1L21700K E 6 ControllerMaintenance

No.
1L21700K-E-6
series
INSTRUCTION MANUAL
Controller Maintenance
■ Read and follow these instructions and all safety blocks carefully.
■ Have only trained and qualified persons install, operate, or service this unit.
■ Give this manual to the operator.
■ For help, call your distributor.

Be Sure to Read Instruction Manuals Before Use
Thank you for using the Daihen "Almega" series arc welding robot.
Please be sure to read the instruction manuals listed below (including this manual) and the instruction manuals
provided with the equipment, and use all the products correctly.
In particular, please be sure to read "Chapter 1 Safety Precautions" in the "Quick Start" instruction manual before
starting to use the products in order to ensure your safety and the safety of others. Store the instruction manual in
a safe place for future reference.
Instruction manuals related to the manipulator “V/B/H/S series”, and the robot control unit “FD11” are as follows.
■Standard Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
QUICK START Point on Safety, Transportation and Installation,
1L21700A
Turning the power on/off and manual operation, etc.
SETUP Safety precautions, installing & connecting method,
1L21700B starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE Specifications of controller, explanation of each parts
1L21700K
and maintenance, parts list, etc.
MANIPULATOR Specifications or maintenance of manipulator, parts
（NB4 / NB4L / NB15 / NV6 / NV6L / NV20 / NH5 1L11130A list, etc.
/ NV20A）
1L11446A
（NS3） list, etc.
1L11312A
（NV50） list, etc.
1L11306A
（NV166 / NV210） list, etc.
BASIC OPERATIONS Explanation of manual operation, teaching, automatic
1L21700C operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
EXTERNAL INPUT/OUTPUT Interfacing method with external control device, list of
1L21700H
I/O signals and start/halt the automatic operation, etc.
Software PLC Create program, Input/output relay lists, List of
1L21700J
command words, etc.
CONTROL AND MAINTENANCE Edit logging, User Check, Troubleshooting, etc.
1L21700L
FUNCTION
■Application Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700F
(ARC WELDING) technique, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700E
(SPOT WELDING) technique, etc.
Instruction manuals are available other than the above for each optional function that you have purchased.
[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual
ones.
3. Although we cautiously compiled this standard specification to eliminate as much error as possible, we do not take any
responsibility for damages resulting from neither direct nor indirect errors.
4. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.
5. No part of this manual may be reproduced without permission.
6. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.
- The warranty does not cover any altered or remodeled products.
-1-
Notice
Notes on Safety
The instructions that you are required to obey in order to prevent injury or physical damage to the operator or other
nearby persons are classified and explained as shown below in the provided instruction manuals (including this
manual).
Cases in which death or serious injury are assured if handed incorrectly, and which
avoidance of such dangers is also considered extremely difficult.
DANGER
Cases in which death or serious injury can be expected if handled incorrectly.

WARNING
Cases in which injury or physical damage can be expected if handled incorrectly.

CAUTION
The following symbols are also used for important checkpoints:
A particularly important checkpoint is shown.

IMPORTANT
INFO.
Useful information is shown.
POINT Info for deeper understanding for the main text is shown.
Note that even the matters which are described as CAUTION can result in serious accident depending on the
conditions. Be sure to keep the safety notes since they describe very important matters.
The meanings of “Serious injury”, “Minor injury”, and “Damage” described above are as follows.
Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
Serious injury temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.
Injury which does not require either hospitalization or long-term treatment as an

Minor injury
outpatient, a burn (high temperature, low temperature), and an electric shock.
Direct and indirect damage in connection with damage of property and

Damage
equipment.
-2-
Contents
Contents
Chapter 1 Point on Safety

1.1 For safe use of the robot system......................................................................................... 1-1
1.1.1 Symbols used in all the instruction manuals .................................................................. 1-1
1.1.2 General precautions for safe use of the robot system.................................................... 1-2
Chapter 2 Configuration
2.1 Function of each part and unit ................................................................................................... 2-1
2.1.1 Multi power supply unit ...................................................................................................... 2-4
2.1.2 Raiser board ...................................................................................................................... 2-5
2.1.3 CPU board ......................................................................................................................... 2-6
2.1.4 System CF ......................................................................................................................... 2-8
2.1.5 Sequence board ................................................................................................................ 2-9
2.1.6 Power unit / Large-capacity power unit ........................................................................... 2-13
2.1.7 IPM drive unit ................................................................................................................... 2-14
2.1.8 Brake releasing cable ...................................................................................................... 2-16
2.1.9 Teach pendant ................................................................................................................. 2-18
2.2 Function of Standard optional equipment ................................................................................ 2-19
2.2.1 Operation Box / Starting Box / Operation panel .............................................................. 2-19
2.2.2 Connection terminal block and selector switch assembly ............................................... 2-20
2.2.3 USB memory ................................................................................................................... 2-24
2.2.4 I/O board .......................................................................................................................... 2-25
2.2.5 Relay unit / Extended relay unit ....................................................................................... 2-26
2.2.6 How to release over travel limit switch (option) ............................................................... 2-27
2.2.7 Brake releasing switch .................................................................................................... 2-30
2.2.8 Step-down transformer (Floor-installation type) .............................................................. 2-31
2.3 Function of Welding-related optional equipment ..................................................................... 2-35
2.3.1 Arc I/F board .................................................................................................................... 2-35
2.3.2 Robot I/F board................................................................................................................ 2-36
2.3.3 CAN I/F board .................................................................................................................. 2-37
2.3.4 Welding interface ............................................................................................................. 2-38
2.4 Basic specifications of robot control unit ................................................................................. 2-43
2.4.1 External view of robot control unit ................................................................................... 2-43
2.4.2 Basic specifications of robot control unit ......................................................................... 2-45
Chapter 3 Parts replacement procedures and adjustment procedure

3.1 Parts replacement procedures .................................................................................................. 3-1
3.1.1 Replacement of board ....................................................................................................... 3-2
3.1.2 Replacement of IPM drive unit .......................................................................................... 3-3
3.1.3 Replacement of power unit ................................................................................................ 3-6
3.1.4 Replacement of battery for CPU board ............................................................................. 3-7
3.1.5 Replacement of cooling fan (for heat sink and regenerative resistance) .......................... 3-8
3.1.6 Replacement of cooling fan (for rack unit) ...................................................................... 3-10
3.2 Adjustment procedure .............................................................................................................. 3-11
3.2.1 Adjustment of touch panel on teach Pendant .................................................................. 3-11
Chapter 4 Warranty / Periodic inspection / Parts list
1
Contents
4.1 Notes on Scope of Warranty and Liability ................................................................................. 4-1
4.2 Periodic Inspection Schedule .................................................................................................... 4-2

4.2.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair ............................. 4-2
4.2.2 Inspection Schedule .......................................................................................................... 4-4
4.2.3 Notes on Periodic Inspection............................................................................................. 4-4
4.2.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ..................................... 4-4
4.2.5 Inspection items................................................................................................................. 4-5
4.2.6 Inspection before the long vacation................................................................................... 4-7
4.2.7 Cleaning the heat sink ....................................................................................................... 4-7
4.2.8 Inspection of enable switch ............................................................................................... 4-8
4.2.9 Inspection of Emergency stop button ................................................................................ 4-8
4.3 Maintenance parts ..................................................................................................................... 4-9
4.3.1 How to store Maintenance parts ........................................................................................ 4-9
4.3.2 Robot controller ............................................................................................................... 4-10
4.3.3 Teach pendant ................................................................................................................. 4-14
4.3.4 Operation box .................................................................................................................. 4-15
4.3.5 Starting box ...................................................................................................................... 4-16
4.3.6 Robot I/F board................................................................................................................ 4-17
4.3.7 CAN I/F board .................................................................................................................. 4-17
4.3.8 Welding interface (2CH / 4CH specifications）............................................................... 4-18
4.3.9 Control Cables ................................................................................................................. 4-19
4.3.10 Warning labels ............................................................................................................... 4-21
Chapter 5 Parts layout and Electrical circuit

5.1 Parts layout ................................................................................................................................ 5-1
5.1.1 FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3)............................ 5-1
5.1.2 FD11-JX(NV50 / NV166 / NV210) / JA(NV20A) ................................................................ 5-2
5.2 Connection of equipment........................................................................................................... 5-3
5.2.1 FD11-JV（NB4/ NV6）/JL（NB4L/ NV6L/ NB15/ NV20）/JS（NH5 / NS3）/ JA（NV20A） .. 5-3
5.2.2 FD11-JX (NV50 / NV166 / NV210) .................................................................................... 5-3
5.3 Electrical circuit diagram (Overall) ............................................................................................. 5-4
5.3.1 FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3)............................ 5-4
5.3.2 FD11-JX (NV50 / NV166 / NV210) / JA(NV20A)).............................................................. 5-5
5.4 Electrical circuit diagram (Power supply section) ...................................................................... 5-6
5.4.1 Power unit .......................................................................................................................... 5-6
5.4.2 Power unit with optional filter board .................................................................................. 5-7
5.4.3 Large-capacity power unit ................................................................................................. 5-8
5.4.4 Large-capacity power unit with optional filter board .......................................................... 5-9
5.5 Electrical circuit diagram (Teach pendant) .............................................................................. 5-10
5.6 Electrical circuit diagram (Operation box & Starting box) ........................................................ 5-11
5.7 Electrical circuit diagram (NB4/ NV6/ NB4L/ NV6L/ NB15/ NV20) .......................................... 5-12
5.7.1 Motors (NB4) ................................................................................................................... 5-12
5.7.2 Motors (NV6) ................................................................................................................... 5-13
5.7.3 Motors (NB4L) ................................................................................................................. 5-14
5.7.4 Motors (NV6L / NB15 / NV20) ......................................................................................... 5-15
5.7.5 Encoders (NB4 / NB4L) ................................................................................................... 5-16
5.7.6 Encoders (NV6 / NV6L / NB15 / NV20) ........................................................................... 5-17
5.8 Electrical circuit diagram (NH5) ............................................................................................... 5-18
5.8.1 Motors (NH5) ................................................................................................................... 5-18
5.8.2 Encoders (NH5) ............................................................................................................... 5-19
5.9 Electrical circuit diagram (NS3) ............................................................................................... 5-20
5.9.1 Motors (NS3) ................................................................................................................... 5-20
2
Contents
5.9.2 Encoders (NS3) ............................................................................................................... 5-21

5.10 Electrical circuit diagram (NV50 / NV166 / NV210) ............................................................... 5-22
5.10.1 Motors (1/2) (NV50 / NV166 / NV210) .......................................................................... 5-22
5.10.2 Motors (2/2) (NV50 / NV166 / NV210) .......................................................................... 5-23
5.10.3 Encoders (NV50 / NV166 / NV210) ............................................................................... 5-24
5.11 Electrical circuit diagram (NV20A) ......................................................................................... 5-25
5.11.1 Motors (1/2) (NV20A)..................................................................................................... 5-25
5.11.2 Motors (2/2) (NV20A)..................................................................................................... 5-26
5.11.3 Encoders (NV20A) ......................................................................................................... 5-27
3
Contents
4
Chapter 1 Point on Safety
This chapter explains the safety precautions to be observed when handling the robot
system. This section describes general precautions and procedures on safety but
does not show all of the safety measures. Therefore, it is necessary for customers to
prepare yourself a safety control standard including your own operational regulations
in accordance with the actual working environment and to conduct safety control in
order to secure the operators' safety.
1.1 For safe use of the robot system ................................................................... 1-1

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

Be sure to thoroughly read this manual and the provided instruction manual before using the robot system to
ensure safe use.
1.1.1 Symbols used in all the instruction manuals

Safety information to prevent the injury to personnel and/or damage to equipment is classified
by the following symbols.
Cases in which death or serious injury can be expected if handled incorrectly, and which
avoidance of the danger is accompanied by difficulty which is beyond the limit of urgency
(degree of urgency), etc.
DANGER
Cases in which death or serious injury can be expected if handled incorrectly.

WARNING
Cases in which injury or physical damage can be expected if handled incorrectly.

CAUTION
The following symbol is also used for important checkpoints:
A particularly important checkpoint is shown.

IMPORTANT
INFO.
Useful information is shown.
POINT Info for deeper understanding for the main text is shown.
1-1
1.1.2 General precautions for safe use of the robot system

This section describes general precautions to prevent the injury to personnel and/or damage to
equipment.
Conditions when a disaster struck while a robot system was used are shown in Table 1.1.1.
Table 1.1.1 Conditions when a disaster struck

Auto operation started without confirming there were no people inside the
Example 1
manipulator’s work area.
A person entered the manipulator’s work area which was in auto operation
Example 2
mode and the manipulator started unexpectedly.
A person paid attention to one manipulator forgetting another one was
Example 3
operating within reach of them.
Example 4 Sudden change of movement from low speed to high speed
Example 5 Manipulation by another operator without permission
The manipulator is operated by different program because of program

Example 6
mistakes or faulty peripheral equipment.
Work at a stop of a manipulator waiting for interlocking is released
Example 7
suddenly, and then the manipulator started to move unexpectedly.
Thus, a disaster by the robot system is caused by unsafe acts and unsafe conditions of an
operator. Therefore, it is important to remove unsafe acts and unsafe conditions by an operator
in order to prevent a disaster.
The followings are general precautions to prevent a disaster.

Be sure to obey the following precautions when you use a robot system,
Do not get near the manipulator.

Fatal or serious injury may result if a person is hit or caught by a manipulator due to
unexpected motion.
DANGER
Only perform work within the manipulator‘s work area after turning off the primary power
supply and circuit breaker on the robot controller.
DANGER
Make sure no one exists in the manipulator’s work area when the power is turned on.
DANGER
Operators must wear helmet, safety shoes and overalls.

DANGER
In case that inspection or maintenance work has to be done with a robot controller’s
power on, a watcher (third person) must be present outside the guarding fence and
watch the work at any time while being ready to press an emergency stop button
DANGER immediately.
1-2
In case that inspection or maintenance work has to be done with a robot controller’s
power on, allocate, confirm and know an escape route prior to beginning work.
DANGER
Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
DANGER The warranty does not cover any altered or remodeled products.
While robot controller is power ON, do not touch any parts in the robot controller.
Because protection against electric shock due to live part, wait 5 minutes after turning
off the mains power before working inside the controller.
DANGER
While robot controller is power ON, do not detach or attach any cables and their
connectors.
Failure to adhere to the precautions may cause the robot and/or controller to fail, break
CAUTION or operate in error.
Precautions to follow above terms are described in the section 1.1.3 or later in the instruction
manual “SETUP”. Understand and observe them precisely.
If the operators are pinched in the manipulator, a brake can be released to move the arm
manually.
For the detailed procedure, refer to section 2.1.8 if a brake release switch is not installed,
IMPORTANT and section 2.2.7 if one is installed.
The robot controller is labeled warning labels that mentions important notes so that the
robot can be safely operated.
IMPORTANT For details, refer to the section 4.3.10
1-3
1-4
Chapter 2 Configuration
This chapter describes the configuration and each unit of robot controller.
2.1 Function of each part and unit .................................................................... 2-1

2.1.1 Multi power supply unit ......................................................................... 2-4
2.1.2 Raiser board ......................................................................................... 2-5
2.1.3 CPU board............................................................................................ 2-6
2.1.4 System CF............................................................................................ 2-8
2.1.5 Sequence board ................................................................................... 2-9
2.1.6 Power unit / Large-capacity power unit............................................... 2-13
2.1.7 IPM drive unit ..................................................................................... 2-14
2.1.8 Brake releasing cable ......................................................................... 2-16
2.1.9 Teach pendant .................................................................................... 2-18
2.2 Function of Standard optional equipment ................................................. 2-19
2.2.1 Operation Box / Starting Box / Operation panel .................................. 2-19
2.2.2 Connection terminal block and selector switch assembly ................... 2-20
2.2.3 USB memory ...................................................................................... 2-24
2.2.4 I/O board ............................................................................................ 2-25
2.2.5 Relay unit / Extended relay unit .......................................................... 2-26
2.2.6 How to release over travel limit switch (option) .................................. 2-27
2.2.7 Brake releasing switch........................................................................ 2-30
2.2.8 Step-down transformer (Floor-installation type) .................................. 2-31
2.3 Function of Welding-related optional equipment ...................................... 2-35
2.3.1 Arc I/F board ....................................................................................... 2-35
2.3.2 Robot I/F board .................................................................................. 2-36
2.3.3 CAN I/F board .................................................................................... 2-37
2.3.4 Welding interface ................................................................................ 2-38
2.4 Basic specifications of robot control unit .................................................. 2-43
2.4.1 External view of robot control unit ...................................................... 2-43
2.4.2 Basic specifications of robot control unit............................................. 2-45
2.1 Function of each parts and unit
2.1 Function of each part and unit

Here explains the function of each unit and part.
The person in charge of maintenance should understand the each unit in the robot controller, allocation of
parts and its function before implementing the operation.
INFO. To confirm the model numbers of the boards, parts and units described in this chapter, refer
to “4.3 Parts List”.
(1) Parts layout of robot controller

The layout of parts of robot controller is shown in Fig. 2.1.1 and Fig. 2.1.2.
Fig. 2.1.1 Layout of parts of robot controller (For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 / NH5 / NS3)
2-1
Fig. 2.1.2 Layout of parts of robot controller (For NV50 / NV166 / NV210 / NV20A)
2-2
(2) Outline of each part

The outline of each part is shown in Table 2.1.1.
Table 2.1.1 Outline of each part

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

You may get injured or have your equipment damaged because of fire, failure or malfunction
caused by altering or remodeling the product.
2-3
2.1.1 Multi power supply unit

The Multi power supply unit supplies the DC+5V, DC+12V and DC+24V power used in the
robot controller. And it is equipped with primary power supply monitoring circuit to notice the
power failure to the CPU board.
F2 (Fuse) F1 (Fuse)
CNPW
CNPW
CNPW
CNFAN
CNFAN
CNFAN
CNSWO
CNSWO
CNRC
CNSWO
CNP24V
CNRC
CNU24V CNP24V
F21 (Fuse)
CNU24V
F21
250V 2A
CNP5V
CNP5V
LED 4 LED 4 +3.3V
LED 3 LED 3 +5V
LED 2 LED 2 +12V
LED 1 LED 1 +24V
<Left view> <Front view>

Fig. 2.1.3 External view of Multi power supply unit
Table 2.1.2 Connectors of Multi power supply unit
Connector Functions Connected to

CNPW AC200V power input Power unit
CNFAN AC200V power output Rack fan
CNSWO AC200V power output Optional equipment and additional axes kit
CNP5V DC+5V power output Disconnected
CNP24V DC+24V power output IPM drive unit
CNU24V DC+24V power output Disconnected (For external connection)
CNRC Power ON/OFF control Disconnected (Optional)
CNPS Power supply to the raiser board Raiser board
Table 2.1.3 Status indication LED of Multi power supply unit

LED Functions
LED1 Lit while DC 24 V of Multi power supply unit works properly.
LED4 Lit while DC 3.3 V (optional) of Multi power supply unit works properly.
Table 2.1.4 Fuses of Multi power supply unit

Fuse Specifications Installed positions
F21 250V T2.0AH Front panel
F1､F2 250V T6.3AH On board
2-4
2.1.2 Raiser board

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

Sequence board
LED4 [+24V]
LED3 [+12V]
LED2 [+5V]
LED1 [+3.3V]
PCI slot (I/O board,etc)
Fig. 2.1.4 External view of Raiser board
Table 2.1.5 Status indication LED of Raiser board

LED Function
LED1 Lit while DC 3.3 V (optional) of Multi power supply unit works properly.
2-5
2.1.3 CPU board

CPU board has following functions; control robots, communicates with the user I/F and
peripheral equipment, and controls them.
Function
- Microprocessor and its peripheral circuit
- RS232C
- Ethernet
(For servo, teach pendant and user)
- PCI bus I/F
- Compact flash card I/F (for system)
- USB memory I/F (for backing up the user data)
CN19LiBAT
CN7(CRT)
CN2(COMA)
CNCF
LiBAT (System CF)
CNLAN3(SERVO)
CN9(FAN) CNLAN2(TP)
CN12LAN
CNUSB3
CNUSB2
CN6,CN11
(Keyboard and mouse)
CNSODIMM1
CNSODIMM2
Fig. 2.1.5 External view of CPU board
2-6
(1) Block diagram

The standard cable connection is shown in Fig. 2.1.6.
Fig. 2.1.6 CPU board peripheral connection

(2) Connectors
Connectors on CPU board are shown in Table 2.1.6.
Table 2.1.6 Connectors on CPU board

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

Standard jumper setting is shown in Table 2.1.7.
(The factory default setting should not be changed.)
Table 2.1.7 Jumper settings of CPU board
Connectors Settings
CN22 (RESET) Open (no socket)
CN20 (FTMODE) Open (no socket)
CN21 (RTC RESET) Short 1 – 2
2-7
2.1.4 System CF
Windows OS and system software are stored in this CF.
The system software is displayed as "Internal memory" for this CF.
The task programs made by a user and various condition files are also stored.
SystemCF
(CNCF)
CPU Board
Fig. 2.1.7 System CF card connector
2-8
2.1.5 Sequence board

The Sequence board controls the sequence in the control panel by the digital I/O signal of the
robot controller and peripheral equipments. The emergency stop circuit is the redundant circuit.
Function
- I/O circuit for inside of robot controller
- Sequence circuit for inside of robot controller
- Emergency stop safety circuit
- Arc I/F Extending function
Fig. 2.1.8 External view of Sequence board
The specifications of sequence board differ depending on the delivery time.

INFO. Wihtout J2,J3 Delivered before November 2012 in single mechanism controller.
With J2,J3: Delivered in or after November 2012 in combination with 3 or more
external axes controller.
For the settings of jumper pins, see Table 2.1.9.
Connectors on sequence board are shown in Table 2.1.8.
Table 2.1.8 Connectors on Sequence board

Connectors Signal names Connected to
CNTP Teach pendant switch signal Teach pendant
CNOP Operation box signal
Operation box
CNOP2 Starting box signal
CNSV I/O signals of IPM drive unit IPM drive unit
CNARC Arc I/F signals Arc I/F board
TBEX1 User connection signals
TBEX2 User connection signals
2-9
(1) Terminal blocks TBEX1 and TBEX2 (User connections)

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

Connecting power supply setting
J1 Short 1-2
Short 1-2: internal, Short 2-3: external
Single mechanism
controller : short 1-2 Switch single or cooperation
J2
Cooperation Shor 1-2: Single, Opne 1-2: Cooperation
controller:Open 1-2
Single mechanism
controller: Short 1-2 Switch single or cooperation
J3
Cooperation Shor 1-2: Single, Opne 1-2: Cooperation
controller:Open 1-2
DO NOT use the sequence board with J2 and J3 short-circuited in the cooperation controller.
The multi power supply unit may break down.
WARNING
(3) Fuse on Sequence board

Table 2.1.10 Fuse on Sequence board
Fuse Specification
F4 250V, 2A
(4) List of fixed I/O

The I/O signals used for controlling the inside of robot controller such as servo ON/OFF are
shown below.
For the fixed I/O signal, the input and output can be just referenced by the software PLC. If you
create the program to be output to the fixed I/O signal, an error is generated at the compiling.
When referencing the input and output, the relay number is used.
Table 2.1.11 List of fixed input relay numbers（1/3）

Relay Descriptions
Fixed input signal name
No. Light on : ON (Input ON) Light off : OFF(Input OFF)
IN 1 Motors-ON X0032 Lit with Motor ON of the operating box.
Lit off when G-STOP input is OFF.
IN 2 G-STOP X0033 For details of G-STOP signal, refer to the section 3.7 in
“SETUP”.
IN 3 Start 1 X0034 Lit when the start 1 button of the operation box 1 is ON.
IN 4 Start 2 X0035 Lit when the start 2 button of the starting box 2 is ON.
Normally, this light is ON. It lights off when any stop buttons of
IN 7 Stop X0038 the teach pendant, the operation box or the start box are pressed
ON.
Lit when the selector switch of operation box is in Playback
IN 8 Playback mode X0039 mode with the external mode select input OFF. It lights off when
the selector switch of operation box is in Teach mode.
Lit when the enable switch and MAT switches (TBEX1: 13-14,
IN 9 Mat switch X0040
15-16) are ON.
IN 10 －－ (Not used)
IN 11 High-speed Teach X0042 Lit when High-speed Teach is ON.
IN 12 P1 correct X0043 Lit when DC 24 V is supplied properly.
2-10

Relay Description
Lit off with the “emergency stop” off or when the external
emergency stop input (TBEX1: 1-2, 3-4) is OFF (on inputting the
IN 13 Ext Emergency stop X0044
emergency stop) is OFF.
Lit by releasing the emergency stop input.
Lit off with the “TP emergency stop” off or when the emergency
stop button of either the operation box or the start box is
IN 14 Emergency stop X0045
depressed (on inputting the emergency stop).
Lit by releasing the entire emergency stop input.
Lit when all the following conditions are met.
IN 15 Safety plug X0046 ･”Playback mode” lights.
･Safety plug input (TBEX1_5-6,7-8) is ON.
IN 16 Confirm motors-ON X0047 Lit with the motor power relays (CRON1 & CRON2) are ON
Lit by releasing the emergency stop input.
IN 17 TP Emergency stop X0048 Lit off with the TP emergency stop button depressed (on
inputting the emergency stop).
Lit when “TEACH mode” is selected by the selector switch of
IN 18 Teach mode X0049
operation box. Light off during “Auto mode”,
IN 20 TP enable SW X0051 Lit when TP enable switch is ON.
Normally, it lights on.
IN 21 Shock sensor X0052
Lit off when the shocke sensor input is ON.
IN 22 CR ON X0053 Lit with the motor power relays (CRON1 and CRON2) are ON.
IN 23 Servo-ON X0054 Lit when the servo ON relay (CRES1) is ON.
IN 24 Servo enable X0055 Lit when Amplifier normal signal is ON.
IN 28 Magnet-ON X0059 Lit when the magnet switches (MS1 and MS2) are ON.
Normally, it lights on with the motor power OFF.
IN 30 Weld detection X0061 Lit off when contact stick occurs in the magnet switch or the relay
with the motor power OFF.
Normally, it lights off.
IN 31 Inconsistency X0062 Lit when the inconsistency of a redundant safety circuit is
detected.
Normally, it lights.
IN 33 Inconsist(GSTOP) － Lit off when the inconsistency of a G-STOP redundant safety
circuit is detected.
IN 34 Inconsist(mode) － Lit off when the inconsistency of a mode input redundant safety
IN 35 Inconsist(MAT-SW) － Lit off when the inconsistency of a MAT-SW redundant safety
IN 36 Inconsist(HI-SP) － Lit off when the inconsistency of a high-speed teaching
redundant safety circuit is detected.
IN 37 Inconsist(Ext ES) － Lit off when the inconsistency of an extension emergency
redundant safety circuit is detected.
IN 38 Inconsist(E.S.) － Lit off when the inconsistency of an emergency redundant safety
IN 39 Inconsist(S.plug) － Lit off when the inconsistency of a safety plug redundant safety
IN 40 Inconsist(TP-ES) － Lit off when the inconsistency of a TP emergency redundant
safety circuit is detected.
2-11

Relay Description
IN 41 Inconsist(ENB-SW) － Lit off when the inconsistency of an enable switch redundant
safety circuit is detected.
IN 42 Inconsist(CRON) － Lit off when the inconsistency of a CRON redundant safety
IN 43
- －－ (Not used)
IN 48
The status of fixed input signal can be monitored by clicking <Service> – [Monitor * (*: 1 - 4)] –
[Fixed input signal]. The input signal is displayed as "Lighting": signal set to “ON” and
"Extinction": signal set to “OFF”.
Table 2.1.14 List of fixed output relay numbers

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

The power unit and large-capacity power unit consist of a connector for distributing AC 200 V
to each location, and an electromagnetic contactor that controls the power supply to the IPM
drive unit.
The power unit and large-capacity power unit have electromagnetic contactors with different
capacities, and the one to use depends on the manipulator and external axis with which it is
combined.
INFO. For details on whether to use the power unit or large-capacity unit, refer to the following.
”4.2.2 Robot Controller”
”1.4 Configuration and parts list” of ”EXTERNAL AXIS”
Electromagnetic
contactor
<Top view: Power unit> Auxiliary

contact
Electromagnetic
contactor
CNMS
<Top view: Large-capacity power unit>
CNRSTIN
F1 (Fuse)
F2 (Fuse)
CNPW
CN200P CNRST
<Front view> <Right view>
Fig. 2.1.9 External view of Power unit
Table 2.1.15 Connectors of Power unit
Connectors Figure Functions Connected to
CNRSTIN Front panel connector 3-phase AC 200 V input Secondary side of no-fuse breaker
CN200P Front panel connector 1-phase AC 200 V output Optional equipment
CNPW Cable drawn 1-phase AC 200 V output Multi power supply unit
CNRST Cable drawn 3-phase AC 200 V output IPM drive unit
CNMS Cable drawn MS control I/F IPM drive unit
Table 2.1.16 Fuse of power unit

Fuse Specification Setting position
F1, F2 250V、8A Front panel
2-13
2.1.7 IPM drive unit

The IPM drive unit is the servo amplifier that servo control CPU is equipped. It is configured
with the encoder I/F, Power supply for driving motor, motor power control circuit, power supply
for brake control, brake control circuit and other items.
CNP4A CNP5A CNP6A

F1 (Fuse) CNP4B CNP5B CNP6B
CNP3B CNP2B CNP1B

CNP3A CNP2A CNP1A
CNRST
CNFAN
CNR
CNPN
< Front view > < Right view >
Fig. 2.1.10 External view of IPM drive unit
Table 2.1.17 Connectors on IPM drive unit (1/2)

Boards included in
Connectors Functions Specifications
IPM drive unit
(Note)
CNP1A / CNP1B Motor I/F Connect to Manipulator motor (Axis 1)
(Note)
Gate drive board CNP2A / CNP2B Motor I/F Connect to Manipulator motor (Axis 2)
(Note)
(Note)
(Note)
Gate drive board CNP5A / CNP5B Motor I/F Connect to Manipulator motor (Axis 5)
(Note)
CNRST Drive power input Connect to Power unit
CNFAN Fan control I/O Connect to Power unit and Fan
PN board Regenerative
CNR Connect Regenerative resistance
resistance I/F
CNPN Option (Not used)
Connect to Servo board
Brake power board CNPB Brake power output
(internal connection)
(Note) The connector may not be installed according to the type of gate drive board.
2-14
Table 2.1.18 Connectors on IPM drive unit (2/2)

Boards included in
Connectors Functions Specifications
IPM drive unit
Connect to Brake power board (internal
CNBKP Brake power input
connection)
CNBK1 Brake control I/F Connect to Manipulator motors (Axis 1 -3)
CNBK2 Brake control I/F Connect to Manipulator motors (Axis 4 -6)
CNEC1 Encoder I/F Connect to Manipulator encoders (Axis 1 -3)
CNEC2 Encoder I/F Connect to Manipulator encoders (Axis 4 -6)
CN78BK Brake control I/F Connect to external axes motors (Axis 7-8)
CN78E Encoder I/F Connect to external axes encoders (Axis 7-8)
CNCOM CPU communication I/F Connect to CPU board
CNVP Control power input Connect to Multi power supply unit
Servo board CNMS MS control I/F Connect to Power unit
CNSV MS control I/F Connect to Sequence board
For brake positive release
Short-circuiting connector is equipped to this
connector as standard.
CNSW Brake positive release
Only to release brake forcedly, connect the
brake releasing relay cable, and then operate
the specified procedures.
For short-circuiting the shock sensor circuit.
Normally, no connector is equipped.
CNMCH Shock sensor input
In case that shock sensor is not used, the
short-circuiting connector should be equipped.
Table 2.1.19 Status indication LED of IPM drive unit

Boards included
No Lighting condition
in IPM drive unit
LED1 Lit when the servo communication link is established.
LED2 Blinks when the servo communication traffic exists.
Servo board
LED3 Lit DC 24 V input is valid.
LED4 Blinks when the servo main loop works.
Capacitors are fully charged.
LED1
PN board (Lights: Capacitors are fully charged. Light off: Capacitors are discharged.)
LED2 Power output relay for fans is ON.
While LED1 on PN board is lighting, DO NOT touch printed circuit boards.

Touching parts accidentally may cause an electric shock hazard because the capacitor is under
the charged condition while LED1 is lighting.
WARNING
Table 2.1.20 Fuses on IPM drive unit
Fuses Specifications Installed position
F1 250V 10A Servo board
F3 250V 3.2A Servo board
Table 2.1.21 Jumper pins and rotary switch of IPM drive unit
Setting
Initial settings Remark
positions
JP2 Short 1-2 Setting of 24 V output of encoder connector
JP3 Short 1-2 Setting of encoder voltage 5.4V
JP4 Open 1-2 Setting of encoder voltage 5.6V DO NOT change the
JP5 Open 1-2 Setting of encoder voltage 6.0V standard settings.
JP6 Short 1-2 Setting of additional axes thermal
ROTSW1 0 Setting of drive unit number
2-15
2.1.8 Brake releasing cable

Installing the Brake releasing cable is enabled to release brake for each axis.
Note that two or more brakes can not be released at the same time.
・If the breaker is turned on while this connector is connected, the manipulator or external axis
brake will be released, and the released axis will fall. Before turning on the power, check
carefully the axis whose brake will be released and support the robot arm securely with a
device such as a crane.
Contact with the arm or becoming trapped between the arm and other equipment may
result in a serious accident or death.
DANGER
・Take special care while working if the axis will fall in the direction of gravity.
・DO NOT connect this connector except releasing the brake.
External view and configuration of the Brake releasing cable is shown in Fig. 2.1.11.
Fig. 2.1.11 Brake releasing cable

If the operators are pinched in the manipulator, follow the procedures to save them
Brake release procedure

1 Press the emergency stop button immediately and stop the manipulator.
2 Turn OFF the robot controller.

nd rd
3 To prevent the manipulator arm from falling off, sling the 2 and the 3 axis arm
(especially upper part) with a wire rope or other items.
Arm of the manipulator may fall off if the power of the robot control unit is turned on after the
wiring work to release a brake was done.
Do the work to prevent the manipulator from falling off “before the power is turned ON”.
WARNING
4 Confirm the brake releasing connector is NOT installed to the connector CNSWA on the
attached brake releasing relay cable.
5 Open the door of the robot controller, and then remove the short-circuiting connector
CNSW from the connector CNSW on the right side of the IPM drive unit.
2-16
Be absolutely sure NOT to expose the controller inside to direct sunlight, a searchlight or
other strong lights before turning on the primary power supply while the controller door is
left open to enable maintenance or other work to be performed.
WARNING Failure to adhere to the precautions may cause the manipulator and/or controller to fail or
operate in error.
6 Connect the brake releasing relay cable to the connector CNSW of the IPM drive unit.
CNSW
(Front view) (Right side view)
Fig. 2.1.12 The position of the connector CNSW of IPM drive unit
7 Insert the brake releasing connector to the axis to release the brake in accordance with
the label of the connector CNSWA.
8 Turn on the robot control unit. Brake on the according axis is released when turning the
power ON.
DO NOT turn on the Servo Power.

WARNING
9 Operate the arms manually to save the personnel pinched in a manipulator.
10 After the work, turn off the robot control unit immediately.
11 Remove the brake releasing connector from the IPM drive unit. And then, insert the
short-circuiting connector CNSW that was removed in the procedure 5.
12 Close the door of the robot control unit.
2-17
2.1.9 Teach pendant

External view of the Teach pendant is shown in Fig. 2.1.13.
(3)
(1)
(4)
(6)
(5)
(7)
(2)
Fig. 2.1.13 External view of Teach pendant (Unit (mm))

(1) EMERGENCY STOP button
Depress this button to urgently stop the robot. The servo power is shut off and the brake
works by pressing this button. To release the emergency stop, then turn this button in the
direction of the arrow. If you wish to bring the robot ready for the operation again, you need to
press “Motors ON” button.
(2) Enable switch
Enable switch is touched by your left hand when the teach pendant is held by both hands.
Enable switch can be operated only in the teach mode. The servo power is ON while the
enable switch is grasped. If the enable switch is released or grasped tightly, the motor power is
turned off, and the robot stops immediately. For the safety reasons, enable switch cannot be
invalid.
(3) TP Selector switch
This switch enables the servo power to be applied from the Teach pendant. This switch is
used in combination with the mode select switch. For details of the operation, refer to the
instruction manual “BASIC OPERATION”.
(4) Touch panel LCD screen
Touch panel LCD screen displays the details of operation currently being performed, the
error log and others. Touch panel enables you to operate easily. For example, the cursor can
be moved to your desired position directly.
(5) Sheet key
A variety of keys including Numerical key, Axis key, Command key are allocated to the sheet
keys. Refer to “BASIC OPERATION” about how to use each key, operation procedures and
so on.
(6) Jog dial
This dial enables you to move cursors by vertical rotating operations and input “Enter” by
pushing the right of it. Combining with the key and/or the other key enables various operations
without getting off both hands from the Teach pendant. For details of operations, refer to
“BASIC OPERATION”.
(7) USB port
Connecting USB memory (Optional) with opening USB cap enables you to use TP external
memory. For details of the precautions for operation or handling, refer to “Chapter 6 file
operations” in “BASIC OPERATOINS”.
Attach USB memory to the USB port only during file operations.
After finishing file operations, remove USB memory and close USB cap.
Using with USB memory attached or with USB cap opened may lose dust resistance and
CAUTION waterproof performance so that the teach pendant may be damaged.
2-18
2.2 Function of Standard optional equipment
2.2.1 Operation Box / Starting Box / Operation panel

Each external view of Operation box, Starting box and Operation panel is shown in Fig. 2.2.1
and Fig. 2.2.2.
(2) (5)
(3) (4)
Fig. 2.2.1 External view of operation box and starting box (Unit: mm)
(2)
(5)
(3) (4) (1)
Fig. 2.2.2 External view of operation panel (Unit: mm)
(1) EMERGENCY STOP button

Press this button to urgently stop the robot. Then, the servo power is shut off and the brake
works. To release this emergency stop, turn this switch to the arrow direction. If you wish to
bring the robot ready for the operation again, you need to press “Motors ON” button.
In case of no use of both the operation box and the operation panel, connect the
short circuit connector (L21766B00) to the connector CNOP on the sequence
board.
CAUTION
(2) MOTOR ON button

By pressing this button, the mode changes to “Motor ON” status. While this button lights off,
it indicates that the status is not in “Motor ON”. In teach mode, this button flushes with “Motor
ON” status. It lights while the servo power is ON in auto mode.
(3) START button
The taught program starts running by pressing this button in PLAYBACK mode. This button
lights while that program is running.
(4) STOP button
A robot temporarily stops by pressing this button during playback operation. This button
lights while the robot is temporarily in halt.
(5) MODE SELECT switch (with key)
This switch is used when switching the mode of robot operation to TEACH/PLAYBACK.
Switching to auto mode can be prohibited by taking out the key.
2-19
2.2.2 Connection terminal block and selector switch assembly

When substituting the function of an operation box (and operation panel) with an external
signal, a “connection terminal block” and “selector switch assembly” are required for mode
selection.
・The external signal of “EMERGENCY STOP” can be input from terminal block TBEX1 of
the sequence board.
Section 3.7.6 in “SETUP”
INFO.
・The “MOTOR ON”, “START” and “STOP” external signals can be input from the general
purpose physical input.
Wiring method: Sections 3.6 and 3.9 in “SETUP”
Setting method: Section 4.6 in “SETUP”
・When a robot system is purchased at the same time as this product, the products are
shipped with the connection terminal block already mounted on the robot controller.
INFO.
Please install the selector switch assembly yourself.
・If this product is purchased after the robot system was purchased earlier, we can perform
the installation work for a fee.
Sequence board
(2) Cable (1) Terminal block TB1
CNOP Cable clamp Grounding terminal
(3) Selector switch
(4) Connecting cable (15m)
(5) Cable flange

Inlet
<Front view (inside)> <Right view (inside)> <Door (inlet)> <Right view>
Fig. 2.2.3 Connection terminal block and selector switch assembly
Table 2.2.1 Components of connection terminal block and selector switch assembly
Part
Part name Component Remarks
number
(1) Terminal block TB1
Required if an operation
Connection (2) Cable
L21767A block (and operation panel)
terminal block (Sequence board CNOP to terminal
will not be connected.
block TB1)
(3) Selector switch Our recommended products.
Selector switch
L21768A (4) Connection cable (15 m) It is also possible for you to
assembly
(5) Cable flange obtain them yourself.
Connect this product with the following procedures.
Connecting the selector switch

Page.2-21
assembly
Fixing the selector switch assembly Page 2-22
2-20
Connecting the selector switch assembly

Connect the selector switch assembly to terminal block TB1.
1 Turn off the breaker of the robot controller and the supply of primary-side power.
2 Open the door of the robot controller.
3 Referring to Fig. 2.2.3, remove the panel on the right surface of the robot controller.
4 As shown in Fig. 2.2.3, pull through the bare wire end of the selector switch assembly
from the right surface of the robot controller, and fix the cable flange.
5 As shown in Fig. 2.2.4, connect the connection cable to the compatible terminal on
terminal block TB1. For the method of inserting wires into the terminal block, refer to
Fig. 2.2.5.
Connecting cable
<Close up view>
Connect to each corresponding terminal on TB1.
Connect to the grounding terminal.

Grounding cable.
Fig. 2.2.4 Connecting the selector switch assembly
Insert a slotted screwdriver (3.5 mm) into the

slot above the wire inlet, and push down the
spring inside to connect the wire.
Slotted screwdriver (3.5 mm)
Wire inlet
Fig. 2.2.5 Method for inserting wires into terminal block TB1
6 As shown in Fig. 2.2.4, connect the ground wire to the ground terminal.
2-21
Fixing the selector switch assembly

Fix the selector switch assembly to your equipment.
1 Turn off the breaker of the robot controller and the supply of primary-side power.
2 Perform the panel processing shown in Fig. 2.2.6 at the location where the selector
switch assembly will be installed.
Allowable panel thickness

t=1.2～4.5mm
Fig. 2.2.6 Diagram of panel processing for selector switch assembly

Unit (mm)
3 Remove the lock lever cover of the selector switch, push the lock lever in the direction
of the arrow in the photograph of Fig. 2.2.7, and remove the contact unit from the
operating unit.
Operating unit
Lock lever
Lock lever cover
Contact unit
Fig. 2.2.7 Lock lever
4 As shown in Fig. 2.2.8, remove the lock nut from the operating unit.
Install the operating unit so that the key faces the operating side of the equipment, and
then fix it with the lock nut. When installing onto the panel, align the TOP mark of the
operating unit and the ejection part (△ mark) of the stop-turning-around ring with the
notch on the panel.
The recommended tightening torque for the lock nut is 2.0 N･m.
Ejection part (△ mark)
Key TOP mark
Notch
Operating unit Packing Lock nut

Panel
Stop-turning-around ring (prepared by customer)
Fig. 2.2.8 Fixing the operating unit
2-22
5 Insert the contact unit by aligning its TOP mark in the same plane as the TOP mark of
the operating unit, and lock by moving the lock lever in the opposite direction to 3.
6 Install the lock lever cover.
This completes the fixing of the selector switch assembly.
Lock nut
Lock lever
Operating unit Lock lever cover
Key Contact unit
Panel
(Prepared by customer)
Fig. 2.2.9 Exterior after completing work
When using a selector switch you obtain yourself

When using a selector switch that you obtain yourself, obtain a 2a2b contact point selector
switch and wiring materials. The cable flange (option) shown in Table 2.2.2 can be used for
pulling through the wires to the robot controller.
Table 2.2.2 Cable Flanges (Option) for passing through I/O Wires
Parts name DWG No.
Cable flange (with cable clamp for the cable diameter φ9 – 19) L21160M
Cable flange (with cable clamp for the cable diameter φ6～12) L21160N
After connecting the wiring materials to the selector switch, connect to terminal block TB1 as
shown in "Connecting the selector switch assembly" on page 2-21.
For the connection destinations of the selector switch, refer to Fig. 2.2.10.
Connect a switch with a contact point configuration of 2a2b, and perform a duplex
configuration for both auto mode and teach mode.
If the connections are incorrect, it will not be possible to change mode.
CAUTION
Controller inside Controller outside
Selector switch
(2a2b)
(Prepared
Terminal block by customer)
TB1
Signal name No
Auto mode A-MODE1-1 1 NO
input 1 A-MODE1-2 2
Auto mode A-MODE2-1 3 NO
input 2 A-MODE2-2 4
Teach mode T-MODE1-1 5 NC
input 1 T-MODE1-2 6
Teach mode T-MODE2-1 7 NC
input 2 T-MODE2-2 8
Fig. 2.2.10 Connection destinations of selector switch
2-23
2.2.3 USB memory

This is a USB memory for "External memory" used to back up user data or upgrade the
version. Installing position of USB memory is shown in Fig. 2.2.11.
For details of operating procedures and precautions, refer to “Chapter 6 File operation” in
“BASIC OPERATIONS”
Precautions when using USB Memory:

- For commercially available USB memory operation is not covered by warranty.
Only the USB memory in “4.3.2 Robot controller” section is guaranteed to operate.
When using USB memory that has been accessed by a different device with this controller,
always check using commercially available anti-virus software that there are no viruses or
CAUTION other malicious software on the USB memory before connecting it to the controller.
- Comply with the instructions in the section 1.1.4 of “SETUP” instruction manual.
CPU board Connectors for USB memory
< Front view (inside) > < Closeup of Rack unit >
Fig. 2.2.11 Installing positions of USB memory
2-24
2.2.4 I/O board

The I/O board controls the digital I/O signal between inside of robot controller and peripheral
equipment.
Function
- I/O circuit for inside of board
- I/O circuit for external interlock
- For details of installation procedures of I/O board, refer to the section 3.6.3 in “SETUP”.
INFO.
- For details of connecting procedures between I/O board and external I/O, refer to the
section 3.9.4 in “SETUP”.
CNIN FCIO CNOUT
F2 (Fuse)
SW1 and silk indication
Fig. 2.2.12 External view of I/O board
Table 2.2.3 Connectors on I/O board

CNIN Digital input Connect the input signal from external
CNOUT Digital output Connect the output signal to external I/O circuit
FCIO Digital I/O Connected with Relay unit or Extended relay unit
CNPCI CPU bus
Connected to Raiser board.
CNP24V CPU bus
Table 2.2.4 Setting of Dip switch SW1 of I/O board

Setting position Setting status
Remarks
Board name No. 2 1
OFF OFF I/O board 1 (Initial setting)
OFF ON I/O board 2
I/O board SW1
ON OFF I/O board 3
ON ON Not used
Table 2.2.5 Fuse of I/O board

Fuse Specification
F2 250V, 1.25A
2-25
2.2.5 Relay unit / Extended relay unit

The Relay unit is the unit that connects the general purpose physical I/O.
This board is combined with I/O board as shown in Table 2.2.6. The relay unit can be used up
to two boards at the same time.
- For details of installation procedures of relay unit, refer to the section 3.6.2 in “SETUP”.
INFO.
- For details of connecting procedures between relay unit and external I/O, refer to the
Fig. 2.2.13 External view of Relay unit
Table 2.2.6 Relay unit, Extended relay unit and I/O board
Number of Relay unit Name of Relay unit Combined I/O board Number of signals
IN 32 pts. / Out 32 pts.
1 pcs Relay unit I/O board 1
in total
Relay unit I/O board 1
IN 64 pts. / Out 64 pts.
2 pcs
in total
Extended relay unit I/O board 2
2-26
2.2.6 How to release over travel limit switch (option)

If some joint moved beyond the software limit and hit the over travel limit switch (option), this
switch must be release manually to operate the robot arm from there. Please refer to the
following procedure.
When “Over travel LS Release” screen or “Software Limit” screen is opened, software limit is
automatically ignored in order to operate the robot arm beyond the normal operating
envelope. Please pay utmost attention to operate the robot arm, otherwise equipments may
WARNING be damaged by miss-operation.
Procedure to release over travel LS (at “Over travel LS Release” screen)
1 Select the teach mode.
2 Set the operator qualification to EXPERT or above.
3 Press <Constant setting> - [3 Machine Constants] – [32 Over travel LS

Release].
>> Following setting screen will appear.
In this screen, current status of over travel limit switch detection is displayed.
All the time LS detection is enabled unless over travel limit switch is released on this
screen.
4 Press [ENABLE] and right key together to align the cursor to "Release”.
5 Press <Complete> key.

>> Over travel limit switches of all mechanism are ignored temporary. So motor
power can be turned ON from now.
6 “LS Detect” is now “Release”.
7 Turn the motor power ON.
8 Keep opening this screen, and operate the target joint (of which over travel
limit switch was activated) to the position inside the software limit by manual
operation.
2-27
9 Press [ENABLE] and left key together to align the cursor to "Enable”.
10 Press <Complete> key.

>> Over travel limit switches of all mechanism are enabled again.
11 “LS Detect” is now displayed “Enable”.
Procedure to release over travel LS (at “Software Limit” screen)
1 Select the teach mode.
2 Set the operator qualification to EXPERT or above.
3 Press <Constant setting> - [3 Machine Constants] – [5 Software Limit].

>> Following setting screen will appear.
All the time LS detection is enabled unless over travel limit switch is released on this
screen.
4 Press <LS Detect> key.

>> Over travel limit switches of all mechanism are ignored temporary. So motor
power can be turned ON from now.
2-28
5 <LS Detect> key display changes to <Release>.

≫ While releasing limit switch, <Record Posi.> <Auto Set> and <Complete> keys
are disabled in order to avoid miss-operation.
6 Turn the motor power ON.
7 Keep opening this screen, and operate the target joint (of which over travel
limit switch was activated) to the position inside the software limit by manual
operation.
8 Press <LS Detect> key.

>> Over travel limit switches of all mechanism are enabled again.
9 <LS Detect> key display changes to <Enable>.

>> <Record Posi.> <Auto Set> and <Complete> keys are now enabled again.
When recovering the robot by using this utility, please select the slow manual speed for
safety. If not doing so, equipments may be damaged by miss-operation.
CAUTION
LS releasing operation is allowed only at “Over travel LS Release” screen and “Software
Limit” screen. If “Reset/R” key is pressed to abort from these screen while LS releasing
operation, LS detection is automatically back to enabled.
CAUTION
2-29
2.2.7 Brake releasing switch

The brake release switch (parts number: L22381A00) can forcibly release the motor brake of
any one axis. This is used if the motor power cannot be turned ON due to a servo error or
other problem, or if a worker is trapped by the robot.
・When the brake is released, the robot arm may fall due to gravity. Before releasing the
brake, check carefully the axis whose brake will be released and support the robot arm
securely with a device such as a crane. Contact with the arm or becoming trapped
between the arm and other equipment may result in a serious accident or death.
DANGER ・Take special care while working if the axis will fall in the direction of gravity. If the brake
release switch is pressed and held, the impact of the arm falling will be larger. Make the
switch pressing time as short as possible.
This switch is installed inside the cover located on the door of the robot controller.
There is no need to open the door of the robot controller or turn off the power to perform
operations.
Brake release procedure

1 Turn on the power of the robot controller.
Never turn on the servo power.

WARNING
2 Open the cover on the door, remove the “CNSW” connector that is inserted into
CNMOD, and insert the “RELEASE” connector (the “CNSW” and “RELEASE”
connectors are fixed with a binding band).
3 Remove the axis selection connector that is inserted in the rightmost position of the
“CNSEL” connector, and insert it into the axis number to be released.
4 Check carefully that the axis whose brake will be released is supported securely with a
device such as a crane, and then press SW1. The brake of the selected axis is released
only as long as the switch is pressed.
5 After completing the brake release, return the connectors changed in 2 and 3 to their
original conditions.
Close the cover securely.
WARNING
BRAKE RELEASE
SWITCH
NK7305
<Warning label>
ブレーキ解除スイッチ WARNING
警告 BRAKE RELEASE
SWITCH
NK7304 NK7305
Brake releasing switch

(Cover closed)
Axis selecting
Brake releasing connector connector
(Normally)
Connector "CNSW" Axis label (J1～J8)
(During releasing)
Connector "RELEASE"
<Front view> <Brake releasing switch (Cover opened)>
Fig. 2.2.14 Brake releasing switch (DWG No.: L22381A00)
2-30
2.2.8 Step-down transformer (Floor-installation type)

The primary-side input voltage of the standard robot controller is 3-phase AC200V+10％, -15％
(50/60Hz). With any other higher input voltage, this transformer enables to convert the
supplied voltage to 200V by being connected with the robot controller.
(1) Types of step-down transformer
The following table shows types of step-down transformer.

The products except L22221A and L22222A are the individual-installation type set up
separately with the robot controller.
Table 2.2.7 Types of step-down transformer
Type Capacity Applicable system configuration (Note) Remarks

NB4 / NV6 / NB4L / NV6L / NB15 / NV20 /
L22221A 3 kVA
NH5 / NS3 / NV20A single mechanism Installed at the bottom of robot
controller
L22222A 6.4 kVA NV50 / NV166 / NV210 single mechanism
(Note) The applicable system configurations in the table above are only the examples. For
selecting a step-down transformer applying to your system, contact our company. The
rated voltage of standard breaker shall be 690 V or less. If more than 690 V is used,
contact us.
(2) Connection of step-down transformer

■Connection of step-down transformer L22221A
Mounting location and connection way of the step-down transformer L22221A is shown below.
Primary power supply
Robot controller
Breaker
Earth terminal
Power unit
Primary side Secondary side

3Φ AC200V
Step down transformer
Fig. 2.2.15 Connection of step-down transformer
2-31
(3) Voltage switching tap of step-down transformer

■ In case of L22221A
The step-down transformer supports the primary input voltage of AC190, 200, 208, 220, 230, 240,
380, 400, 415, 440, 460, 480 and 575V. To choose one of these voltage alternatives, the
step-down transformer is provided with the voltage switching tap as shown in Fig. 2.2.16
Connect the jumper wire as shown in Table 2.2.8 according to the power voltage to be applied for
switching the tap.
Fig. 2.2.16 Voltage switching tap of Step-down transformer
U V W
190V
190V
190V
190V
190V
190V
230V
240V
200V
220V
240V
200V
220V
230V
240V
200V
220V
230V
240V
240V
200V
220V
230V
240V
200V
220V
230V
200V
220V
230V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
287.5V
207.5V
287.5V
207.5V
207.5V
0V
0V
0V
0V
0V
0V
(W15)
(W13)
(W14)
(W10)
(W11)
(W12)
(U14)
(U15)
(U12)
(U13)
(U10)
(U11)
(V15)
(V13)
(V14)
(V10)
(V11)
(V12)
(W1)
(W2)
(W3)
(W4)
(W5)
(W6)
(W7)
(W8)
(W9)
(U1)
(U2)
(U3)
(U4)
(U5)
(U6)
(U7)
(U8)
(U9)
(V1)
(V2)
(V3)
(V4)
(V5)
(V6)
(V7)
(V8)
(V9)
(W)
(U)
(V)
200V
220V
200V
220V
200V
220V
0V
0V
0V
(R1)
(R2)
(S1)
(S2)
(T1)
(T2)
sh
(R)
(S)
(T)
R S T
Fig. 2.2.17 Internal circuit of the step-down transformer
To avoid the electric shock hazard, be sure that the step-down transformer has not been
impressed before switching the voltage switch tap. In addition, hang up a sign “Under
operation” or others beside the power supply switch for enough safety measures.
WARNING
2-32
Table 2.2.8 Connection of jumper wires by the primary-side power voltage

Primary power Connection of the jumper wires
voltage Primary-side tap Secondary-side tap
190V U-U8, U1-U9, U1-V, V-V8, V1-V9, V1-W, W-W8, W1-W9, W1-U
240V U-U8, U6-U14, U6-V, V-V8, V6-V14, V6-W, W-W8, W6-W14, W6-U R - T1
380V U1-U8, U9-V, V1-V8, V9-W, W1-W8, W9-U R1 - S
400V U2-U8, U10-V, V2-V8, V10-W, W2-W8, W10-U S1 - T
415V U3-U8, U11-V, V3-V8, V11-W, W3-W8, W11-U
440V U4-U8, U12-V, V4-V8, V12-W, W4-W8, W12-U
460V U5-U8, U13-V, V5-V8, V13-W, W5-W8, W13-U
480V U6-U8, U14-V, V6-V8, V14-W, W6-W8, W14-U
575V U7-U8, U15-V, V7-V8, V15-W, W7-W8, W15-U
U V W
0V
190V
190V
190V
190V
190V
190V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
287.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
207.5V
287.5V
287.5V
207.5V
207.5V
0V
0V
0V
0V
0V
(W13)
(W14)
(W15)
(W10)
(W11)
(W12)
(U10)
(U11)
(U12)
(U13)
(U14)
(U15)
(V10)
(V11)
(V12)
(V13)
(V14)
(V15)
(W1)
(W2)
(W3)
(W4)
(W5)
(W6)
(W7)
(W8)
(W9)
(U1)
(U2)
(U3)
(U4)
(U5)
(U6)
(U7)
(U8)
(U9)
(V1)
(V2)
(V3)
(V4)
(V5)
(V6)
(V7)
(V8)
(V9)
(W)
(U)
(V)
200V
220V
200V
220V
200V
220V
0V
0V
0V
(R1)
(R2)
(S1)
(S2)
(T1)
(T2)
(T)
(R)
(S)
sh
R S T
Fig. 2.2.18 Connection example of the case - 240V input voltage
U V W
0V
190V
190V
190V
190V
190V
190V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
200V
220V
230V
240V
287.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
287.5V
207.5V
207.5V
0V
0V
0V
0V
0V
(W15)
(W10)
(W11)
(W12)
(W13)
(W14)
(U13)
(U14)
(U15)
(U10)
(U11)
(U12)
(V10)
(V11)
(V12)
(V13)
(V14)
(V15)
(W1)
(W2)
(W3)
(W4)
(W5)
(W6)
(W7)
(W8)
(W9)
(U1)
(U2)
(U3)
(U4)
(U5)
(U6)
(U7)
(U8)
(U9)
(V1)
(V2)
(V3)
(V4)
(V5)
(V6)
(V7)
(V8)
(V9)
(W)
(U)
(V)
200V
220V
200V
220V
200V
220V
0V
0V
0V
(R1)
(R2)
(S1)
(S2)
(T1)
(T2)
(R)
(S)
(T)
sh
R S T
Fig. 2.2.19 Connection example of the case - 415V input voltage
Robot controller may be damaged with the impression of over voltage.

Before turning the power ON, check that the jumper wires suit to the actually supplied
power voltage and are in a proper connection.
WARNING
2-33
■In case of L22222A

The step-down transformer supports the primary input voltage of AC380, 400, 420, 440, 460
and 480V. To choose one of these voltages, connect the cable terminal as shown in the Fig.
2.2.20 and Fig. 2.2.21 according to the power voltage.
Fig. 2.2.20 Voltage switching tap of step-down transformer
Step down transformer

Primary side terminal Connection cable
ＣＮＲＳＴＩＮ
U Secondary side terminal “u” or “R” (Power unit)
u1
V “v” or “S”
v1
W “w” or “T”
w1
Fig. 2.2.21 Connection example: primary-side voltage 480V / secondary-side voltage 200V
2-34
2.3 Function of Welding-related optional equipment
2.3.1 Arc I/F board

Arc I/F board has communication I/F circuit to welding power supply (CAN I/F). The board is
installed on the sequence board. In addition, the board has a general I/O terminal block to
connect the peripheral equipment.
- The Arc I/F board is a standard installation for arc welding specifications. For other
specifications, this board is optional.
- For details of the connection procedures of arc welding power supply, refer to the chapter
INFO. 1 in "APPLICATION (ARC WELDING)".
- For details of installation procedures of Arc I/F board, refer to the section 3.6.1 in
“SETUP”.
- For details of connecting procedures between Arc I/F board and external I/O, refer to the
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Fig. 2.3.1 External view of Arc I/F board
Table 2.3.1 Connectors of Arc I/F board

TBIN Input terminal block Peripheral equipment (For user connection)
TBOUT Output terminal block Peripheral equipment (For user connection)
CNWPS Communication with welding power supply Welding power supply
CNARC I/O signal to the sequence board Sequence board
Table 2.3.2 Jumper pin settings of Arc I/F board

Setting positions Status Remarks
J1 1-2 Open
J2 1-2 Short
J3 1-2 Short DO NOT change the default settings.
J5 1-2 Open
J6 2-3 Short
Table 2.3.3 Switch setting of Arc I/F board

Setting positions Status Remarks
1 OFF
2 OFF
SW1 DO NOT change the default settings.
3 OFF
4 OFF
2-35
2.3.2 Robot I/F board

The Robot I/F board is built in the D-series welding power supply and controls the
communication between the robot controller and that. Applicable combination of welding power
supplies and the Robot I/F board is shown in the table below.
Table 2.3.4 Combined welding power supplies
Model Welding power supplies
L20365A DR350、DL350、DP350/500、DW300、DA300P
L20809A DP400R
INFO. For the details of wiring procedures to the Robot I/F board and the settings of dip switch
DSW1, refer to the chapter 1 in “APPLICATION (ARC WELDING)”.
Fig. 2.3.2 External view of Robot I/F board
Table 2.3.5 Connectors on Robot I/F board

Connectors Function / Connected to
CN 52 Using Synchro communication cable
CN 54
PIO
CN 55
CN 57 Arc I/F board CNWPS
CN 58 2nd welding power supply
CNFLS For maintenance (CAN flash writer card & cable)
CNPLD For maintenance (PC cable)
FC51 Welding power supply inside
Table 2.3.6 Jumper pin setting on Robot I/F board

Setting Setting status
Function Remarks
location (at shipment)
Terminal Do not change from the standard setting.
JP59 1-2 Short-circuit (When using two or more welding power supplies, refer to the
resistance chapter 1 in "APPLICATION (ARC WELDING)".
Table 2.3.7 Test pins on Robot I/F board

Test pin No. TP1 TP2 TP3 TP4 TP5
Connected to 15G -15V +15V GND +5V
2-36
2.3.3 CAN I/F board

CAN I/F board is built in DM350/500 when connecting them and the robot controller.
INFO. For the details of wiring procedures to the board and the setting of jumper pin J101, refer to
Chapter 1 in “APPLICATION (ARC WELDING)”.
J101
CN2 CN3
CH104
CH105
CH103
CN4
CH101
CN1
CH102
Fig. 2.3.3 External view of CAN I/F board
Table 2.3.8 Connectors on CAN I/F board

Connectors Specifications
CN 1 24 V power supply
CN 2 Communication connector
CN 3 CAN input connector
CN 4 CAN output connector
Table 2.3.9 Test pins on CAN I/F board

Test pins Specifications
CH101 24 V
CH102 0 V (GND of 24 V and CAN5V)
CH103 CAN5V
CH104 D5V
CH105 D0V
2-37
2.3.4 Welding interface

(1) What is Welding interface?
Welding interface is required when applying the robot coupling with the general semi-automatic
welding power supply that does not build in the robot I/F function.
INFO. For the details of wiring procedures to the product, refer to the chapter 1 in “APPLICATION
(ARC WELDING)”.
(a) Functions
・ Following the robot task programs to send out the start instruction to the welding power
supply.
・ Calculating the welding conditions taught in the task programs by following the welding
characteristics data stored in the system parameters, and outputting the command voltage
to the welding power supply. There exist two types: 2ch type and 4ch type.
・ Controlling the wire feed unit and the gas solenoid valve.
・ Detecting Arc start failure, Arc outage and Wire stick in the welding end position.
(b) Fixing procedure

Screw 4 pieces of locking nuts (M8) to the anchor bolt.
Fig. 2.3.4 External view of Welding interface (Unit: mm)

(c) Specifications
Table 2.3.10 Specifications of Welding interface
Items Specifications
Rating 1-phase AC 200 V / 220 V, 50/60 Hz, 0.2 kVA
Output command voltage +/- 0 - 5 V, +/- 0 - 10 V, +/- 0 - 15 V (max 50 mA)
Wire feeding motor rating 75 W or less
Applicable gas solenoid valve DC 24V、300 mA x 1
Power indicator Lit when applying current, installed on the front panel
Fuse F10 (250 V, 3 A), installed on the front panel
Outside dimensions 200 (W) x 380 (D) x 378 (H) (mm)
Mass 13 kg
2-38
(d) Model
Table 2.3.11 Model of Welding interface
Model Communication
Power cable Components
2ch type 4ch type cable
FDWF-1005 FDWF-1105
L22169C00 (5m) L22168C00 (5m) The body of welding interface
(Standard) (Standard)
FDWF-1010 FDWF-1110 L22169D00 (10m) L22168D00 (10m) Power cable
FDWF-1015 FDWF-1115 L22169E00 (15m) L22168E00 (15m) (1-phase AC 200 V / 220 V)
Communication cable
FDWF-1020 FDWF-1120 L22169F00 (20m) L22168F00 (20m) (CAN communication and
FDWF-1001 FDWF-1101 L22169B00 (1.6m) L22168B00 (1.6m) emergency stop)
The printed boards built in the Welding interface are described in the items (2) – (4).
INFO.
To confirm the location of each board, refer to “4.2 Parts List”.
(2) Analog I/F board
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Fig. 2.3.5 External view of Analog I/F board
(a) Switch settings of analog I/F board

Refer to the chapter 1 in “APPLICATION (ARC WELDING)”.
(b) Connecting terminal blocks for jig of analog I/F board

2-39
(c) Display of motion status on analog I/F board

Each LED function on the analog I/F board, to display the status of the welding interface, is
shown in Table 2.3.12.
Table 2.3.12 Status LED on analog I/F board (ON: Lights, OFF: Lights off)
Status
Inching
Retracting
Gas checking
Welding
At welding end
emergency stop
During
LED
Colors Functions Descriptions
No.
Emergency stop
Lit off during
LED 1 Green Lit off while inputting the ON ON ON ON ON OFF
emergency stop
emergency stop signal.
Arc start
Lit on while the Arc start Lit on during welding
LED21 Green OFF OFF OFF ON ON OFF
command signal is being output performance
to the welding power supply.
Wire inching Lit on during wire
LED22 Green Lit on while operating inching/ inching/ retracting ON ON OFF OFF OFF OFF
retracting directly on TP. operation
Wire feed
Lit on during welding
Lit on while the wire feed
performance and wire
LED23 Green command signal is output to the ON ON OFF ON ON OFF
inching/ retracting
wire feed unit and the welding
operation
power supply.
Wire feed motor +/- rotation
LED24 Lit on during wire
Green Lit on when rotating the motor of OFF ON OFF OFF OFF OFF
LED29 retracting
wire feed unit the other way.
Lit on when the
welding performance
ends. However, it
Wire stick
lights out if the wire
LED25 Green Lit on while the welding interface OFF OFF OFF OFF ON OFF
stick detection function
is detecting wire stick.
has been set to OFF
in the system
parameter.
Gas valve motion
Lit on during gas
Lit on while the opening
LED27 Green checking or welding OFF OFF ON ON ON OFF
command for gas solenoid valve
performance
is being output.
2-40
(3) Robot I/F board (L21553C00)
Fig. 2.3.6 External view of robot I/F board (L21553C00)
The setting of robot I/F board for the Welding interface is as follows.
Table 2.3.13 Jumper pin settings on Robot I/F board (L21553C00)

Setting Setting status
Function Remarks
position (at shipment)
CAN terminating 1-2 : Short-circuit Terminating
JP59 1-2 Short-circuit
resistance switching 1-2 : Open Relay
INFO. Setting of JP59 is required to change when plural welding power supplies are connected.
For details, refer to the chapter 1 in “APPLICATION (ARC WELDING)”.
INFO. For details of the setting of dip switch DSW1 to specify the welding power supply ID, refer to
the chapter 1 in “APPLICATION (ARC WELDING)”.
(4) Jumper pin settings of DA extension board (4ch type only)

2-41
(5) Sequence of Welding interface
Welding interface outputs a signal to the welding power supply by the timing as shown below,
using the setting of system parameters and the commands such as Arc start/ end or wire
inching given from the robot controller.
Information in the table below is only an example of motion sequence of the Welding interface.
The actual motion may differ depending on the type of welding power supply to be used and
the setting details of system parameters.
- If coupling the welding power supply and the robot both from DAIHEN, the default setting of
wire slow down, hot start voltage and hot start time are all set in advance to the optimum
values for each welding power supply.
For this reason, these parameters cannot be changed on the robot side.
- If coupling the welding power supply from other companies and our robot, wire slow down,
hot start voltage and hot start time can be even specified on the robot side.
Table 2.3.14 Example of the motion sequence of Welding interface

Signals Specifications Timing chart
Dry contact (relay CR21) ON
Welding start OMRON LY2,DC24V
(Torch SW) MAX :5 A, AC 110 V, DC24 V OFF
MIN :0.1 A, DC 5 V
Wire inching FUJITSU COMPONENT VS-24MB
ON/OFF MAX :2.5 A, AC 110 V, DC 24 V OFF
MIN :0.1 A, DC 5 V
0～15 V DC Wire slow down

ワイヤスローダウン
Current value
MAX :50 mA
command
(A polarity differs depending on the Crater filler
クレータフィラ
(REF 1)
type of welding power supply.)
0～15 V DC Hotホッ
start voltage
トスタート電圧
MAX :50 mA Anti wire stick
アンチスティック
Voltage value Anti wire stick for
command (A polarity differs depending on the ワイヤ溶着解除の為の
releasing the wire stick
アンチスティック
type of welding power supply.)
(REF 2)
Hot
ホット start
スタートtime
時間

OMRON LY2, DC 24 V
Wire feeding motor
MAX :5.0 A, AC 110 V, DC 24 V
ON/OFF OFF
MIN :0.1 A, DC 5 V
DC 24 V Output Pre-flow
プリフロー Post-flow
アフターフロー
Gas valve MAX :300 mA

ON/OFF
AS AE
100mA
Wire stick detection DC 24 V Output
current MAX :100 mA
0～500 A (MAX)
Welding current (Depending on the welding
power supply)
WCR-ON WCR-OFF
2-42
2.4 Basic specifications of robot control unit
2.4.1 External view of robot control unit

The external view of robot controller is shown in Fig. 2.4.1 or Fig. 2.4.2.
Fig. 2.4.1 Outside dimensions of robot control unit (Unit : mm) (When operation box is connected.)
2-43
Fig. 2.4.2 Outside dimensions of robot control unit (Unit : mm) (When operation pane is installed.)
2-44
2.4.2 Basic specifications of robot control unit

Table 2.4.1 Basic specifications of robot control unit
Item Specifications
FD11-JV (For NB4 / NV6)
FD11-JL (For NB4L / NV6L / NB15 / NV20)
Model FD11-JA (For NV20A)
FD11-JS (For NH5 / NS3)
FD11-JX (For NV50 / NV166 / NV210)
6 axes (Up to 8 axes can be controlled by built-in extension.)
(Note 1)
Number of control axes Maximum control axes are up to 32 axes. (However, note that the exterior of
(Note 2)
controllers with a total of 9 or more axes is a different specification.)
Driving system AC servo motor
Positional feedback Absolute encoder
Teaching playback
Teaching system Robot language based on JIS SLIM
IEC61131-3 (Software PLC) (Optional)
Number of task programs 9,999
Memory capacity 160,000 steps (by PTP instruction in a single mechanism)
5.7 inch color LCD (640 x 480 pixels, with LED backlight､65536-color display)
Emergency stop button, one-handed 3-postional enable switch, TP Selector switch,
Teach pendant touch panel, sheet key, Jog dial and USB port are included as standard.
IP code: IP65
Standard cable length is 8 m.
Emergency stop button, MOTOR ON button, START button, STOP button and MODE
Operation box SELECT switch (with key) are included as standard.
Standard cable length is 8 m.
Manipulator connecting cable Standard cable length is 5 m
Input 8 points, Output 8 points
Number of signals Extension of input and output is allowed respectively up to 72
points
DC24V 8mA
Connect the relay contact (Dry contact) which minimum
Input specifications
I/O Control over External applicable load is DC24V,5mA, or open-collector device
equipment
(Note 3) whose leakage current is up to 1mA.
Arc I/F board DC24V / AC100V Up to 1A
(Minimum applicable load (reference):
Output specifications Relay unit DC24V, 5mA)
Open-collector device whose rated current
I/O board
is 0.1A at DC24V±3V.
External memory I/F USB memory (Optional)
Structure Closed structure
Cooling system Indirect cooling system
Ambient conditions Temperature: 0 - 45 ℃, Humidity: 20 - 80 %RH (Non-condensing)
Primary power 3-phase AC 200 V / 220 V (+10%､-15%), 50 / 60 Hz
(Note 4)
Manipulator Power capacity
NV6 / NB4 1.5 kVA
NV6L / NB4L / NB15 / NV20 / NV20A 2.4 kVA
Power consumption
NH5 / NS3 1.0 kVA
NV50 5.5 kVA
NV166 / NV210 7 kVA
Grounding Ground the robot controller separately whose resistance is less than 100 ohms.
External dimensions W 580 × D 542 × H 650 (mm) (Excluding projections)
FD11-JV / FD11-JL / FD11-JS : Approx. 62 kg
Mass
FD11-JX : Approx. 65 kg
Color 10GY9/1, Munsell scale
(Note 1) Number of control axes may be limited when the motor capacity per axis is 2 KW or more.
(Note 2) In case that number of control axes exceeds 32, contact us.
(Note 3) The number of I/O can be enlarged to up to 2048 points by installing optional field bus such as CC-link,
DeviceNet or Ethernet/IP, etc.
2-45
(Note 4) Varies according to the application and operation pattern.
2-46
Chapter 3 Parts replacement procedures
and adjustment procedure
This chapter describes the parts replacement procedures and adjustment

procedure.
3.1 Parts replacement procedures .................................................................... 3-1
3.1.1 Replacement of board ........................................................................... 3-2
3.1.2 Replacement of IPM drive unit .............................................................. 3-3
3.1.3 Replacement of power unit ................................................................... 3-6
3.1.4 Replacement of battery for CPU board ................................................. 3-7
3.1.5 Replacement of cooling fan (for heat sink and regenerative resistance)3-8
3.1.6 Replacement of cooling fan (for rack unit)........................................... 3-10
3.2 Adjustment procedure ............................................................................... 3-11
3.2.1 Adjustment of touch panel on teach Pendant ...................................... 3-11
DO NOT DELETE THIS PAGE.
3.1 Parts replacement procedure
3.1 Parts replacement procedures

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

You may get injured or have your equipment damaged because of fire, failure or malfunction
caused by altering or remodeling the product.
Electric shock may cause serious injury or death.

Wiring work should be done after turning off the primary power supply and the circuit
breaker on the robot controller.
WARNING
When you replace the parts, be sure to implement the operation in 5 minutes after turning
OFF the power supply on primary side. Otherwise, you may get electric shock due to the
remaining electric charge of board and electrolysis capacitor.
WARNING Do not implement the operation with wet hands.
If you get electric shock, it will cause heavy injury or fatal accident.
The replacement work should not be implemented by person other than the person who
attended the class of robot school (maintenance course) implemented by our company.
Otherwise, you may get electric shock or may be clipped by unexpectedly operated robot
WARNING and it may cause heavy injury or fatal accident.
A lot of connectors are connected to each printed circuit board. Promote the replacement
carefully not to cause mistake or omission.
The heavy injury or fatal accident may be caused by electric shock or flare.
WARNING
Do not damage the wiring at the replacement.

Do not touch the electronic parts or pattern of printed circuit board or the contact part of
connector at the replacement. Always hold the periphery of printed circuit board.
WARNING If you touch it, the heavy injury or fatal accident may be caused.
Be absolutely sure NOT to expose the controller inside to direct sunlight, a searchlight or
other strong lights before turning on the primary power supply while the controller door is
left open to enable maintenance or other work to be performed.
WARNING Failure to adhere to the precautions may cause the robot and/or controller to fail or operate
in error.
Prior to work, discharge static electricity charged on a worker.

Antistatic wrist band is effective.
To touch electric parts without countermeasures may cause breakdown.
CAUTION
After finishing the work, close the door completely, and lock the door key.. If the door is not
completely closed, dirt, dust and other foreign matter may enter inside the controller,
possibly causing malfunctions.
CAUTION
3-1
3.1.1 Replacement of board

How to remove
1 Turn off the primary power supply and circuit breaker on the controller.
2 Remove all the connectors connected to the replaced board.
3 Remove the fixing screws that fix the board fixing plates, and then pull out the replaced
board.
Fig. 3.1.1 Replacement of board
It is necessary for some kind of boards to remove the fixing plates from the original board
and to attach them to the new one.
IMPORTANT
How to mount
1 Insert the new board along the guide projections, push the board till the connector is fit
to the Raiser board completely, and then fix the board fixing plates by the fixing
screws.
2 Reconnect all the removed cables to the original connectors on the board.
To users of optional software;

If you replace a CPU board, request our Service Center to make resetting of the optional
software. If the resetting is not made, the optional software will be completely locked after a
CAUTION lapse of two weeks.
3-2
3.1.2 Replacement of IPM drive unit
Wait 5 minutes after turning off the mains power before replacing IPM drive unit.
WARNING
・ When you replace the IPM drive unit with new one, check that the new one is same type
before replacement. If the IPM drive unit is replaced with the different type, it will cause a
failure or malfunction.
CAUTION ・ Pay attention not to hooking the removed connectors.
・ Take care not to strike the heat sink at the side face.
・ Take care not to fall it on your foot.
・ Connect the all necessary connectors without fail. If there are connectors that are not
connected, it may result malfunctions etc.
INFO. For the replacement procedure of the IPM drive unit mounted with the additional axis kit,
refer to “EXTERNAL AXES”.
How to remove
2 Remove the connectors that are connected to the IPM drive unit, and remove the two
fixing screws.
Table 3.1.1 Connectors connected on the front panel

Connector Destination
CNCOM CPU board
CNSV Sequence board
CNVP Multi power supply unit
CNMS, CNRST Power unit
CNFAN Cooling fan (Heat sink)
CNR Regenerative resistance
3 Pull the IPM drive unit out 200 mm from the front side.
Fixing screws IPM drive unit

"A"
Pull out
"A"
< Front view (inside) > < View "A"-"A" (Right inside view) >
Fig. 3.1.2 Replace of IPM drive unit (Pull the unit)

(Example: For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 single manipulator)
3-3
4 Remove the connectors connected to the right side of IPM drive unit as shown in Table
3.1.2.
Table 3.1.2 Connectors connected to the right side of IPM drive unit
Connectors Cables Manipulator
CNP1A～CNP6A
CNP2B (except NH5, NS3), Control cable 1 NB4 / NV6 / NB4L
CNBK1, CNBK2 NV6L / NB15 / NV20
NH5 / NS3
CNEC1, CNEC2 Control cable 3
CNP1A～CNP3A,
CNP1B～CNP3B, Control cable 1
CNBK1
CNP4A～CNP6A, NV50 / NV166 / NV210
CNP4B ～ CNP6B (except NV20A
Control cable 2
NV20A),
CNBK2
CNEC1, CNEC2 Control cable 3
CNBK2 CNP4A CNP5A CNP6A
CNBK1
CNEC2 CNEC1
CNP2B
CNP3A CNP2A CNP1A
Control cable 1
(Motor cable)
IPM drive unit
Control cable 3
(Encoder cable)
Power unit
<Robot controller inside: Right view>

Fig. 3.1.3 Replacement of IPM drive unit (Releasing connectors)
(Example: For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 single manipulator)
5 Pull out the IPM drive unit at the front of controller not to hooking the removed
connectors. At this time, hold the plate working part not to contact with the board and
electrolysis capacitor.
3-4
How to mount
The weight of the IPM drive unit is approx. 12kg. Take care not to fall it on your foot.
CAUTION
1 Insert the IPM drive unit from the front face of the controller to the position pulled out
200 mm bearing away the surrounding connectors.
At this time, insert the metal part of the IPM drive unit (both of the upper side and the
lower side) to the gaps of the rail referring to the following picture. The inner side
connecters should be connected in advance.
2 Reconnect the all removed cables on the right side of the IPM drive unit to the original
connectors. When connecting, check that the connect name stickers attached to the
connectors and the insertion positions are correct. After connecting the connectors,
gently pull the cables to check that the connectors have been inserted securely as far
the lock position.
Again, please check that the all connectors are connected

to their proper positions securely.
3 Insert the IPM drive unit to the original position.
4 Fix the IPM drive unit by the two fixing screws.
5 Reconnect the removed cables on the front panel of the IPM drive unit to the original
connectors.
3-5
3.1.3 Replacement of power unit
・ Pay attention not to hooking the removed connectors.

・ Take care not to fall power unit on your foot.
・ Connect the all necessary connectors without fail. If there are connectors that are not
CAUTION connected, it may result malfunctions etc.
How to remove
2 Remove all the connectors connected to the Power unit and wired from the one. The
connectors are as shown in Table 3.1.3.
Table 3.1.3 Connectors on power unit
Connectors Releasing position Connected to

CNRSTIN Remove from the Power unit. The secondary side of breaker.
CN200P Remove from the Power unit. Optional equipment
CNPW Remove from the Multi power supply unit.
CNRST
Remove from the IPM drive unit.
CNMS
3 Remove two fixing screws that fix the Power unit as shown in Fig. 3.1.4.
4 Pull out the Power unit at the front of controller not to hooking the removed connectors.
How to mount
1 Insert the Power unit from the front face of controller bearing away the surrounding
connectors.
2 Fix the IPM drive unit by the two fixing screws.
3 Reconnect the removed cables on the front panel of the power unit to the original
connectors as shown in Table 3.1.3.
Fixing screws Power unit
Fig. 3.1.4 Replacement of power unit
3-6
3.1.4 Replacement of battery for CPU board

1. The replacement of the batteries should be done in principle by a trained technician.
2. Do not use the batteries except the specified use.
3. DO NOT recharge the battery.
CAUTION 4. Do not heat, disassemble, deform, solder and dispose the battery in fire.
5. Do not drop, hit, throw, or give any shock to the battery.
6. Do not put either plus terminal and the minus one oppositely.
7. Do not connect (+) and (-) of the battery.
8. Keep batteries out of reach of babies and little children. If battery is swallowed,
immediately consult a doctor.
9. A leaking or badly smelling battery should be discarded immediately. The leaking
electrolyte may corrode metal parts.
10. If the liquid of the batteries touches the eyes, the eyes may be injured. Do not rub the
eyes but flush the eyes amply with clean water such as city water and then receive
medical treatment without delay.
11. Remove the used batteries immediately.
12. At disposal of the batteries, insulate the terminal parts with tape or the like.
13. Dispose of the used battery according to your domestic regulations.
How to remove
1 Remove CPU board following the section 3.1.1 .
2 Pull out the connector CN19LiBAT for battery.
3 Remove the battery fixing screw to remove the battery.
How to mount
1 Attach the new battery on the CPU board by the battery fixing screw.
2 Insert the battery connector to the connector CN19LiBAT.
3 Attach the CPU board following the section 3.1.1 .
When the battery is replaced with new one, set the date and time newly.
<Constant Setting> - [1 Control Constants] [1 Date and Time]
CAUTION
Battery connector
(CN19LiBAT)
Battery fixing screw
Battery
CPU Board
Fig. 3.1.5 Replacement of battery for CPU board
3-7
3.1.5 Replacement of cooling fan (for heat sink and regenerative resistance)
How to remove
2 After the fan rotation completely stops, remove the installation screws of the fan panel
to be replaced, and remove the panel from the robot controller.
3 Pull out the fan power cable from the fan power connector.
4 Remove the fan grounding fixing screw of fan, and then pull out the fan grounding
cable.
5 Remove the fan fixing screws to remove the fan.
How to mount
1 Attach the fan to the original panel by the fan fixing screws.
2 Fix the fan grounding cable by the fan grounding fixing screw.
3 Insert the fan power cable to the fan power connector.
4 Attach the panel with the fan to the robot controller by the panel fixing screws.
・ The type of the cooling fan for heat sink and regenerative resistance is different from the
one for the rack unit. Be sure to replace it to the proper type after confirming the model by
parts list. To mount the different type of fan may cause breakdown.
CAUTION ・ The fan has an attachment direction. Attach it so that the direction of the wind is set to the
direction indicated by an arrow shown in figure below.
・ Be sure to connect the grounding cable.
Fig. 3.1.6 Replacement of cooling fan (For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 / NH5 / NS3)
3-8
Fig. 3.1.7 Replacement of cooling fans (For NV50 / NV166 / NV210 / NV20A)
3-9
3.1.6 Replacement of cooling fan (for rack unit)

How to remove
2 After the fan rotation completely stops, remove the installation screws of the fan panel
to be replaced, and remove the panel from the robot controller.
3 Remove the fan unit fixing screw on the top of the rack unit.
4 Pull out the fan unit with it lifting.
5 Remove the fan fixing screws to remove the fan from the fan unit.
How to mount
1 Attach the fan to the fan unit by fan fixing screws.
2 Insert the click of the fan unit to the recess hole, and then locate it on the rack unit.
3 Fix the fan unit to the rack unit by fan unit fixing screw.
4 Connect the fan cable to the connector CNFAN of multi power supply unit.
・ The type of the cooling fan for heat sink and regenerative resistance is different from the
one of rack unit. Be sure to replace it to the proper type after confirming the model by
parts list. To mount the different type of fan may cause breakdown.
CAUTION ・ The fan has an attachment direction. Attach it so that the direction of the wind is set to the
direction indicated by an arrow shown in figure below.
・ Be sure to connect the grounding cable.
Fig. 3.1.8 Replacement of cooling fan (for rack unit)
3-10
3.2 Adjustment procedure
3.2.1 Adjustment of touch panel on teach Pendant

This section describes the procedure to adjust the dotting on Touch panel and the screen
response. This operation is called calibration, which is normally implemented at factory shipment.
However, if it is not well accorded across the ages, it is necessary to implement readjustment as
described below.
Calibration of Touch panel
For this setting, it is necessary to switch operator class to EXPERT or above.
It is not available to implement other operation during calibration. For the sake of safety,
turn off the [MOTOR ON] before operating calibration. Also, it is not possible to turn on
IMPORTANT [MOTOR ON] during calibration.
1 Go to ＜Constant setting＞- [7 f-Keys］- [10 Touch screen].

>> When the Touch panel operation is “ON”, the f9 <Calibration> becomes available
as shown in the following screen.
2 Turn off [MOTOR ON] and press f9 <Calibration>.

>> When the [MOTOR ON] is set ON, the following message appears.
3-11
3 Press the center of target cross indicated on Touch panel.

>> As the target moves to 5 locations, press the center of each target until the target is
moved. If the calibration value is not any problem as a result of pressing in all 5
locations, the screen moves to 4. When there is a problem, the target returns to
the center. In this case, press it again.
4 Register the calibration result.

>> Tap the screen to register the new calibration settings.
Press [RESET/R] to cancel.

>> Finish registering or canceling and then return to the screen described in 1.
3-12
Chapter 4 Warranty / Periodic in-
spection / Parts list
This chapter describes the scope of warranty and liability, periodical inspection
and maintenance parts.
4.1 Notes on Scope of Warranty and Liability ................................................... 4-1

4.2 Periodic Inspection Schedule...................................................................... 4-2
4.2.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair . 4-2
4.2.2 Inspection Schedule .............................................................................. 4-4
4.2.3 Notes on Periodic Inspection ................................................................ 4-4
4.2.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts ......... 4-4
4.2.5 Inspection items .................................................................................... 4-5
4.2.6 Inspection before the long vacation ...................................................... 4-7
4.2.7 Cleaning the heat sink .......................................................................... 4-7
4.2.8 Inspection of enable switch ................................................................... 4-8
4.2.9 Inspection of Emergency stop button .................................................... 4-8
4.3 Maintenance parts ...................................................................................... 4-9
4.3.1 How to store Maintenance parts............................................................ 4-9
4.3.2 Robot controller................................................................................... 4-10
4.3.3 Teach pendant .................................................................................... 4-14
4.3.4 Operation box ..................................................................................... 4-15
4.3.5 Starting box ......................................................................................... 4-16
4.3.6 Robot I/F board ................................................................................... 4-17
4.3.7 CAN I/F board ..................................................................................... 4-17
4.3.8 Welding interface (2CH / 4CH specifications） ................................... 4-18
4.3.9 Control Cables .................................................................................... 4-19
4.3.10 Warning labels .................................................................................. 4-21
DO NOT DELETE THIS PAGE.
4.1 Notes on Scope of Warranty and Liability
4.1 Notes on Scope of Warranty and Liability

If there is no special instruction in the estimation sheet, contract sheet, catalog and specification when you order our
robot, following conditions of conformable application and warranty etc. are applied.
1. Warranty period
Warranty period and its information vary according to region.
For details, contact your nearest sales distributor.
2. Disclaimer
The following cases are out of the scope of warranty within the warranty period.
(1) Failure caused by improper condition environment, handling and usage that are not de-
scribed in the instruction manual and catalog
(2) When the cause of failure is due to the reason other than our product
(3) Failure due to the reason other than our product such as customer's equipment or software
(4) Failure caused by the modification and repair implemented by party other than our company
(including the specified service shop)
(5) When the failure is caused by improper maintenance or replacement of consumable parts
described in the instruction manual and catalog (failure etc. caused by the use of goods other
than genuine parts and parts / lubrication oil specified by our company)
(6) When the failure cannot be forecasted by the science / technology level as of purchase
(7) Damage caused by natural disaster such as earthquake, fire, flood disaster or offence by
third party and the failure that has a roots in that damage
(8) Failure caused by movement after delivery and defective storage
(9) Sound, vibration, bleeding of oil, color degradation of coated surface, rust and slight dent on
appearance that have no problem in performance
(10) Failure caused by transportation and construction work out of range of our construction
(11) In case of reselling, assignment and lend-lease (including the rental equipment)
(12) Other case that conforms to above and consumable parts / service parts
However, the assurance here means the assurance of our product single unit, so the loss caused
by the failure of our company is not excluded from the range of assurance.
3. Limitation of liability
(1) We do not accept any responsibility on the opportunity loss, special loss, indirect loss caused
by this equipment, or accident compensation, damage other than out product.
(2) For the programmable this equipment, we do not accept any responsibility on the program-
ming implemented by person other than our company and the result caused by that pro-
gramming.
(3) We do not accept any responsibility on the processing quality when this equipment is used.
(4) If this equipment is repaired or the parts and/or the software are replaced, it is sometimes
necessary to repair or adjust the existing teaching program or parameter.
Note that we do not accept any responsibility on those works and processing quality for the
use of this robot system.
(5) This assurance is applied only when this equipment is installed within the country where the
equipment is purchased. For the transaction and use in the foreign country, please contact
us.
4-1
4.2 Periodic Inspection Schedule

Perform the daily and periodic inspection to prevent troubles, ensure the safety and maintain the performance.
This section describes the notes and details on periodic inspection operation.
4.2.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair

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

You may get injured or have your equipment damaged because of fire, failure or
malfunction caused by altering or remodeling the product.
Do not enter the robot work area while the power is ON.
Do not approach the robot while it is moving.
Approaching the moving robot may cause a fatal accident resulting in a serious injury
WARNING or death.
Do not touch any live electrical parts.

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

“INSPECTION IN PROGRESS” as shown on the right to notify
the operators of that the inspection is going.
PROGRESS
(5) Do not use any devices to possibly cause electromagnetic noises in and around the area
where the inspection is going on.
(6) Operations including the inspection must be performed by 2 or more persons; one for the
practical operation and the other as a monitor.
(7) Only the operators who have been trained for the function, operation and maintenance of ro-
bots can perform the work such as inspection, maintenance, adjustment, repairs and so on.
Also, if the special equipment is provided, be fully acquainted with the equipment in details.
(8) Operators, even if qualified, must not perform the operation of the particular equipment without
thorough knowledge.
4-2
(9) The signals and gestures used for the inspection operator, monitor and other operators of re-
lated devices must be carried out based on the safety management standards of each user.
(10) Monitors must follow the notes below.
(A) Be in a position to overlook the entire robot work area to pay full attention for monitoring.
(B) Always carry the emergency stop button with you so that you can immediately press it when
the error occurs.
(C) Do not allow anybody else to approach the robot work area unless they are engaged in the
operation such as inspection.
(11) Operators to perform the inspection and other works must follow the notes below.
(A) Be sure to check if it is possible to perform some operations outside the robot work area. If
it is the case, perform all the operations outside that area.
(B) Normally, turn off the robot before performing the inspection etc. If you have no choice but
to operate while the robot is working, be sure to report to the safety manager to ask for
permission. After you obtain permission, then perform the operation outside the robot
work area.
(C) If you are required to perform the operation with the robot stand-by, check the procedures
beforehand to safely carry them out. If not specially required, shut off the input power
supply of robot controller, welding power supply etc. before operation. Besides, shut off
the input power supply of jigs and peripheral equipment, or make it invalid unless the spe-
cial procedure is needed.
(D) When entering the robot work area, prepare for the malfunction of robot so that you can
immediately press the emergency stop button.
(E) Be sure to check the safety around your feet before operation. Do not work in an insecure
or elevated (2m or higher) scaffold.
(F) When working in the robot work area, be sure that you could see the entire robot motion.
Never turn your back to the robot.
(G) When replacing the print board inside the robot controller or the teach pendant, take the
antistatic measures such as using a static protective sheet and so on.
(12) Follow the notes below when an error occurs during the operation.
(A) If you find any abnormal motions of robot, press the emergency stop button immediately.
(B) Inform a monitor of the abnormality and turn off the

robot controller. Then, hang out the sign ”Do not
turn ON.” as shown on the left. DO NOT TURN ON
(C) Check that the peripheral equipment has also been turned off.
(D) If you are required to enter the safety fence, be sure to remove the safety plug and keep it
by yourself during operation.
(E) Even if the robot automatically stops by the abnormalities in such as the voltage supply to
robot, oil pressure in the peripheral equipment, air pressure or other factors, be sure to
make it completely stop. Then, inspect the cause of trouble to take the measures against it.
(F) If the fail-safe function of the emergency stop button does not work, shut off the main power
immediately and inspect the cause of trouble to take the measures against it.
(G) When restarting after the emergency stop, inspect the cause of trouble and take the reme-
dies first. Then, insert the safety plug again and restart from the outside the fence.
(13) When you finish the work, be sure to always check that the required connectors, covers and
panel are properly fixed and connected. And then, be sure to close the door and lock the door
key.
4-3
4.2.2 Inspection Schedule

Periodic inspection is essential to efficiently operate Almega series.
Perform the inspection following the schedule as shown below.
“Arc welding robot”
1-year 2-year 3-year

inspection inspection inspection
3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month 3-month
inspection inspection inspection inspection inspection inspection inspection inspection inspection inspection inspection inspection
Daily inspection
1 year & 1 year & 1 year & 2 years & 2 years & 2 years &
0 3 months 6 months 9 months 1 year 2 years 3 years ~
3 months 6 months 9 months 3 months 6 months 9 months
“Handling robot”
Refer to the corresponding “MANIPULATOR” instruction manual.
4.2.3 Notes on Periodic Inspection

(1) Periodic inspection must be performed by those who have received the special training pro-
gram according to your domestic regulation or by us and maintenance instructions offered by
us, or at their presence.
(2) Prior to performing inspection or maintenance, be sure to turn off the primary power supply
and the circuit breaker on the robot controller.
Note that, with turning off only the breaker on the robot controller, the primary power supply is
still being applied with voltage.
In order to show that inspection or maintenance is underway, hang a noticeable sign on
the switch of the external breaker.
警告 WARNING
感電注意 ELECTRIC SHOCK
can kill.
１．通電中は本装置内部の部品に
触れないで下さい。
２．設置および点検時には一次側 ● Do not touch live electrical
Never touch the charged parts. の電源を遮断して下さい。（本

装置のブレーカをＯＦＦにし
parts.
● Disconnect all power
WARNING
ても，ブレーカの一次側には before installing or servicing.
電圧が印加されています。）
● Multiple sources of voltage
３．充電部がありますので，電源
may exist inside this
を遮断した後１分間は本装置
内部の部品に触れないで下さい。
enclosure.
NK3637
4.2.4 Deadline for Supplying/ Repairing the Robot Maintenance Parts

Deadline for supplying the robot maintenance parts described in the guarantee card is 7 years
from the discontinuation date of the product, and that for repairing is for 10 years.
For the detailed information about discontinuation date of the product, please see the guidance
on the maintenance parts in our homepage: http://www.daihen.co.jp/ .
※Repair of the maintenance parts is provided for the above period of time in principle, however,
we will support our customers as long as the stock is available. We will make our every effort to
secure the required maintenance parts. However, please note that it may be occasionally un-
available due to the external factors such as the market situation even during the guaranteed
period.
4-4
4.2.5 Inspection items

When you implement the maintenance and inspection, implement the following items
Table 4.2.1 Inspection items (1/2) ( ●: Replace ◎: Replace when damaged ○: Inspect)
Frequency
of periodi- Mainte
cal inspec- nance
ID number
tion
Inspected point Content of inspection Inspection / treatment method
Annually
Every 3
months
3 years
6 years
Daily
Check the servo power supply is

Teach pendant • Check operation of enable switch
surely turned off at the operation
1 ○ Operation box • Check operation of emergency
of every emergency stop button
Starting box stop button
and enable switch.
Teach pendant • Check indicating lamp and oper-
Operation box ation switch
2 ○ Visual check
Starting box • Check operation of push-button
Other operation switch switch etc.
Visual check and cleaning
If the dust is remarkably attached
3 ○ Indicating plate • Peeling, damage
or the indicating plate is removed,
affix it again.
External surface of con- • Adhesion of spatter and dust etc.
4 ○ Visual check and cleaning
troller • Locking the door key
• Stain of fin of heat sink
Inside or external air
5 ○ • Stain damage of regenerative Visual check and cleaning
room
resistance
• Existence or nonexistence of
6 ○ Inside of controller Visual check and cleaning
dust and dirt
(Note 1)
• Existence or nonexistence of If the dust is remarkably adhered
7 ○ ● ● Cooling fan
adhesion of oil, fumes or dust or the operation status is defec-
tive, replace it with new one.
Control cable
Visual check
Teach pendant cable
• Check of damage, crashing Additional tightening
8 ○ ◎ ◎ Operation box cable
• Looseness of connector If the cable is remarkably dam-
Starting box cable
aged, replace it with new one
Other external wiring
(Note 1)
• Existence or nonexistence of
9 ○ Heat sink of CPU board For details, refer to the section
adhesion of oil, fumes or dust
4.2.7 .
Packing of door • Gap, deformation of packing
10 ○ Visual check
Door key • How the key is locked
• Looseness of screws etc.
Inside of controller Visual check and additional tight-
11 ○ • Looseness of connectors and
Printed circuit board ening
terminal blocks
• Check damage Visual check and cleaning
If the display of liquid-crystal
• Cleaning of seat key
module is remarkably deteriorated
12 ○ ◎ Teach pendant • Check liquid-crystal display
or malfunction of touch panel oc-
• Check operation of touch panel curs, replace it with new one re-
• Check USB cap. spectively.
• Check heat generation, abnor- Checked by visual check and
13 ○ Transformer (Optional)
mal sound or abnormal odor sound
Visual check and additional tight-
14 ○ Grounding terminals • Check looseness and deficit
ening
15 ○ IPM drive unit • Looseness of connectors Additional tightening
Electromagnetic con- Visual check
• Check stain and status of main
16 ○ ● ● tactor If the contact is remarkably dete-
contact / auxiliary contact
riorated, replace it with new one.
Battery for CPU 3.0 V or more
17 ○ ● ● (Note 2) • Check battery voltage
board (Check with a voltmeter)
4-5
Table 4.2.2 Inspection items (2/2) ( ●: Replace ◎: Replace when damaged ○: Inspect)
Frequency
of periodi- Mainte
cal inspec- nance
ID number
tion
Inspected point Content of inspection Inspection / treatment method
Annually
Every 3
months
3 years
6 years
Daily
• Primary power supply voltage

(Measure the primary side voltage of Specification voltage +10%, -15 %
breaker)
• Main circuit power supply of IPM
18 ○ Voltage measurement drive unit
(measure the input voltage of
3-phase AC 200 V +/- 10 %
connector CNRSTIN on the IPM
drive unit while the servo power
supply is activated)
19 ◎ Overhaul
(Note 1) In cleaning, wipe the dusts and the particles with the soft cloth. Don’t use air blow for the cleaning of the fan. The dust and particles invade in the fan. Failure and life of the fan
may be had a bad influence, because the wing of the fan turns with rotational speed over capacity. If you use a vacuum cleaner, use it only wing. Be careful absorbing between
the rotation part and the body.
(Note 2) For details of the inspection for encoder batteries, refer to the instruction manual “MANIPULATOR” you use.
4-6
4.2.6 Inspection before the long vacation

If the long vacation continues, be sure to check the following items before turning OFF the
power supply of robot controller.
- Check whether "A1016 encoder battery voltage reduction" is displayed on the error history and
replace it with new one if an error is displayed. For details of the replacement procedures, refer
to the instruction manual "Manipulator”.
- Check the door is closed and the door keys are locked certainly.
4.2.7 Cleaning the heat sink
CNCF
LiBAT (System CF)
CN9(FAN)
CNSATA
Heat sink
CNEXTBUS
CNSODIMM1
CNSODIMM2
Fig. 4.2.1 Layout of heat sink or CPU board
After reversing the CPU board so that the heat sink becomes lower side, and then remove the
dusts and the particles on the heat sink using a brush etc. At this time, pay attention not to let the
dust and particles stick the surface of the CPU board.
Do not use air blow for the cleaning of the heat sink
Using air flow may cause the adhesion of the dust and particles on the surface of CPU board
CAUTION so that the damage due to short-circuits occurs.
4-7
4.2.8 Inspection of enable switch

Teach pendant has the three-positional enable switch.
According to the operation as follow, confirm to work enable switch.
1 Select teach mode.
2 Push [MOTOR ON] of operation box.
3 Grasp the enable switch.

>> While you grasp the enable switch, the servo power for the manipulator is turned ON.
4 You grasp the enable switch more, or release enable switch.

>> The manipulator is servo OFF.
4.2.9 Inspection of Emergency stop button

A teach pendant, operation box and starting box have an emergency stop button respectively.
According to operation as follow, confirm to work each emergency stop button.
教示
1 Select teach mode.
再生
TEACH PLAYBACK
運転準備
MOTOR ON 2 Push [MOTOR ON] of operation box.
3 Grasp the enable switch.

>> While you grasp the enable switch, the servo power for the manipulator is turned
ON.
4 Push the emergency stop button on the Teach pendant.

>> Servo power is turned OFF and “Emergency Stop” is displayed on the Teach
pendant.
5 In case of connecting operation box and/or starting box, inspect each “Emergency
Stop button”.
4-8
4.3 Maintenance parts
4.3.1 How to store Maintenance parts

The printed circuit board applies the highly reliable parts. Comply with the following notes in
storing them.
• Storage temperature –10 ~ +50 degrees C

When storing parts over the long term, it is recommended to keep in the range of 25 +/- 10 de-
grees C.
Besides, abrupt variations in temperatures (over 10 degrees C / hour) must be avoided.
• Storage humidity 20 ~ 85% RH

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

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

Store the parts in the location with no harmful fumes and the minimal dust.
Besides, no load must be applied while they are in stores.
4-9
4.3.2 Robot controller

Table 4.3.1 Robot controller parts list and references
Model Combined Figure
Table reference
number manipulator reference
FD11-JV□000 NB4 / NV6

Table 4.3.5 for
NB4 / NV6 /
NB4L / NV6L Fig. 4.3.1
FD11-JL□000 NB4L / NV6L /
NB15 / NV20 (page 4-12)
NB15 / NV20 /
Table 4.3.2 Common standard parts NH5 / NS3
FD11-JS□000 NH5 / NS3 Table 4.3.3 IPM drive unit
Table 4.3.4 Common optional parts
FD11-JA□000 NV20A
Table 4.3.6 for
Fig. 4.3.2
NV20A / NV50 /
(Page 4-13)
NV50 / NV166 NV166 / NV210
FD11-JX□000
/ NV210
□: 0: Single mechanism P: External 1 axis 2: External 2 axes 4: External 1 axis x 2

A: Large-capacity additional 1 axis
Table 4.3.2 Common standard parts

Recommended
No. Product name Type Part No. number of Remarks
possessed parts
Multi power supply
1 L21720A00 L21720A00 1
unit
1-1 Fuse SG501306.3-R 100-1631 (1) F21
1-2 Fuse SG5013002-R 100-1632 (2) F1, F2
Printed circuit board
2 L21700R00 L21700R00 1
(Raiser board)
3 L21700C00 L21700C00 1
(CPU board)
(Note 1)(Note 2)
3-1 Battery CR14250SE-CN16 100-1633 (1)
Printed circuit board (Note 3)(Note 4)
4 L22385F00 L22385F00 1
(Sequence board)
4-1 Fuse 217002.MXP 100-1634 (1) F4
5 L21700S00 L21700S00 1
(Arc I/F board)
6 Cooling fan 4715MS-22T-B50-B00 100-0644 1 For rack unit (FM3-1)
7 Key Key for C-1083 100-0801 1
(Note 1) On January 1, 2009, for revision of the UN Recommendations on the Transport of Dangerous Goods, Model
Regulations-15th edition, Transportation regulation of Lithium battery is partially revised. When you transport the
Lithium battery by air, transport it according to providing items of the newest ICAO-TI and IMDG Code of IMO
(Note 2) Replace the CPU battery every 3 years regardless of the operating time.
(Note 3) Jumper pin settings are required when the sequence board is replaced. For details, see “2.1.5 Sequence board”.
(Note 4) The sequence board L21700F00 is also available for single mechanism controller.
For details, see “2.1.5 Sequence board”.
Table 4.3.3 IPM drive unit

Recommended
number of
No. Product name Type Part No. Remarks
possessed
parts
L21730A00 L21730A00 For NV6 / NB4
L21731A00 L21731A00 For NV6L / NB4L / NB15 / NV20
(Note 5)
8 IPM drive unit L21732A00 L21732A00 1 For NH5 / NS3
L21734A00 L21734A00 For NV50 / NV166 / NV210
L21735A00 L21735A00 For NV20A
8-1 Fuse GP100 100-1627 (1) F1
8-2 Fuse HM32 100-1628 (1) F3
(Note 5) The type of IPM drive unit varies depending on the number of used axes of robot and motor capacity of included
axes. Check the number of used axes and specification of motor of included axis.
4-10
Table 4.3.4 Common optional parts

Recommended
possessed parts
9 USB memory L21700U00 L21700U00 (1) 1GB for external memory
10 Relay unit L22254A00 L22254A00 (1) Board with accessories
10-1 Relay unit board L22254C00 L22254C00 (1) Board only
11 Extended relay unit L22255A00 L22255A00 (1) Board with accessories
Extended relay unit
11-1 L22255C00 L22255C00 (1) Board only
board
12 I/O board L21700M00 L21700M00 (1)
12-1 Fuse 2171.25MXP 100-1742 (1) F2
With OA-2,
13 Cable flange L21160M00 L21160M00 (1) for cable diameter 9 – 16 mm (Note 6)
With NC-1,
14 Cable flange L21160N00 L21160N00 (1) for cable diameter 6 – 12 mm (Note 6)
Hook to hang the cable for the
Hook for Teach
15 L20060B25 L20060B25 (1) Teach pendant on the side of robot
pendant cable controller
Connect to CNMCH on the IPM
Shorting connector
16 L21766C00 L21766C00 (1) drive unit in case of disconnecting
(Shock sensor) the shock sensor. (Note 7)
(Note 6) For details, refer to the section 3.6 of the instruction manual “SETUP”.
(Note 7) For details, refer to the section 2.1.7.
Table 4.3.5 Standard parts for FD11-JV□000 (For NB4 / NV6),

FD11-JL□000 (For NB4L / NV6L / NB15 / NV20) and
FD11-JS□000 (For NH5 / NS3)
Recommended
possessed parts
21 Power unit L21721A00 L21721A00 1
21-1 Fuse 61MS080H 100-1637 (2) F1､F2
Electromagnetic
21-2 SD-N11 4340-116 (2)
contactor
21-3 Auxiliary contact UN-AX11 4340-117 (2)
For heat sink (FM1-1)
22 Cooling fan 4715HS-22T-B50-BM0 100-1638 2 For regenerative resistance
(FM2)
23 Auto breaker BW32SAG-3P030 100-1451 1
24 Breaker handle BZ6N10D 100-1452 1
25 Terminal cover BW9BTAA-S3W 100-1453 1 For auto breaker
Regenerative
26-1 L20400K00 L20400K00 1 For NV6 / NB4 / NH5 / NS3
resistance
Regenerative
26-2 L21701K00 L21701K00 1 For NV6L / NB4L / NB15 / NV20
resistance
Table 4.3.6 Standard parts for FD11-JX□000 (For NV50 / NV166 / NV210)
FD11-JA□000 (For NV20A)
Recommended
possessed parts
Large- capacity
31 L21722A00 L21722A00 1
power unit
31-1 Fuse 61MS080H 100-1637 (2) F1､F2
Electromagnetic
31-2 SC-N2/G DC24V 2A2B 4340-124 (2)
contactor
For heat sink (FM1-1,FM1-2)
32 Cooling fan 4715HS-22T-B50-BM0 100-1638 3 For regenerative resistance
(FM2)
33 Auto breaker NF63-CV_3P40A 100-1743 1
34 Breaker handle F-05SV 100-1744 1
35 Terminal cover TCS-05SV3 100-1745 1 For auto breaker
Regenerative re- For NV50 / NV166 / NV210 /
36 L20408K00 L20408K00 1
sistance NV20A
4-11
(7) (1) (3) (4) (8) (5) (12) (9)
(26)-2 (26)-1 (2)

<Inside of cover> <Closeup of rack unit>
(8) (6) (15)

(10)
(22)
(23)(24)(25)
(11)
(21) (13) or (14)

<Left view> <Front view (inside)>
(21)-2
(21)-1
(21)-3 <Top view>
Fig. 4.3.1 Parts list for FD11-JV□000 (For NB4 / NV6),

FD11-JL□000 (For NB4L / NV6L / NB15 / NV20) and
FD11-JS□000 (For NH5 / NS3) robot controller
4-12
(7) (1) (3) (4) (8) (5) (12) (9)
(36) (2)
<Inside cover> <Closeup of rack unit>
(8) (6) (15)

(10)
(32)
(33)(34)(35)
(11)
(31) (13) or (14)

<Left view> <Front view (inside)>
(31)-2
(31)-1
<Top view>
Fig. 4.3.2 Parts list for FD11-JX□000 (For NV50 / NV166 / NV210) robot controller
FD11-JA□000 (For NV20A)
4-13
4.3.3 Teach pendant

Model number: FDTPDSJN - ※L**
※ means the type of sheet key 1 : Global icons (Standard) 3 : Icons with Chinese characters
** is length of the cable. 08：8 m (Standard) 15 : 15 m
Standard model number is FDTPDSJN-1L08.
Table 4.3.7 Parts list of Teach pendant
Recommended
number of
possessed
parts
Top case
Bottom case
Card slot cover
LCD / PWA assembling plate
Rubber packing
Jog dial knob
1 Case L21500B00 L21500B00 1 Enable switch rubber cover
Enable switch resin cover
LCD pressing plate
Leaf spring 1
Leaf spring 2
Tapping screws
2 CPU board L21500C00 L21500C00 1
3 LCD NL6448BC18-07 100-1639 1
4 Touch panel plate W-L02140 W-L02140 1
W-L02534A W-L02534 1 Global icons
Membrane sheet
5 Icons with Chinese
keyboard W-L02586A W-L02586 (1)
characters
6 Cable ASSY. L21500J00 L21500J00 1 Enable switch
7 Cable ASSY. L21500K00 L21500K00 1 Rotary switch
8 Cable ASSY. L21500L00 L21500L00 1 Emergency stop button
9 Cable ASSY. L21500M00 L21500M00 1 Selector switch
10 Cable ASSY. L21500N00 L21500N00 1 USB
11 Belt L21500B10A L21500B10 1
12 Label NC9608 NC9608 1 Logo
13 Label NC9638B NC9638 1 Emergency stop
Control cable (8 m) L21501B00 L21501B00 (1)
14 Select one of them
Control cable (15 m) L21501E00 L21501E00 (1)
< Front view > < Back view >
Fig. 4.3.3 Parts list of Teach pendant
4-14
4.3.4 Operation box

Model number： FDOP-00**
** is length of the cable. 05: 5 m 10: 10 m 15: 15 m
Table 4.3.8 Parts list of Operation box
Recommended
number of
possessed
parts
Press button SW
1 HA1E-V2S2R-TK2354 4250-134 1
(EMERGENCY STOP)
2 Selector SW HW1K-2B22 100-1649 1
2-1 Key AS6-SK-132PN02 100-1655 (1)
3 Stop turning around ring HW9Z-RL 100-1650 1
Lighting press button SW (Red)
4 LA3L-M1C14R 100-1643 1
< STOP >
4-1 LED lamp (Red) LFTD-2R 100-1644 (1)
Lighting press button SW (Green)
5 LA3L-M1C14G 100-1651 1
< MOTOR ON >
5-1 LED lamp (Green) LFTD-2G 100-1652 (1)
Lighting press button SW (White)
6 LA3L-M1C14W 100-1645 1
< START >
6-1 LED lamp (White) LFTD-2W 100-1646 (1)
7 Waterproof cover AL-DH6 100-1647 1
8 Protection cover AL-KH6 100-1648 2
9 Case L21761B01 L21761B01 1
10 Panel L21761B02 L21761B02 1
11 Printed circuit board L9111C00 L9111C00 1
12 Shorting connector L9111G00 L9111G00 3
11 12
9
1
10
2 3 2 -1
5 8 5 -1
6 8 6 -1 4 7 4 -1
Fig. 4.3.4 Parts list of Operation box
4-15
4.3.5 Starting box

Model number: FDST-00**
Table 4.3.9 Parts list of Starting box
Recommended
number of
possessed
parts
Press button SW
1 HA1E-V2S2R-TK2354 4250-134 1
(EMERGENCY STOP)
Lighting press button SW (Red)
2 LA3L-M1C14R 100-1643 1
< STOP >
2-1 LED lamp (Red) LFTD-2R 100-1644 (1)
Lighting press button SW (White)
3 LA3L-M1C14W 100-1645 1
< START >
3-1 LED lamp (White) LFTD-2W 100-1646 (1)
4 Waterproof cover AL-DH6 100-1647 1
5 Protection cover AL-KH6 100-1648 1
6 Case E6039B01 E6039B01 1
7 Panel L9115B02 L9115B02 (1)
3 5 3 -1
2 4 2 -1
Fig. 4.3.5 Parts list of Starting box
4-16
4.3.6 Robot I/F board

Table 4.3.10 Parts list of Robot I/F board
Recommended
number of
No. Item Type Part No. Remarks
possessed
parts
For DR350､DL350､
L20365A L20365A00
DP350/500､DA300
1 Robot I/F board 1
L20809A L20809A00 For DP400R
For DR350､DL350､DP350､
DP500､DA300P､DW300
L9123C21 L9123C21
Length is 230 mm
(For L20365)
2 Flat cable 1
For DP400R
HIF6H-60D-AA-5.0JJ 5096-555 Length is 50 mm.
(For L20809A)
② ①
Fig. 4.3.6 Parts list of Robot I/F board
4.3.7 CAN I/F board

Table 4.3.11 Parts list of CAN I/F board
Recommended
No. Item Type / Part No. number of Remark
possessed parts
1 CAN I/F board L9129C 1 For DM350/500
Fig. 4.3.7 Parts list of CAN I/F board
4-17
4.3.8 Welding interface (2CH / 4CH specifications）

Model number : 2CH: FDWF-10**､4CH: FDWF-11**
Table 4.3.12 Parts list of Welding interface
Recommended
number of
possessed
parts
FDWF-10** L8770E00 L8770E00
1 Power board 1
FDWF-11** L8775E00 L8775E00
2 Analog I/F board Common L8770L00 L8770L00 1
2-1 Fuse (F1-F3) Common 250V-0.5A 100-0907 3
FDWF-10** 1
3 Robot I/F board L21553C00 L21553C00
FDWF-11** 2
Constant-voltage
4 Common ZWS50-5/J 4814-033 1
power supply 5V
Constant-voltage FDWF-10** ZWS50-24/J 4814-034
5 1
power supply 24V FDWF-11** LDA100W-24 5096-527
6 DC fan Common 3610KL-05W-B40-L00 5096-526 1
UL,CSA-FGMT250V-3A
7 Fuse (F10) Common 4610-130 1
ﾏﾀﾊ UXM 250V 3A
FDWF-10**
8 DA extended board
FDWF-11** L8775L00 L8775L00 １
Fig. 4.3.8 Parts list of Welding interface (2CH specification)
Fig. 4.3.9 Parts list of Welding interface (4CH specification)
4-18
4.3.9 Control Cables

(1) Cables connecting Manipulator ~ Robot controller
(For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 / NH5 / NS3)
Table 4.3.13 Control cable 1,3 (For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 / NH5 )
Model number / Part No. (Composition)
Ref. No Specifications
(1) Control cable 1 (2) Control cable 3
FDRB-1005 L22091C00 L22092C00 Cable length 5 m
FDRB-1010 L22091D00 L22092D00 Cable length 10 m
FDRB-1015 L22091E00 L22092E00 Cable length 15 m
Table 4.3.14 Control cable 1,3 (For NS3 )

(1) Control cable 1 (2) Control cable 3
FDRB-1405 L22528C00 L22453C00 Cable length 5 m
FDRB-1410 L22528D00 L22453D00 Cable length 10 m
FDRB-1415 L22528E00 L22453E00 Cable length 15 m
Fig. 4.3.10 Cables between the manipulator and robot controller (For NB4 / NV6 / NB4L / NV6L / NB15 / NV20 / NH5 / NS3)
INFO. For details of the cables around the welding power supply, refer to Chapter 1 in the instruc-
tion manual “APPLICATION (ARC WELDING)”.
4-19
(2) Cables connecting Manipulator ~ Robot controller (For NV50 / NV166 / NV210 / NV20A)
Table 4.3.15 Control cable 1,2,3 (For NV50 / NV166 / NV210)

(1) Control cable 1 (2) Control cable 2 (3) Control cable 3
FDRB-1305 L22107C00 L22108C00 L22109C00 Cable length 5 m
FDRB-1310 L22107D00 L22108D00 L22109D00 Cable length 10 m
FDRB-1315 L22107E00 L22108E00 L22109E00 Cable length 15 m
Table 4.3.16 Control cable 1,2,3 (For NV20A)

(1) Control cable 1 (2) Control cable 2 (3) Control cable 3
FDRB-1505 L22557C00 L22540C00 L22558C00 Cable length 5 m
FDRB-1510 L22557D00 L22540D00 L22558D00 Cable length 10 m
FDRB-1515 L22557E00 L22540E00 L22558E00 Cable length 15 m
Fig. 4.3.11 Cables between the manipulator and robot controller (For NV50 / NV166 / NV210 / NV20A)
4-20
4.3.10 Warning labels

A manipulator and a robot controller are labeled warning labels that mentions important notes
so that the robot can be safely operated. If it is peeled off or damaged, contact your nearest
distributor for order.
(1) FD11-JV□000 / FD11-JL□000 / FD11-JS□000 / FD11-JA□000
Table 4.3.17 Warning labels on robot controller
Pasted parts Name Parts No. Q’ty

Robot controller Warning label NK7251 1
(FD11-JV□000 / FD11-JL□000 / FD11-JS□000 / Warning label NK7252 1
FD11-JA□000) Warning label NK7253 1
NK7253 NK7252
1.通電中は本装置内部の部品に触れないでください。
1.接地等の接続を行う際は取扱説明書をよくお読み下さい。 2.設置及び点検時には一次側の電源を遮断してくだ
2.接地ケーブルおよび一次側電源ケーブルを制御装置内部のさい。
　所定の端子に接続して下さい。 3.充電部がありますので、電源を遮断した後５分間
　(接地ケーブルを先に接続して下さい。) は本装置内部の部品に触れないでください。
3.接地ケーブルが正しく接続され、接地抵抗が100Ω以下と
　なっていることを確認して下さい。
4.主電源投入前に接地ケーブルの接続、一次側電源の電圧
　および周波数を再度確認して下さい。
1.Do not touch live electrical parts.
2.Disconnect all power before installing or
servicing.
3.Multiple sources of voltage may exist inside
this enclosure.
● Read manual for connection procedures.
● Connect grounding conductor and input
conductors to proper terminals inside
unit-grounding conductor first.
● Be sure grounding conductor goes to a proper 1.主電源ON時には　ロボットの動作範囲内に入らな
earth ground and has less than 100 ohms of いでください。
resistance. 2.必ずロボット動作範囲外に取り付けてください。
● Doublecheck grounding conductor,input 3.取扱説明書をよくお読みください。
voltage,and frequency before applying power. 4.保守点検時は、ブレーカに鍵をかけてください。
通気口をふさぐと機器に損傷を及ぼすことがあります。 1.Keep out of robot area when main　power is on.

制御装置の通気口は、通気のため壁から0.1m以上離して 2.Do not locate this device in robot work area.
設置してください。 3.Read instruction manual.
また熱源の近くは避けてください。 4.Lockout and tagout equipment, before
servicing.
To avoid damage to the robot controller.

Keep the air inlet and outlet clear. 制御装置内にヒュームやほこりが侵入すると、
(At least 0.1m from wall) 故障や誤動作の原因となります。
・ロボット制御装置の扉は、ドアキー（２カ所）を
かけて確実に閉めてください。
・未使用のケーブル引き込み口には、
カバを取り付けてください。
NK7251 Fume or dust will cause failures and

malfunctions of the Controller.
- Close the door of the Controller and lock
the 2 door keys certainly.
- Attach covers to the unused cable ports on
the Controller.
< Left view > < Front view >
1.接地等の接続を行う際は取扱説明書をよくお読み下さい。
2.接地ケーブルおよび一次側電源ケーブルを制御装置内部の
　所定の端子に接続して下さい。
　(接地ケーブルを先に接続して下さい。)

● Be sure grounding conductor goes to a proper
earth ground and has less than 100 ohms of
resistance.
● Doublecheck grounding conductor,input
voltage,and frequency before applying power.
通気口をふさぐと機器に損傷を及ぼすことがあります。
制御装置の通気口は、通気のため壁から0.1m以上離して
設置してください。
また熱源の近くは避けてください。

Keep the air inlet and outlet clear.
(At least 0.1m from wall)
1. 通電中は本装置内部の部品に触れないでください。
2. 設置及び点検時には一次側の電源を遮断してくだ
さい。
3. 充電部がありますので、電源を遮断した後３分間
は本装置内部の部品に触れないでください。

servicing.
this enclosure.
1.主電源ON時には　ロボットの動作範囲内に入らな
いでください。
2.必ずロボット動作範囲外に取り付けてください。
3.取扱説明書をよくお読みください。
4.保守点検時は、ブレーカに鍵をかけてください。
1.Keep out of robot area when main　power is on.

2.Do not locate this device in robot work area.
3.Read instruction manual.
4.Lockout and tagout equipment, before
servicing.
制御装置内にヒュームやほこりが侵入すると、
故障や誤動作の原因となります。
Fume or dust will cause failures and

the Controller.
1.ケーブル接続時には、コネクタに表示された接続先に従って正しく接続してください。
誤って接続すると、機器に損傷を及ぼすことがあります。
< Front view (door open) >
2.接続方法の詳細は取扱説明書を参照してください。
3.万一、作業者がロボットに挟まれブレーキの解放が必要になった場合、下記の手順で解放してください。
1)アームの落下を防止するため、第2，3軸のアームをワイヤロープ等で吊り下げてください。
2)IPMドライブユニット内のサーボ基板に接続のジャンパコネクタCNSWを取り外してください。
　3)「ブレーキ強制解除ケーブル」のCNSWAのジャンパコネクタを解放したい軸の表示のある箇所に
接続してください。
　4)「ブレーキ強制解除ケーブル」をサーボ基板のCNSWに接続してください。
　5)制御装置の電源を投入してください。但しサーボ電源は絶対に投入しないでください。
作業後は「ブレーキ強制解除ケーブル」を必ず外してジャンパコネクタCNSWを接続してください。
（下図参照）
1.ケーブル接続時には、コネクタに表示された接続先に従って正しく接続してください。
誤って接続すると、機器に損傷を及ぼすことがあります。
2.接続方法の詳細は取扱説明書を参照してください。
3.万一、作業者がロボットに挟まれブレーキの解放が必要になった場合、下記の手順で解放してください。
1. Connect each cable to the corresponding P.C.B. and servo driver as indicated on the
1)アームの落下を防止するため、第2，3軸のアームをワイヤロープ等で吊り下げてください。
2)IPMドライブユニット内のサーボ基板に接続のジャンパコネクタCNSWを取り外してください。
　3)「ブレーキ強制解除ケーブル」のCNSWAのジャンパコネクタを解放したい軸の表示のある箇所に
接続してください。
　4)「ブレーキ強制解除ケーブル」をサーボ基板のCNSWに接続してください。
　5)制御装置の電源を投入してください。但しサーボ電源は絶対に投入しないでください。
作業後は「ブレーキ強制解除ケーブル」を必ず外してジャンパコネクタCNSWを接続してください。
（下図参照）
connectors respectively. Wrong connection may damage the control unit and/or manipulator.
1 . Conn ect ea ch cab le to the co rre spo nding P.C.B. an d servo d river as ind ica ted on the
co nn ecto rs respe ctively. Wro ng con ne ctio n ma y da ma ge the con trol unit and/or manipulator.
2 . As for d etails o f ea ch cab le con ne ctio n, rea d Instruction Manuals.
3 . If the ope rator was ca ugh t in the rob ot, ta ke the fo llo win g p rocedu re to release the bra ke.
1)To p re ve nt the rob ot a rm fro m fa llin g, lift th e Axis 2 a nd 3 o f robot by wire ropes.
2)Re mo ve sho rtin g plug in CNSW o f th e se rvo bo ard in the IPM drive unit.
3 )Co nne ct sho rting plu g to CNSWA to b e rele ase d a s indicated on the co nne ctor.
4 )Co nne ct "Fo rce d B rake Rele ase Ca ble " to CNSW of th e servo b oard.
5)Tu rn o n th e Primary Po we r switch o f th e Ro bo t Controller.
2. As for details of each cable connection, read Instruction Manuals.

(DO NOT TURN ON THE S ERVO POWER.)
A fter work is fin ishe d,be sure to d isco nn ect "Force d Brake Release Cable" and connect
jumpe r co nn ecto r CNSW. (Se e the drawing)
3. If the operator was caught in the robot, take the following procedure to release the brake.
1)To prevent the robot arm from falling, lift the Axis 2 and 3 of robot by wire ropes.
2)Remove shorting plug in CNSW of the servo board in the IPM drive unit.
3)Connect shorting plug to CNSWA to be released as indicated on the connector.
4)Connect "Forced Brake Release Cable" to CNSW of the servo board.
5)Turn on the Primary Power switch of the Robot Controller.
(DO NOT TURN ON THE SERVO POWER.)
After work is finished,be sure to disconnect "Forced Brake Release Cable" and connect
jumper connector CNSW. (See the drawing)
Fig. 4.3.12 Warning labels on Robot controller (FD11-JV□000 / FD11-JL□000 / FD11-JS□000 / FD11-JA□000)
4-21
(2) FD11-JX□000
Table 4.3.18 Warning labels on robot controller
Pasted parts Name Parts No. Q’ty

Warning label NK7303 1
Robot controller
(FD11-JX□000)
NK7253 NK7252
1.接地等の接続を行う際は取扱説明書をよくお読み下さい。 2.設置及び点検時には一次側の電源を遮断してくだ
2.接地ケーブルおよび一次側電源ケーブルを制御装置内部のさい。
　所定の端子に接続して下さい。 3.充電部がありますので、電源を遮断した後５分間
　(接地ケーブルを先に接続して下さい。) は本装置内部の部品に触れないでください。
servicing.
this enclosure.
● Be sure grounding conductor goes to a proper 1.主電源ON時には　ロボットの動作範囲内に入らな
earth ground and has less than 100 ohms of いでください。
resistance. 2.必ずロボット動作範囲外に取り付けてください。
● Doublecheck grounding conductor,input 3.取扱説明書をよくお読みください。
voltage,and frequency before applying power. 4.保守点検時は、ブレーカに鍵をかけてください。
通気口をふさぐと機器に損傷を及ぼすことがあります。 1.Keep out of robot area when main　power is on.

制御装置の通気口は、通気のため壁から0.1m以上離して 2.Do not locate this device in robot work area.
設置してください。 3.Read instruction manual.
また熱源の近くは避けてください。 4.Lockout and tagout equipment, before
servicing.

Keep the air inlet and outlet clear. 制御装置内にヒュームやほこりが侵入すると、
(At least 0.1m from wall) 故障や誤動作の原因となります。

the Controller.
Left view Front view
1.接地等の接続を行う際は取扱説明書をよくお読み下さい。
2.接地ケーブルおよび一次側電源ケーブルを制御装置内部の
　所定の端子に接続して下さい。
　(接地ケーブルを先に接続して下さい。)

● Be sure grounding conductor goes to a proper
earth ground and has less than 100 ohms of
resistance.
● Doublecheck grounding conductor,input
voltage,and frequency before applying power.
通気口をふさぐと機器に損傷を及ぼすことがあります。
制御装置の通気口は、通気のため壁から0.1m以上離して
設置してください。
また熱源の近くは避けてください。

Keep the air inlet and outlet clear.
(At least 0.1m from wall)
2.設置及び点検時には一次側の電源を遮断してくだ
さい。
3.充電部がありますので、電源を遮断した後３分間
は本装置内部の部品に触れないでください。

servicing.
this enclosure.
1.主電源ON時には　ロボットの動作範囲内に入らな
いでください。
2.必ずロボット動作範囲外に取り付けてください。
3.取扱説明書をよくお読みください。
4.保守点検時は、ブレーカに鍵をかけてください。
1.Keep out of robot area when main　 power is on.

2.Do not locate this device in robot work area.
3.Read instruction manual.
4.Lockout and tagout equipment, before
servicing.
制御装置内にヒュームやほこりが侵入すると、
故障や誤動作の原因となります。

the Controller.
Front view (Door opened)

NK7303
Fig. 4.3.13 Warning labels on Robot controller (FD11-JX□000)
4-22
Chapter 5 Parts layout and Electrical
circuit
This chapter describes the parts layout and electric circuit diagram.
5.1 Parts layout ................................................................................................. 5-1

5.1.1 FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3) 5-1
5.1.2 FD11-JX(NV50 / NV166 / NV210) / JA(NV20A) .................................... 5-2
5.2 Connection of equipment ............................................................................ 5-3
5.2.1 FD11-JV（NB4/ NV6）/JL（NB4L/ NV6L/ NB15/ NV20）/JS（NH5 / NS3）/ JA
（NV20A） .................................................................................................... 5-3
5.2.2 FD11-JX (NV50 / NV166 / NV210) ........................................................ 5-3
5.3 Electrical circuit diagram (Overall) .............................................................. 5-4
5.3.1 FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3) 5-4
5.3.2 FD11-JX (NV50 / NV166 / NV210) / JA(NV20A)) .................................. 5-5
5.4 Electrical circuit diagram (Power supply section) ........................................ 5-6
5.4.1 Power unit ............................................................................................. 5-6
5.4.2 Power unit with optional filter board ...................................................... 5-7
5.4.3 Large-capacity power unit ..................................................................... 5-8
5.4.4 Large-capacity power unit with optional filter board .............................. 5-9
5.5 Electrical circuit diagram (Teach pendant) ................................................ 5-10
5.6 Electrical circuit diagram (Operation box & Starting box) .......................... 5-11
5.7 Electrical circuit diagram (NB4/ NV6/ NB4L/ NV6L/ NB15/ NV20) ............ 5-12
5.7.1 Motors (NB4)....................................................................................... 5-12
5.7.2 Motors (NV6)....................................................................................... 5-13
5.7.3 Motors (NB4L)..................................................................................... 5-14
5.7.4 Motors (NV6L / NB15 / NV20) ............................................................. 5-15
5.7.5 Encoders (NB4 / NB4L)....................................................................... 5-16
5.7.6 Encoders (NV6 / NV6L / NB15 / NV20) ............................................... 5-17
5.8 Electrical circuit diagram (NH5) ................................................................ 5-18
5.8.1 Motors (NH5) ...................................................................................... 5-18
5.8.2 Encoders (NH5) .................................................................................. 5-19
5.9 Electrical circuit diagram (NS3)................................................................. 5-20
5.9.1 Motors (NS3)....................................................................................... 5-20
5.9.2 Encoders (NS3) .................................................................................. 5-21
5.10 Electrical circuit diagram (NV50 / NV166 / NV210) ................................. 5-22
5.10.1 Motors (1/2) (NV50 / NV166 / NV210) .............................................. 5-22
5.10.2 Motors (2/2) (NV50 / NV166 / NV210) .............................................. 5-23
5.10.3 Encoders (NV50 / NV166 / NV210)................................................... 5-24
5.11 Electrical circuit diagram (NV20A) .......................................................... 5-25
5.11.1 Motors (1/2) (NV20A) ........................................................................ 5-25
5.11.2 Motors (2/2) (NV20A) ........................................................................ 5-26
5.11.3 Encoders (NV20A) ............................................................................ 5-27
5.1 Parts layout
5.1.1 FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3)

Sequence board Cooling fan (for rack unit)
CPU board Arc I/F board
Multi power
supply unit
I/O board
Raiser board
Regenerative resistance
< Inside cover > < Close-up of rack unit >
IPM drive unit
Cooling fan
Breaker
Power unit
< Left view > < Front view (inside) >
Fig. 5.1.1 Parts Layout for Robot controller (FD11-JV(NB4/ NV6)/JL(NB4L/ NV6L/ NB15/ NV20)/JS(NH5 / NS3))
5-1
5.1.2 FD11-JX(NV50 / NV166 / NV210) / JA(NV20A)
Sequence board Cooling fan (for rack unit)

CPU board Arc I/F board
Multi power
supply unit
I/O board
Raiser board
Regenerative resistance
< Inside cover > < Close-up of rack unit >
IPM drive unit
Cooling fan
Breaker
Power unit
< Left view > < Front view (inside) >
Fig. 5.1.2 Parts Layout for Robot controller (FD11-JX (NV50 / NV166 / NV210)/JA (NV20A))
5-2
5.2 Connection of equipment
5.2.1 FD11-JV（NB4/ NV6）/JL（NB4L/ NV6L/ NB15/ NV20）/JS（NH5 / NS3）/ JA（NV20A）

Control cables 1 and 3:
In case of NV20A,
there are 3 control cables.
Manipulator
Operation box
Robot controller
Teach pendant
Starting box
Fig. 5.2.1 Connection of equipment (FD11-JV(NB4/ NV6)/JL(NB4L/ NV6L/ NB15/ NV20)/ JS(NH5 / NS3)/
JA(NV20A))
5.2.2 FD11-JX (NV50 / NV166 / NV210)
Control cable 3
Control cable 2
Control cable 1
Manipulator
Operation box
Robot controller
Starting box
Fig. 5.2.2 Connection of equipment (FD11-JX (NV50 / NV166 / NV210))
5-3
5.3 Electrical circuit diagram (Overall)
5.3.1 FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3)
Fig. 5.3.1 Electrical circuit diagram (Overall) (FD11-JV(NB4/ NV6) / JL(NB4L/ NV6L/ NB15/ NV20) / JS(NH5 / NS3))
5-4
5.3.2 FD11-JX (NV50 / NV166 / NV210) / JA(NV20A))
Fig. 5.3.2 Electrical circuit diagram (Overall) (FD11-JX (NV50 / NV166 / NV210) / JA(NV20A))
5-5
5.4 Electrical circuit diagram (Power supply section)
5.4.1 Power unit
Sequence board
IPM drive unit
Raiser board
Multi power supply unit
Power unit
Fig. 5.4.1 Electrical circuit diagram (Power supply section) (Power unit)
5-6
5.4.2 Power unit with optional filter board
Sequence board
Raiser board
IPM drive unit

Power unit
Fig. 5.4.2 Electrical circuit diagram (Power supply section) (Power unit with optional filter board)
5-7
5.4.3 Large-capacity power unit
Sequence board
Raiser board
IPM drive unit

Large-capacity
power unit
Fig. 5.4.3 Electrical circuit diagram (Power supply section) (Large-capacity power unit)
5-8
5.4.4 Large-capacity power unit with optional filter board
Sequence board
Raiser board
IPM drive unit

Large-capacity
power unit
Fig. 5.4.4 Electrical circuit diagram (Power supply section) (Large-capacity power unit with optional filter board)
5-9
5.5 Electrical circuit diagram (Teach pendant)
Teach Pendant
Robot controller
Fig. 5.5.1 Electrical circuit diagram (Teach pendant)
5-10
5.6 Electrical circuit diagram (Operation box & Starting box)
Operation BOX
Robot controller
Fig. 5.6.1 Electrical circuit diagram (Operation box & Starting box)
5-11
5-12
Robot controller Manipulator Diagram of connection insertion position
IPM drive unit
NV20)
CN1 CN1 Upper side
Gate drive board
CN1-1
CNP1A CN1-2
Axis 1 motor CN1-3
CN1-4
CN1-5
CNP2A CN1-6
Axis 2 motor
5.7.1 Motors (NB4)
CNP2B Lower side
View from fitting face

on Manipulator
CNP3A
Fig. 5.7.1
Axis 3 motor
Gate drive board
CNP4A
Axis 4 motor
CNP5A
Axis 5 motor
CNP6A
Servo board
Axis 6 motor
CNBK1
Welding power supply Manipulator
Wire feed control unit
To the grounding terminal Color CN4

on the chassis BK : Black
CNBK2
Electrical circuit diagram (Motors) (For NB4)

WH : White
GY : Gray
BW Brown
LU : Blue
PL : Purple
To the grounding terminal RD : Red
on the chassis PK Pink
OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
5.7 Electrical circuit diagram (NB4/ NV6/ NB4L/ NV6L/ NB15/
IPM drive unit
CN1 CN1 Upper side
Gate drive board
CN1-1
CNP1A CN1-2
Axis 1 motor CN1-3
CN1-4
CN1-5
CNP2A CN1-6
Axis 2 motor Lower side
5.7.2 Motors (NV6)
CNP2B

on Manipulator
CNP3A
Fig. 5.7.2
Axis 3 motor
Gate drive board
CNP4A
Axis 4 motor
CNP5A
Axis 5 motor
CNP6A
Servo board
Axis 6 motor
CNBK1
Color
BK : Black CN4
To the grounding terminal WH : White
Electrical circuit diagram (Motors) (For NV6)

CNBK2 on the chassis
GY : Gray
BW Brown
LU : Blue
PL : Purple
RD : Red
To the grounding terminal PK Pink
on the chassis OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
5-13
5-14
IPM drive unit
CN1 CN1 Upper side
Gate drive board
CN1-1
CNP1A CN1-2
Axis 1 motor CN1-3
CN1-4
CN1-5
CNP2A CN1-6
CNP2B
5.7.3 Motors (NB4L)

on Manipulator
CNP3A
Fig. 5.7.3
Axis 3 motor
Gate drive board
CNP4A
Axis 4 motor
CNP5A
Axis 5 motor
CNP6A
Servo board
Axis 6 motor
CNBK1
Color
BK : Black CN4
To the grounding terminal
Electrical circuit diagram (Motors) (For NB4L)

CNBK2 on the chassis WH : White
GY : Gray
BW Brown
LU : Blue
PL : Purple
RD : Red
To the grounding terminal PK Pink
on the chassis OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
IPM drive unit
CN1 CN1 Upper side
Gate drive board
CN1-1
CNP1A CN1-2
Axis 1 motor CN1-3
CN1-4
CN1-5
CNP2A CN1-6
CNP2B
Fig. 5.7.4
on Manipulator
CNP3A
Axis 3 motor
Gate drive board
CNP4A
Axis 4 motor
5.7.4 Motors (NV6L / NB15 / NV20)
CNP5A
Axis 5 motor
CNP6A
Servo board
Axis 6 motor
CNBK1
To the grounding terminal Color

CN4
CNBK2 on the chassis BK : Black
WH : White
GY : Gray
BW Brown
Electrical circuit diagram (Motors) (For NV6L / NB15 / NV20)

LU : Blue
PL : Purple
on the chassis
RD : Red
PK Pink
OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
5-15
5.7.5 Encoders (NB4 / NB4L)
Fig. 5.7.5 Electrical circuit diagram (Encoders) (For NB4 / NB4L)
5-16
5.7.6 Encoders (NV6 / NV6L / NB15 / NV20)
Fig. 5.7.6 Electrical circuit diagram (Encoders) (For NV6 / NV6L / NB15 / NV20)
5-17
5-18
IPM drive unit
CN1
CN1 Upper side
Gate drive board
CN1-1
CNP1A CN1-2
Axis 1 motor CN1-3
CN1-4
CNP2A CN1-5
CNP2A CN1-6
5.8.1 Motors (NH5)
Lower side
CNP2B Axis 2 motor
on Manipulator
CNP3A
Fig. 5.8.1
Axis 3 motor
Gate drive board
CNP4A
Axis 4 motor
CNP5A
Axis 5 motor
CNP6A
Axis 6 motor
5.8 Electrical circuit diagram (NH5)
Servo board
CNBK1
Color CN4
To the grounding terminal BK : Black
Electrical circuit diagram (Motors) (For NH5)

CNBK2 on the chassis WH : White
GY : Gray
BW Brown
LU : Blue
PL : Purple
RD : Red
on the chassis PK Pink
OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
5.8.2 Encoders (NH5)
Fig. 5.8.2 Electrical circuit diagram (Encoders) (For NH5)
5-19
5-20
Robot controller Manipulator
CN1
CNP7A
IPM drive unit

Gate drive board
Axis 7 Motor
CNP1A
Axis 1 Motor
5.9.1 Motors (NS3)
CNP2A
Axis 2 Motor
Fig. 5.9.1
CNP3A
Axis 3 Motor
Gate drive board
CNP4A
Axis 4 Motor
CNP5A
Axis 5 Motor
CNP6A
5.9 Electrical circuit diagram (NS3)
Axis 6 Motor
Servo board
CNBK1(1/2)
CNBK2(1/2) Color Diagram of connection insertion position
BK : Black CN1 Upper side
CNBK1(2/2)
WH : White
Electrical circuit diagram (Motors) (For NS3)

GY : Gray CN1-1
BW Brown CN1-2
LU : Blue CN1-3
CNBK2(2/2) CN1-4
PL : Purple
CN1-5
RD : Red CN1-6
PK Pink
OR : Orange Lower side
YL : Yellow
GR : Green View from fitting face
SB : Sky blue on Manipulator
To the grounding terminal To the grounding terminal
on the chassis on the chassis
IPM drive unit CN2
Diagram of connection insertion position
CN2 Upper side

Axis 1 Encoder
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
Axis 2 Encoder
CN2-6
Lower side
5.9.2 Encoders (NS3)

Axis 3 Encoder on Manipulator
Fig. 5.9.2
Color
BK : Black
Axis 4 Encoder WH : White
GY : Gray
BW Brown
LU : Blue
PL : Purple
RD : Red
Axis 5 Encoder PK Pink
OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
Axis 6 Encoder
Axis 7 Encoder
Electrical circuit diagram (Encoders) (For NS3)
5-21
5-22
IPM drive unit Robot controller Manipulator
CNR01
Gate drive board CN1 Upper side
Axis 1
CNP1A motor
Fig. 5.10.1
CNP1B
Axis 2
CNP2A motor
CNP2B
Lower side
5.10.1 Motors (1/2) (NV50 / NV166 / NV210)
on Manipulator
Axis 3
CNP3A motor
CNP3B
Servo board (1/2)
CNBK1
Electrical circuit diagram (Motors) (1/2) (NV50 / NV166 / NV210)

on the chassis
5.10 Electrical circuit diagram (NV50 / NV166 / NV210)
on the chassis
IPM drive unit Robot controller Manipulator
CNR02
Gate drive board
CNP4A Axis 4
motor
CNP4B
CN2 Upper side
Fig. 5.10.2
CNP5A Axis 5
motor
CNP5B
CNP6A Axis 6 Lower side

motor
5.10.2 Motors (2/2) (NV50 / NV166 / NV210)
CNP6B on Manipulator
Gate drive board
CNP7A
CNP7B Axis 7
Servo board (2/2)
Electrical circuit diagram (Motors) (2/2) (NV50 / NV166 / NV210)

CNBK2 To the grounding terminal
on the chassis

on the chassis
5-23
5.10.3 Encoders (NV50 / NV166 / NV210)
Fig. 5.10.3 Electrical circuit diagram (Encoders) (NV50 / NV166 / NV210)
5-24
IPM drive unit
CN1 CN1 Upper side
CNP1A
CN1-1
CNP1B
CN1-2
CN1-3
CNP2A
CNP2B
Fig. 5.11.1
5.11.1 Motors (1/2) (NV20A)
Lower side
on Manipulator
CNP3A
CNP3B
Servo board
CNBK1
Welding power supply Manipulator Wire feed control unit

5.11 Electrical circuit diagram (NV20A)
on the chassis
CN4
Color
To the grounding terminal BK : Black
on the chassis WH : White
GY : Gray
BW : Brown
Electrical circuit diagram (Motors) (1/2) (NV20A)

LU : Blue
PL : Purple
RD : Red
PK : Pink
OR : Orange
YL : Yellow
GR : Green
SB : Sky blue
5-25
5-26
CN2
IPM drive unit
CNP4A
CNP5A
Fig. 5.11.2
5.11.2 Motors (2/2) (NV20A)
CNP6A
CNBK2

on the chassis
Color To the grounding terminal CN2 Upper side
on the chassis
BK : Black
WH : White
Electrical circuit diagram (Motors) (2/2) (NV20A)

GY : Gray CN2-1
BW : Brown CN2-2
LU : Blue CN2-3
PL : Purple CN2-4
RD : Red CN2-5
PK : Pink CN2-6
OR : Orange
YL : Yellow Lower side
GR : Green
SB : Sky blue View from fitting face
on Manipulator
5.11.3 Encoders (NV20A)
Fig. 5.11.3 Electrical circuit diagram (Encoders) (NV20A)
5-27
5-28

1L21700K E 6 ControllerMaintenance

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No.

■ Give this manual to the operator.

■ For help, call your distributor.

Cases in which death or serious injury can be expected if handled incorrectly.

Cases in which injury or physical damage can be expected if handled incorrectly.

The following symbols are also used for important checkpoints:

A particularly important checkpoint is shown.

Injury which does not require either hospitalization or long-term treatment as an

Direct and indirect damage in connection with damage of property and

Chapter 1 Point on Safety

Chapter 3 Parts replacement procedures and adjustment procedure

Chapter 4 Warranty / Periodic inspection / Parts list

4.1 Notes on Scope of Warranty and Liability ................................................................................. 4-1

4.2 Periodic Inspection Schedule .................................................................................................... 4-2

Chapter 5 Parts layout and Electrical circuit

5.9.2 Encoders (NS3) ............................................................................................................... 5-21

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

1.1 For safe use of the robot system

1.1.1 Symbols used in all the instruction manuals

Cases in which death or serious injury can be expected if handled incorrectly.

Cases in which injury or physical damage can be expected if handled incorrectly.

The following symbol is also used for important checkpoints:

A particularly important checkpoint is shown.

1.1.2 General precautions for safe use of the robot system

Table 1.1.1 Conditions when a disaster struck

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

Example 5 Manipulation by another operator without permission

The manipulator is operated by different program because of program

The followings are general precautions to prevent a disaster.

Do not get near the manipulator.

Operators must wear helmet, safety shoes and overalls.

Do not alter or remodel our products.

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

2.1 Function of each part and unit

(1) Parts layout of robot controller

(2) Outline of each part

Table 2.1.1 Outline of each part

Do not alter or remodel our products.

2.1.1 Multi power supply unit

LED 4 LED 4 +3.3V

LED 3 LED 3 +5V

LED 2 LED 2 +12V

LED 1 LED 1 +24V

<Left view> <Front view>

Table 2.1.2 Connectors of Multi power supply unit

Connector Functions Connected to

Table 2.1.3 Status indication LED of Multi power supply unit

Table 2.1.4 Fuses of Multi power supply unit

2.1.2 Raiser board

Multi power board

PCI slot (I/O board,etc)

Fig. 2.1.4 External view of Raiser board

Table 2.1.5 Status indication LED of Raiser board

2.1.3 CPU board

Fig. 2.1.5 External view of CPU board

(1) Block diagram

Fig. 2.1.6 CPU board peripheral connection

Table 2.1.6 Connectors on CPU board

(3) Jumper settings

Fig. 2.1.7 System CF card connector

2.1.5 Sequence board

Fig. 2.1.8 External view of Sequence board

The specifications of sequence board differ depending on the delivery time.

Table 2.1.8 Connectors on Sequence board