA series)
A1SJ61QBT11(QnAS series)
Master station

AJ61BT11(A series)

FX series products are not supported.

A1SJ61BT11(AnS series)
A80BD-J61BT11(personal computer
board)
Communication cable

Shielded 3-core twisted cable
This cable may be manufactured by the customer.

Terminal resistor

110Ω or 130Ω is recommended.

Display

Robot arm

Inverter

I/O unit

Partner manufacturers' devices
Cc-Link interface
(this option)
Controller

Fig.3-36 ： Example of CC-Link Product Configuration
3-86 Options

Sequencer

Personal computer

3Controller

■ Specifications
Table 3-31 ： Specifications
Item

Specifications

Communication function

Bit data and word data can be transmitted. Word data are used by the registers.

Station type

Intelligent device station

Support station

Number of stations

Transmission speed

Multiple CC-Link interface cards cannot be
inserted. Note2)

1 to 64 stations

When four stations are occupied, continuous
station numbers are used. The station
numbers are set by a DIP switch.

10M/5M/2.5M/625K/156K bps

Number of occupied stations

Remote
registers

No master station function

Slot 2 only

Number of mountable CC-Link interface cards

Number of
I/O points

Note1)

Local station

Mountable option slot

Remote I/O

Remarks

One or four occupied stations can be set.

This is set by the rotary SW.
When four stations are occupied, continuous
station numbers are used. The station
numbers are set by a DIP switch.

When one station is
occupied

Input: 30 points

Output: 30 points

The last two points of 32 points cannot be
used.

When four stations
are occupied

Input: 126 points

Output: 126 points

The last two points of 128 points cannot be
used.

When one station is
occupied

Input: 4 registers

Output: 4 registers

One register consists of 16 bits.

When four stations
are occupied

Input: 16 registers

Output: 16 registers

Note1)The CC-Link interface supports neither the transient transmission function nor the FX series.
Note2)This product cannot be used together with a PROFIBUS interface card.
■ Functions
(1) Communication function
・ The number of usable points is 126 points maximum for bit control and 16 points maximum for word control.
・ Up to 2,048 points of input bit data can be monitored by a unit being connected. (Input only, output is disabled.)
・ Up to 256 points of input word data can be monitored by a unit being connected. (Input only, output is disabled.)
(2) Easy setup
・ The CC-Link interface card can be set by a rotary switch or DIP switch.
・No separate space is required to mount the CC-Link interface card as it is embedded in the robot controller (can
only be mounted into slot 2).
・ Easy wiring since only four terminals need to be connected.
・ Dedicated commands have been added to MELFA-BASIC IV (robot programming language); thus, no complex
interface programming is required.
(3) High-speed response
・The link scan time when connecting 64 stations is approximately 7.2 ms, achieving superior high-speed response
performance.
・ A transmission speed can be selected from 10M, 5M, 2.5M, 625K and 156K bps according to the transmission
distance.

Options 3-87

3Controller

(8) Ethernet interface
■ Order type: ● 2A-HR533-E
■ Outline
The Ethernet interface is the option to add an Ethernet communication function to
the robot controller.
Caution) This option can only be used with the robot controller's main unit software
version E2 or later.
Also, compatible version differs for each function. Refer to "Table 3-36:
Software Versions and Functions of the Controller" for details.

■ Configuration
Table 3-32 ： Configuration deviceon
Part name

Type

Qty.

Ethernet interface

2A-HR533-E

Instruction Manual

BFP-A8108

Ferrite core

E04SR301334

Remarks

Be sure to install this for noise countermeasure.

Table 3-33 ： Procured by the customer
Part name

Type

Qty.

Remarks

Personal computer
(A network interface is required.)

Windows 95/98/Me/NT 4.0/2000/XP compatible. Installed
with TCP/IP network functions, including Linux OS
(However, operation has not be verified.)

From 1 unit.

Ethernet cable
(Select either straight cable or cross cable
depending on the connection mode.)

10BASE-T or 10BASE-5

From 1 cable.

Table 3-34 ： Items required as needed
Part name
Hub (Required for use in LAN environment)

Type
(Commercially sold)

Qty.

Remarks

Windows compatible robot controller
(Separately sold) Personal computer support software
programming support tool for Mitsubishi CRn500 series controllers

Windows compatible development tool

(Commercially sold) Microsoft Visual C++, Visual Basic, etc.

■ Specifications
Table 3-35 ： Specifications
Item

Specifications

Mountable optional slots

Slot 1 only

Number of mountable interface cards

LAN interface

10BASE-T or 10BASE-5(changeover type)

Transmission speed

10Mbps

Connector specification

RJ-45

Remarks

A personal computer and the robot controller that communicates with that personal computer must be located on
the same network. They cannot communication with each other crossing a firewall (from the Internet) or gateway
(from another adjacent network, etc,). If such form of communication must be implemented, consider communicating via a server connected to the same network as that of the robot controller. Be cautious about safety and
response performance in this case.

3-88 Options

3Controller

■ Functions
(1) Controller communication function
・ This function allows communication with the robot controller via Ethernet.
(Program upload/download, status monitoring, etc.)
The personal computer support software (sold separately) is available as a robot controller programming support
tool.
・ This function allows communication with a maximum of 16 clients on other end.
(2) Data link function
・ The data link function allows to link numerical values and position data between robot programs and a personal
computer using the MELFA-BASIC IV language (OPEN/PRINT/INPUT instruction).
・ Data can be exchanged one to one by specifying the COM number at the communication open destination.
・ This function allows to communicate with up to eight applications of clients on other end by changing COM
numbers.
・ Either server mode or client mode can be selected as the TCP/IP function.
・ The customer needs to write application programs on the personal computer side.
(3) Real-time external control function
・The real-time external control function loads the position command data and performs operation in control cycle
units of the robot. The joint, orthogonality and motor pulse can be specified as the position data. Also, this
function monitors I/O signals and outputs signals at the same time.
・The data that can be monitored include the encoder feedback values, current command, and current feedback of
the position data type mentioned above.
・ This function is valid only for the following models:
RP-1AH/3AH/5AH series
RV-1A series
RV-2A/3AJ series
RV-4A/5AJ/3AL/4AJL series
RH-5AH/10AH/15AH series
RV-6S/6SL/12S/12SL series
RV-3S/3SJ/3SB/3SJB series
・ In order to control the robot, an application program on the personal computer side must be created by the
customer. It must communicate one to one.
Table 3-36 ： Software Versions and Functions of the Controller
Software version of the
robot controller

Controller communication
function

Versions A*, B*, C*, D*
and E1

Data link function
(server)

Data link function
(server/client)

Real-time external control
function

The Ethernet option is disabled.

Versions E2 to E4

○

Versions F*, G* and H1 to
H6

○

Versions H7 and later

○

○ ..... Can be used.
× ..... Cannot be used.

Options 3-89

3Controller

(9) Additional axis interface
■ Order type: ● 2A-RZ541-E
■ Outline
The additional axis interface is an interface, which uses the general-purpose servo
amplifier of Mitsubishi and the corresponding servomotors in order to allow the plural
above servomotors to be controlled from the robot controller.
Caution) Additional axis interface can be used with a robot controller software
version of G9 or later.
Servo systems that can be used with the additional axis interface are shown in Table
3-37.
Table 3-37 ： Applicable servo systems
Servo amplifier name
MELSERVO-J2-Super series

Type

Note1)

Maker name

MR-J2S- □ B (ABS must be designated.)

Mitsubishi Electric

Note1) The J2-Super Series servo amplifiers, use the servo amplifiers with software version of B0 or later.
■ Configuration
Table 3-38 ： Configuration deviceon
Part name

Type

Qty.

Additional interface

2A-RZ541-E

Instruction Manual

BFP-A8107

Ferrite core

E04SR301334

Remarks

Be sure to install this for noise countermeasure.

The products necessary in addition to the additional axis interface are listed in Table 3-39.
For these main products, refer to "Instruction Manual for Servo Amplifier and Servomotor".
Table 3-39 ： Procured by the customer
Part name
Servo amplifier, servomotor, option, peripheral
device

Type
Refer to "Instruction Manual for Servo Amplifier and
Servomotor".

Battery (for absolute position detection system) MR-BAT or A6BAT
Setup software
(For setup the parameter of servo amplifier and
the graph indication, etc. )

MRZJW3-SETUP131 if the MELSERVO-J2-Super is used.
MRZJW3-SETUP41 or later if the MELSERVO-J2-B is used.

Qty.
Amplifier
quantity
1

Communication cable
MR-CPCATCBL3M
(Communication cable between personal
computer and servo amplifier for setup software)

Bus cable between controller and amplifier
(Exclusive cable for communication between
controller and servo amplifier)

MR-J2HBUS □ M
(Cable length in : 0.5, 1 and 5 [m])
Note) The MR-J2HBUS □ M-A can't be used, caution.

Terminator

MR-A-TM

Bus cable between amplifier and amplifier
(Exclusive cable for communication between
servo amplifier and servo amplifier)

MR-J2HBUS □ M
(Cable length in : 0.5, 1 and 5 [m])

3-90 Options

1
Amplifier
quantity-1

Remarks

3Controller

■ Specifications
Table 3-40 ： Specifications
Item

Specifications

Specification of user mechanism

Number of controllable robots (mechanisms)

Number of control axes (total)
Number of control axes (for each mechanism)
Applicable amplifier
Applicable encoder

8 axes
2 axes

3 axes
MELSERVO-J2-Super series

ABS method only (absolute value encoder)

Communication method

SSCNET (differential communication) of Mitsubishi

Mountable optional slots

Slot 1 or 3

Number of mountable interface cards
Control function
Path control method
Acceleration/deceleration
Position control
Minimum command value
Maximum motion range

1
Synchronous interpolation control
CP control/PTP control

PTP control

The trapezoidal method/acceleration/deceleration time pattern can be set.
Distance control/angle control can be selected.
Actual value control with pitch/deceleration ratio setting
0.01mm or 0.001mm (can be changed by a parameter)
Max. .80000.00(0) deg. to +80000.00 (0) deg.

■ Functions
(1) Additional robot axis function
・ The robot controller can control a maximum of 2 axes such the travel axis, etc., as the 7th and 8th axes of the
robot arm.
・ Additional axes are controlled in such a way that they start moving and stop simultaneously with the standard
robot axes.
(2) Multi-mechanism function
・ The robot controller can control user-created mechanisms, such as a rotation axis and a linear driving axis, for
up to 2 units as multi-mechanisms.
・The robot controller controls multi-mechanisms independent of the standard robot axes (asynchronous control).
It can control up to 3 axes of user-created mechanisms per unit.
(3) Programming language
・ The additional axes can be programmed with MELFA-BASICIV language method and MOVEMASTER command
method.
・ User-created mechanisms can only be controlled using the MELFA-BASIC IV language.

Options 3-91

3Controller

(10) Extension memory cassette
■ Order type: ● 2A-HR432
■ Outline
Used to increase the total number of teaching points in the robot program.

■ Configuration
Table 3-41 ： Configuration device
Part name
Extension memory cassette

Type

Qty.

2A-HR432

Remarks
27,900 total teaching points
With a battery backup feature

■ Specifications
Table 3-42 ： Specifications
Items

Specifications

External dimensions

Approx. 95(W)X65(D)X15(H) mm

Mass

Approx. 0.2 kg

Connection method
Memory size

Backup

Note1)

Remarks
Excluding the connection connector

Connection using a special connector
Teaching point number: 25,400
Steps number: 50,800
Program number: 100

The battery backup function is provided.
Together with 2,500 points of standard teaching
positions, the total number of teaching positions is
27,900 points.

Backup using the controller's internal battery

Note1) As for the standard 2,500 points, after adding an expansion memory cassette, the information in all backup
memory areas in the controller is copied into the expansion memory cassette. Therefore, please note that
if the expansion memory cassette is removed after it has been added, there will be no program left in the
controller.
［CAUTION］
･ Inserting and removing the memory cassette
A memory cassette cannot be inserted or removed while the control power is on. Please turn off the control
power before handling the memory cassette to avoid destroying the memory information in the cassette.
･ Memory backup
Retaining the contents of memory in a memory cassette is not covered by the warrantee when the memory
cassette is removed from the control unit. Nonetheless, memory is retained under the following conditions.
(Conditions) If the power has been on for at least a half-hour before the power is turned off and the cassette
is removed, the contents of memory can be retained for approximately one hour. (Not covered by
the warrantee.)

3-92 Options

3Controller

■ Installation

The installation method to the CR2B-574 controller is shown below.
1) Completely back up the memory information in the robot controller using the personal computer support
software. (This must be performed as a preventive measure in case the contents of the internal memory are
destroyed while inserting a memory cassette.)
2) Turn off the controller power.
3) Remove the dust-proof cover installed in the rear of the controller.
4) Install the attached fixing plate of memory cassette with the screw which fixed the dust-proof cover.
5) Attach a memory cassette to the controller.
・ As shown in Fig. 3-37, insert the memory cassette all the way to the back with the ” ▲
L ” facing up.
・ Securely tighten the fixing screws.
Note) Be careful not to over-tighten the screws, as it may deform the memory cassette.
6) Turn on the controller power.
Error C.0023 will occur when using the software version J1 edition.
Press the reset button to clear the error.
At this point, a new file system has been created in the memory cassette.
[CAUTION]
The programs that are stored in the control unit will be copied into the memory cassette; they will be deleted from
the memory in the control unit. Please be careful not to remove the memory cassette, since if you remove it,
there will be no program information residing in the controller (the information is in the memory cassette).
Although the program information (****.MB4) is copied into the memory cassette, the parameter information
(****.PRM) is still stored in the control unit.

CR2A-572 controller
Dust-proof cover

Remove

Memory cassette
(Option)

Fixing screw
two places

▲
L

Fixing plate of memory cassette
(Attachment)
M4 screw (2)

Fig.3-37 ： Installation method of extension memory cassette

Options 3-93

3Controller

The following describes a sample installation to the R6x2CPU.
7) Completely back up the memory information in the robot controller using the personal computer support
software. (This must be performed as a preventive measure in case the contents of the internal memory are
destroyed while inserting a memory cassette.)
8) Turn off the control power.

CAUTION

Turn off the primary power.
Failure to observe this could lead to electric shock accidents.

9) Open the controller front door.
10) Attach a memory cassette to the control unit.
・ As shown in Fig. 3-38, insert the memory cassette all the way to the back with the ” ▲
R ” facing up.
・ Securely tighten the fixing screws.
Note) Be careful not to over-tighten the screws, as it may deform the memory cassette.
11) Turn on the control power.
Error C.0023 will occur when using the software version J1 edition.
Press the reset button to clear the error.
At this point, a new file system has been created in the memory cassette.
[CAUTION]
The programs that are stored in the control unit will be copied into the memory cassette; they will be deleted from
the memory in the control unit. Please be careful not to remove the memory cassette, since if you remove it,
there will be no program information residing in the controller (the information is in the memory cassette).
Although the program information (****.MB4) is copied into the memory cassette, the parameter information
(****.PRM) is still stored in the control unit.

Fixing screw.
Two places.

Fig.3-38 ： Installation of extension memory cassette

3-94 Options

3Controller

(11) Personal computer support software/Personal computer support software mini
(MELSOFT RT ToolBox)
■ Order type ： ● Personal computer support software
*For windows CD-ROM
: 3A-01C-WINE
● Personal computer support software mini
*For windows CD-ROM
: 3A-02C-WINE
■ Outline
This is handy software that fully uses the personal computer functions. It can be used in
various stages from the robot specifications study (tact study, etc.) to the design support
(creation and editing of programs), start up support (execution, control and debugging of
program), and maintenance (remote maintenance.)
The "personal computer support software" which supports these function fully, and the
"personal computer support software mini" which does not have the simulation function
are available. Select according to the required application.

■ Configuration
Table 3-43 ： Product configuration
Part name

Type

Medium

Remarks

Personal computer support software

3A-01C-WINE

CD-ROM

One operation manual included

Personal computer support software mini

3A-02C-WINE

CD-ROM

One operation manual included

■ Features
(1) Simple operation with guidance method and menu method
The Windows standard is used for windows operation, so the controller initialization and startup operations
can be carried out easily by following the instructions given on the screen. Even a beginner can easily carry
out the series of operations from program creation to execution.
(2) Increased work efficiency with ample support functions
The work efficiency is greatly improved with the multi-window method that carries out multiple steps and displays in parallel. The renumbering function, and copy, search, syntax check and step execution are especially
sufficient, and are extremely useful when editing or debugging the program.
With the simulation function support, the program can be debugged and the tact checked before starting the
machine at the site. This allows the on-site startup work efficiently to be greatly improved.
(3) Increased maintenance efficiency with remote maintenance function
With remote operations over a telephone line, the robot's operation status can be monitored without going to
the site. Losses incurred while moving to the site can be reduced, and the time required to investigate the
trouble and determine measures to be taken can be shortened.
(4) The maintenance forecast function increases the efficiency of maintenance work. Analyze the load condition
while the robot is actually operating. Based on this analysis, calculate the time for maintenance, such as lubrication and belt replacement. By utilizing this information, the line stop time as well as the maintenance costs
can be reduced.
Note) The maintenance forecast function is supported by Personal Computer Support Software Version E1 or
later.
(5) The position recovery support function increases the recovery efficiency in the event of origin position dis placement. This function compensates the origin settings and position data by just reproducing several previous teaching points when hand and/or arm displacement occurs, when replacing the motor and the belts, or
when reloading the robot. This function can reduce the time required for recovery.
Note) The position recovery support function is supported by Personal Computer Support Software Version
E1 or later.

Options 3-95

3Controller

■ Functions
Table 3-44 ： Functions
Function
Compatible model
Program editing
functions

○

Debugging functions

Personal computer running Microsoft Windows98/2000/NT 4.0/Me/XP.

○

・ MELFA BASIC IV language compatible
・ Multiple editing screen simultaneously display
・ Command input, comment writing
・ Position data editing
・ File operation (writing to controller, floppy disk, personal computer)
・ Search and replace function (using characters, line Nos., labels)
・ Copy, cut, paste, insert (per character, line), undo (per command
statement, position conversion)
・ Line No. automatic generation, renumbering
・ Batch syntax check
・ Command template
・ Position conversion batch editing
・ Position variable template
・ Print, print preview

○

・ Program file control (list, copy, movement, delete, content comparison, name change, protect)

○

・ Direct editing of program in controller
・ Confirmation of robot program operation (step execution, direct execution)
・ Tact time measurementNote2)

○

・ Off-line simulation of robot program operation using CG (computer
graphics)
・ Tact time calculation

○

・ Robot operation monitor (robot operation state, stop signal, error
monitor, program monitor (execution program, variables), general-purpose input/output signals (forced output possible), dedicated input/
output signals, operation confirmation (operation range, current position, hand, etc.)
・ Operation monitor (working time statistics, production information,
robot version)
・ Servo monitor (position, speed, current, load, power)

○

・ Parameter setting
・ Batch, divided backup

○

・ Monitoring and maintenance of robot state at remote site using telephone line.
(A separate modem is required for this function.)

Monitor functions

Maintenance
function
Remote maintenance function

Details

○

Editing functions

Control functions

Simulation functionNote3)

Functional existenceNote1)

Personal computer support software mini
（3A-02C-WINE）
Personal computer support software
（3A-01C-WINE）

Note1)The functions included with the personal computer support software and the personal computer support
software mini are shown below. ○ : Function provided × : Function not provided
Note2)When using the "personal computer support software mini", connect with the controller and measure.
Note3)A simulation function is available only with "MELFA-BASIC Ⅳ ".

3-96 Options

3Controller

(12) Instruction Manual(bound edition)
■ Order type ： ● 4S-MAP-102 ： In the case of CR2B-574controller
● 4S-MAP-105 ： In the case of CR3-535M controller
■ Outline
This is a printed version of the CD-ROM (instruction manual) supplied with this
product.

■ Configuration
Table 3-45 ： Product configuration
Part name
Instruction Manual(CR2B-574 controller version）

Type
4A-MAP-102

Specifications
Instruction manual set for the CR2B-574 controller

Safety Manual

BFP-A8006

Items relating to safety in handling the robot

Standard Specifications

BFP-A8322

Specification of the robot arm and controller

Robot Arm Setup & Maintenance

BFP-A8323

Installation method of the robot arm, jog operation, and
maintenance and inspection procedures

Controller Setup, Basic Operation and Maintenance

BFP-A5991

Installation method of the controller, basic operation, and
maintenance and inspection procedures

Detailed Explanation of Functions and Operations

BFP-A5992

Functions of the controller and T/B, operation method, and
explanation of MELFA-BASIC Ⅳ

Troubleshooting

BFP-A5993

Causes of errors occurred and their countermeasures

Instruction Manual(CR3-535M controller version）

4A-MAP-105

Instruction manual set for the CR3-535M controller

Safety Manual

BFP-A8006

Items relating to safety in handling the robot

Standard Specifications

BFP-A8322

Specification of the robot arm and controller

Robot Arm Setup & Maintenance

BFP-A8323

Installation method of the robot arm, jog operation, and
maintenance and inspection procedures

Controller Setup, Basic Operation and Maintenance

BFP-A8324

Installation method of the controller, basic operation, and
maintenance and inspection procedures

Detailed Explanation of Functions and Operations

BFP-A5992

Functions of the controller and T/B, operation method, and
explanation of MELFA-BASIC Ⅳ

Troubleshooting

BFP-A5993

Causes of errors occurred and their countermeasures

Additional axis interface

BFP-A8107

Functions and operation method of the additional axis interface.

Options 3-97

3Controller

3.11 Maintenance parts
The consumable parts used in the controller are shown in Table 3-46. Purchase these parts from your dealer
when required. Some Mitsubishi-designated parts differ from the maker's standard parts. Thus, confirm the part
name, robot arm and controller serial No. and purchase the parts from your dealer.
Table 3-46 ： Contloller consumable parts list
No.

Type Note1)

Part name

Qty.

Usage place

Manufacturer

CR2B-574 controller
1

Lithium battery

Filter

ER6

Control unit

Bottom of the controller

Mitsubishi Electric System
& Service;Co.,Ltd

CR3-535M controller
3

Lithium battery

Control unit

Fan (40 square)

ER6

Amplifier unit
Converter unit

Fan (90 square)

Inside of the controller

Filter

Rear of the controller

Mitsubishi Electric System
& Service;Co.,Ltd

Note1)Confirm the robot arm serial No., and contact the dealer or service branch of Mitsubishi Electric Co., for
the type.

3-98 Maintenance parts

4Software

4 Software
4.1 List of commands
The available new functions in MELFA-BASIC IV are given in Table 4-1.
Table 4-1 ： The available new functions in MELFA-BASIC IV
Class
Robot Status Variable

Command example

Function

P_TOOL

keep current tool length

M_SPD

keep current speed (linear/circular interpolation)

ABS

Produces the absolute value

VAL

Converts a character string into a numeric value

ATN

Calculates the arc tangent

STR$

Converts the numeric expression value into a decimal character string

ZONE

Check current position area

P1=P1*P2

Relative calculation of position data

M1=M1*M2

Multiplication of numerical variable

P1.X=10

Operation of the position element data

SELECT CASE

More than one condition branch

ON GOSUB

Condition branch by the value

WHILE WEND

Repeat with condition

Optimum acceleration/
deceleration control

LOADSET

Load condition setting

OADL

valid/invalid setting for the optimum acceleration/deceleration

Float control
(compliance in the XYZ
coordinate system)

CMP POS

Compliance control

CMPG

Force control

Parallel execution
(Multitask)

XRUN, XSTP, XRST,
XLOAD, XCLR

Parallel executions of another task, the stops, the resets the clear, and, the loads

Conveyor trucking
[Special specification]

TRKON, TRKOFF

Valid/invalid of the trucking

TRBASE

Setting the base coordinate for the trucking

Impact detection

COLCHK

Set to enable/disable the impact detection.

COLLVL

Set the detection level of the impact detection.

MVS P1 TYPE 0,2

Pass a singular point using linear interpolation.

Built-in functions

Operation function

Conditional branching

Singular point passage

List of commands 4-99

4Software

(1) MELFA-BASIC Ⅳ commands
Table 4-2 ： List of MELFA-BASIC IV commands
Type

Class

Function

Joint interpolation
Linear interpolation
Circular interpolation

Moves to the designated position with joint interpolation.
Moves to the designated position with linear interpolation.
Moves along a designated arc (start point → passing point → start point
(end point)) with 3-dimensional circular interpolation (360 degrees).
Moves along a designated arc (start point → passing point → end point) with
3-dimensional circular interpolation.
Moves along the arc on the opposite side of a designated arc (start point →
reference point → end point) with 3-dimensional circular interpolation.
Moves along a set arc (start point → end point) with 3-dimensional circular
interpolation.
Designates the speed for various interpolation operations with a percentage
(0.1% unit).
Designate the speed for joint interpolation operation with a percentage
(0.1% unit).
Designates the speed for linear and circular interpolation with a numerical
value (mm/s unit).
Designates the acceleration/deceleration time as a percentage in respect to
the predetermined maximum acceleration/deceleration. (1% unit)
Automatically adjusts the acceleration/deceleration according to the parameter setting value.
ets the hand and work conditions for automatic adjustment of the acceleration/deceleration.
Adds a process unconditionally to the operation.
Adds a process conditionally to the operation.
Designates smooth operation.
Designates the positioning completion conditions with a No. of pulses.
Turns the servo power ON/OFF for all axes.
Limits the operation of each axis so that the designated torque is not
exceeded.
Designates the base conversion data.
Designates the tool conversion data.
The robot arm rigidity is lowered and softened. (XYZ coordinate system)
The robot arm rigidity is lowered and softened. (TOOL coordinate system)
The robot arm rigidity is returned to the normal state.
The robot arm rigidity is designated.

Position and operation control

Speed designation

Operation

Position control
Float control

Input format (example)
MOV P1
MVS P1
MVC P1,P2,P1
MVR P1,P2,P3
MVR2 P1,P9,P3
MVR3 P1,P9,P3
OVRD 100
JOVRD 100
SPD 123.5
ACCEL 50,80
OADL ON
LOADSET 1,1
WTH
WTHIF
CNT 1,100,200
FINE 200
SERVO OFF
TORQ 4,10
BASE P1
TOOL P1
CMP POS ,&B00000011
CMP TOOL ,&B00000011
CMP OFF
CMPG
1.0,1.0,1.0,1.0,1.0,1.0,1.0,1.0

Defines the pallet.

Branching

Operates the pallet grid point position.
Branches unconditionally to the designated place.
Branches according to the designated conditions.

Program control

Pallet

Repeats until the designated end conditions are satisfied.

DEF PLT
1,P1,P2,P3,P4,5,3,1
PLT 1,M1
GOTO 120
IF M1=1 THEN GOTO 100
ELSE GOTO 20
END IF
FOR M1=1 TO 10

Repeats while the designated conditions are satisfied.

NEXT M1
WHILE M1<10

Branches corresponding to the designated expression value.
Executes program block corresponding to the designated expression value..

WEND
ON M1 GOTO 100,200,300
SELECT
CASE 1
BREAK
CASE 2

Impact detection

4-100 List of commands

Moves the program process to the next line.
Set to enable/disable the impact detection.
Set the detection level of the impact detection.

BREAK
END SELECT
SKIP
COLCHK ON/OFF
COLLVL 100,80,,,,,,

4Software

Type

Class

Executes the designated subroutine. (Within program)
Returns from the subroutine.
Executes the designated program.
Defines the program argument executed with the CALLP command.
Executes the subroutine corresponding to the designated expression value.

Interrupt

Defines the interrupt conditions and process.

Program control

Subroutine

End
Hand open
Hand close

Enables/disables the interrupt.
Defines the start line of the program to be executed when an interrupt is
generated from the communication line.
Enables the interrupt from the communication line.
Disables the interrupt from the communication line.
Stops the interrupt from the communication line.
Designates the wait time, and the output signal pulse output time. (0.01s
unit)
Waits until the variable becomes the designated value.
Stops the program execution.
Generates an error. During program execution, continue, stop or servo OFF
can be designated.
Ends the program execution.
Opens the designated hand.
Closes the designated hand.

Assignment
Input
Output

Defines the input/output variables.
Retrieves the general-purpose input signal.
Calls out the general-purpose output signal.

Wait

Parallel execution

Input/output

Hand

Stop

Input format (example)
GOSUB 200
RETURN
CALLP "P10",M1,P1
FPRM M10,P10
ON M1 GOSUB
100,200,300
DEF ACT 1, M1=1 GOTO
100
ACT 1=1
ON COM(1) GOSUB 100
COM(1) ON
COM(1) OFF
COM(1) STOP
DLY 0.5
WAIT M_IN(1)=1
HLT
ERROR 9000
END
HOPEN 1
HCLOSE 1
DEF IO PORT1=BIT,0
M1=M_IN (1)
M_OUT(1) =0

Mechanism designation
Selection
Start/stop

Definition

Others

Function

Clear
File

Comment
Label

Acquires the mechanism with the designated mechanism No.
Releases the mechanism with the designated mechanism No.
Selects the designated program for the designated slot.
Carries out parallel execution of the designated program.
Stops parallel execution of the designated program.
Returns the designated program's execution line to the head and enters the
program selection enabled state.
Defines the integer type or real number type variable.
Defines the character string variable.
efines the layout variable. (Up to 3-dimensional possible)
Defines the joint variable.
Defines the position variable.
Defines the function.
Clears the general-purpose output signal, variables in program, variables
between programs, etc.
Opens a file.
Closes a file.
Inputs data from a file.
Outputs data to a file.
Describes a comment.
Indicates the branching destination.

GETM 1
RELM 1
XLOAD 2,"P102"
XRUN 3,"100",0
XSTP 3
XRST 3
DEF INTE KAISUU
DEF CHAR MESSAGE
DIM PDATA(2,3)
DEF JNT TAIHI
DEF POS TORU
DEF FNTASU(A,B)=A+B
CLR １
OPEN "COM1:" AS #1
CLOSE #1
INPUT# 1,M1
PRINT# 1,M1
REM "ABC"
*SUB1

List of commands 4-101

4Software

4.2 List of parameters
(1) List of parameters
show the main parameter in the Table 4-3.
Table 4-3 ： List of parameters
Parameter

Details

Standard tool coordinates.

MEXTL

Set the default value for the tool data.
Unit: mm or deg.

Standard base coordinates

MEXBS

Set the relation of the world coordinate system and robot coordinate system.
Unit: mm or deg.

XYZ operation range

MEPAR

Designate the overrun limit value for the world coordinate system.

JOINT operation range

MEJAR

Set the overrun limit value for each joint axis.

Free plane limit

This is the overrun limit set with the free plane.
Create a plane with the three coordinates x1, y1, z1 to x3, y3, z3, and set the outer side of
the plane as the outside operation range (error). The following three types of parameters are
used.
SFC1P
:
SFC8P

Eight types of free plane limits can be set in SFC1P to SFC8P.
There are nine elements, set in the order of x1, y1, z1, x2, y2, z2, x3, y3, z3.

SFC1ME
:
SFC8ME

Designate which mechanism to use eight types of set free plane limits.
The mechanism No. to use is set with 1 to 8.

SFC1AT
:
SFC8AT

Set the validity of the eight types of set free plane limits.
(Valid 1/Valid 2/invalid = 1/-1/0)

User-defined area

An area (cube) defined with two XYZ coordinate points can be designated and that area set
as the outside operation range. Furthermore, a signal can be output when the axis enters
that area. Up to eight types of area can be designated.
AREA1P1
:
AREA8P1

Designated the 1st point of the area.
There are eight elements, set in the order of x, y, z, a, b, c, L1, L2.
(L1 and L2 are the additional axes.)

AREA1P2
:
AREA8P2

Designated the 2nd point of the area.
There are eight elements, set in the order of x, y, z, a, b, c, L1, L2.
(L1 and L2 are the additional axes.)

AREA1ME
:
AREA8ME

Designate which mechanism to use the eight types of set area.
The mechanism No. to use is set with 1 to 8

AREA1AT
:
AREA8AT

Designate the area check type.
(Invalid/zone/interference = 0/1/2)
Zone: The dedicated output signal USRAREA turns ON.
Interference: An error occurs..

Automatic return setting

RETPATH

Set to restart the program after returning to the interrupt position when resuming operation
after an interruption.

Buzzer ON/OFF

BZR

Designate whether to the turn buzzer ON or OFF.

Jog setting

JOGJSP

Designate the joint jog and step operation speed.
(Set dimension H/L amount, max. override.)

JOGPSP

Designate the linear jog and step operation speed.
(Set dimension H/L amount, max. override.)

JOGSPMX

Limit the operation speed during the teaching mode. Max. 250[mm/s]

Jog speed limit value

4-102 List of parameters

4Software

Parameter

Details

Hand type

HANDTYPE

Set the hand type of the single/double solenoid, and the signal No.
(Single/double = S/D)
Set the signal No. after the hand type. Example) D900

Stop input B contact designation

INB

Change the dedicated input (stop) between the A contact and B contact.

User-designated origin

USERORG

Designate the user-designated origin position.

Program selection memory

SLOTON

Select the program selected previously when initializing the slot. The non-selected state will
be entered when not set.

Communication setting

CBAU232

Set the baud rate.

CLEN232

Set the character length.

CPRTY232

Set the parity.

CSTOP232

Set the stop bit.

CTERM232

Set the end code.

Slot table

SLT1
:
SLT32

Make settings (program name, operation type, order of priority, etc.) for each slot during slot
initialization.

No. of multi-tasks

TASKMAX

Designate the No. of programs to be executed simultaneously. (Max. 32)

Select the function of
singular point adjacent alarm

MESNGLSW

Designate the valid/invalid of the singular point adjacent alarm.
（Invalid/Valid ＝ 0/1）
When this parameter is set up "VALID", this warning sound is buzzing even if parameter:
BZR (buzzer ON/OFF) is set up "OFF".

Specification of singular point
passage jog mode

FSPJOGMD

Specify an operation mode for singular point passage jog.

Display language.Note1)
表示言語 Note1)

LNG

Change the language to display on the LCD display of teaching pendant.
テ ィ ーチ ングボ ッ ク スの表示 LCD な どに表示する言語を切 り 替え ます。

Note1)The procedure of Language as shown in "(2) Change the display language / 表示言語の切 り 替え ".
注 1) 表示言語切 り 替え方法の詳細を "(2) Change the display language / 表示言語の切 り 替え " に示 し ます。

List of parameters 4-103

4Software

(2) Change the display language / 表示言語の切 り 替え
The language to display on the LCD display of teaching pendant can be changed by "the display language parameter". (Japanese or English)
Show the details of the parameter in the Table 4-3. Refer to the separate "Instruction Manual/Detailed Explanation of Functions and Operations" for details on changing the parameter.
The parameter is set up based on the order specifications before shipment. Order to dealer when the instruction
manual of the other language is necessity.
More, the caution seals that stuck on the robot arm and the controller are made based on the language of the
order specification. Use it carefully when selecting the other language.
表示言語設定パラ メ ー タ によ っ て、 テ ィ ーチ ングボ ッ ク スの表示 LCD な どに表示する言語を切 り 替え る
こ と がで き ます。 （日本語、 または英語） Table 4-3 にそのパラ メ ー タ の詳細を示 し ます。 パラ メ ー タ の変
更方法は、 別冊の 「取扱説明書／機能 と 操作の詳細解説」 を参照願います。
なお、 出荷時はご注文仕様に基づき弊社で設定いた し ます。 別の言語の取扱説明書を ご希望の場合はご
用命願います。
また、 ロボ ッ ト 本体 と コ ン ト ロー ラ に貼 り 付けてある注意シールは、 ご注文仕様に基づいた言語で製作
いた し ます。 本パラ メ ー タ を変更 し て言語を切 り 替えてご使用の場合はご注意願います。
Table 4-4 ： Display language parameter / 表示言語設定パラ メ ー タ
Parameter
パラ メ ー タ

Parameter
name
パラ メ ー タ 名

Display language
表示言語設定

LNG

No. of arrays
No. of characters
配列数
文字数

Details explanation
内容説明

Character string 1 Set up the display language.
文字列 １
"JPN" ： Japanese
"ENG" ： English
The following language is changed.
(1)The display LCD of teaching pendant.
(2) Personal computer support software.
*alarm message of the robot.
*Parameter explanation list.
(3)Alarm message that read from the robot with external
communication. (Standard RS232C, Extended serial I/
F, Ethernet I/F)
表示言語を設定 し ます。
"JPN" ： 日本語表示
"ENG" ： 英語表示
以下に示す表示言語が変更 さ れます。
(1) テ ィ ーチ ングボ ッ ク スの表示 LCD
(2) パソ コ ンサポー ト ソ フ ト ウ ェ ア
・ ロボ ッ ト のア ラ ーム メ ッ セージ
・ パラ メ ー タ 説明 リ ス ト
(3) 外部通信で ロボ ッ ト から 読み出 し たア ラ ーム メ ッ
セージ （標準 RS232C、 増設シ リ アルイ ン タ
フ ェ ース、 イ ーサネ ッ ト イ ン タ フ ェ ース）

4-104 List of parameters

Default
setting
出荷時
設定
1

5Instruction Manual

5 Instruction Manual
5.1 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.
Instruction manuals enclosed in dashed lines in the list below are for optional products.
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
Specifications

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

Robot Arm
Setup &
Maintenance

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

Controller
Setup, Basic
Operation and
Maintenance

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

Detailed
Explanation of
Functions and
Operations

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

Troubleshooting

Extended serial
interface

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

Explains the specifications, functions and operations of the expansion serial interface
optional.

The details of each instruction manuals 5-105

5Instruction Manual

CC-Link interface

Explains the specifications, functions and operations of the CC-Link interface optional.

ETHERNET
interface

Explains the specifications, functions and operations of the ETHERNET interface optional.

Additional axis
interface

Explains the specifications, functions and operations of the additional axis interface optional.

Personal computer Support
software

Explains the specifications, functions and operations of the Personal computer Support software optional.

5-106 The details of each instruction manuals

6Safety

6 Safety
6.1 Safety
Measures to be taken regarding safety of the industrial robot are specified in the "Labor Safety and Sanitation
Rules". Always follow these rules when using the robot to ensure safety.

6.1.1 Self-diagnosis stop functions
This robot has the self-diagnosis stop functions shown in Table 6-1 and the stop functions shown in Table 6-2
for safe use.
Table 6-1 ： Self-diagnosis stop functions
No.

Function

Details

Overload protection function

Activates when the total servo current time exceeds The drive circuit is shut off. The robot stops, and
the specified value.
an alarm displays.

Overcurrent diagnosis
function

Activates when an overcurrent flows to the motor
circuit.

The drive circuit is shut off. The robot stops, and
an alarm displays.

Encoder disconnection
diagnosis function

Activates when the encoder cable is disconnected.

The drive circuit is shut off. The robot stops, and
an alarm displays.

Deflection over diagnosis
function

Activates when an error occurs between the command value and actual position, and the error
exceeds the specified amount.

The drive circuit is shut off. The robot stops, and
an alarm displays.

AC power voltage drop
diagnosis function

Activates when the AC power voltage drops below
the specified value.

The drive circuit is shut off. The robot stops, and
an alarm displays.

CPU error detection func- Activates when an error occurs in the CPU.
tion

The drive circuit is shut off. The robot stops, and
an alarm displays.

Overrun
prevention
function

Software limit This is the limit provided by the software to enable
detection
operation only in the operation range.

The drive circuit is shut off. The robot stops, and
an alarm displays.

Mechanical
stopper

The robot mechanically stops, and function 1 or 2
activates.

This is the mechanical stopper provided outside the
software.

Remarks

Table 6-2 ： List of stop functions
Stop
function

Operation
panel

Teaching
pendant

External
input

Emergency
stop

◯

This is the stop with the highest degree of emergency. The servo power is shut off,
and the mechanical brakes (all axes) activate to stop the robot.
To recover, reset the alarm, and turn the servo ON with the servo ON command.

Stop

◯

This is a stop operation with a high degree of emergency. The robot immediately
decelerates and stops.
Note that the servo power is not shut off. Use this when using the collision evasion
sensor, etc.

Details

6.1.2 External input/output signals that can be used for safety protection measures
Table 6-3 ： External input/output signals that can be used for safety protection measures
Signal

Input

External emergency stop
Stop
Servo OFF
Automatic operation enable

Output

In servo ON

Command

Functions

(Input signal) This servo power is shut off, and the robot
stops immediately.
STOP
SRVOFF
AUTOENA
SRVON

Waiting

STOP

In alarm

ERRRESET

Usage method
Externally installed emergency stop switch.
Door switch on safety protection fence.
Stopping at high-level error occurrence.

The program execution is stopped, and the
robot stops. The servo power is not shut off.

The robot is stopped when a peripheral device
fault occurs. The servo power is not shut off.

The servo power can be shut off.

The robot is stopped when a peripheral device
fault occurs. The servo power is not shut off.

Disables automatic operation when inactive.

Door switch on safety protection fence

The servo power ON/OFF state is output.

The servo power ON/OFF state is shown and
alerted with the display lamps.

Outputs that the robot is temporarily stopped.

The temporary stop state is shown and alerted
with the display lamps.

Outputs when an alarm occurs in the robot.

The alarm state is shown and alerted with the display lamps.

［Caution］ The external emergency stop input is prepared as a b contact for safety proposes. Thus, if the emergency stop input circuit is opened when the robot is started up, the robot will not operate. Refer to
"Fig. 6-1 Example of safety measures"for details.

Safety 6-107

6Safety

6.1.3 Precautions for using robot

The safety measures for using the robot are specified in the "Labor Safety and Sanitation Rules". An outline of
the rules is given below.
(1) Robot installation
・ Secure sufficient work space required to safely perform work such as teaching and maintenance related to the
robot.
・ Install the controller outside the robot's motion space. (If a safety fence is provided, install outside the fence.)
・ Install the controller where the entire robot operation can be viewed.
・ Install display lamps, etc., to indicate the robot's operation state.
・ Securely fix the robot arm onto the fixing table with the designated bolts.
(2) Prevention of contact with operator
・ Install a safety fence or enclosure so that the operator cannot easily enter the robot's motion space.
・ Install an interlock function that will stop the robot if the safety fence or enclosure door is opened.
(3) Work procedures
・ Create and observe work procedures for the robot teaching, operation, inspection and emergencies.
・ Create hand signals to be followed when several operators are working together.
・ Create displays such as "Teaching in Progress" and "Inspection in Progress" to be put up when an operator is
in the robot's motion space so that other operators will not operate the operation panel (controller, control
panel).
(4) Training
・ Train the operators about the operations, maintenance and safety required for the robot work.
・ Only trained and registered operators must operate the robot.
Participation in the "Special training for industrial robots" sponsored by the Labor Safety and Sanitation Committee, etc., is recommended for safety training.
(5) Daily inspection and periodic inspection
・ lways inspect the robot before starting daily operations and confirm that there are no abnormalities.
・ Set the periodic inspection standards in view of the robot's ambient environment and operation frequency, and
perform periodic inspections.
・ Make records when periodic inspections and repairs have been done, and store the records for three or more
years.

6.1.4 Safety measures for automatic operation

(1) Install safety fences so that operators will not enter the operation area during operation and indicate that
automatic operation is in progress with lamps, etc.
(2) Create signals to be given when starting operation, assign a person to give the signal, and make sure that the
operator follows the signals.

6.1.5 Safety measures for teaching

Observe the following measures when teaching, etc., in the robot's operation range.
(1) Specify and follow items such as procedures related to teaching work, etc.
(2) Take measures so that operation can be stopped immediately in case of trouble, and measures so that operation can be restarted.
(3) Take measures with the robot start switch, etc., to indicate that teaching work is being done.
(4) Always inspect that stop functions such as the emergency stop device before starting the work.
(5) Immediately stop the work when trouble occurs, and correct the trouble.
(6) Take measures so that the work supervisor can immediately stop the robot operation when trouble occurs.
(7) The teaching operator must have completed special training regarding safety. (Training regarding industrial
robots and work methods, etc.)
(8) Create signals to be used when several operators are working together.

6.1.6 Safety measures for maintenance and inspections, etc.

Turn the power OFF and take measures to prevent operators other than the relevant operator from pressing the
start switch when performing inspections, repairs, adjustments, cleaning or oiling.
If operation is required, take measures to prevent hazards caused by unintentional or mistaken operations.
(1) Specify and follow items such as procedures related to maintenance work, etc.
(2) Take measures so that operation can be stopped immediately in case of trouble, and measures so that operation can be restarted.
(3) Take measures with the robot start switch, etc., to indicate that work is being done.
(4) Take measures so that the work supervisor can immediately stop the robot operation when trouble occurs.
(5) The operator must have completed special training regarding safety. (Training regarding industrial robots and
work methods, etc.)
(6) Create signals to be used when several operators are working together.

6-108 Safety

6Safety

6.1.7 Examples of safety measures
Two emergency stop input circuits are prepared on the user wiring terminal block of the controller. Create a circuit as shown below for safety measures
.

MC2

MC1

＋
To servo main circuit power

External emergency
stop input

RA1
RA3

External emergency
stop input

RA11

RA31

S/W-EMG

Operation panel
emergency stop

Door switch
External emergency
stop

T/B remove
switch

Teaching pendant
emergency stop

T/B remove
switch

Teaching pendant
emergency stop

24V

Teaching pendant
deadman switch

2
RA1

RA1

RA2

Door switch
input
RA2

RA2

Teaching pendant
deadman switch
Software emergency
stop

RA3

Teaching pendant
deadman switch

RA21

Door switch
input

Software emergency
stop

RA31

5
External emergency
stop output

RA4

MC1
MC1

MC2
MC2

24V

1
2
RA11

RA11

RA21

3
4
5
External emergency
stop output

RA41

[Caution] Some information has been omitted for explanation proposes, so some parts may differ.
Fig.6-1 ： Example of safety measures
(1) Use a 2-contact type switch for all switches.
(2) Install a limit switch on the safety fence's door. With a constantly open contact (a contact), wire to the door
switch input terminal so that the switch turns ON (is conducted) when the door is closed, and turns OFF (is
opened) when the door is open.
(3) Use a manual-return type 2b-contact for the emergency stop button.
(4) Classify the faults into minor faults (faults that are easily restored and that do not have a great effect) and
major faults (faults that cause the entire system to stop immediately, and that require care in restoration),
and wire accordingly.
[Caution] The emergency stop input(terminal block) on the user wiring in the controller can be used for safety
measures as shown in Fig. 6-1. Note that there are limits to the No. of switch contacts, capacity and
cable length, so refer to the following and install.
・ Switch contact .......................................... Prepare a 2-contact type.
・ Switch contact capacity........................ Use a contact that operates with a switch contact capacity of
approx. 1mA to 100mA/24V.
・ Cable length................................................ The length of the wire between the switch and terminal block
must be max. 15m or less.
・ Emergency stop output capacity....... Set it within 300 mA/24 VDC.
Connecting an external device outside of the above range will
cause a controller failure.

Safety 6-109

6Safety

[Reference] The specifications of the RA1 and RA2 coil shown in Fig. 6-1 are as follow.
・ Rated voltage ............................ DC24V ± 10％
・ Rated excitation current ...... 12.5mA ± 10％ （at25 deg.）
* Note that these specifications are subject to change without prior notice for modification purposes.
The emergency stop circuit in the robot is a duplex type to ensure safety.
Thus, if a 1b contact type is used, faults such as fusing in the emergency stop circuit will not be detected, and
could lead to fires.
If a 1b contact type is used and the emergency stop is input with only one side (across No. 1-2 or No. 5-6), the
contact fusing alarm will occur, and resetting of the alarm will not be possible.

6-110 Safety

6Safety

6.2 Working environment
Avoid installation in the following places as the equipment's life and operation will be affected by the ambient
environment conditions. When using in the following conditions, the customer must pay special attention to the
preventive measures.
(1) Power supply
・ Where the voltage fluctuation will exceed the input voltage range.
・ Where a momentary power failure exceeding 20ms may occur.
・ Where the power capacity cannot be sufficiently secured.

CAUTION

Please use the controller with an input power supply voltage fluctuation rate of 10% or
less. In the case of 200 VAC input, for example, if the controller is used with 180 VAC
during the day and 220 VAC during the night, turn the servo off once and then on again.
If this is not performed, an excessive regeneration error may occur.

(2) Noise
・ Where a surge voltage exceeding 1000V, 1μs may be applied on the primary voltage. Near large inverters, high
output frequency oscillator, large contactors and welding machines. Static noise may enter the lines when this
product is used near radios or televisions. Keep the robot away from these items.
(3) Temperature and humidity
・ Where the atmospheric temperature exceeds 40 degree , lower than 0 degree.
・ Where the relative humidity exceeds 85%, lower than 45%, and where dew may condense.
・ Where the robot will be subject to direct sunlight or near heat generating sources such as heaters.
(4) Vibration
・ Where excessive vibration or impact may be applied. (Use in an environment of 34m/s2 or less during transportation and 5m/s2 or less during operation.)
(5) Installation environment
・ Where strong electric fields or magnetic fields are generated.
・ Where the installation surface is rough. (Avoid installing the robot on a bumpy or inclined floor.)

Working environment 6-111

6Safety

6.3 Precautions for handling
(1) This robot has brakes on all axes. The precision of the robot may drop, looseness may occur and the reduction
gears may be damaged if the robot is moved with force with the brakes applied.
(2) Avoid moving the robot arm by hand. When unavoidable, gradually move the arm. If moved suddenly, the accuracy may drop due to an excessive backlash, or the backed up data may be destroyed.
(3) Note that depending on the posture, even when within the movement range, the wrist section could interfere
with the base section. Take care to prevent interference during jog. Note1)
(4) The robot arm is configured of precision parts such as bearings. Grease is used for lubricating these parts.
When cold starting at low temperatures or starting operation after long-term stoppage, the position accuracy
may drop or servo alarms may occur. If these problems occur, perform a 5 to 10 minute running-in operation at
a low speed (about a half of normal operating speed).
(5) The robot arm and controller must be grounded with Class D grounding to secure the noise resistance and to
prevent electric shocks.
(6) The items described in these specifications are conditions for carrying out the periodic maintenance and
inspections described in the instruction manual.
(7) When using the robot arm on a mobile axis or elevating table, the machine cables enclosed as standard configuration may break due to the fixed installation specifications. In this case, use the machine cable extension (for
flexed)" factory shipment special specifications or options.
(8) If this robot interferes with the workpiece or peripheral devices during operation, the position may deviate, etc.
Take care to prevent interference with the workpiece or peripheral devices during operation.
(9) The hanging installation jig can be borrowed from the maker. Order to dealer when need.
(10) Do not attach a tape or a label to the robot arm and the controller. If a tape or a label with strong adhesive
power, such as a packaging tape, is attached to the coated surfaces of the robot arm and controller, the
coated surface may be damaged when such tape or label is peeled off.
(11) If the robot is operated with a heavy load and at a high speed, the surface of the robot arm gets very hot. It
would not result in burns, however, it may cause secondary accidents if touched carelessly.
(12) Do not shut down the input power supply to stop the robot. If the power supply is frequently shut down during
a heavy load or high-speed operation, the speed reducer may be damaged, backlash may occur, and the program data may be destroyed.
(13) If the J1, J2 and J3 axes collide with the mechanical stopper during the automatic operation of the robot, it is
necessary to replace the resin part of the mechanical stopper unit. For the replacement of the resin parts,
please contact Mitsubishi or Mitsubishi's dealer.
If the resin part is not replaced, the mechanism unit and the speed reducer may be damaged significantly when
the axes collide with the mechanical stopper next or subsequent time.
(14) During the robot's automatic operation, a break is applied to the robot arm when the input power supply is
shut down by a power failure, for instance. When a break is applied, the arm may deviate from the operation
path predetermined by automatic operation and, as a result, it may interfere with the mechanical stopper
depending on the operation at shutdown. In such a case, take an appropriate measure in advance to prevent
any dangerous situation from occurring due to the interference between the arm and peripheral devices.
Example) Installing a UPS (uninterruptible power supply unit) to the primary power source in order to reduce
interference.
(15) Do not conduct an insulated voltage test. If conducted by mistake, it may result in a breakdown. If conducting
an insulation test, although it is not covered by warranty, set the leakage current to 100 mA. If a leakage current of 10 mA is set, a low measurement value will be shown due to the leakage current of the built-in AC line
filter.
(16) The fretting may occur on the axis which moving angle is the 30 degree or less, or moving distance is the
30mm or less, or not moves. The fretting is that the required oil film becomes hard to be formed if the moving
angle is small, and wear occurs. The axis which not moved is moving slightly by vibration etc. To prevent the
fretting, recommends to move these axes about once every day the 30 degree or more, or the 30mm or more.

Note1) Jog operation refers to operating the robot manually using the teaching pendant.
6-112 Precautions for handling

7Appendix

7 Appendix
Appendix 1 ： Specifications discussion material
■ Customer information
Company name

Name

Address

Telephone

■ Purchased mode
Specification
Standard specification
Clean specification

Type

Note1)

□ RV-6S
□ RV-6SC

□ RV-6SL
□ RV-6SLC

□ RV-6S-SM

□ RV-6SL-SM

Note1) Replaced with the CR3-535M controller in the case of the "-SM" specification.
■ Shipping special specifications (Settings can be made only at time of shipment)
Item

Standard specifications

Robot arm Machine cable Note1) □ 5m fixed type
Controller Controller structure □ CR2B-574 controller :
■ Floor type

Special shipping specifications
□ 2m fixed type: 1S-02CBL-1
□ CR3-535M controller :
□ Floor type □ Caster specifications controller

Note1) This specification only applies to the CR2B-574 controller.
■ Options (Installable after shipment)
Item

Type

Robot arm

Stopper for changing the
operating range of the J1 axis
Solenoid valve set
Hand input cable
Hand output cable
Hand curl tube
Teaching pendant

Controller

Pneumatic hand interface

Provision, and specifications when provided.

1A-DH-02
1S-VD0 □ -02/
1S-VD0 □ E-02
1S-HC25C-01
1S-GR35S-01
1E-ST040 □ C
R28TB- □□

J1 axis + side: □ +135° □ +90° □ +45°
J1 axis - side: □ -135° □ -90° □ -45°
□ 1 set □ 2 set □ 3 set □ 4 set
□ Not provided □ Provided
□ Not provided □ Provided
□ Not provided □ 1 set □ 2 set □ 3 set □ 4 set
□ Not provided □ 7m □ 15m

Parallel I/O interfaceNote1)

2A-RZ365/2A-RZ375 □ Not provided □ Provided
2A-RZ361/2A-RZ371 □ Not provided □ 1pc. □ 2pcs. □ 3pcs. □ 4pcs. □ 5pcs. □ 6pcs. □ 7pcs.

External I/O cable

2A-CBL □□

□ Not provided □ 5m-1pc.
□ 5m-2pcs. □ 5m-3pcs.
□ 15m-1pcs. □ 15m-2pcs. □ 15m-3pcs.

CC-Link interface

2A-HR575-E

□ Not provided □ Provided

Ethernet interface

2A-HR533-E

□ Not provided □ Provided

Extended serial interface

2A-RZ581-E

□ Not provided □ Provided

Extended memory cassette

2A-HR432

□ Not provided □ Provided

Personal computer cable
Personal computer support
software

RS-MAXY-CBL

□ Not provided □ Provided

3A-01C-WINE

□ Not provided □ Windows98/2000/NT4.0/Me/XP CD-ROM

3A-02C-WINE

□ Not provided □ Windows98/2000/NT4.0/Me/XP CD-ROM

Personal computer support
software mini

Note1) Up to eight units, including the one unit mounted as a standard.

■ Maintenance parts (Consumable parts)
Maintenance parts □ Backup batteries A6BAT (

) pcs. □ Backup batteries ER6 (

) pcs.

□ Grease (

) cans

■ Robot selection check list
Work description
Workpiece mass (

□ Material handring □ Assembly □ Machining L/UL □ Sealing □ Testing and inspection □ Other (
)ｇ

Hand mass (

)ｇ

)

Atmosphere □ General enveronment □ Clean □ Dust provided □ Other(

)

Remarks

Copy this page and use the copy.

Specifications discussion material Appendix-113

HEAD OFFICE: TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
NAGOYA WORKS: 5-1-14, YADA-MINAMI, HIGASHI-KU, NAGOYA 461-8670, JAPAN

JUL..2007 MEE Printed in Japan on recycled paper.

Specifications are subject to change without notice.

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