GENERAL CONTENTS IMPORTANT TRAINING COURSES LIMITED WARRANTY SAFETY WARNING 1. FUNDAMENTAL SPECIFICATIONS1.1 What is External Axes Controller? .......................................................................... .............................. . 1-1 1.2 Specifications of External Axes Controller ............................................................................................ 1-1 1.3 External Dimensions of External Axes Controller .......................................................................... ....... 1-3 2. FOUNDATION WORK AND INSTALLA TION 2.1 Foundation Work for Installation of Robot Controller with External Axes Controller ...................... 2-2 2.2 Transport Method of Robot Controller with External Axes Controller ............................................. 2-4 2.3 Installation of Robot Controller with External Axes Controller ........................................................ 2-6 2.3.1 Installation Dimensions of Robot Controller with External Axes Controller ............................. 2-6 2.3.2 Installation of Robot Controller with External Axes Controller ................................................. 2-7 2.3.3 Installation of External Axes Controller onto Robot Controller. .................................... ........... 2-8
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7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.5.1 Where to connect External Axis/Axes Cable 1 & 2 ................................................................3-18
3.5.2 Adding One External Axis ......................................................................................................3-23
3.5.3 Adding Two External Axes .....................................................................................................3-27
3.5.3.1 Adding One 2-axis Peripheral Jig ..............................................................................................3-27
3.5.3.2 Adding Two 1-axis Peripheral Jigs ............................................................................................3-30
3.5.4 Adding Three External Axes
(When adding a standard 1-axis slider and a standard 2-axes positioner.)..................... 3-38
3.5.5 Adding Four External Axes (When adding two standard 2-axis positioners.) ......................3-47
3.5.6 Adding One Manipulator.........................................................................................................3-57
3.5.7 Adding one 4.5 kW Motor .......................................................................................................3-613.5.8 Adding one 4.5 kW Motor and one 1.5 kW Motor ..................................................................3-65
5.2.1 Functions of External Axes Board ..........................................................................................5-11
5.2.2 Operating State Indicators of External Axes Board ...............................................................5-12
5.2.3 Relays on External Axes Board..............................................................................................5-12
5.2.4 Fuses on External Axes Board...............................................................................................5-12
5.2.5 Connectors of External Axes Board .......................................................................................5-13
5.2.6 Test Pins on External Axes Board .........................................................................................5-13
5.2.7 Jumper Pin Settings of External Axes Board ......................................................................... 5-14
5.3 Servo Unit ......................................................................................................................................5-15
5.3.1 Functions of Servo Unit .......................................................................................................... 5-155.3.2 Control Module W-L00958 .....................................................................................................5-17
5.4 Power Unit L4800P........................................................................................................................5-19
5.4.1 Functions of the Power Unit ...................................................................................................5-19
5.4.2 Connectors of the Power Unit ................................................................................................5-20
5.5 Charging Unit L4797P ...................................................................................................................5-21
5.5.1 Functions of the Charging Unit...............................................................................................5-21
5.5.2 Connectors of the Charging Unit ............................................................................................5-21
When combining a manipulator with robot peripheral jigs such as a positioner and/or a slider, anoptional controller to control jigs needs to be added to the standard robot controller.This controller is called "External Axes Controller", and it is capable of connecting up to 6 axes of
peripheral jigs. (“1.2 Specifications of External Axes Controller”: Note 3)The standard robot controller can control a single mechanism (one manipulator: 6 axes) only.
1.2 Specifications of External Axes Controller
Item Specifications
Name External Axes Controller
Driving system AC servo
In case of connecting robot peripheral jigs
(Controlling the External Axes Controller without a combinationof motors of 800 W or below and those of 1500 W)
Combination of
corresponding motorsModel
Combination of
corresponding motorsModel
800 W or below x 1 axis L5380 1500 W x 1 axis L5561
800 W or below x 2 axes L5381 1500 W x 2 axes L5562
800 W or below x 3 axes L5382 1500 W x 3 axes L5563
800 W or below x 4 axes L5562
800 W or below x 5 axes
800 W or below x 6 axesL5563
In the case of connecting robot peripheral jigs
(Controlling the External Axes Controller with acombination of motors of 800 W or below and those of
1500 W)
Combination of corresponding motors Model
1500 W x 1 axis + 800 W or below x 1 axis
1500 W x 1 axis + 800 W or below x 2 axesL5562
1500 W x 2 axes + 800 W or below x 1 axis
1500 W x 1 axis + 800 W or below x 3 axes
1500 W x 2 axes + 800 W or below x 2 axes
1500 W x 1 axis + 800 W or below x 4 axes
L5563
4500 W x 1 axis + 1500 W x 1 axis L5930
4500 W x 2 axes + 1500 W x 1 axis
4500 W x 1 axis + 1500 W x 2 axesL5931
4500 W x 2 axes + 1500 W x 3 axes
4500 W x 3 axes + 1500 W x 1 axisL5932
In the case of connecting a manipulator made by DAIHEN Corporation
Manipulator Model
DR-3200/4200/600/500 series L5554
Number of axes / model(Note 1, 2, 3)
DR-4200L/4300/4400 L5564
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Note (1) Since the model of External Axes Controller differs according to a robot peripheral jig, select a
corresponding model when ordering one(2) For a combination of motors other than specified above, contact your nearest distributor.(3) By adding another External Axes Controller, a maximum of 12 external axes can be added (18 in
total). The number of axes that can be added depends on the system. Contact your nearest
distributor for more details.(4) Position data are backed up by absolute encoders. The period of the battery backup while the
primary power is OFF is approximately 10 days. The duration of battery backup may be shorter
due to an ambient temperature, service conditions and so on. After the backup, absolute offsetadjustment work and recharging of the battery must be done due to a loss of position data
(5) If External Axes Cable is plugged off either from External Axes Controller or peripheral jigs intimes of reinstallment, absolute encoder data will be lost. Once the External Axes Cable isdisconnected, “absolute offset setting” must be performed after the reinstallement.
(6) The rated values of the primary-side power source here (in this table) are only for External Axes
Controller. Be aware that the rated values for a robot system are the sum of the rated values forExternal Axes Controller and those for Robot Controller. For the rated value of a controller,refer to “Installation: 3.3.1 Connecting the Primary Power Cable” in "INSTALLATION &
MAINTENANCE" for model DR series.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Installing External Axes Controller properly is very important for maintaining the proper function ofperipheral jigs and for safely. Correct installation not only keeps safety of workers around the peripheral jigs
but also extends life of the External Axes Controller.This chapter describes how to install the External Axes Controller. See "Installation: Chapter 2" in
"INSTALLATION and MAINTENANCE" for DR series.
WARNING
1. Disconnect the power before installing arobot and connecting cables. Touchinglive electrical parts will cause anelectrical shock or a burn that may
results in a loss of life.
WARNING
Do not touch live electrical
ELECTRIC SHOCKcan kill.
parts.
Disconnect all power
Multiple sources of voltage
may exist inside this
enclosure.
before installing or servicing.
NC8051
2. Install the External Axes Controller
outside the working range of the robot.If anyone approaches the moving robot,an accident that results in a loss of lifemay occur.
Keep out of robot area whenmain power is on.Do not locate this device
in robot work area.Read instruction manual.
WARNING
NC8050
3. When the External Axes Controller,
welding power source, etc., are to beinstalled at such an elevated position(over 2 m high) as on a frame, provide aworking floor shown in Fig. 2.0.0.1 to
allow adjustment, maintenance andinspection.
4. Be sure to fix Robot Controller with
External Axis Controller to a proper place
for installment. Do not lean against thecontroller. If the controller falls down, notonly the controller may break down butalso a fatal accident may occur.
min.0.6m
(Rear)
Robotcontrol unit
(Front)
min.1m
Fig. 2.0.0.1 Installing an External Axes Controller
at an Elevated Position
CAUTION
1. Provide at least 20-cm-wide spacebetween the External Axes Controller unitand a wall. TO AVOID DAMAGE TO THE ROBOTCONTROL
UNIT, KEEP THE AIR INLET AND EXHAUST
CLEAR. (AT LEAST0.2M FROM WALL.)
CAUTION
NC8054
2. Upon completion of the installation, make absolute offset adjustments until the robot peripheral jigagrees with the position coordinate data stored in the robot control unit. For the adjustingprocedure, see “Installation: Section 4.2 Absolute Offset Adjustment” in “Installation and
Maintenance” for DR series.
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2.1 Foundation Work for Installation of Robot Controllerwith External Axes Controller
WARNING
A robot controller does not have any mobile parts as a manipulator does, however it should befixed when installed so that it will not fall down from the elevated position or on the floor.
When installing a controller directly on the floor, use M12 concrete anchor to fix it as shown in Fig.2.1.0.1.If the strength of the floor is insufficient, embed J-shaped foundation bolt as shown in Fig. 2.1.0.3.
Fig. 2.1.0.1 Installation Dimensions of Robot Controller with External Axes Controller
Fig. 2.1.0.2 Installation of Concrete Anchor
Fig. 2.1.0.3 Foundation Drawing
for Installation by enbedding
Anchor Bolt. (Unitmm)
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Transport Method of Robot Controller with External Axes Controller
(1) Robot Controller with External Axes Controller should be transported to the place for installation
with a crane, a forklift, or a hand lifter .When transporting it with a crane, use two eyebolts as shown in Fig. 2.2.0.1. When transportingit with a forklift or hand lifter, be careful not to let the robot controller fall down.
CAUTION
External axes controller and robot controller are equipped with printed circuit boards and other
precision parts. Thus, do not give a shock to the controllers while transporting them.
(2) The mass of the robot controller with the external axes controller is approximately 80 kg . Wearhelmet, safety shoes and other protectives, and work in an appropriate working clothes.
Fig. 2.2.0.1 Transport Method for Robot Controller with External Axes Controller
Wooden Protector
Fix wire ropes tightto eyebolts usingshackles.
Wire Rope
Fixing Rope
Forklift
Prepare shackleswhose maximumload-carrying capacityis 0.4 t or more.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(3) Robot Controller for 4.5kW motors with External Axes Controller should not be suspended
together when transported.Load it on a pallet and transport it with a forklift as shown in Fig. 2.2.0.2. When suspend it whiletransporting, separate Robot Controller and External Axes Controller and suspend each unit.
CAUTION
External axes controller and robot controller are equipped with printed circuit boards and otherprecision parts. Thus, do not give a shock to the controllers while transporting them.
(4) The mass of the robot controller for 4.5kW motors with the external axes controller isapproximately 145 kg . Wear helmet, safety shoes and other protectives, and work in anappropriate working clothes.
Fig. 2.2.0.2 Transport Method for Robot Controller for 4.5kW Motors with External Axes Controller
Fixing Rope
Forklift
Wooden Protector
Wire Rope
Fix wire ropes tightto eyebolts usingshackles.
Prepare shackles that meetthe following requirements.
Model SC- 10Withstand Load0.4 tJIS B2801
Withstand Loadmin. 1400 kgLength min. 1.5 m
Wire Rope
Prepare shackles that meet thefollowing requirements.
Model SC- 14Withstand Load1.2 tJIS B2801
Withstand Loadmin. 270 kgLength min. 1.5m
For External Axes Controller For Large- capacity External Axes Controller
7/18/2019 DR External Axis Controller (1L4805A-E-3)
2.3.2 Installation of Robot Controller with External Axes Controller
When installing Robot Controller with External Axes Controller on the floor, fix the support channelattached to the bottom of robot controller to the foundation bolt (M12) with 4 lock nuts (M12) as shown
in Fig. 2.3.2.1. (Clamping Torque : 42.2 Nm)
WARNING
Robot Controller does not have any mobile parts as a manipulator does, however it should be fixedwhen installed so that it will not fall down from the elevated position or on the floor.
Fig. 2.3.2.1 Installation of Robot Controller with External Axes Controller
Support Channel
Robot Controller
Anchor Bolt
Lock Nut (M12)(Clamping Torque : 42.2Nm)
Spring Washer
Flat Washer
Foundation
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http://slidepdf.com/reader/full/dr-external-axis-controller-1l4805a-e-3 17/1602-8 FOUNDATION WORK AND INSTALLATION
2.3.3 Installation of External Axes Controller onto Robot Controller.
Refer to the following method to install the External Axes Controller on Robot Controller.
1 Do the foundation work for the installation of Robot Controller with External Axes Controller
according to the section 2.3.2.
2 Remove the lock nuts that are fixing Robot Controller.
3 Hang the robot controller 60 mm upward from the earth with a crane, forklift or hand lifter.
4 Remove the support channels fixed at the lower part of each side of the Robot Controller and then
fix support channels (Parts No. : L4805B04) that are the accessories of External Axes Controlleras shown in Fig. 2.3.3.1.
5 Install the Robot Controller to the installation place and then fix the support channels as shown in
Fig. 2.3.3.1.
6 Remove two eyebolts with spring washers and flat washers fixed on the top of the Robot
Controller and then drive them into the two M10 tapped holes on the top of the External AxesController.
7 Put the External Axes Controller on the top of the Robot Controller with a crane.
8 Fix the lower part of the External Axes Controller and the upper part of the Robot Controller
together at both sides with a plate (Parts No. : L4794B03A) and four M6 screws that are
accessories of the External Axes Controller (clamping torque : 11.5 Nm (117 kgf cm)). (Refer to
Fig. 2.3.3.2.) Apply LOCKTITE after the clamping.
9 Use grounding cable to connect grounding studs of the Robot Controller and the External Axes
Controller as shown in Fig. 2.3.3.3.
Fig. 2.3.3.1 Fixing Support Channels for the External Axes Controller to the Robot Controller
Remove it.
Remove it.
Support Channel(Type : L4805B04)
Robot Controller
Screw (M6)
Screw (M6)
Support Channel(Type : L4805B04)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
http://slidepdf.com/reader/full/dr-external-axis-controller-1l4805a-e-3 18/160FOUNDATION WORK AND INSTALLATION 2-9
Fig. 2.3.3.2
Installation of External Axes Controller to Robot Controller
Fig. 2.3.3.3
Installation of External Axes Controller for 4.5kW motors to External Axes Controller
4 M616
External Axes Controller
Robot Controller
(Type : L4794B03B)
Fixing Plate (accessory of External Axes Controller)
Screw
4 M616Screw
Eyebolt (removed from the Robot Controller
Fixing Plate (accessory of External Axes Controller)
(Type : L4794B03B)
Put a toothed lock washer betweenthe fixing plate and a screw sothat the notched side of the washer may dig into the fixing plate.
Toothed Lock Washer
4 M616
External Axes Controller
External Axes Controller for 4.5kW Motors
L4794B03B
Screw
L4794B03B
4 M616
Toothed Lock Washer
Put a toothed lock washer betweenthe fixing plate and a screw so thatthe notched side of the washer maydig into the fixing plate.
Fixing Plate(accesory of External Axes Controller)
Fixing Plate(accesory of External Axes Controller)
Screw
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Fig. 2.3.2.4 Connecting between Robot Controller
and External Axes Controller for 4.5kW Motors with Grounding Cable
FC3
CN4
Front
PCB2Main Board
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
CN301 CN302
SW301
Robot Controller
External AxisController
Right (inside)
View "A" "A""A"
"A"
CN203
CN201
Grounding Stud
Grounding Cableor
External Axes Controller for 4.5kW Motors
7/18/2019 DR External Axis Controller (1L4805A-E-3)
This chapter provides information on the connections of Jig Control cables, and on the settings of variousswitches in Robot Controller and External Axes Controller that are necessary to connect a robot peripheral
jig, such as positioners and sliders. See each instruction manual for installation of robot peripheral jigs.
WARNING
1. Disconnect the power before installing a
robot and connecting cables. Touchinglive electrical parts will cause anelectrical shock or a burn that may
results in a loss of life.
WARNING
Do not touch live electrical
ELECTRIC SHOCKcan kill.
parts.
Disconnect all power
Multiple sources of voltage
may exist inside this
enclosure.
before installing or servicing.
NC8051
2. Install the External Axes Controlleroutside the working range of the robot.
Approaching approaches the movingrobot may lead to an accident that results
in a loss of life.
Keep out of robot area whenmain power is on.Do not locate this device
in robot work area.Read instruction manual.
WARNING
NC8050
CAUTION
Upon completion of the installation, make absolute offset adjustments until the robot peripheral jigagrees with the position coordinate data stored in the robot control unit. For the adjusting procedure,see “Installation: 4.2 Absolute Offset Adjustment” in “INSTALLATION & MAINTENANCE” for model DR
series.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.2 Connecting Peripheral Jigs to External Axes Controller
3.2.1 System Configuration
A max. of 3 axes of peripheral jigs can be connected to a External Axes Controller. Some typicalexamples of the system configuration are presented in Table 3.2.1.1.
Table 3.2.1.1 Examples of System Configuration
Peripheral Jig
Examples of ConfigurationNo. ofaxes Jig 1 Jig 2
Type of External Axis (Axes) Cable Q'ty
1-axis positioner 1 axis
1-axis slider External Axis Cable for 1 axis 1 set
A peripheral jig is connected to the External Axes Controller with External Axes Cables listed in Table3.2.2.1. To connect a peripheral jig, a set of 2 external axes cables - one motor cable (External AxesCable 1) and one encoder cable (External Axes Cable 2) - is required.
Table 3.2.2.1
External Axes Cables for Peripheral Jigs
Component
Type Item Part No. Q'ty Cable length Remarks
External Axis Cable 1 L5372B00 1L5372
External Axis Cable 2 L5372C00 13m
External Axis Cable 1 L5373B00 1L5373
External Axis Cable 2 L5373C00 15m
External Axis Cable 1 L5374B00 1L5374
External Axis Cable 2 5374C00 110m
External Axis Cable 1 L5375B00 1L5375
External Axis Cable 2 L5375C00 115m
For 1-axisperipheral jig
External Axes Cable 1 L5376B00 1L5376
External Axes Cable 2 L5376C00 13m
External Axes Cable 1 L5377B00 1L5377
External Axes Cable 2 L5377C00 15m
External Axes Cable 1 L5378B00 1L5378
External Axes Cable 2 L5378C00 110m
External Axes Cable 1 L5379B00 1L5379
External Axes Cable 2 L5379C00 115m
For 2-axisperipheral jig
External Axis Cable 1 L5919B00 1L5919
External Axis Cable 2 L5372C00 13m
External Axis Cable 1 L5920B00 1L5920
External Axis Cable 2 L5373C00 15m
External Axis Cable 1 L5921B00 1L5921
External Axis Cable 2 L5374C00 110m
External Axis Cable 1 L5922B00 1L5922
External Axis Cable 2 L5375C00 115m
For 1-axisperipheral jig
(for 4.5 kW motor)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.3 Internal Jumper Pin Settings of External Axes Controller
In order to connect a robot peripheral jig such as a positioner or a slider to External Axes Controller, it is
necessary to change the settings of jumper pins on each printed circuit board in the External AxesController. Jumper pins that need change in their settings are listed in Table 3.3.0.1.
Table 3.3.0.1
Jumper pin settings of each printed circuit board in External Axes Controller
Printed circuit board Jumper pin
Ref. No. Name No. Name On Off Default
JP201 CN271 overrun Open Short-circuit Short-circuited
JP202 CN272 overrun Open Short-circuit Short-circuited
JP203 CN273 overrun Open Short-circuit Short-circuited
JP204 CN274 overrun Open Short-circuit Short-circuited
JP205 CN275 overrun Open Short-circuit Short-circuited
JP206 CN276 overrun Open Short-circuit Short-circuited
JP207 CN39 overrun Open Short-circuit Short-circuited
JP211 CN7A shock sensor Open Short-circuit Short-circuited
JP212 CN39 shock sensor Open Short-circuit Short-circuited
JP221 1-2: short-circuited
JP222 1-2: short-circuited
PCB103External Axes
board
JP223 1-2: short-circuited
PCB102 Servo I/F board JP1
Never change
these settings.
Open
CAUTION
1. Open jumper pins JP105 & JP106 on the mother board in the Robot Controller when connecting
the External Axes Controller. If they are short-circuited, overrun limit switches and shocksensors do not operate. (Refer to “Maintenance: 5.2.7 Jumper Pin Settings of Mother Board” in"INSTALLATION and MAINTENANCE" for model DR series.)
2. After setting jumper pins JP201 to 207, 211 or 212, be sure to check the operation of thecorresponding overrun limit switches or shock sensors.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.4 Connecting External Axes Controller to Robot Controller
3.4.1 Fixing Method of Servo I/F Board
In order to connect the External Axes Controller to the Robot Controller, it is necessary to connect
Servo I/F board to the main board of the Robot Controller. When connecting the External AxesController to the External Axes Controller for 4.5kW motors, it is necessary to connect Servo I/F boardto the main board of the External Axes Controller for 4.5kW motors.
(1) Follow the instructions in “Maintenance: 5.1.5 Precautions for Replacing Main Board” of"INSTALLATION & MAINTENANCE" for model DR series to remove the main board from theRobot Controller or the External Axes Controller for 4.5kW motors.
(2) Connect CN50 of the main board to the corresponding connector CN50 of the Servo I/F board asshown in Fig. 3.4.1.1.
(3) Sandwich and fix an insulating support between the main board and Servo I/F board on both
sides with four screws (M36) as shown in Fig. 3.4.1.1.
(4) Follow the instructions in “Maintenance: 5.1.5 Precausions for Replacing Main Board” of
“INSTALLATION & MAINTENANCE” for model DR series to transfer the teaching data andsystem parameters after installing the main board with the Servo I/F board into the RobotController or the External Axes Controller for 4.5kW motors.
Fig. 3.4.1.1 Fixing Method of Servo I/F Board
Inslating Support
ScrewsM36
ScrewsM36
M a i n B o a r d
P C B 2
PCB102
Servo I/F Board
CN50
CN50
FC10IC138
FC27
FC23FC24
CN16
CN44
CN1 CN7
CN111
CN19
CN18
CN41
CN30
CN73
CN38
CN40
CN37
CN150
CN80
CN67
TB1
CN250
CN251
FC10
Front
PCB3Mother Board
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
CN302
CN50
JP1
CN151
PCB102
Servo I/F Board
CN203
CN201
CN301 CN302
SW301
Robot Controller
FC10IC138
FC27
FC23FC24
CN16
CN44
CN1 CN7
CN111
CN19
CN18
CN41
CN30
CN73
CN38
CN40
CN37
CN150
CN80
CN67
TB1
FC10
PCB3Mother Board
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
CN302
CN50
JP1
CN151
PCB102
Servo I/F Board
CN203
CN201
CN301 CN302
SW301
External Axes Controller for 4.5kW Motors
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN14A
CN149
External Axes Controller
External Axes Controller
Front
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Follow the instructions in “2.3.2 Installation of Robot Controller with External Axes Controller” to
install the External Axes Controller on the Robot Controller.
(b) Connect one end of connector CN40 of the cable attached to the External Axes Controller with
connector CN40 of the mother board, and connect the other end with connector CN40 of theExternal Axes board.
CAUTION
1. Open jumper pins JP105 & JP106 on the mother board in the Robot Controller when connecting
External Axes Controller. If they are short-circuited, overrun limit switches and shock sensorsdo not operate. (Refer to “Maintenance: 5.2.7 Jumper Pin Settings of Mother Board” in"INSTALLATION & MAINTENANCE" for model DR series.)
(c) Connect CN80 and CN81 of the cable attached to the External Axes Controller with connectorCN81 of the mother board and connector CN81 of the External Axes board.
Connect CN302 and CN301 of the cable attached to the External Axes Controller with connector CN302
of the Servo I/F board in the Robot Controller and connector CN301 of the control module in the externalaxes respectively.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
< When using L5003 for External Axes Controller for 4.5kW motors>
Connector CN40 PCB3 Mother Board Connector CN40 PCB103 Control Module
(a) Follow the instructions in “2.3.2 Installation of Robot Controller with External Axes Controller” toinstall the External Axes Controller on the Robot Controller.
(b) Connect one end of connector CN39 of the cable attached to the cable L8203C00 withconnector CN40 of the External Axes Board for the External Axes Controller for 4.5kW motors,
and connect the other end with connector CN40 of the External Axes board for the External Axes Controller.
CAUTION
1. Open jumper pins JP105 & JP106 on the mother board in the Robot Controller when connectingExternal Axes Controller. If they are short-circuited, overrun limit switches and shock sensors
do not operate. (Refer to “Maintenance: 5.2.7 Jumper Pin Settings of Mother Board” in"INSTALLATION & MAINTENANCE" for model DR series.)
(c) Connect CN81A and CN81 of the cable attached to the External Axes Controller with connector
CN81A of the External Axes Controller for 4.5kW motors and connector CN81 of the External Axes Board respectively.
(d) Connect CN302 and CN301 of the cable attached to the External Axes Controller withconnector CN302 of the Servo I/F Board and connector CN301 of the Control module in the
External Axes Board respectively.
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(b) When the power source for the Robot Controller is other than 3 , AC200V (+10%, -15%)
Secondary-side of the breaker NFB1 Terminal U, V, W(Robot Controller) The primary-side of Aux. Transformer TF10
(Step-down Transformer)
Connector CN101 PCB1 Power unit Terminal R, S, T(Robot Controller) The secondary-side of Aux. Transformer TF10
(Step-down Transformer)
Connector CN101 PCB1 Power unit Connector CN101A
PCB101 Power unit
(Robot Controller) (External Axes Controller)
WARNING
1. Be sure to turn OFF the power source before connecting a power cable in order to avoid electric
shock.
2. For selecting the voltage of Step-down Transformer, refer to “Maintenance: 5.16.4 Voltage
Selector Mounting Position” in "INSTALLATION & MAINTENANCE" for model DR series.
3. Applying a voltage that exceeds its allowance will damage the robot controller. Prior to turning
on the robot controller, make sure that the jumper wires of Step-down Transformer are properlyconnected and suitable for the power supply voltage that are actually supplied.
CAUTION
Do not bind this cable with signal cables.
(b)-1 Remove the side cover of the Robot Controller on the right.
(b)-2 Lead CN101 of cable assembly (L4794D00) attached to Step-down Transformer into theboard through the bottom of the panel of the Robot Controller, and connect it to the rightcolumn, viewed from the back of the panel, of CN101 of the power unit.
(b)-3 Connect No.4 to 6 terminals of the cable assembly (L4794D00) with the secondary-side
terminals of the breaker in the Robot Controller from left in order.
(b)-4 Lead the remaining connector of the cable assembly (L4794D00) to the Step-downTransformer through the inlet on the base of the Robot Controller, and then fix the cableflange to the Robot Controller. After that, connect the terninals U, V, W, R, S and T of thecable to the corresponding terminals U, V, W, R, S and T of Aux. Transformer TF10,respectively.
(b)-5 Connect CN101 of the cable assembly (L4794F00) of the Step-down Transformer with theleft column of CN101, viewed from the back of the panel, of the power unit inside the RobotController.
(b)-6 Connect CN101A of the cable assembly (L4794F00) to the upper row of CN101A of thepower unit in the External Axes Controller.
(b)-7 Put the side cover of the Robot Controller back in place.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
This section provides the method of connecting External Axis/Axes Cable 1 & 2 and some examples
of the system configuration to show the method in detail.
3.5.1 Where to connect External Axis/Axes Cable 1 & 2
Where to connect External Axis/Axes Cable 1 & 2 depends on “motor axis Nos.” and “driver Nos.”described below.
(1) Axis Nos. of motors
Axis Nos. 1 -6 of External Axes Motor are basically defined from 1 in order according to the
priority described in Fig. 3.5.1.1. The bigger the capacity of a motor is, the smaller the axis numberof the motor is. Moreover, the axis number of a slider is smaller than positioners’ when thecapacity of their motors are the same.
Fig. 3.5.1.1 Priority of Axis No.
(2) Driver Nos. of motors
Connectors for connecting External Axes of External Axes Controller and of External Axes Controllerfor 4.5kW Motors are shown in Fig. 3.5.1.2 and Fig. 3.5.1.3 respectively.Nos. 7 – 12 on CN201, 203, 205 (for External Axes Controller) are called “DRIVER Nos.”.
Fig. 3.5.1.2 Connectors for External Axis/Axes Cables
Small
Large
Axis No.
1500 W Motor
Slider (800 W)
Tilt axis of 2-axis positioner (800 W)
Table axis of 2-axis positioner (800 W)
1-axis positioner (800 W)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
See Table 3.5.1.1 for driver Nos. (7 – 12) that correspond to “axis Nos.” (1 -6 ) and “the combination
of motors”. After that, connect the motor cable(s) (External Axis/Axes Cable 1) and the encoder cable(s) (External Axis/Axes Cable 2) as shown in Fig. 3.5.1.2.
Fig. 3.5.1.1 Driver Nos. that Correspond to “the Number of Axes” and “the Combination of Motors”
The combination of motors(pieces)
Axis No. of External Axes Motor(External Axis 1-6 Motor)
The number
of axes
External Axis/Axes
Controller 1500 W 800 W or below 1 2 3 4 5 6
Remarks
L4805 0 1 81 axis
L5521 1 0 8
L4806 0 2 8 10
2 0 8 102 axesL5522
1 1 8 10
L4807 0 3 8 10 12
L5522 1 2 8 9 10
2 1 8 10 123 axes
L55233 0 8 10 12
L5522 0 4 7 8 9 101 3 8 9 10 124 axesL5523
2 2 8 10 11 12
0 5 7 8 9 10 125 axes L5523
1 4 8 9 10 11 12
L5523 0 6 7 8 9 10 11 12
L4808 DR-3200/4200/600/503S 12 10 8 11 9 76 axes
L5524 DR-4200L/4300/4400 12 10 8 11 9 7(Note 1)
Note 1) In these cases, connect encoder cables to CN7A.
2) 1 -6 are axis Nos. of motors. Ex.) 3 implies External Axis 3.
3) 1500 W motors are connected to inverter modules that correspond to driver Nos. in shadedrectangles.
Ex.) External axes: 1500 W motor + RP2E-300N (2-axis double support positioner)
Combination of motors: 1500 W motor x 1 + 800 W x 2
The axis Nos. for these motors obtained from Fig 3.5.1.0. are as follows.
Since the External Axes Controller to be used is L5522 for 3 External Axes Specifications, driver Nos.obtained from Table 3.5.1.1 are as follows.
CAUTION
In case of connecting a peripheral jig, the axis No. of the motion axis of the unit is defined by thedata settings of System Parameter. Therefore, connect the motion axis of the unit properly as
defined by System Parameter.
Wrong settings cause not only the malfunction of the unit but also the movement of the unit in wrongdirections or breakage of the unit itself, creating a very dagerous situation.
1500 W motor
RP2E-300N tilt axis
RP2E-300N table axis
1
2
3
1500 W motor
RP2E-300N tilt axis
RP2E-300N table axis
8
9
10
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.1.2 Driver Nos. that Corresponds to “the Number of Axes” and “the Combination of Motors”(for External Axes Controller for 4.5kW Motors)
The combination of motors(pieces)
Axis No. of External Axes Motor(External Axis 1-6 Motor)
The numberof axes
Controllerfor 4.5kW, etc.
4.5kW 1.5kW or below 1 2 3 4 5 6
1 axis L5930 1 0 8
L5930 1 1 8 72 axes
L5931 2 0 8 10
1 2 8 7 9L5931
2 1 8 10 73 axes
L5932 3 0 8 10 12
L5932 1 3 8 7 9 11
L5931 2 2 8 10 7 94 axes
L5932 3 1 8 10 12 7
1 4 8 7 9 10 11
2 3 8 10 7 9 115 axes L5932
3 2 8 10 12 7 9
1 5 8 7 9 10 11 122 4 8 10 7 9 11 12L5932
3 3 8 10 12 7 9 116 axes
L5003 3 3 12 10 8 11 9 7
Note 1) 1 -6 are axis Nos. of motors. Ex.) 3 implies External Axis 3.
2) The crosshatched sections show that 4.5kW motor is connected.3) The axes Nos. are smaller as the motor capacity is larger and the axes Nos. of the slider are
smaller when the motor capacity is the same.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(3) Where to connect brake cable(s) (External Axis/Axes Cable 1)Basically, connect brake cable(s) (External Axis/Axes Cable 1) according to the number of
external axes and axis Nos. (1 -6 ) as shown in Table 3.5.1.3.
Table 3.5.1.3 Where to Connect Brake Cables
The number
of externalaxes
Which column(s) of CN67A
to connect brake cable(s)
1 B1
2 B1, B3
3 B1, B3, B5
4 B1 – B4
5 B1 – B5
6 B1 – B6
Examples of connecting External Axes Cables are shown on the next page onwards.
Table 3.5.1.4 Examples of System Configuration
Robot peripheral jigs
ConfigurationThe number of axes
Jig 1 Jig 2
Referencepage
1-axis positioner 1 axis
1-axis slider pp. 3-23
2-axis positioner pp. 3-272 axes
1-axis positioner 1-axis positioner pp. 3-32
3 axes 1-axis slider 2-axis positioner pp. 3-40
4 axes 2-axis positioner 2-axis positioner pp. 3-49
6 axes Manipulator pp. 3-60
1 axes (4.5kW motor) 4.5kW motor pp. 3-64
2 axes (4.5kW motor) 4.5kW motor + 1.5kW motor pp. 3-68
1
1
2
1
2
3
1
2
3
4
1
2
3
4
5
1
2
3
4
5
6
7/18/2019 DR External Axis Controller (1L4805A-E-3)
The driver No. that corresonds to the External Axis Motor is “8” according to Table 3.5.1.1.Therefore, connect the motor cable, the encoder cable and the brake cable to CN201-8, CN272 and
CN67A-B1, respectively.
Fig. 3.5.2.1 Where to Connect External Axis Cables
(1) Connecting External Axis Cable 1
Jig 1
Cannon plug CN1 Connector CN201-8
Connector CN67A-B1
Grounding cable
External Axis Controller
PCB103 External Axes board
External Axis Controller
(a) Connect CN1 of the External Axis Cable 1 to the corresponding connector CN1 of jig 1.
(b) Lead connectors CN201, CN67 and the grounding cable into the External Axis Controllerthrough the shaded area on the right side of the External Axis Controller as shown in Fig.
3.5.2.2, and then fix the cable flange in place without leaving any clearance with that of theExternal Axis Cable 2.
(c) Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to theright side of the External Axis Controller.
(d) Connect CN67 to the corresponding connector CN67A-B1 of the External Axes board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axis Controller. (Be sure to fix the grounding cable to this stud.)
Connecting External Axis Cable 1 when Adding 1 External Axis
CAUTION
1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axis Cable 1 as far apart as possible from External Axis Cable 2 inside theExternal Axis Controller. (Do not bind them together.)
3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. When using it in such moving sections, please contact us forconsultation.
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN41A
CN149
CN205
PCB103
CN301 CN302
SW301
PCB152
CN203
CN201
CN67A
CN201
PCB2
External Axes Board
External Axis Controller
Connect here
Clamp this grounding cable withthat of External Axis Cable 2.
ControlModule
Connect here
External Axis Cable 2
External Axis Cable 1
Right Side (inside)
View "A" "A"
Front
Robot Controller Main Board
"A"
"A"
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axis Cable 2 to the corresponding connector CN2 of jig 1.
(b) Lead connector CN272 and the grounding cable into the External Axis Controller through the
shaded area on the right side of the External Axis Controller as shown in Fig. 3.5.2.3, and thenfix the cable flange in place without leaving any clearance with that of the External Axis Cable 1.
(c) Connect CN272 to the corresponding connector CN272 of the External Axes board.
(d) If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with anoverrun limit switch, open the corresponding jumper pin JP202 by reinserting only one side of
the pin. (Refer to Table 3.3.0.1.)
CAUTION
If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with an overrun
limit switch, open the corresponding jumper pin JP202 by reinserting only one side of the pin.If it is short-circuited, the overrun limit switch connected to CN272 does not operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axis Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of the jumper pin JP202, be sure to check the operation of the
corresponding overrun limit switch in Teach mode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Connecting External Axis Cable 2 when Adding 1 External Axis
CAUTION
1. Arrange External Axis Cable 2 as far apart as possible from the primary power cable and the
welding cable.
2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 in theExternal Axis Controller. (Do not bind them together.)
3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving/bending sections of a slider cableveyor, etc. When using it in such moving sections, please
contact us for consultation.
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
PCB103
CN301 CN302
SW301
PCB152
"A"
CN203
CN201
PCB2
External Axes Board
External Axis Controller
ControlModule
External Axis Cable 2
External Axis Cable 1
Front Right Side (inside)
View "A" "A"
Main Board
"A"
Clamp this grounding cable withthat of External Axis Cable 1.
Robot Controller
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN1 of External Axes Cable 1 to the corresponding connector CN1 of jig 1.
(b) Lead connectors CN201, CN203, CN67 (2) and the grounding cable into the External Axes
Controller through the shaded area on the right side of the External Axes Controller as shown in
Fig. 3.5.3.2, and then fix the cable flange in place without leaving any clearance with that ofExternal Axes Cable 2.
(c) Connect CN201 and CN203 with the corresponding connectors CN201-8 and CN203-10 of the junction cables fixed to the right side of the External Axes Controller, respectively, as shown inFig. 3.5.3.1.
(d) As well, connect CN67 to CN67A-B1 on the External Axes board as shown in Fig 3.5.3.1.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of
the External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector CN2 of jig 1.
(b) Lead connectors CN272, CN274 and the grounding cable into the External Axes Controller
through the shaded area on the right side of the External Axes Controller as shown in Fig.3.5.3.3, and then fix the cable flange in place without leaving any clearance with that of External
Axes Cable 1.
(c) Connect CN272 and CN274 to the corresponding connectors CN272 and CN274 of theExternal Axes board, respectively.
(d) If a peripheral jig such as a positioner or a slider connected to CN272 and CN274 is equippedwith an overrun limit switch(es), open the corresponding jumper pin JP202 and/or JP204 by
reinserting only one side of the pin(s).
CAUTION
If a peripheral jig such as a positioner or a slider, which is connected to CN272 and CN274, isequipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP202
and/or JP204 by reinserting only one side of the pin(s).If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN272 and CN274does(do) not operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of
the External Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After setting jumper pin JP202 and/or JP204, be sure to check the operation of the correspondingoverrun limit switch(es) of the peripheral jig, which is connected to CN272 and CN274, in Teachmode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Connecting External Axes Cable 2 when Adding One 2-Axis Jig
CAUTION
1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 2 as far apart as possible from External Axes Cable 1 in the External
Axes Controller. (Do not bind them together.)
3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. When using it in such moving sections, please contact us forconsultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
PCB103External Axes Board
CN301 CN302
SW301
PCB152
ControlModule
Robot Controller
External AxesController
Right Side (inside)
View "A" "A""A"
"A"
CN203
CN201
Clamp this grounding cable withthat of External Axes Cable 1.
External Axes Cable 1
External Axes Cable 2
PCB2Main Board
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN1 of External Axis Cable 1 for External Axis 1 to the corresponding connector CN1
of jig 1.
(b) Lead connectors CN201, CN67 and the grounding cable into the External Axes Controller
through the shaded area on the right side of the External Axes Controller as shown in Fig.3.5.3.5, and then fix the cable flange in place without leaving any clearance with that of External
Axis Cable 2 for External Axis 1.
(c) Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to the rightside of the External Axes Controller.
(d) Connect CN67A to the corresponding connector CN67A-B1 on the External Axes board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Connecting External Axis Cable 1 for External Axis 1 when Connecting Two 1-Axis Jigs
CAUTION
1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axis Cable 1 as far apart as possible from External Axis Cable 2 in the External
Axes Controller. (Do not bind them together.)
3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. When using it in such moving sections, please contact us for
consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
PCB103
External Axes Board
CN301 CN302
SW301
PCB152ControlModule
Robot Controller
External AxesController
Right Side (inside)
View "A" "A"
"A"
"A"
CN203
CN201
Clamp this grounding cable withthat of External Axis Cable 2.
External Axis Cable 2for External Axis 2
CN67A
External Axis Cable 1for External Axis 2
Connect here
CN201
PCB2
Main Board
External Axis Cable 1for External Axis 1
External Axis Cable 2for External Axis 1
Connect here
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(2) Connecting the External Axis Cable 2 for External Axis 1 (Jig 1)
Jig 1
Cannon plug CN2(External Axis 1)
Connector CN272
Grounding cable
PCB103
External Axes board
External Axes Controller
(a) Connect CN2 of the External Axis Cable 2 for External Axis 1 to the corresponding connector
CN2 of jig 1.
(b) Lead connector CN272 and the grounding cable into the External Axes Controller through theshaded area of the right side of the External Axes Controller as shown in Fig. 3.5.3.6, and then
fix the cable flange in position without leaving any clearance with that of External Axis Cable 1.
(c) Connect CN272 to the corresponding connector CN272 of the External Axes board.
(d) If a peripheral jig such as a positioner or a slider connected to CN272, is equipped with anoverrun limit switch, open the corresponding jumper pin JP202 by reinserting only one side ofthe pin.
CAUTION
If a peripheral jig such as a positioner or a slider, which is connected to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin.
If it is short-circuited, the overrun limit switch connected to CN272 does not operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of the jumper pin JP202, be sure to check the operation of thecorresponding overrun limit switch.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Connecting External Axis Cable 2 for External Axis 1 When Adding Two 1-axis Jigs
CAUTION
1. Arrange External Axis Cable 2 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 in theExternal Axes Controller. (Do not bind them together.)
3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider, etc. If it is to be used in such moving sections, please contact us for
consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276
CN7A
CN1A
CN14A
CN149
CN205
PCB103External Axes Board
CN301 CN302
SW301
PCB152
ControlModule
Robot Controller
External AxesController
Right Side (inside)
View "A" "A"
"A"
"A"
CN203
CN201
Clamp this grounding cable withthat of External Axis Cable 1.
External Axis Cable 1for External Axis 1
External Axis Cable 2
for External Axis 2
External Axis Cable 2
for External Axis 1
External Axis Cable 1for External Axis 2
PCB2Main Board
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN1 of the External Axis Cable 1 for External Axis 2 to the corresponding connectorCN1 of jig 2.
(b) Lead connectors CN203, CN67 and the grounding cable into the External Axes Controllerthrough the shaded area on the right side of the External Axes Controller as shown in Fig.3.5.3.7, and then fix the cable flange in place without leaving any clearance with the cableflange of the External Axis Cable 2 for External Axis 2.
(c) Connect CN203 to the corresponding connector CN203-10 of the junction cable fixed to theright side of the External Axes Controller.
(d) Connect CN67 to CN67A-B3 on the External Axes board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.3.7 Connecting External Axis Cable 1 for External Axis 2 when Adding Three 1-Axis Jigs
CAUTION
1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axis Cable 1 as far apart as possible from the External Axis Cable 2 in theExternal Axes Controller. (Do not bind them together.)
3. Since this cable is intended for use in non-moving sections of a jig, do not use it in the moving /bending sections of a slider , etc. If it is to be used in such moving sections, please contact us forconsultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
PCB103External Axes Board
CN301 CN302
SW301
PCB152
ControlModule
Robot Controller
External AxesController
Right Side (inside)
View "A" "A"
"A"
"A"
CN203
CN201
Clamp this groundning cable withthat of External Axis Cable 2.
External Axis Cable 1for External Axis 1
External Axis Cable 2
for External Axis 2
CN67A
External Axis Cable 2
for External Axis 1
External Axis Cable 1for External Axis 2
Connect here
CN203
PCB2Main Board
Connect here
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axis Cable 2 for External Axis 2 to the corresponding connector
CN2 of jig 2.
(b) Lead connector CN274 and the grounding cable into the External Axes Controller through theshaded area on the right side of the External Axes Controller as shown in Fig. 3.5.3.8, and thenfix the cable flange in place without leaving any clearance with that of the External Axis Cable 1.
(c) Connect CN274 to the corresponding connector CN274 of the External Axes board.
(d) If a peripheral jig such as a positioner or a slider connected to CN274 is equipped with anoverrun limit switch, open the corresponding jumper pin JP204 by reinserting only one side of
the pin .
CAUTION
If a peripheral jig such as a positioner or a slider, which is connected to CN274, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP204 by reinserting only oneside of the pin .If it is short-circuited, the overrun limit switch connected to CN274 does not operate.
(e) Fix the grounding cable to the grounding stud provided at the upper left to the inlet of theExternal Axis Cable 2 for External Axis 2. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of the jumper pin JP204, be sure to check the operation of thecorresponding overrun limit switch.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.5.4 Adding Three External Axes(When adding a standard 1-axis slider and a standard 2-axes positioner.)
This section illustrates the method of connecting External Axis/Axes Cables with the case that
standard 1-axis slider (slider henceforth) and a standard 2-axis positioner are added.The rated value of the motors used for a standard slider and a standard positioner are 800 W.Therefore, the axis Nos. of the motors in this particular case, which can be obtained from Fig. 3.5.1.1,
are listed in Table 3.5.4.1.
Table 3.5.4.1 Axis Nos of Motors.
Axis Name Axis No. Rated value of motor
Slider 1
Tilt axis of 2-axis positioner 2
Table axis of 2-axis positioner 3
800 W
According to Table 3.5.1.1, driver Nos. are “8” for a slider, “10” for the tilt axis of 2-axis positioner and
“12” for the table axis of 2-axis positioner.Thus, where to connect External Axis/Axes Cables is shown in Table 3.5.4.2.
Table 3.5.4.2 Where to connect External Axis/Axes Cables
Cable Name Constituents Cable nameWhere to ConnectExternal Axis/Axes
Cable
Motor Cable CN201-8External Axis Cable 1
for Slider Brake Cable CN67A-B1
External Axis Cable 2
for SliderEncoder Cable
Slider axis
CN272
Tilt axis
for 2-axis positioner
CN203-10
Motor CableTable axis
for 2-axis positionerCN205-12
External Axes Cable1 for Positioner
Brake Cable 2-axis positioner CN67A-B3
Tilt axis
for 2-axis positionerCN274
External Axes Cable
2 for PositionerEncoder Cable
Table axisfor 2-axis positioner
CN276
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.4.1 Where to connect External Axis/Axes Cables
(1) Connecting External Axis Cable 1 for a slider
Slider
Cannon plug CN1(External Axis 1)
Connector CN201
Connector CN67A-B1
Grounding cable
External Axes Controller
PCB103 External Axes board
External Axes Controller
(a) Connect CN2 of the External Axis Cable 1 for a slider to the corresponding connector CN1 of aslider.
(b) Lead connectors CN201, CN67 and the grounding cable into the External Axes Controllerthrough the shaded area (inlet) on the right side of the External Axes Controller as shown in Fig.3.5.4.2, and then fix the cable flange in place without leaving any clearance with the cableflange of the External Axis Cable 2 for a slider.
(c) Connect CN201 to the corresponding connector CN201-8 of the junction cable fixed to the sideof the External Axes Controller.
(d) Connect CN67 to the corresponding connector CN67A-B1 on the External Axes board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.4.2 Connecting External Axis Cable 1 for Slider (External Axis 1)When Adding Both Slider and 2-axis Positioner
CAUTION
1. Arrange External Axis Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axis Cable 1 as far apart as possible from the External Axis Cable 2 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Axis Cable 1 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN14A
CN149
CN205
PCB103
External Axes Board
CN301 CN302
SW301
PCB152
ControlModule
Robot Controller
External AxesController
Right Side (inside)
View "A" "A"
"A"
"A"
CN203
CN201
Clamp this gounding cable withthat of External Axis Cable 2.
External Axes Cable 2
for 2-axis Positioner
CN67A
External Axes Cable 1for 2-axis Positioner
Connect here
CN201
PCB2
Main Board
External Axis Cable 1for Slider
External Axis Cable 2
for Slider
Connect here
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axis Cable 2 for a slider to the corresponding connector CN2 of a
slider.
(b) Lead connector CN272 and the grounding cable into the External Axes Controller through theshaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.4.3, andthen fix the cable flange in place without leaving any clearance with the cable flange of the
External Axis Cable 1 for a slider.
(c) Connect CN272 to the corresponding connector CN272 of the External Axes board.
(d) If a peripheral jig such as a positioner or a slider connected to CN272 is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin.
CAUTION
If a peripheral jig such as a positioner or a slider, which is connected to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin.
If it is short-circuited, the overrun limit switch connected to CN272 does not operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of jumper pin JP202, be sure to check the operation of the
corresponding overrun limit switch of the the peripheral jig, which is connected to CN272, in Teachmode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.4.3 Connecting External Axis Cable 2 for Slider (External Axis 1)When Adding Both Slider and 2-axis Positioner
CAUTION
1. Arrange External Axis Cable 2 as far apart as possible from the primary power cable and the
welding cable.
2. Arrange External Axis Cable 2 as far apart as possible from the External Axis Cable 1 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please
contact us for consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276
CN7A
CN1A
CN41A
CN149
CN205
PCB103External Axes Board
CN301 CN302
SW301
PCB152
ControlModule
Robot Controller
External AxesController
Right Side (inside)
View "A" "A"
"A"
"A"
CN203
CN201
Clamp this grounding cable withthat of External Axis Cable 1.
External Axis Cable 1for Slider
External Axes Cable 2
for 2-axis Positioner
External Axis Cable 2
for Slider
External Axes Cable 1for 2-axis Positioner
PCB2Main Board
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(3) Connecting External Axes Cable 1 for 2-axis Positioner
2-axis Positioner
Cannon plug CN1(External Axis 2 & 3)
Connector CN203
Connector CN205
Connector CN67A-B3
Grounding cable
External Axes Controller
External Axes Controller
PCB103 External Axes board
External Axes Controller
(a) Connect CN1 of the External Axes Cable 1 for 2-axis positioner to the corresponding connectorCN1 of 2-axis positioner.
(b) Lead connectors CN203, CN205, CN67 x 2 and the grounding cable into the External Axes
Controller through the shaded area (inlet) on the right side of the External Axes Controller asshown in Fig. 3.5.4.4, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2 for 2-axis positioner.
(c) Connect CN203 and CN205 to the corresponding connectors CN203-10 and CN205-12 of the junction cable fixed to the side of the External Axes Controller.
(d) Connect CN67 to the corresponding connector CN67A-B3 on the External Axes board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of
the External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.4.4 Connecting External Axes Cable 1 for 2-axis Positioner (External Axis 2 & 3)When Adding Both Slider and 2-axis Positioner
CAUTION
1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 1 as far apart as possible from the External Axes Cable 2 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN41A
CN149
CN205
CN301 CN302
SW301
PCB152
"A"
"A"
CN203
CN201
CN67A
PCB2
Connect here
PCB103
External Axes Board
External AxesController
Robot Controller
Main Board
Clamp this grounding cable withthat of External Axis Cable 2.
Connect here
ControlModule
Front Right Side (inside)
View "A" "A"
External Axes Cable 2for Positioner
External Axes Cable 1for Positioner
External Axis Cable 1for Slider
External Axis Cable 2for Slider
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(4) Connecting External Axes Cable 2 for 2-axis Positioner
2-axis Positioner
Cannon plug CN2(External Axis 2 & 3)
Connector CN274
Connector CN276
Grounding cable
PCB103 External Axes board
PCB103 External Axes board
External Axes Controller
(a) Connect CN2 of the External Axes Cable 2 for 2-axis positioner to the corresponding connector
CN2 of a slider.
(b) Lead CN274, CN276 and the grounding cable into the External Axes Controller through the
shaded area (inlet) on the right side of the External Axis Controller as shown in Fig. 3.5.4.5, andthen fix the cable flange in place without leaving any clearance with the cable flange of theExternal Axes Cable 1 for 2-axis positioner.
(c) Connect CN274 and CN276 to the corresponding connectors CN274 and CN276 of the External Axes board.
(d) If a peripheral jig such as a positioner or a slider, which is connected to CN274 and CN276, is
equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP204and/or JP206 by reinserting only one side of the pin(s). (Refer to Table 3.3.0.1.)
CAUTION
If a peripheral jig such as a positioner or a slider, which is connected to CN274 and CN276, isequipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP204and/or JP206 by reinserting only one side of the pin(s).If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN274 and CN276does(do) not operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of jumper pin JP204 and/or JP206, be sure to check the operation of thecorresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN274 andCN276, in Teach mode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.4.5 Connecting External Axes Cable 2 for 2-axis PositionerWhen Adding Both Slider and 2-axis Positioner
CAUTION
1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 2 as far apart as possible from the External Axes Cable 1 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Axes Cable 2 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN1A
CN41A
CN149
CN205
CN301 CN302
SW301
PCB152
"A"
"A"
CN203
CN201
PCB2
PCB103External Axes Board
External AxesController
Robot Controller
Main Board
ControlModule External Axes Cable 2for Positioner
External Axes Cable 1for Positioner
External Axis Cable 1for Slider
External Axis Cable 2for Slider
Front Right Side (inside)
View "A" "A"
Grounding stud
7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.5.5 Adding Four External Axes(When adding two standard 2-axis positioners.)
This section illustrates the method of connecting External Axes Cables with the case that twostandard 2-axis positioners are added.
The rated value of the motor used for a standard 2-axis positioner is 800 W.The axis Nos. of the motors in this particular case, which can be obtained from Fig. 3.5.1.1, are listedin Table 3.5.5.1.
The Nos. of positioners, whether Positioner 1 or 2, have been set beforehand.
Table 3.5.5.1 Axis Nos. of Motors
Axis Name Axis No. Rated value of motor
Tilt axis of Positioner 1 1
Table axis of Positioner 1 2
Tilt axis of Positioner 2 3
Table axis of Positioner 2 4
800 W
Therefore, the corresponding driver Nos. obtained from Table 3.5.1.1 are listed in Table 3.5.5.2.
Table 3.5.5.2 Driver Nos. of Motors
Axis Name Drver No.
Tilt axis of Positioner 1 7
Table axis of Positioner 1 8
Tilt axis of Positioner 2 9
Table axis of Positioner 2 10
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN1 of the External Axes Cable 1 for Positioner 1 to the corresponding connector CN1of Positioner 1
(b) Lead connectors CN201-7, CN201-8, CN67 x 2 and the grounding cable into the External Axes
Controller through the shaded area (inlet) on the right side of the External Axes Controller asshown in Fig. 3.5.5.2, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2 for Positioner 1.
(c) Connect CN201-7 and CN201-8 to the corresponding connectors CN201-7 and CN201-8 of the junction cable fixed to the right side of the External Axes Controller.
(d) As well, connect CN67 to the corresponding connector CN67A-B1 on the External Axes Board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of
the External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.5.2 Connecting External Axes Cable 1 for Positioner 1 (External Axis 1 & 2)When Adding 2 Standard 2-axis Positioners
CAUTION
1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 1 as far apart as possible from the External Axes Cable 2 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN41A
CN149
CN205
PCB103External Axes Board
CN301 CN302
SW301
PCB152ControlModule
Robot Controller
External Axes Controller
"A"
"A"
CN203
CN201
Connect here
CN67A
PCB2Main Board
Front Right Side (inside)
View "A" "A"
External Axes Cable 2for Positioner 2
External Axes Cable 1for Positioner 1
External Axes Cable 1for Positioner 2
External Axes Cable 2for Positioner 1Clamp this grounding cable withthat of External Axes Cable 2.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.5.3 Connecting External Axes Cable 2 for Positioner 1 (External Axis 1 & 2)When Adding 2 Standard 2-axis Positioners
CAUTION
1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 2 as far apart as possible from the External Axes Cable 1 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Axes Cable 2 is intended for use in non-moving sections of a jig, do not use it inthe moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN7A
CN1A
CN41A
CN149
CN205
PCB103
External Axes Board
CN301 CN302
SW301
PCB152
"A"
"A"
CN203
CN201
PCB2
CN276
External Axes Cable 2for Positioner 2
External Axes Cable 1for Positioner 2
External Axes Cable 1for Positioner 1
External Axes Cable 2for Positioner 1
Right Side (inside)
View "A" "A"
Front
External Axes Controller
Robot Controller
Control
Module
Main Board
Clamp this grounding cable withthat of External Axes Cable 1.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN1 of the External Axes Cable 1 for Positioner 2 to the corresponding connector CN1of Positioner 2.
(b) Lead connectors CN203-9, CN203-10, CN67 x 2 and the grounding cable into the External Axes
Controller through the shaded area (inlet) on the right side of the External Axes Controller asshown in Fig. 3.5.5.4, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2 for Positioner 2.
(c) Connect CN203-9 and CN203-10 to the corresponding connectors CN203-9 and CN203-10 ofthe junction cable fixed to the right side of the External Axes Controller.
(d) As well, connect CN67 to the corresponding connector CN67A-B3 on the External Axes Board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of the
External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axes Cable 2 for Positioner 2 to the corresponding connector CN2
of Positioner 2.
(b) Lead CN273, CN274 and the grounding cable into the External Axes Controller through the
shaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.5.5,and then fix the cable flange in place without leaving any clearance with the cable flange of theExternal Axes Cable 1 for Positioner 2.
(c) Connect CN273 and CN274 to the corresponding connectors CN273 and CN274 of theExternal Axes board.
(d) If a peripheral jig such as a positioner or a slider, which is connected to CN273 and CN274, is
equipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP203and/or JP204 by reinserting only one side of the pin(s). (Refer to Table 3.3.0.1.)
CAUTION
If a peripheral jig such as a positioner or a slider, which is connected to CN273 and CN273, isequipped with an overrun limit switch(es), be sure to open the corresponding jumper pin JP203and/or JP203 by reinserting only one side of the pin(s).If it(they) is(are) short-circuited, the overrun limit switch(es) connected to CN273 and/or CN273does(do) not operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of jumper pin JP203 and/or JP204, be sure to check the operation of thecorresponding overrun limit switch(es) of the the peripheral jig, which is connected to CN273
and/or CN274, in Teach mode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
This section describes the method of connecting External Axes Cables when a manipulator is used asan external axis.
(1) Connecting External Axes Cable 1 for a manipulator
Manipulator Cannon plug CN1 Connector CN250
Connector CN251
Connector CN67A
Grounding cable x 2
External Axes Controller
External Axes Controller
PCB103 External Axes board
External Axes Controller
(a) Connect CN1 of the External Axes Cable 1 to the corresponding connector CN1 of themanipulator.
(b) Lead connectors CN250, CN251, CN67 and the grounding cable into the External AxesController through the shaded area (inlet) on the right side of the External Axes Controller as
shown in Fig. 3.5.6.1, and then fix the cable flange in place without leaving any clearance withthe cable flange of the External Axes Cable 2.
(c) Connect CN250 and CN251 to the corresponding connectors CN250 and CN251 of the junctioncable fixed to the right side of the External Axes Controller.
(d) As well, connect CN67 to the corresponding connector CN67A-B1 on the External Axes board.
(e) Fix the grounding cables (x 2) to the grounding stud provided at the lower-right corner of thebase of the External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.6.1 Connecting External Axes Cable 1 when Adding One Manipulator
CAUTION
1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 1 as far apart as possible from the External Axes Cable 2 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Axes Cable 1 is intended for use in non-moving sections of a jig, do not use it in
the moving / bending sections of a slider, etc. If it is to be used in such moving sections, pleasecontact us for consultation.
External Axes Cable 2for Manipulator
External Axes Cable 1for Manipulator
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN276CN7A
CN1A
CN41A
CN149
CN251
PCB103
CN301 CN302
SW301
PCB152
"A"
"A"
CN250
Connect here
CN67A
PCB2
Front Right Side (inside)
View "A" "A"
External Axes Controller
Robot Controller
External Axes Board
ControlModule
Clamp this grounding cable withthat of External Axes Cable 2.
Main Board
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(2) Connecting External Axes Cable 2 for a manipulator
Manipulator Cannon plug CN2 Connector CN7A
Grounding cable
PCB103 External Axes board
External Axes Controller
(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector CN2 of the
manipulator.
(b) Lead CN7A and the grounding cable into the External Axes Controller through the shaded area
(inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.6.2, and then fix thecable flange in place without leaving any clearance with the cable flange of the External AxesCable 1.
(c) Connect CN7A to the corresponding connector CN7A on the External Axes board.
(d) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base ofthe External Axes Controller. (Be sure to fix the grounding cable to this stud.)
(e) In order to operate the overrun limit switch of Axis 1 of the manipulator, open JP201 by
reinserting only one side of the pin except when DR-500s is in use.Since DR-500s is not equipped with an overrun limit switch, DO NOT open JP201.
CAUTION
If Axis 1 of a manipulator (except for DR-500s) is equipped with an overrun limit switch, be sure to
open the corresponding jumper pin JP201 by reinserting only one side of the pin.If it is short-circuited, the overrun limit switch mounted on the manipulator does not operate and themanipulator may be damaged.
CAUTION
After changing the setting of jumper pin JP201, be sure to check the operation of thecorresponding overrun limit switch of the manipulator in Teach mode.
(f) When using a torch with a shock sensor, open JP211 by reinserting only one side of the pin inorder to operate the shock sensor. (See Table 3.3.0.1.)
CAUTION
When using a torch with a shock sensor, be sure to open JP211 by reinserting only one side of the
pin.
If it is short-circuited, the shock sensor does not operate and the torch or a peripheral jig may bedamaged.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.6.2 Connecting External Axes Cable 2 when Adding One Manipulator
CAUTION
1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and thewelding cable.
2. Arrange External Axes Cable 2 as far apart as possible from the External Axes Cable 1 inside theExternal Axes Controller. (Do not bind them together.)
3. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please
contact us for consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274
CN275
CN7A
CN1A
CN41A
CN149
PCB103
External Axes Board
CN301 CN302
SW301
PCB152
ControlModule
Robot Controller
External Axes Controller
Right Side (Inside)
View "A"--"A""A"
"A"
External Axes Cable 2for Manipulator
External Axes Cable 1for Manipulator
PCB2Main Board
CN276
CN251
CN250
Clamp this grounding cable withthat of External Axes Cable 2.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
As is shown in Table 3.5.1.2, the driver No. for 4.5kW motor is “8.”Therefore, connect motor cable, encoder cable, and brake cable to CN257, Cn272, and to CN67-B2
respectively.
Fig. 3.5.7.1 Where to Connect External Axes Cables
(1) Connecting External Axes Cable 1
Connector CN257 External Axes Controllerfor 4.5kW Motor
Connector CN67-B2External Axes Controller
for 4.5kW Motor
4.5kW Motor
Cannon plug CN1(for motor)
Grounding cable External Axes Controllerfor 4.5kW Motor
(a) Connect Connector of the External Axes Cable 1to the corresponding Cannon plug CN1(for motor) of 4.5kW motor
(b) Lead the rest of connectors CN257, CN67, and the grounding cable into the External Axes
Controller through the shaded area (inlet) on the right side of the External Axes Controller as shownin Fig. 3.5.7.2, and then fix the cable flange in place without leaving any clearance with the cableflange of the External Axes Cable 2.
(c) Connect CN201 to the corresponding connector CN257 of the junction cable fixed to the right sideof the External Axes Controller.
(d) As well, connect CN67 to the corresponding connector CN67A-B2 on the External Axes Board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of the
External Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
3.5.7.2 Connecting External Axes Cable 1 when adding 4.5kW Motor
CAUTION
1. Arrange External Axes Cable 1 as far apart as possible from the primary power cable and thewelding cable.
2. Since External Cable 1 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please contactus for consultation.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axes Cable 2 to the corresponding Cannon plug CN2 of 4.5kW motor.
(b) Lead the rest of CN272 and the grounding cable into the External Axes Controller through theshaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.7.3, andthen fix the cable flange in place without leaving any clearance with the cable flange.
(c) Connect CN272 to the corresponding connector CN272 on the External Axes board.
(d) If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting onlyone side of the pin. (See Table 3.3.0.1).
CAUTION
If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only oneside of the pin. If it is short-circuited, the overrun limit switch connected to CN202 does not
operate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of the
External Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of jumper pin JP202, be sure to check the operation of thecorresponding overrun limit switch of the manipulator in Teach mode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.7.3 Connecting External Axes Cable 2 when adding 4.5kW Motor
CAUTION
1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and the
welding cable.
2. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please contactus for consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN14A
CN149
PCB003
External Axes Board
External Axes Controller for 4.5kW Motors
Right Sideinside
View "A" "A""A"
"A"
External Axes Cable 2
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Connector CN257 External Axes Controllerfor 4.5kW Motor
Connector CN67-B2 External Axes Controller
for 4.5kW Motor
External Axis 1
Cannon plug CN1(4.5kW Motor) (for motor)
Grounding cable External Axes Controller
(a) Connect Connector of the External Axes Cable 1 to the corresponding Cannon plug CN1(for motor) of 4.5kW motor
(b) Lead the rest of connectors CN257, CN67, and the grounding cable into the External AxesController through the shaded area (inlet) on the right side of the External Axes Controller as shownin Fig. 3.5.8.1, and then fix the cable flange in place without leaving any clearance with the cable
flange of the External Axes Cable 1.
(c) Connect CN257 to the corresponding connector CN257 of the junction cable fixed to the right sideof the External Axes Controller.
(d) As well, connect CN67 to the corresponding connector CN67A-B2 on the External Axes Board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector of a peripheral jig of
External Axes 1.
(b) Lead the rest of CN272 and the grounding cable into the External Axes Controller through theshaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.8.3, andthen fix the cable flange in place without leaving any clearance with the cable flange.
(c) Connect CN272 to the corresponding connector CN272 on the External Axes board.
(d) If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting onlyone side of the pin. (See Table 3.3.0.1).
CAUTION
If a peripheral jig, such as a positioner or a slider connedcted to CN272, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP202 by reinserting only one
side of the pin. If it is short-circuited, the overrun limit switch connected to CN202 does notoperate.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of jumper pin JP202, be sure to check the operation of thecorresponding overrun limit switch of the peripheral jig, which is connected to CN271, in Teachmode.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Fig. 3.5.8.3 Connecting External Axes Cable 2 for External Axes 1 when adding 4.5kW motor
CAUTION
1. Arrange External Axes Cable 2 as far apart as possible from the primary power cable and thewelding cable.
2. Since External Cable 2 is intended for use in non-moving sections of a jig, do not use it in themoving / bending sections of a slider, etc. If it is to be used in such moving sections, please contact
us for consultation.
Front
CN81
CN80A
CN67A
CN39 CN40
CN29A
CN271
CN272
CN273
CN274CN275
CN276CN7A
CN14A
CN149
PCB003
External Axes Board
External Axes Controller for 4.5kW Motors
Right Sideinside
View "A" "A""A"
"A"
External Axes Cable 2
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Grounding cable External Axes Controllerfor 4.5kW Motor
(a) Connect Connector of the External Axes Cable 2 to the corresponding connector of a peripheral jigof External Axes 2.
(b) Lead the rest of connectors CN256, CN67, and the grounding cable into the External AxesController through the shaded area (inlet) on the right side of the External Axes Controller as shownin Fig. 3.5.8.4, and then fix the cable flange in place.
(c) Connect CN256 to the corresponding connector CN256 of the junction cable fixed to the right sideof the External Axes Controller.
(d) As well, connect CN67 to the corresponding connector CN67A-B1 on the External Axes Board.
(e) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(a) Connect CN2 of the External Axes Cable 2 to the corresponding connector of a peripheral jig of
External Axes 2.
(b) Lead the rest of CN271 and the grounding cable into the External Axes Controller through theshaded area (inlet) on the right side of the External Axes Controller as shown in Fig. 3.5.8.5, andthen fix the cable flange in place without leaving any clearance with the cable flange.
(c) Connect CN271 to the corresponding connector CN271 on the External Axes board.
CAUTION
If a peripheral jig, such as a positioner or a slider connedcted to CN271, is equipped with anoverrun limit switch, be sure to open the corresponding jumper pin JP201 by reinserting only oneside of the pin. If it is short-circuited, the overrun limit switch connected to CN271 does notoperate.
(d) Fix the grounding cable to the grounding stud provided at the lower-right corner of the base of theExternal Axes Controller. (Be sure to fix the grounding cable to this stud.)
CAUTION
After changing the setting of jumper pin JP201, be sure to check the operation of the
corresponding overrun limit switch of the manipulator in Teach mode.
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This chapter provides instructions on major parts and components of the External Axes Controller.
For a robot controller, a wire feed unit, welding expendables and robot peripheral jigs, see the respectiveinstruction manuals. A robot system based on special specifications may have different parts numbers fromthose of a standard robot system. Therefore, when you place an order for replacement parts, be sure to
check the actual parts No. of each specific item and advise us of the model No. stamped each on themanipulator and the robot control unit, together with the parts No. information.
For the delivery time and prices of maintenance parts, please contact our local distributor or salesrepresentatives in your country.
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5.2.1 Functions of External Axes Board.......................................................................................... 5-11
5.2.2 Operating State Indicators of External Axes Board ............................................................... 5-12
5.2.3 Relays on External Axes Board ............................................................................................. 5-125.2.4 Fuses on External Axes Board............................................................................................... 5-12
5.2.5 Connectors of External Axes Board ....................................................................................... 5-13
5.2.6 Test Pins on External Axes Board ......................................................................................... 5-13
5.2.7 Jumper Pin Settings of External Axes Board ......................................................................... 5-14
5.3 Servo Unit ...................................................................................................................................... 5-15
5.3.1 Functions of Servo Unit .......................................................................................................... 5-15
5.3.2 Control Module W-L00958 .....................................................................................................5-17
5.4 Power Unit L4800P........................................................................................................................ 5-19
5.4.1 Functions of the Power Unit ...................................................................................................5-19
5.4.2 Connectors of the Power Unit ................................................................................................ 5-20
5.5 Charging Unit L4797P ................................................................................................................... 5-21
5.5.1 Functions of the Charging Unit............................................................................................... 5-21
5.5.2 Connectors of the Charging Unit............................................................................................ 5-21
5.6.1 Functions of the Charging Battery ......................................................................................... 5-22
5.6.2 Specifications of the Charging Battery ................................................................................... 5-225.6.3 Replacing the Charging Battery ............................................................................................. 5-22
This chapter provides information on the following components of the External Axes Controller with respectto their functions, displays of operating states, switch settings and so on.
Components of External Axes Controller
(1) Servo I/F Board L4805C(2) External Axes Board L4805D(3) Servo Unit (4) Power Unit L4800P
(5) Charging Unit L4797P(6) Charging Battery L6390N(7) Cooling Fan
Figs. 5.0.0.1 and 5.0.0.2 show the parts arrangement plan and the block diagram of the External AxesController, respectively.
Components of External Axes Controller for 4.5 kW Motor
(1) Main Board L5000C
(2) Mother Board L5000F(3) Servo Driver(4) Brake Unit L5573G(5) Power Unit L4800P(6) Memory Battery L3391V(7) Auxiliary Transformer W-L00699
(8) Cooling Fans(9) Constant Voltage Power Supply(10) External Axes Board L4805D
(11) Charging Unit L4797P(12) Charging Battery L6390N(13) Relay Unit (optional)
For these components’ functions, displays of operating states, and switch settings, see the correspondingsection of MAINTENANCE in the Instruction Manual.
Table 5.0.0.1 Where to refer in “INSTALLATION & MAINTENANCE” for model DR series
ItemWhere to refer in “INSTALLATION & MAINTENANCE”
for model DR seriesMain Board “5.1 Main Board L5000C”Mother Board “5.2 Mother Board L5000F”Power Unit “5.3 Power Unit L4800P”Servo UnitControl ModuleSWR Module
“5.4 Servo Unit”
Servo UnitSmall Signal Backplane BoardInverter ModulePower Supply ModuleLarge Current Backplane Board
Additional Edition of BV80/120“7.1 Servo Unit”
Memory Battery “5.6 Memory Battery L3391V”Relay Unit (optional) “5.8 Relay Unit L5550”
Figs. 5.0.0.3 and 5.0.0.4 show the parts arrangement plan and the block diagram of the External Axes
Controller for 4.5 kW Motor, respectively.
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For inspection, maintenance, adjustments, repairs or other similar work on the robot system, entering
into the robot working range or working with the primary-side power or servo power turned on may benecessary. In any case, be sure to take the following precautions for inspection, maintenance,adjustments and repairs.
WARNING • NEVER enter the robot working range when the power is ON.
• Approaching an operating robot may result in a fatal injury.
WARNING • NEVER touch any charged parts.
• Touching any charged part may result in a fatal electric shock hazard or burn.
WARNING
• NEVER put your hand, finger, hair, clothes or the like close to any rotatingsection.
• Putting your hand, finger, hair or clothes close to the wire feed roll of the wirefeed unit may cause you to get caught, resulting in a serious injury.
• Similarly, putting your hand, finger, hair or clothes close to the rotating section
of a cooling fan may cause you to get caught and hurt.
(1) Prior to carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a
helmet, safety shoes, gloves and other protective means that may be deemed necessary, asspecified by law. To be more specific, wear clothes that are suited to each specific work.
(2) Prior to initiating work, press the EMERGENCY Stop button or the Stop button to check if the
robot system stops instantly. Furthermore, if a safety plug, a dead man switch and/or other
protective devices are added to the robot system, they must be checked for their proper operation.Should any fault be detected, stop the inspection work, turn off the main power immediately, checkfor causes and take necessary countermeasures accordingly.
(3) Ensure that no one, except those who are involved in robot-related work, approach the safety
fence of the robot system.
(4) Prior to starting work, put up a sign “Under
Inspection” at a visible place to inform those
around the robot system that inspection isnow being carried out.
Under Inspection
(5) Do not use any devices that may generate electromagnetic noise, in and around the area whereinspection is being performed.
(6) At least two workers should involve in the inspection or maintenance work, one to perform actual
work and the other to serve as a watcher.
(7) Personnel to be involved for robot inspection, maintenance, adjustment and/or repairs shouldreceive instructions and training on robot functions, operation and maintenance. In addition, if
special devices or facilities are provided in the robot system, their entire mechanism must also befully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who arequalified by receiving special training. Moreover, even if they have received such special training,they are not allowed to perform inspection, maintenance, adjustment or repairs of machinery other
than those they are fully familiar with.
(9) Any sign that may be given to workers, watchers and/or operators of related machines must be in
conformity with the Customer’s safety management standards.
(10) The watcher must observe the following. He shall:
(a) stand at a place that commands a view of the entire robot working range, and devote himself
to the duty of watching the work.
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(b) always hold the EMERGENCY Stop button to be able to press it immediately whenever any
abnormality occurs.
(c) make sure that no one except those who are involved in inspection, and so on come close to
the robot working range.
(11) Workers to be involved in inspection or other work must observe the following.
(a) If work can be carried out OUTSIDE the robot working range, specify the work details before
starting the work and make sure to carry out the work OUTSIDE the robot working range in any
case.(b) In principle, perform inspection and the like while a robot is stopped. In case inspection or
other work needs to be performed while the robot is operating, be sure to report that to a safetymanager who is responsible. With permission obtained, the operator may perform the workduring the operation OUTSIDE the robot working range.
(c) If a robot is required to be in an operable condition during inspection or the like, specify the
work procedure in detail beforehand to be able to perform work safely and efficiently. If not,carry out the work while the robot control unit, the welding power supply and other input-sidepower supplies are all turned off. Except in special occasions, be sure to turn off the
input-side power supplies for jigs and peripheral devices or make them inactive.
(d) When working in the robot working range, make sure to be ready to press the EMERGENCYStop button immediately whenever a robot malfunctions.
(e) Check your footing carefully before starting the work. Make sure to avoid an unstable scaffoldor a scaffold provided at an elevated position (more than 2 meters high).
(f) When working in the robot working range, do not work with your back facing the manipulator.
(g) When replacing PCBs provided in Robot Controller or Teach Pendant, take countermeasuresagainst static electricity such as applying protective sheets.
(12) If any abnormality occurs during work, follow the following procedure carefully.
(a) If any malfunction is observed in the robot system, press the EMERGENCY Stop button
immediately.
(b) Report that to the watcher immediately, turn
off the control power of the Robot Controller,
and then put up a sign “Do Not Switch ON”.Do Not Switch ON
(c) Make sure that all the related machines are stopped.
(d) When one has to go inside the safety fence, be sure that the one who is going to enter pullsout the safety plug oneself, carries it along and proceeds with the work concerned.
(e) Even when the robot has automatically stopped due to a fault in supply voltage to the robotsystem, hydraulic pressure or air pressure of related devices, make sure to stop the robotcompletely before investigating causes and taking necessary countermeasures.
(f) If the EMERGENCY Stop button or other safety devices have failed to operate, turn off the
main power immediately, investigate causes and take necessary countermeasures.
(g) When restarting the robot after stopping it by pressing the EMERGENCY Stop button,
investigate causes, take necessary countermeasures, replace the safety plug, and then restartit from outside the safety fence.
(13) Make sure that all the necessary connectors, covers, panels, etc. have been mounted and wiredcorrectly when finishing the work.
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This PCB controls various I/O signals, both internal and external, of the External Axes Controller andhas the following functions.This PCB has the following functions with respect to its control over various I/O signals both inside
and outside (, both internal and external,) the External Axes Contorller.
(1) Function to control the sequence circuits for high voltage and 24 V systems of the External AxesController
(2) Function to relay signals from peripheral devices, which are connected to the External AxesController, to the SERVO unit.
(3) Function to send and receive I/O signals to and from the External Axes Controller and peripheral
jigs.(4) Function to control the brakes of peripheral jigs.(5) Function to supply power to the charging unit for absolute encoder data backup while the
primary-side power is ON.
Fig. 5.2.1.1 External View of External Axes Board
125
185
CN81
JP222JP221
CN80A
CN67A
TP13A
TP12ATP15ATP14A
F7
F6
TP3A
TP4A
JP212 JP207
CN39
CN40
F5
JP211
JP223
J
P201
JP202
JP203
JP204
JP205
JP206
CR4ACR1A
CN29A
CN271
CN272
CN273
CN274
CN275
CN276
CN7A CN1A
CN14ACN149
LED
100A
LED
105A
LED
107A
3 1 3 1
31
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5.2.2 Operating State Indicators of External Axes Board
LEDs listed in Table 5.2.2.1 are provided on the External Axes Board to indicate the operating state of
the sequence circuit, etc. inside the External Axes Controller. For each LED location, see Fig.5.2.1.1.
Table 5.2.2.1 Operating State Indicators of External Axes Board
LED No. Function Status
LED100A (green) Break Release ON when brake relay is turned.
LED105A (green) OVERRUN Detection Input OFF when peripheral jigs overrun.
LED107A (green) Shock Sensor OFF when shock sensor operates.
5.2.3 Relays on External Axes Board
Relays listed in Table 5.2.3.1 are provided on the external axes board to indicate the operating stateof the sequence circuit, etc. inside the robot controller. For each relay location, see Fig. 5.2.1.1.
Table 5.2.3.1 Relays on External Axes BoardRelay No. Function Status Related LED
CR 1A OVERRUN Contact opens when peripheral jigs overrun. LED105A OFF
CR 3D BRAKE D Contact closes when brake D is released.
CR 3E BRAKE A Contact closes when brake A is released.
CR 3F BRAKE F Contact closes when brake F is released.
LED100A ON
CR 4A Shock Sensor Contact opens when shock sensor operates. LED107A OFF
5.2.4 Fuses on External Axes Board
Fuses listed in Table 5.2.4.1 below are provided on the External Axes board to protect the robot
system. When replacing blown fuses, be sure to eliminate all the causes of the fusing and replacewith those of the same rating.
Table 5.2.4.1 Fuses on External Axes Board
Fuse No. Rating Application Parts No.
F5 250 V, 2A, glass tube type24 V power supply inside External
Axes Controller4610-009
F6 250 V, 2A, glass tube type AC 12 V power supply for External Axes Controller charging unit
4610-009
F7 250 V, 2A, glass tube typePower to release the unit brake ofperipheral jigs
4610-009
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Jumper pins listed in Table 5.2.7.1 below are provided on the external axes board. Performnecessary jumper pin setting in accordance with the specific robot system.
Table 5.2.7.1 Jumper Pin Setting of External Axes Board
Jumper Pin Function Standard Setting
JP201 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN7A or CN271.When overrun sensor is provided in a peripheral device (such as a
slider or a positioner) that is connected to CN7A or CN271, set this jumper pin at "ON" (OPEN).
1-2 Short : OFF
JP202 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN272.When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN272, set this jumper pin
at "ON" (OPEN).
1-2 Short : OFF
JP203 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN273.
When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN273, set this jumper pinat "ON" (OPEN).
1-2 Short : OFF
JP204 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN274.When overrun sensor is provided in a peripheral device (such as a
slider or a positioner) which is connected to CN274, set this jumper pinat "ON" (OPEN).
1-2 Short : OFF
JP205 ON-OFF selection of OVERRUN signal of a peripheral device which is
connected to CN275.When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN275, set this jumper pinat "ON" (OPEN).
1-2 Short : OFF
JP206 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN276.
When overrun sensor is provided in a peripheral device (such as aslider or a positioner) which is connected to CN276, set this jumper pinat "ON" (OPEN).
1-2 Short : OFF
JP207 ON-OFF selection of OVERRUN signal of a peripheral device which isconnected to CN39.When an optional device is connected to CN39, set this jumper pin at
"ON" (OPEN).
1-2 Short : OFF
JP211 ON-OFF selection of shock sensor which is connected to CN7A.When shock sensor is provided in a peripheral device (such as a slider
or a positioner) which is connected to CN7A, set this jumper pin "ON"
(OPEN).
1-2 Short : OFF
JP212 ON-OFF selection of shock sensor which is connected to CN39.
When an optional device is connected to CN39, set this jumper pin at"ON" (OPEN).
1-2 Short : OFF
JP221 1-2 Short : OFF
JP222 1-2 Short : OFF
JP222
(For optional devices)
Do not change the standard setting.
1-2 Short : OFF
WARNING
When replacing the External Axes board with a new one, make sure that the jumper pin settings areproper. Wrong settings may result in the failure of peripheral jigs to perform OVERRUN or in
malfunction of the detecting circuit, creating a dangerous situation.
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The servo unit controls servo system of up to six axes and supplies power to servo motors inaccordance with a specific control signal, and it consists of the following modules.The only difference between this unit and the servo unit L4800J of Robot Controller is in control
module.
Table 5.3.1.1 Configuration of Servo Unit for External Axes Controller L5380L5382, L5554
Module name DWG No. Q’ty
Parts No. Remarks
Backplane W-L00950 1
5096-204 1
Control module W-L00958
1 5096-225
Inverter module W-L00956
4 5096-224 1
SW Regulator module W-L00953
1 5096-207 1
Capacitor module W-L00954 1 5096-208 1
Power supply module W-L01146
1 5096-321 1
Table 5.3.1.2 Configuration of Servo Unit for External Axes Controller L5561L5564
Module name DWG No. Q’ty Parts No. Remarks
Backplane W-L00950 1
5096-204 1
Control module W-L00958
1 5096-225
Inverter module W-L00960
4
5096-305 3
SW Regulator module W-L01170
1 5096-338
3
Capacitor module W-L00954
1 5096-208 1
Power supply module W-L01146
1 5096-321 1
1 Used commonly for Robot Controller IRBC-602/621/631.
2 Used commonly for Robot Controller IRBC-602/621.
3 Used commonly for Robot Controller IRBC-631.
4 The quantity differs according to the number of extended axes.
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This module controls the servo system of up to six axes, and has the following functions. Function to receive commands from the main board and generate signals for driving an inverter
module
Function to perform high-speed arithmetic operations required for servo control.
Function to detect a servo-related alarm signal sent from an absolute encoder and to send thisalarm to the control module.
Function to receive absolute offset data from an absolute encoder. Function to detect various alarms related to the servo system.
Fig. 5.3.2.1 External View of the Control Module
(2) Operating State Indicators of Control Module
Seven LEDs, one small-signal power supply LED (LED PWR: green) and six alarm LEDs (LEDs 1-6:red), are provided on the control module panel.
If any faulty occurs in the servo unit, the corresponding LED will be lit up.
The operating state information given by these LEDs can be checked on Teach Pendant, thus it isnot necessary to monitor those LEDs on the control module panel.
CAUTIONMay cause electric shock.Don't touch this systemduring power ON or 5 min.
135
12220
184
56
Backplane
PWR
6
5
4
3
2
1
AC SERVO SYSTEM
W L00958
Front View
Left-side View Rear View
Bottom View
CN1 CN2
CN215
CN
220
CN215
CN220
CN301 CN302
CN301 CN302
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(3) Precautions to be taken for replacing control module with a new one.
When replacing the control module, proceed as follows.
(a) Disconnect the cable from connector CN301 provided at the bottom of the control module.
CAUTION
Prior to removing the control module to be replaced, be sure to disconnect this cable.
(b) Remove the side cover on the left from the External Axes Controller.
(c) Remove the upper and lower screws (2 pcs. each) that are fixing the control module to theservo frame.
(d) Remove the control module to be replaced.
(e) Insert a replacement control module in place (at the rightmost on the lower level of a servo
frame), and connect it to connectors CN215 & CN220 on the backplane.
(f) Check, by viewing from the front, that the above two connectors are fully inserted to their
respective ends.
CAUTION
If those connectors of the control module are not fully inserted to their respective ends, they maysuffer a
contact failure, resulting in malfunction of the robot system. Therefore, make sure that theyare fully inserted and firmly connected.
(g) Fix the control module to the servo frame , using the above upper and lower screws (2 pcs.
each).
CAUTION
Vibrations or shocks may cause a contact failure of connectors and that could lead to a malfunction ofthe robot system. Therefore, be sure to fix the control module to the servo frame with screws.
Fig. 5.3.2.2 Fixing the Control Module to the Servo Frame
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The power unit is provided with connectors as listed in Table 5.4.2.1 below, to supply power to eachinner unit.
Table 5.4.2.1 Connectors of Power Unit
Connector No. Peripheral devices to be connected to
CN101 3 AC200 V power supply input (inside the robot control unit)
CN104 (Reserved) (inside the robot control unit)
CN105 Power relay MS1servo unit (inside the External Axes Controller)
CN106 Power relay MS1 (inside the External Axes Controller)
CN107 Pilot lamp (PL1) (inside the Robot Controller)
CN108 (Reserved) (inside the External Axes Controller)
CN109 (Reserved) ( inside the External Axes Controller)
CN110 External Axes board (inside the External Axes Controller)
CN112 Cooling fan FM14 (inside the External Axes Controller)
CN113 Cooling fan FM 11 (inside the External Axes Controller)
CN114 Cooling fan FM 12 (inside the External Axes Controller)
CN115 Cooling fan FM 13 (inside the External Axes Controller)
CN116 (Reserved) (inside the External Axes Controller)
CN306 (Reserved) (inside the External Axes Controller)
WARNING
Since some connector pins of the power unit are applied with a high voltage, touching themaccidentally during maintenance or other work may result in an electric shock hazard. Therefore,DO NOT touch live electrical parts.
CAUTION
Never use the reserved connectors in Table 5.4.2.1 for purposes other than specified.
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This charging unit is used to supply power to absolute encoders and has the following functions
(1) Charges the charging battery while the control power is ON.(2) Detects overdischarge of the charging battery to thereby disconnect the load.
(3) Backs up the data of each absolute encoder using the charging battery when the control poweris OFF.
Fig. 5.5.1.1 External View of the Charging Unit
5.5.2 Connectors of the Charging Unit
This charging unit is equipped with connectors in Table 5.5.2.1 to back up data of the absoluteencoders.
Table 5.5.2.1 Connectors of the Charging Unit
Connector No. Peripheral devices to be connected to
CN30 AC200 V power supply input (inside the robot controller)
CN31 Backup power supply output to each encoder (inside peripheral devices)
CN32 Charging battery
WARNING
1. When the power is ON, never touch any parts of the robot control unit except the charging batterybecause that may result in an electric shock hazard.
2. Disconnecting CN32 while the control power is turned off results in a loss of absolute-encoderdata.
3. Power of the charging battery is supplied to an absolute encoder of each axis via the charging unitconnector CN31 and External Axes Cable. Therefore, disconnecting the connector or the
External Axes Cable irrespective of whether the control power is ON or OFF results in a loss of
absolute-encoder data. When either of them is disconnected for maintenance or inspection, besure to make absolute offset adjustments for each peripheral jig.
For the absolute offset adjustments, see “Installation: 4.2 Absolute Offset Adjustments” in“INSTALLATION & MAINTENANCE” for DR series.
TP1
TP2
TP3
VR1
CR1
CN30
C
N32
CN31
1
3
2
8
1
1
L4797P
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A charging battery is provided in the External Axes Controller to back up data of each absolute
encoder with which peripheral jigs are equipped. It is charged while the control power is ON, andsupplies power to the absolute encoder for data backup purposes when the control power is OFF.Therefore, when the robot system is not used for an extended period of time, the residual battery
capacity will decrease, eventually failing to supply power to the absolute encoder.
In that case, priorto initiating automatic operation, be sure to make absolute offset adjustments for each manipulator.
WARNING
Removing External Axes Cable while the control power is off results in a loss of absolute encoderdata. In such a case, be sure to make absolute offset adjustments for each peripheral jig.
For the absolute offset adjustments, see “Installation: 4.2 Absolute Offset Adjustments” in“INSTALLATION & MAINTENANCE” for model DR series.
CAUTION
1. The data backup period of the absolute encoder while the control power is OFF is approximately10 days. After the period, absolute offset adjustments need to be carried out
2. The data backup period of the absolute encoder may be shorter depending on environmentalconditions, operating conditions and other factors.
5.6.2 Specifications of the Charging Battery
Nominal Voltage
Discharge VoltageThe Lowest Possible Voltage for Recharging
: 4.0 V (5.0 Ah)
: 3.8 V 4.2 V: 3.7 V
The above specifications are applicable when absolute encoder, charging unit and other loads are
connected.
5.6.3 Replacing the Charging Battery
The charging battery characteristics gradually deteriorate with repeated charge-discharge cycles.Therefore, it is necessary to replace the charging battery with a new one at the 3-year periodicinspection in accordance with the procedure described below.
WARNING
Because of a possible fire or electric shock hazard, NEVER attempt to short terminals (+) and (-)with a wire or other similar conductive materials when replacing the charging battery with a new oneor conveying it.
(1) Perform block operation in accordance with the origin position check program <such as P999>
and make sure that the origin position is in alignment with a matchmark <>. If not, mark that
position.
(2) With the control power of the robot controller ON, remove the two bolts (M58) that are fixing
the charging battery to the External Axes Controller in order to remove the battery.
(3) Remove the tab-on terminals of the connecting cable from the charging battery.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(1) Disconnecting the charging battery with the control power OFF results in a loss of absolute-encoder data. Be sure to turn on the control power when replacing the charging battery.
(2) When the power is ON, NEVER touch any parts of the robot control unit except the chargingbattery because that may result in an electric shock hazard.
(4) Connect a connecting cable to the new charging battery <namely, the wire identification mark[+] (white wire) to the plus terminal of the charging battery, and the mark [-] (blue wire)to the minus terminal, respectively>.
(5) Fix the charging battery in position using the two bolts (M58) that were removed in procedure
(3).
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The External Axes Controller is of an enclosed type and is internally air-cooled by four cooling fans as
shown in Fig. 5.7.0.1.
Cooling fans FM111 and FM112 are mounted on the air cooling unit.
Cooling fan FM113 is mounted on the left-side cover of the robot control unit.
Cooling fan FM114 is mounted on the bottom of the servo frame.
Fig. 5.7.0.1 Cooling Fans
WARNING
NEVER put your hand, finger, hair or clothes close to a rotating fan becauseyou may be caught and injured.
WARNING
When you are performing maintenance or checking on the servo unit or other
devices, NEVER attempt to remove the side cover while the power is ONbecause you may get your hand, finger, hair or clothes caught by a rotating fanand be injured.
CAUTION
Dust accumulation on the radiation fins of the cooling unit causes a decline in cooling capability, thusclean the fins periodically.
7/18/2019 DR External Axis Controller (1L4805A-E-3)
6.3 Electrical Connection Diagram for External Axes Cable
(1) External axes cable 1 for 1-axis peripheral jig
Note: Connectors on the left-hand side in this figure are the destinations when one 1-axis peripheral
jig is used. When using the peripheral jig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.
(2) External axes cable 2 for 1-axis peripheral jig
Note: Connectors on the left-hand side in this figure are the destinations when one 1-axis peripheral jig is used. When using the peripheral jig for other combinations, see “3.5 Connecting External
Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.
B
E
H
C
J
F
External Axes Controller Positioner CN2
+SD
GND
VCC
CN272
G
A
E
I GND
D
-SD
RESET(+)
BAT
OVRN LS-1
OVRN LS-COM
RESET(-)
SHIELD
AC12V A
ABSRST
2
E0V
8
6
3
1
OVRUN
9
E5V
BAT
10
+SD
OVCOM
-SD
5
7
4
AC12V B
W
E
E
B2
B
A
B3
B1
F
External Axes Controller
U
CN1
GND
GND
CN201
CN67
B
C
D
V
A
Positioner
Brake (-)
Brake (+)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
(3) External axes cable 1 for 2-axis peripheral jig
Note: Connectors on the left-hand side in this figure are the destinations when one 2-axis peripheral
jig is used. When using the peripheral j ig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.
(4) External axes cable 2 for 2-axis peripheral jig
Note: Connectors on the left-hand side in this figure are the destinations when one 2-axis peripheral jig is used. When using the peripheral j ig for other combinations, see “3.5 Connecting External Axis Cable 1 & 2” and check where to connect the above-mentioned connectors.
P RESET(-)
S RESET(-)
E SHIELD
E0V
-SD2
+SD2
OVRUN2
OVCOM2
AC12VA
AC12VB
+SD
J -SD
G GNDT RESET(+)
F VCC
RESET(+)
K
OVRN LS-COM
N.C.
H1
2
3
6
7
8
CN274
BAT
5
4
9
10
E5V2
ABSRST2
10
C4
5
VCC
BAT
-SD
CN272
E
AC12VA
8
7
6
3
2
1
N
D
B
M
L
R
CN2
-SD1
OVRN LS-1
E5V1
E0V
+SD1
ABSRST1
BAT
A
GND
+SD
AC12VB
OVRUN1
OVCOM1
9
External Axes Controller Positioner
GND
GND
W
G
B2
2
1
B3
B2
B1
B3
B1
F
E
J
I
H
External Axes Controller Positioner
U
W
CN1
CN67
U
V
GND
GND
CN201
CN203
B
C
D
V
A
Brake (-)
Brake (+)
7/18/2019 DR External Axis Controller (1L4805A-E-3)
Note: Connections on the left-hand side in this figure are the destinations when one 4.5 kW motor axisis used. When using the peripheral jig for other combinations, see “3.5 Connecting External Axis
Cable 1&2” and check where to connect the above-mentioned connectors. For External axes cable2 for1-axis 4.5 kW motor, use external axes cable 2 for 1-axis peripheral jig.
7/18/2019 DR External Axis Controller (1L4805A-E-3)