Taxen-053-017 Install en Rev17 PDF

AX CONTROLLER
OPERATING MANUAL
Installation Manual
17th Edition
■ Before attempting to operate the robot, please read through this operating
manual carefully, and comply with all the safety-related items and
instructions in the text.
■ The installation, operation and maintenance of this robot should be
undertaken only by those individuals who have attended one of our robot
courses.
■ This operating manual must be given without fail to the individuals who will
actually be operating the robot.
■ Please direct any in queries about parts of this operating manual which
may not be completely clear or any inquiries concerning the after-sale
service of this robot to any of the service centers of NRE (Nachi Robotic
Engineering) listed on the back cover.
0812, TAXEN-053-017, 001

Table of Contents
Table of Contents
Chapter 1 Point on Safety

1.1 For safe use of the robot ........................................................................................................... 1-1
1.1.1 Safety Measures on manipulator....................................................................................... 1-3
1.1.2 Safety measures in teaching and inspection..................................................................... 1-5
1.1.3 Safety measures in test run............................................................................................... 1-7
1.1.4 Auto operation ................................................................................................................... 1-8
1.1.5 Movement, alienation and selling of robot......................................................................... 1-9
1.1.6 Storage of robot ................................................................................................................. 1-9
1.1.7 Disposition of Robot ........................................................................................................ 1-10
1.1.8 Labels and marks on robot and controller....................................................................... 1-11
1.2 To ensure the safety of arc welding ........................................................................................1-14
1.2.1 Preventing electric shock accidents ................................................................................ 1-14
1.2.2 Protection from fumes and gases given off during welding ............................................ 1-15
1.2.3 Protection from the arc light generated during welding................................................... 1-16
1.2.4 Preventing fire- and explosion-related accidents caused by the base metal, spatter, slag or
arc sparks ................................................................................................................................. 1-17
1.2.5 Preventing gas cylinder from toppling over or rupturing and protecting gas flow regulators
from overheating, impact, etc. .................................................................................................. 1-18
1.2.6 Precautions for undertaking work inside the robot’s work area ...................................... 1-19
Chapter 2 Transportation and Installation

2.1 Transportation............................................................................................................................ 2-1
2.1.1 ST series............................................................................................................................ 2-1
2.1.2 AX20 controller .................................................................................................................. 2-2
2.1.3 V/B series .......................................................................................................................... 2-3
2.1.4 AX21 controller .................................................................................................................. 2-5
2.2 Robot Installation ....................................................................................................................... 2-6
2.2.1 Safety measures relating to installation............................................................................. 2-6
2.2.2 Installation locations and ambient conditions.................................................................... 2-9
2.2.3 Installation method ............................................................................................................ 2-9
2.2.4 Installation method .......................................................................................................... 2-10
2.2.5 Installation surface accuracy ........................................................................................... 2-12
2.2.6 Strength of rack ............................................................................................................... 2-13
2.2.7 Installing the manipulator and jigs on the common frame base...................................... 2-14
2.2.8 Using Optional Manipulator Stand for Installation ........................................................... 2-15
2.3 Installation of controller............................................................................................................ 2-16
2.3.1 AX20 controller Installation .............................................................................................. 2-16
2.3.2 AX21 controller installation .............................................................................................. 2-17
Chapter 3 Connections
3.1 How to read this chapter............................................................................................................ 3-1
3.2 Cable connections (AX20)......................................................................................................... 3-2

3.2.1 Robot connections............................................................................................................. 3-2
3.2.2 Teach pendant connection ................................................................................................ 3-2
3.3 Power supply connections (AX20) ............................................................................................ 3-3
3.3.1 Before connecting the primary power supply .................................................................... 3-3
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3.3.2 Primary power supply connections.................................................................................... 3-3

3.3.3 Concerning grounding ....................................................................................................... 3-4
3.4 Signal line connections (AX20).................................................................................................. 3-5
3.4.1 Selecting an optional function for I/O signal connection ................................................... 3-5
3.4.2 I/O connection using I/O board UM212............................................................................. 3-6
3.4.3 Input signal connector ....................................................................................................... 3-8
3.4.4 Output signal connector ..................................................................................................3-14
3.4.5 I/O connection using Fieldbus function ........................................................................... 3-20
3.5 Cable connections (AX21)....................................................................................................... 3-21
3.5.1 Manipulator connection ................................................................................................... 3-22
3.5.2 Teach pendant connection .............................................................................................. 3-24
3.5.3 Operation box connection ............................................................................................... 3-25
3.5.4 Start box connection ........................................................................................................ 3-26
3.5.5 Connection of TP interconnection board ......................................................................... 3-27
3.5.6 Connecting Digital Welding Power Supply ...................................................................... 3-31
3.6 Power connections (AX21) ...................................................................................................... 3-47
3.6.1 Primary power supply connections.................................................................................. 3-47
3.6.2 Grounding........................................................................................................................ 3-49
3.7 Signal line connections (AX21)................................................................................................ 3-51
3.7.1 Connecting I/O signals to Relay board............................................................................ 3-51
3.7.2 Specification of I/O signals .............................................................................................. 3-51
3.7.3 Wiring............................................................................................................................... 3-52
3.7.4 Input signal connections.................................................................................................. 3-53
3.7.5 Output signal connections ............................................................................................... 3-57
3.8 Safety-related signal connections (AX20/21) .......................................................................... 3-59
3.8.1 I/O sequence board ......................................................................................................... 3-59
3.8.2 Position of the terminal block .......................................................................................... 3-60
3.8.3 External emergency stop input (TBEX1 : 1-2, 3-4) ......................................................... 3-64
3.8.4 Safety plug input (TBEX1 : 5-6, 7-8) ............................................................................... 3-65
3.8.5 Enable switch inputs (TBEX1 : 9-10, 11-12).................................................................... 3-66
3.8.6 Connections when the robot controller is used by itself.................................................. 3-66
3.8.7 Emergency stop output connection (TBEX2 : 1-2, 3-4) .................................................. 3-67
3.8.8 Each External Input Signal Connection........................................................................... 3-68
Chapter 4 Setup
4.1 Power-on ................................................................................................................................... 4-1
4.1.1 Power-on ........................................................................................................................... 4-1
4.2 Configuration ............................................................................................................................. 4-3
4.2.1 Performing encoder reset and encoder correction (For DAIHEN) .................................... 4-3
4.2.2 Performing encoder reset and encoder correction (For NACHI) .................................... 4-10
4.3 Motor power (servo power) ON ...............................................................................................4-11
4.3.1 Motor power-on ............................................................................................................... 4-11
4.3.2 Motor power-off ............................................................................................................... 4-12
4.4 Installing a tool......................................................................................................................... 4-13
4.4.1 Mounting the tools (for the ST-166-02) ........................................................................... 4-13
4.4.2 Mounting the tools (for the NV6/NV6L/NV20) ................................................................. 4-14
4.5 Tool constant settings.............................................................................................................. 4-15
4.5.1 Tool name ........................................................................................................................ 4-16
4.5.2 Tool length ....................................................................................................................... 4-17
4.5.3 Tool angle ........................................................................................................................ 4-23
4.5.4 Center of gravity (COG) and weight of tool ..................................................................... 4-25
4.5.5 Tool’s moment of inertia................................................................................................... 4-30
4.5.6 Max, radius of tool ........................................................................................................... 4-42
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Table of Contents
4.5.7 Tool length and angles of Daihen’s arc welding torch ..................................................... 4-43
4.5.8 Tool Exchange ................................................................................................................. 4-49
4.6 Signal attribute settings ........................................................................................................... 4-54
4.6.1 Standard signal attributes assignment ............................................................................ 4-56
4.6.2 Basic input signals........................................................................................................... 4-57
4.6.3 Basic output signals......................................................................................................... 4-59
4.7 Concerning the qualifications of the operators ........................................................................ 4-65
4.7.1 Operation qualifications ................................................................................................... 4-65
4.7.2 Procedure for changing the operator qualifications ........................................................ 4-66
4.7.3 How to change the passwords ........................................................................................ 4-67
4.7.4 How to set the operator qualifications class at power-on................................................ 4-68
4.8 I/O area mapping function ....................................................................................................... 4-69
4.8.1 I/O are mapping............................................................................................................... 4-69
4.8.2 Relation with software PLC ............................................................................................. 4-72
4.8.3 Setting method ................................................................................................................ 4-73
4.8.4 Example 1 : Making only field bus as external input / output signal in PLC cutoff .......... 4-76
4.8.5 Example 2: Using only standard IO board – field bus CH1 in PLC cutoff ....................... 4-77
4.8.6 Example 3: Forcibly inputting / outputting signals of additional IO board 1 as 1-32 signals
with PLC enabled ..................................................................................................................... 4-78
4.9 High Speed Interference Detection Function (Revised).......................................................... 4-79
4.9.1 Outline of High Speed Interference Detection Function.................................................. 4-79
4.9.2 Objective machine types ................................................................................................. 4-79
4.9.3 Setting at Robot Start ...................................................................................................... 4-80
4.9.4 Setting Most Suitable Threshold Value for Work Program .............................................. 4-82
4.9.5 Switching Detection Level by Function............................................................................ 4-86
4.10 Setting the application type ................................................................................................... 4-87
4.11 Setting the [Clamp / Arc] key ................................................................................................. 4-89
4.12 Setting the software limit (operating range)........................................................................... 4-92

4.12.1 Outline ........................................................................................................................... 4-92
4.12.2 [Position record] screen settings ................................................................................... 4-93
4.12.3 [Data input] screen settings........................................................................................... 4-94
4.12.4 [Auto Set] screen settings ............................................................................................. 4-95
Chapter 5 Spot welding setup

5.1 Overview of setup work ............................................................................................................. 5-1
5.2 Assignment of spot welding input/output signals....................................................................... 5-3

5.2.1 Spot welding input signals ................................................................................................. 5-3
5.2.2 Spot welding output signals............................................................................................... 5-4
5.3 Settings inherent to a servo gun................................................................................................ 5-5
5.3.1 Servo gun condition........................................................................................................... 5-5
5.3.2 Tip consumption detection................................................................................................. 5-8
Chapter6 Arc welding setup

6.1 Outline of setup work ................................................................................................................. 6-1
6.1.1 Setup relating to welding power supply............................................................................. 6-1
6.1.2 Setup relating to external input/output signals .................................................................. 6-1
6.2 Checking the welding characteristics data and wire feed characteristics data ......................... 6-2
6.3 Allocating the dedicated arc welding input/output signals......................................................... 6-4

6.3.1 Allocating the dedicated arc welding input/output signals................................................. 6-4
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Table of Contents
6.3.2 Table of input signals ......................................................................................................... 6-5

6.3.3 Table of output signals....................................................................................................... 6-6
Chapter 7 Preparations for auto operation

7.1 Specification of the operation method ....................................................................................... 7-1
7.1.1 Controller operation ........................................................................................................... 7-1
7.1.2 External operation ............................................................................................................. 7-1
7.1.3 Multi-station operation ....................................................................................................... 7-5
7.2 Setting multi-station operation ................................................................................................... 7-6
7.2.1 Connecting the operation boxes and start boxes.............................................................. 7-6
7.2.2 Registering the number of stations.................................................................................... 7-6
7.2.3 Allocating the start signals (only when using stations 5,6) ................................................ 7-7
7.2.4 Allocating the input/output signals for multi-station use .................................................... 7-7
7.2.5 Allocating the program to be started.................................................................................. 7-8
7.3 Home position registration......................................................................................................... 7-9
7.3.1 Home position registration by referencing the program .................................................... 7-9
7.3.2 Home position registration by manual recording............................................................. 7-12
7.3.3 Home position registration by numeric input ................................................................... 7-13
7.4 Registering Start Enable Area ................................................................................................. 7-14
7.4.1 Registering the start enable area .................................................................................... 7-14
7.4.2 Checking the unit if it is in the start enable area ............................................................. 7-16
7.4.3 Checking which axis is out of the start enable area ........................................................ 7-17
7.5 READY status output signals .................................................................................................. 7-18
7.5.1 Controller READY signals ............................................................................................... 7-18
7.5.2 Unit READY signal .......................................................................................................... 7-18
7.5.3 Status output signals ....................................................................................................... 7-21
4
Chapter 1 Point on Safety
This chapter explains the safety precautions to be observed when handling the robot. This
section describes general precautions and procedures on safety but does not show all of
the safety measures. Therefore, it is necessary for customers to prepare yourself a safety
control standard including your own operational regulations in accordance with the actual
working environment and to conduct safety control in order to secure the workers' safety.
1.1 For safe use of the robot .......................................................................................... 1-1

1.1.1 Safety Measures on manipulator ....................................................................... 1-3
1.1.2 Safety measures in teaching and inspection ..................................................... 1-5
1.1.3 Safety measures in test run ............................................................................... 1-7
1.1.4 Auto operation .................................................................................................... 1-8
1.1.5 Movement, alienation and selling of robot ......................................................... 1-9
1.1.6 Storage of robot.................................................................................................. 1-9
1.1.7 Disposition of Robot ......................................................................................... 1-10
1.1.8 Labels and marks on robot and controller ....................................................... 1-11
1.2 To ensure the safety of arc welding ....................................................................... 1-14
1.2.1 Preventing electric shock accidents ................................................................. 1-14
1.2.2 Protection from fumes and gases given off during welding ............................. 1-15
1.2.3 Protection from the arc light generated during welding ................................... 1-16
1.2.4 Preventing fire- and explosion-related accidents caused by the base metal,
spatter, slag or arc sparks ......................................................................................... 1-17
1.2.5 Preventing gas cylinder from toppling over or rupturing and protecting gas flow
regulators from overheating, impact, etc................................................................... 1-18
1.2.6 Precautions for undertaking work inside the robot’s work area....................... 1-19
ぺージあわせのため白文字（白文字のため印刷されないなので気にしないでください。削除しないでください。
）
1.1 For safe use of the robot

Read this manual and all other attached documents carefully prior to installation, operation, maintenance, or
inspection and use equipment correctly. Use the robot only after fully understanding the equipment, all
safety points, and comments/suggestions.
Importance varies with the following symbols in this manual.
Cases where a mistake made in handling is likely to cause the user to be

exposed to the danger of death or serious injury and where the degree of the urgency
(imminence) of the warning given for the danger to occur is at the high end of the
DANGER scale (including high-level danger).
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury.
WARNING
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of minor injuries or of property damage only.
CAUTION
The following symbol is also used for particularly important checkpoints:。
This is a particularly important checkpoint.
Precautions when performing adjustment, operation or maintenance

(1) Operators must wear overalls, helmet and safety shoes.
(2) Make sure there is no one in the robot work area when the power is turned on.
(3) Only perform work within the robot work area after making sure the motor power is off.
(4) There are cases where inspection or maintenance work has to be done with motor power on. In these
cases, perform the work in pairs. One person must stand guard and be able to press an emergency stop
button at any time. The other person must work quickly while being very careful of the robot operating
range. Always allocate, confirm and know an escape route prior to beginning work.
It is possible the robot will make an emergency/safe stop if an abnormal situation occurs, this is due to
various selfdiagnostic functions and abnormality detecting functions provided. However, the robot is not 100%
safe.
Robot accidents occurred in the past are mostly due to the following situations:
Auto operation started without confirming there were no people inside the robot
operating area.
A person entered the operating area of a robot which was in auto operation mode
and the robot started unexpectedly.
A person paid attention to one robot forgetting another one was operating within
reach of them.
Carelessness common to the above accidents are:

"Safety procedures were neglected." and "The robot started suddenly although
such was unthinkable."
1-1
In other words, we can summarize the above by unsafe activities caused by human error such as
"careless mistakes" and "not following the established procedures." Workers can not take
appropriate actions such as "emergency stop" or "escape from the danger" in such a surprise attack,
so-to-speak, which, hence, may result in a big accident.
Such surprise-attack patterns include:
• Sudden change of movement from low speed to high speed
• Manipulation by another worker
• The robot is operated by different program because of program mistakes or faulty peripheral equipment.
• Abnormal behavior due to noise, fault and error
• Mishandling
• Operation at a high speed in spite of playback intended at a low speed
• Work being transferred by the robot dropped or was scattered.
• Work at a stop waiting for interlocking is released suddenly.
• Adjacent or rear robots started operation.
The above incidents are only examples, and many other patterns of surprise-attack accidents exist. It is
difficult to stop or escape from a robot that starts unexpectedly. Therefore, the following important points
should be observed;
Do not get near the robot.

Fatal or serious injury may result if a person is hit or caught by a robot due to
DANGER unexpected motion.
If operation of the robot is not necessary, lock the robot so as to prevent it from
running.
If it is necessary to observe the robot's behavior, have another person (watcher)

carefully monitor the robot constantly during operation.
Perform the operation while being ready to press the emergency button at any time
when the robot operation is necessary.
LOCKOUT AND TAG OUT EQUIPMENT, Door lock
BEFORE SERVICING.
Detailed
WARNING view
Only qualified service personnel may install or service the robot system.
And ensure compliance with all local and national safety and electrical codes for
DANGER the installation and operation of the robot system.
In order to follow these rules, it is necessary to thoroughly understand the cautions described hereafter and
observe them precisely.
1-2
1.1.1 Safety Measures on manipulator
The manipulator is of such design that no unnecessary protrusions or sharp corners

exist. It is made of suitable material for use in the environment for which it was designed
and has fail-safe construction to minimize damage or accidents during operation. The
robot maintains a good level of safety because various safety functions exist; such as
those to detect incorrect operation and stop the robot, or to make emergency stops,
interlocking with peripheral equipment, when either device threatens to damage the
other.
The robot is of multi-articular arm construction, thus each articular angle varies all
the time with robot movement. Take care and avoid getting pinched in various
articulations, especially when teaching. Pay careful attention to the stopper blocks
mounted on the moving tip of the articulations. The arm may fall under its own weight
WARNING
when motors are removed or brakes are released. Therefore take action to prevent
dropping and check that conditions are safe before starting work.
Unless the arm is supported properly, it will drop if the motor is removed. Before
removing the motor, make absolutely sure that the arm is supported properly.
WARNING
When the motor is removed The arm will drop.

without holding the arm properly...
Do not rely on the positioning pin alone to secure the arm since it may be inserted
incorrectly or inserted only half way in. Use a wooden block, sling or other means to
support the arm properly before attempting to remove the motor. The robot arm must
NOT be supported by a person's hand.
Never remove or disassemble a balance spring as it is compressed under great

pressure.
Removal is a very dangerous act.
CAUTION
Use specified bolt sizes and number. Be sure to tighten them to specified torque with a
torque wrench when fitting equipment onto the end effector flange or arms.
Use clean rust-free bolts. Otherwise bolts may loosen during operation leading to
CAUTION serious accidents and injuries.
When fabricating the end effector, set its weight and static load moment within the
range of the permissible load levels of the robot wrist.
CAUTION
1-3
Provide a failsafe construction which will ensure that the work gripped will not be
released or scattered even when the power or air supply to the end effector is cut off.
Also remove any sharp edges or protrusions in its construction to prevent injury to
CAUTION personnel and damage to property.
In order to operate the robot, services such as electric power, plant air and cooling
water for welding should be supplied. However, non-specified services may effect
the robot performance and cause abnormal behavior, errors or damage, resulting in a
CAUTION dangerous situation. Never use unspecified resources.
It is not possible to eliminate electromagnetic interference completely using the

technology available today although the extent of its elimination depends on the type and
strength of the interference concerned. In terms of what action to take while the robot is
operating and while the power is on, follow the precautions to be observed during
CAUTION operation. In some cases, electromagnetic waves, other forms of noise or defective
circuit boards may erase the recorded programs. As a safeguard, make backups of the
programs, constants, etc. on a Compact Flash card or other media.
1-4
1.1.2 Safety measures in teaching and inspection
Robot operators must only be those who have completed specified training and are
fully aware of safety and functions of the robots. Accidents may occur due to mishandling
of the robot during operation by those who do not know the correct procedures well.
CAUTION
When entering the robot operating area with Motors-on, the emergency stop button
must be readily accessible. In addition, a watcher must be present outside the operating
area ready to press the emergency button immediately. In doing so an emergency stop
CAUTION can be made quickly.
Wear protective gear such as a helmet and safety boots when operating the robot or
entering its operating area.
WARNING
Keep the robot's key switch and a safety plug for changing to Auto operation with you
when entering the robot operating area so other people can not change the switch to Auto
operation accidentally. If the key is left in the switch other workers may accidentally start
WARNING Auto operation leading to serious accidents.
Display (attach) a sign showing "Teaching Under Way" on the operation panel when
teaching. Other workers are required to notice this fact. If not, they may start the Auto
WARNING operation, resulting in serious or fatal accidents.
When a number of workers are involved in the teaching of a robot, the operator
holding the teach pendant is in charge and must give commands and the others must
follow.
Commands given by numerous operators may invite incorrect manipulation,
CAUTION
leading to accidents.
Consider methods to communicate with other workers such as hand signals when
conversation takes place between a number of workers positioned separately, in a
large system (plant) for example. Accidents are likely to occur due to misinterpreted
CAUTION intentions in a noisy site.
Keep a safe place (escape route) in mind at all times to quickly escape in an
emergency.
CAUTION
Pay attention to the robot's movement at all times and never work with your back
toward the robot. An operator may not notice the start of a robot if he/she is not facing it
WARNING resulting in an accident.
1-5
Press the emergency stop button immediately if you notice any abnormality. Make
this practice very clear to every operator.
WARNING A sudden movement may be imminent if you are watching something abnormal.
Prepare an appropriate working code and checklist for start up of the robot, how to
operate it and what actions to take in an emergency. Proceed with operation according to
the working code. Accidents are likely to occur due to forgetfulness and error of operators
CAUTION if relying on memory alone.
Proceed with work with the robot's power off when operation or manipulation of the
robot are not necessary. It can never run with its power off.
CAUTION
When teaching, always check the program number and step number before
operating the robot. Editing of incorrect programs or steps may cause accidents.
CAUTION
Protect completed programs from accidental editing by using the memory protect
function.
(The memory protect function disabling the editing of various programs and constants is
CAUTION available on the AX Controller.)
Check robot movement at a low speed using the check go/back function and the
velocity override function after completing teaching. Accidents due to collision are
likely to occur if a program containing a mistake is checked at 100% full speed in the
CAUTION playback mode.
Clean the area within the guarding fence and check that tools, etc. are not left there after
teaching is complete. A workplace fouled with oil or grease and tools is a hazardous
place and may lead to an accident due to stumbling. "Cleaning the workplace" is a step
CAUTION toward safety.
Be absolutely sure to observe the following precautions before turning on the primary
power supply while the controller door is left open to enable maintenance or other work to
be performed. Failure to adhere to the precautions may cause the robot and/or controller
to fail or operate in error.
WARNING
1. Do not expose the controller to direct sunlight.
2. After opening the door, do not directly expose the parts inside the controller to a
searchlight or other strong lights.
LOCKOUT AND TAG OUT EQUIPMENT, Door lock
BEFORE SERVICING.
Detailed
WARNING view
1-6
1.1.3 Safety measures in test run

In the test run, design errors, teaching errors or manufacturing errors may exist in addition to
probable errors in the teaching program, jigs, sequence, etc. Therefore the test run requires
greater safety consciousness. Perform a test run paying attention to the following points;
Check all buttons to stop the robot, such as the emergency stop button, other
stop buttons, and the deadman switch and that their signals work well. Then check the
functions associated
with detection of abnormalities.
WARNING
Confirmation of "stop" is most important. Accident or injury may result due to the
failure of a stop button or signal in an emergency.
When performing the test run, start the robot up at a low speed (about 5% to 10%),
with the velocity override function, to check the movement. Repeat this about 2 to 3
cycles. Correct any errors, if any, at once.
Then gradually increase the speed (50% → 70% → 100%) and repeat 2 to 3 cycles at
CAUTION
each speed to confirm the movement.
It is difficult to stop a robot, when an error occurs, before it causes damage if checking is
started at a full speed.
Confirmation of the program should NEVER be made from within the guarding fence as
unexpected things may occur in the test run. The test run stage is one of low
DANGER predictability, thus a high probability of unexpected accidents exists.
1-7
1.1.4 Auto operation
Clean the workplace and keep everything in order at the beginning and end of work.
If the workplace is littered with various items, accidents, such as tripping, may occur.
CAUTION
Ensure a daily inspection according to the specified check list is done before startup.
By discovering abnormalities in advance, accidents can be avoided. (Refer to
Maintenance Manual for the daily inspection items. It is mandatory to check all of the
CAUTION items in the check list prepared based on the above Maintenance Manual.)
An "OFF LIMITS" sign should be displayed at all entrances of the guarding fence and all
employees made aware of this rule. If not, they may enter the guarding fence thinking that
the robot is inoperable.
CAUTION
Always confirm there is no one within the guarding fence before starting auto
operation.
DANGER Accidents caused by neglecting to confirm a person's presence are the most typical.
Start auto operation after confirming the program number, step number, mode and
startup select are all ready for auto operation. If the robot is started with an incorrect
program or step selected, unexpected incorrect movement may occur resulting in an
CAUTION accident.
Check that the robot is in a good position to start for auto operation. Check the
program number and the step number match the current robot position. If the robot is in
an incorrect position, even though the program and the step are OK, it will act differently,
CAUTION resulting in a probable accident.
Before Start up, make sure the emergency stop button can be pressed immediately.
This is vital in dealing with unexpected occurrences.
CAUTION
Operators should be familiarized with the robot's movement path, operating behavior,
running sound, etc. so that abnormalities can be detected. Failures may be avoided by
recognizing abnormal behavior as abnormalities may indicate an imminent system failure.
CAUTION In order to detect these operators need to be fully aware of the normal status of operation.
Make an emergency stop immediately if any abnormal behavior is observed and

report the incident to superiors or the person in charge of maintenance, and take
appropriate action. The "It's moving. That's OK" attitude can cause not only a stop in
WARNING production due to failure but serious injury.
1-8
When verifying operation after remedial measures have been taken to deal with the
occurrence of fault, refrain from conducting any operations—such as conducting
low-speed playback to verify operation—while an operator is still inside the safety
fence until it is confirmed that the fault has indeed been remedied. What will happen in
WARNING
this kind of situation cannot be reliably predicted so other fault may occur or unforeseen
accidents may result.
Install a guarding fence so that no one enters the robot work area during Automatic
operation.
WARNING
1.1.5 Movement, alienation and selling of robot
Hand over all manuals and documents received when purchasing the robot to the
new owner when moving, alienating or selling a robot. In particular, if the robot is to be
moved, transferred or sold overseas, the user is responsible for preparing and supplying
the operating and maintenance manuals in the appropriate language, amending the
CAUTION language used for the labels and displays and complying with the laws of the country
concerned. Accidents may occur if the new robot owner (operator) operates the robot
incorrectly or performs unsafe work tasks due to not receiving and reading the Operating
Instructions.
When the robot is moved, transferred or sold (either in the country or overseas) by
the user, whatever was agreed upon at the time of the robot's initial sale inclusive of the
safety-related items is not transferable to the new owner unless a special agreement has
been concluded.
CAUTION
The user must conclude a new agreement with the new owner.
1.1.6 Storage of robot
For storing a robot, following ambient conditions shall be met.
1) Storage temperature：0℃～50℃
（For long-term storage, 25℃±10℃ are recommended to maintain the reliability.）
CAUTION
2) Storage humidity：20％～85％（Non condensing）
3) There shall be little dirt, dust, lampblack, and water.
4) There shall be no flammable or corrosive liquids and gases.
5) The robot must not receive any shocks or vibrations.
1-9
1.1.7 Disposition of Robot
Do not disassemble, heat or burn batteries used in the controller and robot as they
may catch fire, burst or burn.
CAUTION
Do not disassemble the controller in detail smaller than PCBs or units. Sharp edges or
electric wire of small disassembled pieces may cause injury.
CAUTION
Do not disassemble wire harnesses or robot external wiring further than disconnecting
wiring from connectors or terminal blocks. Disassembled pieces, eg. Semiconductors
etc., may cause injury to hands or eyes.
CAUTION
Use extreme care when scrapping so as to avoid accidents and injury such as pinching
hands or fingers.
CAUTION
Cautions about Batteries

1. Do not recharge, disassemble, deform, heat above 212°F, incinerate of expose
contents to water.
2. Do not solder anything directly to the batteries.
3. Do not connect (+)(-) of the batteries with wire and do not carry or keep metallic
necklace, hairpin, etc. together with batteries.
4. A leaking or badly smelling battery should be discarded immediately. The leaking
electrolyte may corrode metal parts.
5. Do not mix and use “different types of batteries” nor “used and new batteries” together.
6. At disposal of the batteries, insulate the terminal parts with tape or the like.
WARNING
7. If the liquid of the batteries touches the eyes, the eyes may be injured. Do not rub the
eyes but flush the eyes amply with clean water such as city water and then receive
medical treatment without delay.
8. Keep batteries out of reach of babies and little children.
9. If battery is swallowed, immediately consult a doctor.
10. The (+) terminal of this battery is sealed with glass seal. Do not drop, hit, throw, or give
any shock to the battery.
11. Do not dispose of batteries in fire. If the batteries are put in fire, they may explode by
rapid heating.
12. The replacement of the batteries should be done in principle by a trained technician.
13. At disposal of the batteries, insulate the terminal parts with or the like.
Discard scrapped items safely to avoid injury.

CAUTION
1-10
1.1.8 Labels and marks on robot and controller
Supplementary explanation is made below concerning the labels and warning plates attached to
the robot and the controller.
This mark indicates danger of an electric shock.
In the controller, a primary power voltage (AC

200V to AC 480V) exists, which may cause serious electrocution. Turn off the power at
both the controller breaker and the power distribution panel when doing maintenance.
CAUTION
Motor power and detector unit power is supplied to connectors and terminal blocks under
various connector covers on the robot mark.
Do not touch connectors or terminal blocks directly, or indirectly with conductive
items with mains power supplied, as electrocution may occur. If connectors or terminal
DANGER
blocks are removed with mains power on, electric shock or malfunction of the robot may
result. Turn off mains power on the controller when performing any maintenance.
This label indicates a high voltage. Use caution when

touching units carrying this label. Electrically charged parts
in the controller exist even after the mains power is turned
off. Therefore it is very dangerous (i.e. electric shock) to
touch them too soon after turning off the mains power.
Wait 5 minutes after turning off the mains power before working inside the controller.
Do not work with wet hands otherwise electrocution may result.
If parts get wet, it may lead to a malfunction or failure.
CAUTION
Under a cover displaying this mark on the controller, a primary power voltage (AC
200V to AC 480V) exists, which may cause serious electrocution. Turn off the power at
both the controller breaker and the power distribution panel when doing maintenance
CAUTION requiring the removal of any of these covers.
1-11
This mark indicates hot parts on the robot.
Check that the part bearing this mark is not hot before touching it. Carelessly touching
labeled hot parts may result in serious burns.
CAUTION
This mark indicates an area operators may get caught by

the robot.
Places bearing this mark should never be touched.

Brakes can be released not only during teaching but also while the motors are off.
Take adequate steps to prevent your hands or other parts of your body from being
CAUTION pinched when these areas are touched during maintenance work, etc.
This label indicates that robot arms may fall when motors
are removed from the robot.
Never put yourself under the arm when removing a motor. The arm driven by the
motor being removed will drop if not restrained.
CAUTION
Unless the arm is supported properly, it will drop if the motor is removed.
Before removing the motor, make absolutely sure that the arm is supported properly.
Do not rely on the positioning pin alone to secure the arm since it may be inserted
incorrectly or inserted only half way in. Use a wooden block, sling or other means to
WARNING
support the arm properly before attempting to remove the motor. The robot arm must
NOT be supported by a person's hand.
This label warns of stored electrical energy. Therefore use

caution when disassembling the robot units labeled as
such.
1-12
Never disassemble the parts bearing this mark, even when disassembling the robot for
maintenance. Disassembly of these parts may cause fatal or serious accidents.
CAUTION
1-13
1.2 To ensure the safety of arc welding
1.2.1 Preventing electric shock accidents
Before commencing the welding work, read through, familiarize yourself with, understand and
comply with the related safety regulations and basic checkpoints below in addition to the instructions
given in the manual of the welding power supply.
Follow the instructions below in order to avoid electric shock accidents.
Do not touch any of the electrically charged areas.

If you touch any of the electrically charged areas, you may receive a fatal shock
WARNING or suffer burns.
(1) The casing and base metal of the welding power supply and the jigs which are electrically connected to the
base metal must be grounded by a qualified electrician in accordance with the relevant laws and regulations
(technical standards for electrical apparatus).
(2) Do not touch any of the electrically charged areas.
(3) Wear dry insulated gloves and work overalls at all times. Never wear gloves or work overalls which are torn
or wet.
(4) Before undertaking installation, inspection, maintenance or other such work, be absolutely sure to turn off
all the incoming power supplies. Even when the incoming power supplies have been turned off, the
capacitors and other components may remain charged. After having turned off the power, therefore, wait 5
minutes, and then check that no charging voltage is present before proceeding with the work.
(5) Do not use any connecting cables which have an insufficient capacity, which are damaged or whose
conductors are now exposed.
(6) Securely tighten up the areas where the cables have been connected, and insulate them in such a way that
they cannot easily be touched.
(7) Do not use the welder with its casing or covers removed.
(8) Pay sufficient attention to where you will be stepping before undertaking the work. Do not perform any work
wherever your footing is unstable or high above the ground (higher than 2 meters).
(9) Perform the inspections and maintenance regularly, and repair any damaged parts or areas before using
them.
(10)Be absolutely sure to keep the incoming power of equipment which is not in use turned off.
1-14
1.2.2 Protection from fumes and gases given off during welding
Ensure that operators and other personnel follow the instructions below in order to protect themselves
from the fumes and gases which are given off during welding.
・Do not inhale the fumes.

Fumes and gases generated by welding have a harmful effect on human body.
・ Provide adequate ventilation and, wherever so required, wear a protective
WARNING mask, etc.
When welding work is performed in confined spaces, a deficiency of oxygen
may arise, and you may run the risk of suffocation.
(1) Keep your face as far away from the fumes as possible during welding and do as much as you can to refrain
from inhaling them.
(2) Use a forced exhaust pipe during welding.
(3) To avoid a build-up of fumes and gases, provide adequate ventilation.
(4) If the ventilation is inadequate, use the kind of breathing apparatus stipulated by the relevant laws and
regulations.
(5) Read and familiarize yourself with the warning labels on all of the containers relating to the welding
materials, and comply with the instructions given.
(6) Prior to use, be absolutely sure to look over and understand the instruction manual and the test data relating
to the materials.
(7) To prevent gas poisoning and suffocation, use the kind of local exhaust ventilation or breathing apparatus
stipulated by the relevant laws and regulations (Industrial Safety and Health Law, and the regulations for
preventing dust generation).
(8) When welding work is to be performed in confined spaces, be absolutely sure to provide adequate
ventilation or wear breathing apparatus and ensure that the work is monitored in the presence of a trained
observer.
(9) Do not perform welding work near degreasing, cleaning or spraying work. If it is performed in the vicinity of
such work, noxious gases may be generated.
(10) If covered steel sheets are to be welded, provide adequate ventilation or wear breathing apparatus since
noxious fumes and gases will be generated.
1-15
1.2.3 Protection from the arc light generated during welding
Ensure that instructions below are followed in order to protect the eyes and skin of the operators
and other personnel from the arc light which is generated during welding and in order to protect
their ears from the noise.
• Install a light-shielding wall in the area where arcs occur.

Arc light may lead to inflammation of the eyes and/ or burning of the skin.
• Wear the appropriate clothing and protective gear to protect your eyes, ears
and skin.
WARNING
The spatter and slag which are scattered around are harmful to the eyes and
cause burns on the skin.
Noise can cause hearing problems.
(1) When performing welding work or observing the welding, wear protective goggles with a high light-filtering
capability or the kind of protective face mask designed for welding.
(2) Take steps to install a protective curtain in the vicinity of the welding work area so that the operator and
other personnel will not have their eyes exposed to the arc light.
(3) Wear protective goggles at all times in the vicinity of the welding work area.
(4) Where there is loud noise, use ear protectors.
(5) When performing welding work, wear protective gear such as the kind of protective leather gloves designed
for welding, work overalls with long sleeves, leg coverings, and a leather apron which are appropriate for
the purpose at hand.
(6) To protect your eyes from spatter and slag, wear protective goggles.
1-16
1.2.4 Preventing fire- and explosion-related accidents caused by the base metal,
spatter, slag or arc sparks
Ensure that the instructions below are followed in order to avoid fire- and explosion-related accidents
and injury to operators caused by the base metal which will still be hot immediately after
welding or by spatter, slag and arc sparks.
• Install a light-shielding wall in the area where arcs occur.

Arc light may lead to inflammation of the eyes and/ or burning of the skin.
• Wear the appropriate clothing and protective gear to protect your eyes, ears
and skin.
WARNING
The spatter and slag which are scattered around are harmful to the eyes and
cause burns on the skin.
Noise can cause hearing problems.
(1) Do not place any ignitable or inflammable objects in the vicinity of the welding work.
(2) In order to prevent burns caused by the base metal which will still be hot immediately after welding or by
spatter, slag and arc sparks, operators should wear protective gear such as the kind of protective leather
gloves designed for welding, work overalls with long sleeves, leg coverings, and a leather apron which are
the appropriate for the purpose at hand.
(3) At all times observe the scene to ensure that nothing has caught on fire.
(4) Take fire precautions in advance by placing fire extinguishers in the vicinity of the welding work area and
ensuring that the operators know exactly how to use them.
(5) Do not allow the base metal, jigs, etc. which will still be hot immediately after welding to touch any wood,
cloth or other objects that will catch fire easily. Otherwise, not only may a fire be caused but you may burn
yourself as well.
(6) Do not bring the base metal which will still be hot immediately after welding near inflammable objects.
(7) Remove inflammable or ignitable objects from the welding work area so that the spatter which is scattered
around will not come into contact with them. If they cannot be removed, place non-combustible covers over
the inflammable objects.
(8) Do not use inflammable gases in the vicinity of the welding work area.
(9) Securely tighten up all areas where the cables have been connected, and insulate them.
(10)Connect the cables on the base metal side as close to where the workpiece will be welded as possible.
(11)Do not attempt to weld gas pipes with gases sealed inside or airtight tanks, pipes, etc. since they may
rupture in the process.
(12)Do not perform any welding work on top of wood, cloth or other objects that catch fire easily.
(13)When performing welding work on the ceilings, floors, walls, etc. of large structures, remove all ignitable
and inflammable objects on the hidden side of the base metal as well.
1-17
1.2.5 Preventing gas cylinder from toppling over or rupturing and protecting
gas flow regulators from overheating, impact, etc.
Ensure that the instructions below are followed to prevent gas cylinders from toppling over or rupturing
and to protect gas flow regulators from overheating, impact, etc.
• Secure the gas cylinders to a stand which has been specially constructed to
accommodate them.
When a gas cylinder topples over, it may result in bodily injury.
• Install the gas cylinders at a distance from the welding arcs and other
WARNING
welding-related equipment.
Since gas cylinders contain gas under high pressure, if they are mishandled, the
high-pressure gas may burst forth, possibly resulting in bodily injury.
(1) Secure the gas cylinders to a stand specially constructed to accommodate them by using insulated chains or
straps, etc. which are equivalent to chains so that they do not fall down.
(2) Insulate the gas cylinders from the gas cylinder stand. Do not use either the gas cylinders or the gas
cylinder stand as a ground for electrical circuitry.
(3) Install the gas cylinders at a distance from the welding arcs and high-temperature equipment.
(4) Install the gas cylinders at a distance from passageways or aisles used by work personnel and vehicles.
(5) For the guidelines on handling gas cylinders, comply with the applicable laws and regulations and with the
internal standards established at the user's company.
(6) Do not expose gas cylinders to high temperatures.
(7) When a valve on a gas cylinder is to be opened, keep your face away from the gas outlet.
(8) When a gas cylinder is not going to be used, be absolutely sure to close its valve and attach its protective
cap.
(9) Do not apply the welding torch to a gas cylinder or allow the electrodes to touch a gas cylinder.
(10)As the gas flow regulators, use ones supplied by us as accessories or ones recommended by us.
(11)Before using a gas flow regulator, be absolutely sure to read through its operating instructions, and
observe the precautions given.
(12)Check and repairs for a gas flow regulator shall be performed periodically and before operating.
1-18
1.2.6 Precautions for undertaking work inside the robot’s work area
Ensure that all the personnel involved in working inside the robot's work area will wear the following
protective gear.
• Do not enter inside the robot's operating ranges while the power is still on.
WARNING Approaching the robot while it is moving may result in fatal bodily injury.
(1) Inside the robot's work area, wear a protective helmet at all times.
(2) Inside the robot's work area, wear protective goggles with the proper light-shielding glass at all times.
(3) While power is supplied to it, a welder generates magnetic fields around it, and these will adversely affect
the operation of a pacemaker.
Therefore, persons fitted with a pacemaker should not approach a welder while it is operating or the
welding work area unless they are permitted to do so by their physicians.
(4) Before entering the robot's operation area or welding work area, be absolutely sure to turn off the incoming
power of the robot and welder.
(5) Follow the instructions below to safeguard against the effects of the electromagnetic noise which is
generated by the welding arcs.
① Install precision instruments, etc. at a distance from the welding arcs.
② Use one incoming power supply for the welder and another for the precision instruments, etc.
(6) Since touching a rotating part inadvertently can result in injury, be absolutely sure to follow the instructions
below.
• Do not allow your hands, fingers, hair or articles of clothing, etc. to come too
close to the rotating parts.
If you bring your hands, fingers, hair or articles of clothing, etc. too close to a
rotating part such as the feed roll of a wire feeder, they may become
WARNING
caught by or tangled up in the rotating part, possibly resulting in injury.
If you bring your hands, fingers, hair or articles of clothing, etc. too close to a
rotating part of the cooling fan, they may become caught by or tangled up in the
rotating part, possibly resulting in injury.
1-19
）
Chapter 2 Transportation and Installation
This chapter describes the procedures to be followed in terms of transportation,

installation, etc. when the robot is delivered. The details provided in this manual
on transporting and installing the robot body are for a typical robot only. For
further details, refer to the Maintenance Manual of the particular robot model
concerned.
2.1 Transportation ...............................................................................................2-1

2.1.1 ST series .................................................................................................2-1
2.1.2 AX20 controller........................................................................................2-2
2.1.3 V/B series................................................................................................2-3
2.1.4 AX21 controller........................................................................................2-5
2.2 Robot Installation ..........................................................................................2-6
2.2.1 Safety measures relating to installation..................................................2-6
2.2.2 Installation locations and ambient conditions .........................................2-9
2.2.3 Installation method..................................................................................2-9
2.2.4 Installation method................................................................................2-10
2.2.5 Installation surface accuracy ................................................................2-12
2.2.6 Strength of rack.....................................................................................2-13
2.2.7 Installing the manipulator and jigs on the common frame base...........2-14
2.2.8 Using Optional Manipulator Stand for Installation ................................2-15
2.3 Installation of controller...............................................................................2-16
2.3.1 AX20 controller Installation ...................................................................2-16
2.3.2 AX21 controller installation ...................................................................2-17
）
2.1 Transportation
2.1 Transportation
Ensure that the robot is moved into position by individuals who have acquired the
permits or licenses needed for carrying out slinging work, operating cranes, driving
forklift trucks, etc. The weights of the robot and controller are given in the Operation
Manual and Maintenance Manual. After checking the weights, adopt handling
WARNING
procedures
which are commensurate with these weights.
When hoisting the robot and/or the controller, follow the method set forth in this
manual or in the Maintenance Manual. Moving the robot into position using a method
not specified by the manufacturer may cause the robot to topple over or fall, which
WARNING may lead to accidents.
Take more than enough care to ensure that the wiring is not damaged during the
moving and installation processes. After having positioned the units, take protective
measures such as providing protective covers to ensure that the wiring will not be
WARNING damaged by the operators and other individuals or by the forklift trucks.
2.1.1 ST series
The details provided below apply to the ST series. The specifications differ according to the robot model. For
further details, refer to the Maintenance Manual of the robot concerned.
As a basic rule, use a crane to transport the robot body.

First, place it in the posture shown below, attach the four hanging bolts(M20) to the swivel base, and then be
absolutely sure to use four wires to hoist the robot. For further details on the size of the hanging bolts and lengths
of the wires, refer to the Maintenance Manual of the robot concerned.
Fig. 2.1.1 Robot transportation method (ST166-02, ST200-02)
2-1
2.1 Transportation
2.1.2 AX20 controller
Transfer the controller to its installation place by use of a crane, a forklift, or a hand
lifter.When to transfer it by use of a crane, use eye bolts (at 2 portions). And when to
WARNING use a forklift or a hand lifter, transfer the controller so that it should not fall down.
The weight of the AX20 controller is as shown below.

When working, put on protective gears such as a helmet, safety shoes and so forth,
and carry out the work while wearing safe working clothes appropriate for the work.
WARNING
Approx. 85kg (transless specifications)
Approx. 165kg (specifications with transformer)
Printed boards and other precision devices are used in the controller, therefore, do
not give any impact during transfer. When hoisting the controller using a crane, take
WARNING care that none of the parts on the controller will be damaged by the wires.
Use the following wires and the eye bolts for lifting the controller.
Hanging wires
Load resistance : 450kg or higher / Length : 1.5m or longer
Eye bolts
CAUTION
B-130-16 (service load 450kgf) (Takigen)
Hanging wires
Eye bolt (2 bolts)
POWER
Fig. 2.1.2 AX20 controller lifting diagram
2-2
2.1 Transportation
2.1.3 V/B series

The following procedure applies to the NB4 and the NV6. The specifications differ according to the robot model.
For further details, refer to the Maintenance Manual of the robot concerned.
Use a crane or forklift truck to transport the robot when it is to be unpacked or carried from one location to
another.
Before the robot is to be transported, be absolutely sure to place it in the posture shown in Fig. 2.1.3 & Fig. 2.1.4
(shipment posture).
When using a crane to transport the robot, use shackles to affix the rope to the two M12 eye-bolts attached to the
robot, and hoist the robot, as shown in Fig. 2.1.3, Fig. 2.1.4.
When using a forklift truck to transport the robot, secure it first atop a pallet so that it will not topple over and then
transport it, as shown in Fig. 2.1.5, Fig. 2.1.6. Since the NB4 manipulator is 165kg, and that of NV6 robot alone
weighs 155 kg, ensure that the pallet used is strong enough to withstand this weight.
Be sure to prevent impacts especially against Section during transport.

When transporting or installing the manipulator, take ample care not to apply load by
WARNING such as putting your weight on or pulling the End arm part, Axis J6 part, etc.
Wire Rope
ロープ
Withstand Load : min.0.8t (1760 lb)
耐荷重：800kg以上
Length : min. 1.5m (60 in.)
End arm
長さ　：1.5m以上
エンドアーム
Shackles
シャックル
Prepare shackles that meet the following requirements.
Model :SC-12
Withstand Load: 0.9t (1980 lb)
ISO 2415
シャックルは下記のものをご用意ください
型番　：SC-12
Ａ耐荷重：0.9t
JIS B2801
J6 Unit Ａ Eyebolts (M12)

J6軸部Ｍ１２アイボルト
Pre-installed at our factry.
アイボルトは出荷時
取り付けられています
Note) When transporting, keep the level posture for the axis J2, the soft limit posture (the most folded-up posture) for the axis
J3, and the 90 deg. rotated posture for the axis J4 as shown in the figure.
Fig. 2.1.3 Robot transportation method (using a crane) (NB4)
2-3
2.1 Transportation
Wire Rope
ロープ
Withstand Load : min.0.8t (1760 lb)

耐荷重：800kg以上
Length : min. 1.5m (60 in.)
長さ　：1.5m以上
Shackles
シャックル
Prepare shackles that meet the following requirements.
Model :SC-12
Withstand Load: 0.9t (1980 lb)
ISO 2415
Ａシャックルは下記のものをご用意ください
型番　：SC-12
耐荷重：0.9t
JIS B2801
Ａ Eyebolts (M12)
Ｍ１２アイボルト
Pre-installed at our factry.
アイボルトは出荷時
取り付けられています
Fig. 2.1.4 Robot transportation method (using a crane) (NV6)
Protector
緩衝材
Fixing Rope or Belt

ベルト類
Pallet Forklift
パレットフォークリフト
Fig. 2.1.5 Robot transportation method (using a forklift truck) (NB4)
Protector
緩衝材
Fixing Rope or Belt

ベルト類
Pallet Forklift
パレットフォークリフト
Fig. 2.1.6 Robot transportation method (using a forklift truck) (NV6)
2-4
2.1 Transportation
2.1.4 AX21 controller
Bear in mind the following points when transporting the AX21 controller.
• Use a crane, forklift truck or hand-lift truck to transport the controller to its installation
location.
When transporting the controller using a crane, use the two eye-bolts. When
transporting the controller using a forklift truck or hand-lift truck, take steps to ensure
WARNING
that it will not topple over.
• The controller weighs approximately 77 kg. When performing the work, wear a
protective helmet, work boots and other required protective gear, and wear safe
overalls suitable for the work at hand.
Wooden protection pad

Rope to secure robot
Forklift truck
Wire rope
Withstand load: Over425kg (935lb.)
Length: 1.5m (60in.) or longer
Use shackles to affix the wire rope

to the eye-bolts securely.
Provide the following kind of shackles.

Model number: SC-12
Withstand load: 0.9t (1980lb.)
JIS B2801
Fig. 2.1.7 Controller transportation method (AX21)
Printed circuit boards and other precision components are employed inside the
controller. Therefore, ensure that the controller is not subjected to impact while it is
WARNING being transported, etc.
2-5
2.2 Robot Installation
The location in which the robot body is installed and the method used to install it are critical for ensuring that the
functions of the robot will be maintained.
The ambient atmosphere in the installation location not only affects the lifespan estimation of the mechanisms
but it also has a bearing on safety. Ensure that the environmental conditions set forth in the Maintenance
Manual of the robot concerned are met without fail. To ensure safety, special attention must be paid to the
installation method of the robot body and its foundation. For this reason, ensure that “2.2.1 Safety measures
relating to installation” below are taken without fail.
What is paramount when the robot is to be installed is to study ways in which the safety of the operators can be
assured and take measures to assure their safety. Outlined below are the precautions to be observed in order
to achieve this goal.
2.2.1 Safety measures relating to installation
■ Measures to ensure the safety of personnel entering inside the operating range of the robot
While the robot is operating, there is a danger that the operators will come into contact
with the robot. For this reason, erect a guarding fence (safety protection fence) to ensure
that the operators will be kept at a distance from the robot. Accidents may occur if
DANGER operators or other individuals gain admittance inside the operating range of the robot by
mistake.
Guard fence
Refer to information in EN294: Safety of machinery – Safety distances to prevent danger
zone being reached by the upper limbs
DANGER
J1 axis (swivel axis) stop time and stop angle (from the point when the emergency stop
signal was generated while the maximum speed is designated.)
Reference data: 0.8 sec stop time, 0.7 rad stop angle (In case of ST series)
The guarding fence must be constructed in such a way that it cannot be easily climbed
over or easily moved. If the guarding fence is too low, individuals may climb over it and
DANGER enter inside the operating range of the robot, leading to accidents.
2-6
Provide a door in the guarding fence to allow access in and out of the operating range.
Be absolutely sure to install a safety plug in the door, and construct the door in such
a way that it will not open unless the plug is removed. The entry of an individual
CAUTION inside the guarding fence can be detected by means of the signals from the safety plug.
Take steps to provide an interlock so that the servo power (motor power) of the robot
is turned off when the safety plug has been removed or ensure that the motor power is
turned off while the guarding fence is open. The robot can be stopped automatically
when an individual has made an attempt to enter inside the guarding fence. (The
CAUTION
controller has a safety plug input.)
Provide the emergency stop button of the robot in a location where it can be pressed
immediately by the operator.
Accidents may occur since the emergency stop operation cannot be initiated
CAUTION immediately. (The controller has an external emergency stop input.)
If it is not possible to erect a guarding fence, install photoelectric switches, mat

switches, etc. in every location where individuals can enter inside the operating range of
the robot in place of the safety plug. The robot can be stopped automatically when an
DANGER individual has entered inside the operating range of the robot.
Color-code the floor so that the danger area (operating range of the robot) can be easily
identified visually.
CAUTION
■ Safety measures for positioning the robot and its peripheral devices
Do not position the operation and adjustment controls inside the operating range of the
robot. The robot may cramp the access to these controls.
Place the robot control panel, interlock panel and all other operation panels in positions
DANGER where they can be operated outside the guarding fence.
If an operation stand is to be provided, provide it with an emergency stop button as

well. Emergency stop can be initiated immediately even when fault occurs during
operation using the operation stand.
CAUTION
Do not route the wires and hoses between the robot body and the control panel, interlock
panel, etc. in such a way that the operators will trip over them or the forklift trucks will run
straight over them. Otherwise, operators may fall over, wires may break or become
WARNING disconnected, causing accidents.
Do not place the control panel, interlock panel, operation stand, etc. in positions where
the movements of the robot body are not visible.
If the robot movements cannot be seen, the operator will be slow to respond even when
DANGER fault has occurred, and this may lead to a serious accident. Accidents may also be
caused if the presence of the operators cannot be verified.
2-7
Place restrictions on the operating range of the robot if the necessary work range of the
robot is smaller than the range in which the robot can be operated. Restrictions can be
placed using limit switches and mechanical stoppers. Even if the robot has moved out of
the normal work range due to a fault, for instance, it can be stopped ahead of time.
CAUTION (Refer to the axis constant setting mode in the Operation Manual and to the Maintenance
Manual of the robot.)
In the range where the movements of the robot body can be seen satisfactorily, install
light-shielding boards, covers, etc. in the directions where operators may be exposed to
spatter while welding is in progress. Operators may be injured by the light emitted during
CAUTION welding, by spatter, etc.
Ensure that the display of the automatic and manual modes indicating the operating
status of the robot is large and conspicuous enough to enable the modes to be easily
recognized from a distance. The use of a buzzer, alarm or other warning to signal the
WARNING start of auto operation is also effective. Make sure that the fact that auto operation is
underway can be easily verified from a distance.
Minimize the number of protruding parts on the devices around the robot.
If necessary, place covers over them. Protruding parts are dangerous when they touched
the operator even under normal circumstances, and they constitute a hazard as well if
the robot should suddenly move, surprising and possibly knocking over the operator in
CAUTION
the process.
Avoid the kind of layout where operators need to put their hands inside the fenced area
to load and unload the workpieces. The robot may move to the place where an operator
DANGER has placed his or her hands inside the fenced area.
■ Measures to ensure the safety of the installation work
In installing the robot, it is important to position the robot where the operator will not be
cramped. While tools are still installed on the robot, the robot must not be operated in its
WARNING maximum operating range so that it touches its peripheral devices.
The designated method for installing the robot must be followed without fail. Following a
method which is not designated may cause the robot to move or topple over during
WARNING operation which is extremely dangerous.
Before proceeding to connect the wires between the robot and controller or peripheral
devices, ensure that the connection methods are thoroughly understood. Faults may be
WARNING caused in the operation of the robot by taking the wrong steps.
Ensure that the grounding work is done properly. If there are any welders or other
devices that generate significant levels of noise, proceed with the designated grounding
WARNING work for them.
2-8
When moving the robot into position and installing it, be very careful not to damage the
wiring. Furthermore, after having positioned the units, take protective measures such as
providing protective covers to ensure that the wiring will not be damaged by the
WARNING operators and other individuals or by the forklift truck.
2.2.2 Installation locations and ambient conditions

(1) The ambient temperature must be in the 0 to 40 degrees Celsius range.
(2) The ambient relative humidity must be in the 20 to 80%RH range, and there must be no condensation.
(3) The amounts of dust, dirt, oily vapors, water, etc. must be minimal.
(4) There must be no flammable or corrosive liquids or gases present.
(5) There must be no major sources of impact or vibration.
(6) No major sources of electrical noise must be in the vicinity of the robot.
(7) The vibration level must be less than 0.5G (4.9m/s2 ).
2.2.3 Installation method

When the robot accelerates or decelerates, a major reactive force is exerted on the swivel base from all
directions.
Consequently, the foundation must be able to withstand not only static loads but the reactive force exerted
during acceleration and deceleration as well, and the robot must be installed in such a way that the swivel base
will not move.
The details provided below apply to the ST series and the V/B series (NB4/NV6/NB4L/NV6L/NV20). The
specifications differ according to the robot model. For further details, refer to the Maintenance Manual of the
robot concerned.
Before installing the robot on a floor, smooth out any unevenness in the floor surface and repair any cracks, etc.
if the floor has a concrete layer thicker than 150 mm so that the flatness is within 1.0 mm. If the floor has a
concrete layer less than 150 mm thick, a separate foundation must be laid. This must be looked into and laid
prior to installation.
ST-02 series (ST166-02, ST166L-02, ST166T-02, ST200-02, ST200T-02)

Install the robot body using eight bolts equivalent to or larger than M20x65 (JIS: strength classification 12.9)
(option) and using flat washers with a thickness of at least 4.5 mm and a hardness of HRC35 or above (option).
Apply lubricating oil to the bolt threads, and tighten the bolts at a tightening torque of 560 ±30N•m. Use the
locating pin (option) in order to install the robot in its precise position.
Table 2.2.1 Installation bolt load

Repeated tensile load per bolt
Romot model
when the robot has been installed using 8 bolts
ST166-02, ST166L-02, ST166T-02 Approx. 40,000 N
ST200-02, ST200T-02 Approx. 48,000 N
V/B Series (NB4／NV6／NB4L／NV6L／NV20)

Install the robot body using four bolts (standard accessories) equivalent to or larger than M16x50 (JIS: strength
classification 10.9) and using spring washers (standard accessories). If the floor has a concrete layer less than
150 mm thick, a separate foundation must be laid. This must be looked into and laid prior to installation.
2-9
2.2.4 Installation method

Before installing the robot body, secure the swivel base of the robot body.
Fig. 2.2.1 Example of robot body installation dimensions (ST166-02)
The mechanical stopper limit is at that position which is 10 degrees beyond the limit of
the operating range (software limit) given in the specifications for the J1 axis (swivel
axis). When a guarding fence is to be erected, install it with due consideration given to
CAUTION the wrist posture, shape of the end effector, etc.
Restrictions can be placed on the operating ranges of the J1, J2 and J3 axes to ensure
that they will be operated safely. (Option) The optional parts must be used to enforce
these restrictions. Do not move the standard parts (such as the stopper blocks) on their
DANGER own.
For the installation bolts, use the ones specified in the Maintenance Manual without fail.
Death or serious injury may result if the
DANGER
2-10
RP
RP
RP :Reference Plane
(a)NB4/NV6
RP
RP
RP :Reference Plane
(b)NB4L/NV6L/NV20
Fig. 2.2.2 Example of robot body installation dimensions
Each robot model has its own outline drawing. For further details, refer to the Maintenance Manual of the robot
concerned.
2-11
2.2.5 Installation surface accuracy

When installing the robot body, strictly observe the following precautions to ensure that the swivel base will not
be deformed.
The details provided below apply to the ST series. The specifications differ according to the robot model. For
further details, refer to the Maintenance Manual of the robot concerned.
(1) Ensure that the flatness of the four plates on the installation surface of the robot body is within 1.0 mm.
(2) Ensure that the mutual error in the height vis-a-vis four places on the installation surface of the base plates is
within 1.0 mm (±0.5 mm).
Fig. 2.2.3 Robot installation surface accuracy (ST series)
(3) If it is not possible to adhere to the two precautions above, install the robot body using jack bolts while
ensuring that the body touches the installation surfaces evenly at four points.
Fig. 2.2.4 Jack bolt (ST series)
If the above standard cannot be satisfied, the swivel base axis bearings may sustain premature
damage.
2-12
2.2.6 Strength of rack

The details provided below apply to the ST series. In the case of the V/B series, a stand is provided as an
optional accessory. Ask us for further details. The specifications differ according to the robot model. For further
details, refer to the Maintenance Manual of the robot concerned.
Table 2.2.2 Strength of rack (ST-02 series)

Maximum vertical Maximum horizontal Maximum vertical Maximum horizontal
Robot model
generative force FV generative force FH generative moment MV generative moment MH
ST166-02, ST166L-02 48,700 N 34,800 N 92,400 N･m 79,900 N･m
ST200-02 54,000 N 39,700 N 111,300 N･m 96,700 N･m
ST166T-02 50,400 N 36,000 N 91,100 N･m 78,800 N･m
ST200T-02 55,900 N 41,100 N 109,800 N･m 95,400 N･m
Fig. 2.2.1 Maximum Robot Generative Force(ST166-02, ST166L-02, ST200-02)
Fig.2.2.2 Maximum Robot Generative Force(ST166T-02, ST200T-02)
2-13
2.2.7 Installing the manipulator and jigs on the common frame base
This section illustrates NB4/NV6/NB4L/NV6L/NV20.
For other manipulators, see Instruction Manual “Manipulator 1L10460A”.
Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong and rigid.
Therefore, when the manipulator and jigs are to be mounted together on the same common frame base, the
frame base must be at least 20 mm in thickness and the manipulator must be firmly fixed using four hex. Socket
head cap bolts (M16) and a spring washer supplied with your manipulator with a tightening torque of 215.8 N･m).
For the mounting method of the manipulator on the base, see Fig. 2.2.5.
Fig. 2.2.6 Installing Manipulator Directly on Common Frame Base (MV4AP/MV6 / MV4LAP/MV6L /MV16)
(NB4/NV6/NB4L/NV6L/NV20)
Each robot has its own outline drawing. For further details, refer to the Maintenance Manual of the robot
concerned.
2-14
2.2.8 Using Optional Manipulator Stand for Installation

This section illustrates NB4/NV6/NB4L/NV6L/NV20.
For other manipulators, see Instruction Manual “Manipulator 1L10460A”.
Movements of the manipulator cause a large force of inertia, requiring the installation floor to be strong and
rigid. When the concrete floor thickness is more than 200 mm, use anchor bolts as follows.
If the floor is not strong enough, use J-type anchor bolts as follows.
For the installation method for an anchor bolt, follow the maker index.
(Prepare separately concrete anchors, J-type anchor bolts, and jack bolts, etc.)
Jack Bolt(M12)
Lock Nut Anchor Bolt(M16)
(M12) Lock Nut(M16)
(Tightening Torque: 107.8 N*m）
Spring Washer(M16)
420
4-M12 320
Flat Washer(M16)
4-φ18
Manipulator Stand
Supporting Plate
420
Foundation
500
View A
NB4/NV6/NB4L/NV6L/NV20
Fig. 2.2.7 Using manipulator stand (Unit :mm）
2-15
2.3 Installation of controller
2.3.1 AX20 controller Installation

Bear in mind the following points when selecting the installation location for the robot controller.
(1) When installing the controller, leave a clearance of at least 20 cm between the controller and the wall
behind it in order to ensure proper ventilation inside the robot controller.
(2) When the robot controller, welding power supply, etc. are to be installed on a rack or some other high
position, install an adequate work floor to enable the adjustments, maintenance, inspections and other
work to be performed.
200mm
制御装置
600mm
120°
• Once the installation location of the controller has been decided upon, be absolutely
sure to lock the casters so that the controller will not move out of its installation
location.
• Close the door completely, and make sure that the door key is locked. If the door is
not shut completely, dust and dirt will get in the robot controller, causing a failure.
After the AX controller has been installed, padlock the circuit breaker of the AX controller as shown in Fig. 2.3.1. Be
absolutely sure to entrust the safekeeping of the key for the circuit breaker padlock to a specially designated person or the
person in charge of safety management. (The padlock is to be provided by the user.)
Japan / CE specifications North America specifications
Fig. 2.3.1 Concerning the circuit breaker lock
2-16
2.3.2 AX21 controller installation
Robot controller installation
Although AX21 controller does not have any of the moving parts like the manipulator, it must still be secured at
its installation location without fail in order to prevent it from falling when it has been installed in a high place or
from toppling over when it has been installed on the floor.
View of detail A
Fig. 2.3.2 Dimensions for robot controller installation
Installation place of robot controller
(1) When installing the controller, leave a clearance of at least 20 cm between the controller and the wall
behind it in order to ensure proper ventilation inside the robot controller.
(2) When the robot controller, welding power supply, etc. are to be installed on a rack or some other high
position, install an adequate work floor to enable the adjustments, maintenance, inspections and other work
to be performed.
400mm or longer
Wall Min. 0.6m
100mm or longer
(Rear)
Fig. 2.3.3 Installation of robot controller
Robot
(3)To install a robot controller and welding power supply, etc. controller
on a place two or more meters in height such as a frame base,
a foothold is required so that adjustment and maintenance, etc. can be performed.
(4)A robot controller has a through-hole for an external (Front)
connection cable on its right side and back side.
To install a robot controller, secure a space of 400 mm at least for external
connection cable. Min. 1m
Foothold for high work
2-17
When the AX21 controller is to be installed on the floor, first fit M12 concrete anchors as shown in Fig. 2.3.4,
and follow Fig. 2.3.2 to secure the support channels on the bottom of the AX21 controller to the anchor bolts
using four M12 lock nuts (M12). (Tightening torque: 42.2 N•m (431 kgf•cm))
If the floor is not strong enough, embed J-shaped anchor bolts in the floor as shown in Fig. 2.3.4, and follow
Fig. 2.3.2 to secure the AX21 controller.
Robot controller
Anchor bolt (M12)

Lock nut (M12)
(Tightening torque: 42.2Nm)
Support Spring washer
channel
Flat washer
Foundation
Drill holes using a Insert the anchor. Knock it into place

concrete drill. The using a hammer.
diameter and depth
differ depending on
the type concerned.
How to anchor the robot to a concrete foundation
J-shaped anchor bolt

(M12-250L)
View of detail B
Diagram of foundation with embedded

anchor bolt for installing the robot（unit：mm）
Fig. 2.3.4 Concerning the AX21 controller installation method
After the AX21 controller has been installed, shut the door completely, and check that the door has been locked
by the keys provided for this purpose. Dirt, dust and other foreign matter may find their way inside the robot
controller if its door is not completely shut, possibly causing it to fail. Also lock the circuit breaker of the AX21
controller shown in Fig. 2.3.5 using the key provided for this purpose. Be absolutely sure to entrust the
safekeeping of the key for the circuit breaker padlock to a specially designated person or the person in charge of
safety management. (The padlock is to be provided by the user. Padlock dimensions:φ4-5)
Door key
Detailed
view
Padlock
Fig. 2.3.5 Concerning the circuit breaker lock
2-18
Chapter 3 Connections
This chapter describes how to connect the robot body to the controller, teach
pendant and power supply and how to perform the I/O connections with the
peripheral devices.
Chapter 3 Connections ................................................................................................
3.1 How to read this chapter...............................................................................3-1
3.2 Cable connections (AX20)............................................................................3-2
3.2.1 Robot connections .................................................................................3-2
3.2.2 Teach pendant connection .....................................................................3-2
3.3 Power supply connections (AX20) ...............................................................3-3
3.3.1 Before connecting the primary power supply ........................................3-3
3.3.2 Primary power supply connections ........................................................3-3
3.3.3 Concerning grounding............................................................................3-4
3.4 Signal line connections (AX20).....................................................................3-5
3.4.1 Selecting an optional function for I/O signal connection .......................3-5
3.4.2 I/O connection using I/O board UM212 .................................................3-6
3.4.3 Input signal connector............................................................................3-8
3.4.4 Output signal connector .......................................................................3-14
3.4.5 I/O connection using Fieldbus function................................................3-20
3.5 Cable connections (AX21)..........................................................................3-21
3.5.1 Manipulator connection........................................................................3-22
3.5.2 Teach pendant connection ...................................................................3-24
3.5.3 Operation box connection ....................................................................3-25
3.5.4 Start box connection ............................................................................3-26
3.5.5 Connection of TP interconnection board .............................................3-27
3.5.6 Connecting Digital Welding Power Supply ..........................................3-31
3.6 Power connections (AX21) .........................................................................3-47
3.6.1 Primary power supply connections ......................................................3-47
3.6.2 Grounding.............................................................................................3-49
3.7 Signal line connections (AX21)...................................................................3-51
3.7.1 Connecting I/O signals to Relay board ................................................3-51
3.7.2 Specification of I/O signals...................................................................3-51
3.7.3 Wiring ...................................................................................................3-52
3.7.4 Input signal connections ......................................................................3-53
3.7.5 Output signal connections ...................................................................3-57
3.8 Safety-related signal connections (AX20/21) .............................................3-59
3.8.1 I/O sequence board .............................................................................3-59
3.8.2 Position of the terminal block...............................................................3-60
3.8.3 External emergency stop input (TBEX1 : 1-2, 3-4) .............................3-64
3.8.4 Safety plug input (TBEX1 : 5-6, 7-8)....................................................3-65
3.8.5 Enable switch inputs (TBEX1 : 9-10, 11-12)........................................3-66
3.8.6 Connections when the robot controller is used by itself ......................3-66
3.8.7 Emergency stop output connection (TBEX2 : 1-2, 3-4).......................3-67
3.8.8 Each External Input Signal Connection ...............................................3-68
3.1 How to read this chapter
3.1 How to read this chapter

In this chapter, the sections that should be read differ from each other depending the controller type
(AX20/AX-21). Please refer to the flow-chart shown below and read the appropriate sections.
START
NACHI What is the controller type? OTC DAIHEN

”AX20” ”AX21”
[Cables] [Cables]
「3.2 Cable connections (AX20)」 (Including welders)
「3.5 Cable connections (AX21)」
[Primary power]
「3.3 Power supply connections (AX20)」 [Primary power]
「3.6 Power connections (AX21)」
[I/O Signals]
「3.4 Signal line connections (AX20)」 [I/O Signals]
「3.7 Signal line connections (AX21)」
[Safety related signals]

3.8 Safety-related signal connections (AX20/21)
END
3-1
3.2 Cable connections (AX20)

Connect the robot and controller using the wire harnesses (cables). Then connect the teach pendant to the
controller.
3.2.1 Robot connections
Set the primary power supply and circuit breaker on the controller to the OFF
position.
Check that the voltage of the primary power supply tallies with the voltage
WARNING
specification of the controller. The voltage of the controller is indicated near
the circuit breaker.
The cables that connect the robot and controller are called wire harnesses.
Rear panel of
controller
Wire harnesses
CNR2
CNR4
CNR1
Connected to connectors
Fig. 3.2.1 Robot connections (AX20)
3.2.2 Teach pendant connection
position.
WARNING
Connect the teach pendant cable to the connector on the controller. The position of the connector differs
depending on the type of the controller.
Teach pendant
Connector (CNTP) on controller
Fig. 3.2.2 Teach pendant connection
3-2
3.3 Power supply connections (AX20)
3.3.1 Before connecting the primary power supply

position.
CAUTION
* The primary power supply specifications of the AX20 controller are as shown below.
In the case of AX20-0000 (transless specifications) : AC200V/220V ± 10% (3φ50/60Hz)
In the case of AX20-1101 (specifications with transformer) : AC380V ~ 480V ± 10% (3φ50/60Hz)
* Electricity consumption per robot is as shown below.
ST/SB/SG/SC heavy load transfer series : about 5kVA, SC35/50 : about 3kVA, SC15/06 : about 2kVA
3.3.2 Primary power supply connections

(1) Remove the primary power supply inlet panel by the side of the breaker.
Use a cable of 3.5mm2 or higher for the primary power supply cable.
Primary power supply inlet pane Provide type D grounding A cable of
using a grounding wire with a 3.5mm 2 or
diameter of at least 5.5 mm2. thicker
Power cable
Grounding wire
Grounding terminal
Circuit breaker
Grounding terminal Circuit
breaker
(2) In the panel, drill a hole matching the size of the power cable to be used, and pass the power
cable through it.
Drill the hole here.
Primary power supply inlet panel

Power cable
(one of its wires serves as Use the appropriate cable clamps to ensure
the grounding wire) that no water will leak inside.
(3) Connect the power cable to the circuit breaker and its grounding wire to the grounding terminal
(PE).
As for the crimping terminal, use a round crimping terminal for M5 (R3. 5-5).
Work the cable to suit the shape of the connector.

Power cable
Grounding wire
Grounding terminal Circuit Remove the cable Use a solderless spectacle

breaker covering and connect. terminal.
(4) Attach the primary power supply inlet panel to the controller.
Primary power supply inlet pane
Circuit breaker
Ensure that the primary power supply inlet panel and cable clamps are installed without fail so
that water or dust will not enter inside the controller.
3-3
3.3.3 Concerning grounding

Connect the controller properly to ground in order to safeguard against electric shocks and
combat noise. Use a grounding wire with a diameter of at least 5.5 mm2 to provide a dedicated ground
(type D ground) where the wires from the installation position are made as short as possible. In order to
establish the same potential as that for the peripheral jigs and other devices, ground the
peripheral jigs and other devices also as shown in the figure below. The effect that establishes the
same potential will be lost if the wiring connections are too long. Therefore, make the connections as
short as possible. Also take steps to ensure that the same potential is established for the nearby
operation panels, cable conduits, etc.
In order to safeguard against electric shocks and combat noise, it is essential that the same
potential be established as far as possible within a certain amount of space which is grounded.
If only specific objects are connected to a ground installed far away, a potential difference will
arise between those objects and the nearby objects, and the grounding effect may be lost.
"Kind D grounding" is applied in Japan. In countries other than Japan, refer to respective
country laws and device specifications, and carry out an appropriate grounding work.
Hand
Controller Hand
Controller
Work Switch Work
board
Robot body Robot body
Type D Type D ground Type D ground

Type D ground ground
Fig. 3.3.1 How to connect the grounding wire of the AX controller
A terminal (PE) for connecting the grounding wire is provided inside the controller.
Connect the external grounding wire to this box. (Its location differs from one model to another.)
Grounding terminal
Circuit
breaker
Fig. 3.3.2 Grounding wire location of the AX controller

・ Precautions for installing the leakage circuit breaker (when a servo transformer (T11) is not available)
The robot controller is equipped with a leakage circuit breaker with a 100 mA current sensitivity.
If a leakage circuit breaker is to be installed at the primary power supply side, use one with a current sensitivity
of 100 mA or more.
・ Precautions for connecting the power cables
The power cables of the welding power supplies carry heavy currents: for this reason, leave spaces of at least
200 mm between these cables and the robot cables.
When running cables inside the same duct, insert partitions to separate the cables clearly.
The power cables of TIG welders, plasma cutting machines, etc. have high-frequency noise: for this reason, do
not run more than one such cable inside the same duct and keep them as far away from one another as
possible.
・ Precautions when turning on the primary power supply
Before turning on the primary power, re-check the connections and the power supply specifications of the AX
controller and of the power supply.
3-4
3.4 Signal line connections (AX20)
3.4.1 Selecting an optional function for I/O signal connection

It is necessary to choose an optional function (i) or (ii) when purchasing the robot controller.
As standard specification, AX20 controler does not have I/O signals that can be used
for connection with external devices e.g. PLC etc. Therefore, please do not forget to
choose one of optional function shown as below.
(i) I/O board (UM212)

Choose one from the option products shown as below.
Table 3.4.1 Option product No. of respective configurations of UM212 I/O board
Option product
Number of UM212 Number of the signals
No.
Total
1 AX20-OP125-A
IN 32pts. / OUT 32pts.
Total
2 AX20-OP125-B
1
Total
(Internal power supply AX20-OP125-C
spec.)
(ii) Fieldbus function

When using one of the functions listed as below, please refer to the respective option manuals.
DeviceNet
PROFIBUS
INTERBUS-S
CC-LINK
JEMA-NET (OPCN-1)
FL-NET (OPCN-2)
SHARP I/F (JW32CV module)
3-5
3.4.2 I/O connection using I/O board UM212

The positions of the board(s) and the connecters are shown as below.
CPUﾕﾆｯﾄ拡大図
CNOUT (1st)
増設(1枚目)CNOUT
CNIN (1st)
増設(1枚目)CNIN
CB1 CPU UNIT
Installed
増設箇所 position
CN7E AX20-OP125-A,-C)の場合
DC増設1枚(AX20-OP125-A, -C
CNP7
CNOUT (2nd)
CNP12V
CN24V
CNPM
CNOUT (1st)
CNBK24VA
CNBK24V
MULTI POWER
SUPPLY UNIT
CNACRT
CNPWA
DRIVE CNIN (2nd)

増設(2枚目)CNIN
UNIT
CPAC
CNSVA
CNIN (1st)
増設(1枚目)CNIN
CNRST
CNPW
CNAC
CNR
CNPN
Installed position (1st)

増設箇所(1枚目)
Installed
増設箇所(2枚目) position (2nd)
FRONT VIEW AX20-OP125-B
制御装置FRONT DC増設2枚(AX20-OP125-B)の場合
In case of AX20-OP125-C, make a connection as follows.
CNSQ
CB1 CPU UNIT Cable (AX20-125-C08-001)

ｹｰﾌﾞﾙ(AX20-125-C08-001)
CNP24V
CN7E
CNP24V
CNP7
CNP12V
CN24V
CNPM
CNBK24VA
CNBK24V
MULTI POWER
SUPPLY UNIT
CNACRT
CNPWA
DRIVE
UNIT
CPAC
CNSVA
CNRST
CNPW
CNAC
CNR
CNPN
FRONT VIEW
制御装置FRONT
DIPSW Settings
Setting position ON / OFF Descriptions
Board name No. 2 1
1st board
OFF OFF
I/O board (AX20-OP125-A, AX20-OP125-C)
SW1
(UM212) 2nd board
OFF ON
(AX20-OP125-B)
3-6
Wiring procedures
(1) Open the side panel or the back side panel of the controller.
*When placing the controllers in close formation, the use of the side panel is not recommended from the
viewpoint of the maintenance convenience.
(2) Drill a hole in the panel, and pass the signal line cable through it.
Drill the hole suitable for the
size of the signal cable.
Panel Signal line cable
Use the appropriate cable clamps to

ensure that no water will leak inside.
(3) Connect the wires to the connectors and terminal block.

UM212
Connectors provided
Input connector
CNOUT
Soldering
Output connecto
CNIN
Signal line cable
Solder the connections to the connectors provided (for CNIN and CNOUT).
Ask a specialist to do the job if the available personnel lack the necessary soldering
skills.
(4) Attach the panel to the controller.

Panel
Before using the controller, be sure to close the door and lock the lock key shown in the
figure below. Using the controller without locking the lock key may cause dust, spatters
from welding, or else to enter the controller, thus resulting in failures.
CAUTION
3-7
3.4.3 Input signal connector

The AX controller has 32 DC 24V input signals per board.
The pins to be allocated to general input signals and the pins to be allocated to the status input signals can be
selected as desired.
This figure shows the connector (CNIN) pin layout as viewed from the soldered
surface.
Connector model: MR-50LM (by Honda Tsushin Kogyo)
） Pin 33
Pin 50
HONDA
Pin 19
Pin 1 Pin 32
Pin 18
Fig. 3.4.1 Input signal connector pin layout
3-8
Table 3.4.2 List of input signals (1st board : CNIN) in case of AX20-OP125-A
Connector pin Signal name
Function allocated as initial setting
No. (I*)
1 I1
2 I2
3 I3
4 I4
5 I5 General-purpose input signals
6 I6
7 I7
8 I8
9 Common Common for pins 1 to 8
10 I9
11 I10
12 I11
13 I12
15 I14
16 I15
17 I16
19 I17
20 I18
21 I19
23 I21
24 I22
25 I23
26 I24
28
29
30 Not used
31
32
33 I25
34 I26
35 I27
36 I28
38 I30
39 I31
40 I32
42
43
44
45
46 Not used
47
48
49
50
3-9
Table 3.4.3 List of input signals (2nd board : CNIN) in case of AX20-OP125-B
No. (I*)
1 I33
2 I34
3 I35
4 I36
6 I38
7 I39
8 I40
10 I41
11 I42
12 I43
13 I44
15 I46
16 I47
17 I48
19 I49
20 I50
21 I51
22 I52
24 I54
25 I55
26 I56
28
29
30 Not used
31
32
33 I57
34 I58
35 I59
36 I60
38 I62
39 I63
40 I64
42
43
44
45
46 Not used
47
48
49
50
3-10
Table 3.4.4 List of input signals (1st board : CNIN) in case of AX20-OP125-C
No. (I*)
1 I1
2 I2
3 I3
4 I4
6 I6
7 I7
8 I8
10 I9
11 I10
12 I11
13 I12
15 I14
16 I15
17 I16
19 I17
20 I18
21 I19
22 I20
24 I22
25 I23
26 I24
28
29
30 Not used
31
32
33 I25
34 I26
35 I27
36 I28
38 I30
39 I31
40 I32
42
43 Not used
44
45
46 P1 DC+24V
47
48
49 M1 GND(0V)
50
(NOTE) In case of AX20-OP125-C, internal power supply (DC24V - 0V) is available.
3-11
How to supply power (DC24V - 0V) to the signal lines

Option type name Internal power supply (DC24V - 0V)
AX20-OP125-A
Not available
AX20-OP125-B
Please prepare an external power supply unit
Available
AX20-OP125-C
DC24V : 45,46,47pin of the CNIN
0V : 48,49,50pin of the CNIN
(NOTE)
• When using an external power supply unit, keep the specification shown as below.
Specification of the external power supply : DC+24V±10%
• Do not use power with the wrong polarity.
• The specification of the internal power supply unit is shown as below.

Capacity of the intenal power supply unit: DC+24V, 0.8A
(Because the other circuits in the controller (standard I/O circuits, other additional DC input / output circuits
etc.) also use the internal power supply unit, please set the total capacity for both the input and output
circuits to below this level.)
• The electrical specifications per input circuit are listed below.

Input impedance Approximately 3KΩ
Input current 8mA
• Internal and external power supplies can be used together since there is a separate common for every
eight input circuits.
(Example)
Input signals Power supply
I33 ～ I40 Internal
I57 ～ I64 External
3-12
Basic configuration
of the input circuit
CNIN UM212
(Additional)
Relay contact etc. I**
I**
…
…
…
I**
Common
External power CNIN

UM212
GND
Internal power of
DC+24V the controller
45 - 47pin
DC+24V
48 - 50pin
Select one of these ways GND
to supply the power.
User side Controller side

(External connection)
UM212 (1st)
(AX20-OP125-C only)
Fig. 3.4.2 Basic configuration of input circuitry
3-13
3.4.4 Output signal connector

The AX controller has 32 DC 24V output signals per board.
The pins to be allocated to general output signals and the pins to be allocated to the status output signals can
be selected as desired.
This figure shows the connector (CNOUT) pin layout as viewed from the soldered
surface.
Connector model: MR-50LF (by Honda Tsushin Kogyo)
Pin 1
Pin 18
HONDA
Pin 19
Pin 33 Pin 32
Pin 50
Fig. 3.4.3 Output signal connector pin layout
3-14
Table 3.4.5 List of output signals (1st board : CNOUT) in case of AX20-OP125-A
No. (O*)
1 O1
2 O2
3 O3
4 O4
5 O5 General-purpose Output signals
6 O6
7 O7
8 O8
10 O9
11 O10
12 O11
13 O12
15 O14
16 O15
17 O16
19 O17
20 O18
21 O19
22 O20
24 O22
25 O23
26 O24
28
29
30 Not used
31
32
33 O25
34 O26
35 O27
36 O28
38 O30
39 O31
40 O32
42
43
44
45
46 Not used
47
48
49
50
3-15
Table 3.4.6 List of output signals (2nd board : CNOUT) in case of AX20-OP125-B
No. (O*)
1 O33
2 O34
3 O35
4 O36
6 O38
7 O39
8 O40
10 O41
11 O42
12 O43
13 O44
15 O46
16 O47
17 O48
19 O49
20 O50
21 O51
22 O52
24 O54
25 O55
26 O56
28
29
30 Not used
31
32
33 O57
34 O58
35 O59
36 O60
38 O62
39 O63
40 O64
42
43
44
45
46 Not used
47
48
49
50
3-16
Table 3.4.7 List of output signals (1st board : CNOUT) in case of AX20-OP125-C (Internal power spec.)
No. (O*)
1 O1
2 O2
3 O3
4 O4
6 O6
7 O7
8 O8
10 O9
11 O10
12 O11
13 O12
15 O14
16 O15
17 O16
19 O17
20 O18
21 O19
22 O20
24 O22
25 O23
26 O24
28
29
30 Not used
31
32
33 O25
34 O26
35 O27
36 O28
38 O30
39 O31
40 O32
42
43 Not used
44
45
46 P1 DC+24V
47
48
49 M1 GND(0V)
50
(NOTE) In case of AX20-OP125-C, internal power supply (DC24V - 0V) is available.
3-17
How to supply power (DC24V - 0V) to the signal lines

Option type name Internal power supply (DC24V - 0V)
AX20-OP125-A
Not available
AX20-OP125-B
Please prepare an external power supply unit
Available
AX20-OP125-C
DC24V : 45,46,47pin of the CNOUT
0V : 48,49,50pin of the CNOUT
(NOTE)
• When using an external power supply unit, keep the specification shown as below.
Specification of the external power supply : DC+24V±10%
• Do not use power with the wrong polarity.
• The specification of the internal power supply unit is shown as below.

Capacity of the intenal power supply unit: DC+24V, 0.8A
(Because the other circuits in the controller (standard I/O circuits, other additional DC input / output circuits
etc.) also use the internal power supply unit, please set the total capacity for both the input and output
circuits to below this level.)
• The electrical specifications per output circuit are listed below. Be absolutely sure to use the robot within
these ratings.
Rated switching capacity DC24V ± 3V , 0.1A
• Be absolutely sure to use a surge suppression diode for the load.
• Internal and external power supplies can be used together since there is a separate common for every
eight output circuits.
(Example)
Output signals Power supply
O33～O40 Internal
O41～O48 Internal
O49～O56 Internal
O57～O64 External
3-18
Basic configuration
of the output circuit
CNOUT UM212
Relay etc. (Additional)
O**
Surge supprettion O**

diode
…
…
O**
Common
External power CNOUT

UM212
GND
Internal power of
DC+24V the controller
45 - 47pin
DC+24V
48 - 50pin
Select one of these ways GND
to supply the power.
User side Controller side

(External connection) UM212 (1st)
(AX20-OP125-C only)
Fig. 3.4.4 Basic configuration of output circuitry
3-19
3.4.5 I/O connection using Fieldbus function

For the details about the I/O connectin using Fieldbus function, refert to the respective option
manuals.
3-20
Notes on connection
1. Before connecting cables to the robot controller, be sure to turn OFF the switch
WARNING on the primary switchboard and breaker inside the robot controller, and then
check that the voltage is not impressed.
2. Be sure to firmly tighten the joint part (connector and terminal) of cables and
hoses.
3. Do not place anything on cables.
4. Do not cross cables each other.
5. Do not lay cables under the welding power supply.
6. Lay out the welding cable and other control cables separately, not binding
together.
7. To draw cables in, refer to the directions in the following page and after.
8. After connecting the cables to the robot controller, close the door completely, and
lock the door key. If the door is not completely closed, dust or dirt will enter the
robot controller, which may cause breakdown.
How to open the robot controller

1. Unlock the breaker.
2. Release the door key by 2 places on top and bottom using an attachment key.
3. Turn the breaker handle to “Open Reset”, and open the door. Then, the primary power of the robot
controller is shut off.
If compelled to open the robot controller door with the power ON for inspection etc. in the event of emergency,
follow the instructions.
1. Release the door key by two places on top and bottom using an attachment key.
2. Turn the part indicated as “Release” to the arrow direction below using a Phillips screwdriver, but not
turning the breaker handle. Then, the door is opened with the power ON.
If compelled to apply the primary power with the robot controller door opened for
inspection etc. in the event of emergency, follow the instructions below. Otherwise,
it will cause breakdown or malfunction of the manipulator or robot controller.
WARNING 1. Do not expose the robot controller to the direct sunlight.
2. While the door is opened, do not apply any strong light such as a penlight
directly to the components inside the robot controller.
1. Even if the breaker of this unit is OFF, voltage is still impressed to the primary
side of breaker. Before opening the door for inspection etc., shut off the power
source first.
WARNING 2. There are many high-voltage parts inside the robot controller. Do not touch
them. Otherwise, you may get an electric shock. If compelled to open the door
with the power ON in the event of emergency, take special care that you never
touch any parts inside.
3-21
3.5.1 Manipulator connection
position.
WARNING specification of the controller. The voltage of the controller is indicated near the
circuit breaker.
The cable that connects the manipulator and controller is called “Control cable”. The connection ports on each
manipulator and robot controller (connector) and the control cables are both indicated by the corresponding
connector name. Follow Fig. 3.5.1 and Fig. 3.5.2 to properly connect the cable by each corresponding name.
Some cables are provided with “male” connector, and the others “female” connector of which key grooves are
different each other. This is how wrong connection can be avoided. However still, if forcing to insert into a
wrong port, it will get broken.
■ Connection on Manipulator Side
Control Cable 1,2
Fig. 3.5.1 Control cable 1 and 2:Manipulator side
3-22
■ Connection on Robot Controller Side

position.
WARNING specification of the controller. The voltage of the controller is indicated near the circuit
breaker.
Connect the connectors (control cables 1 and 2), which are the opposite ones from the manipulator side that
have already been connected to the robot, to the controller. refer to Fig. 3.5.2.for the connector position (CNR1
CNR2).
(1) Turn off the power at the supply source, and set the circuit breaker of the controller to the OFF position.
(2) Connect the controller cable into the connector of back side of robot controller ( CN1 CN2).
CNR2
(Control Cable 2)
CNR1
(Control Cable 1)
Fig. 3.5.2 Connecting the control cables : Controller side (back view of the contrroller)
1. Be sure to arrange the control cable 2 away from the primary power cable and the
power cable that is connected with Arc welding power supply.
2. Since one of the wire harnesses (control cable 2) is a cable to be used in
CAUTION non-moving areas, do not use it in moving or bending areas inside the cable bears
of a slider, etc. If it is to be used in a moving area, consult with us.
After the cables have been connected to the controller, close the door securely. If the
door is not completely closed, dirt, dust and other foreign matter may enter inside the
controller, possibly causing malfunctions.
CAUTION
3-23
3.5.2 Teach pendant connection
Teaching of manipulator is operated by Teach pendant.

Described here are the connections for the teach pendant that is used with the AX-C robot controller.
Set the primary power supply and circuit breaker on the robot controller to the OFF
position.
WARNING specification of the robot controller. The voltage of the robot controller is indicated
near the circuit breaker.
Refer to Fig. 3.5.3. for the position of teach pendant connector “CNTP”.
1. Turn off the power at the source, and set the circuit breaker of the robot controller to the OFF.
2. Connect the teach pendant connector securely to the connector on the side face of robot controller.
Teach Pendant
Connector
CNTP
Fig. 3.5.3 Connecting the robot controller-dedicated teach pendant
3-24
3.5.3 Operation box connection

Switching operation of Playback/ Teach mode and manipulator operation in Playback mode are performed on
Operation box.
This section describes the connection of robot controller-dedicated teach pendant and operation box.
As with the robot controller, install the operation box outside the guarding fence.
1. Install the operation box in a location where it will not be directly exposed to the
welding fumes, spatter, slag and other flying matter.
WARNING 2. The operation box is not provided as a standard accessory when a jig control unit or
other device is to be used to provide the functions of the operation box (when an
external start system is involved). The user is responsible for providing the
emergency stop," "motor power," "start" and "stop" buttons, etc.
position.
Check that the voltage of the primary power supply tallies with the voltage specification
WARNING of the robot controller. The voltage of the robot controller is indicated near the circuit
breaker.
Refer to Fig. 3.5.4.for position of the operation box connector “CNOP”.
(1) Turn off the power at the supply source, and set the circuit breaker of the robot controller to the OFF
position.
(2) Connect the cable of the operation box to the “ CNOP” connector which is located on the TP
interconnection board. The TP interconnection board is attached to the inner right panel of the robot
control unit.
CNOP
TBOP1, TBOP2
TP
Interconnection
Board
Grounding
Frontal Figure Right Side Figure

(Inside of Operation Box) (Inside of Operation Box)
Fig. 3.5.4 Connecting the operation box
3-25
3.5.4 Start box connection
As with the robot controller, install the operation box outside the guarding fence.
1. Install the operation box in a location where it will not be directly exposed to the
welding fumes, spatter, slag and other flying matter.
WARNING 2. The operation box is not provided as a standard accessory when a jig control unit or
other device is to be used to provide the functions of the operation box (when an
external start system is involved). The user is responsible for providing the
"emergency stop," "motor power," "start" and "stop" buttons, etc.
position.
Check that the voltage of the primary power supply tallies with the voltage specification
WARNING of the robot controller. The voltage of the robot controller is indicated near the circuit
breaker.
Follow the procedures below to connect the start box with operation box.
(1) Shut off the power at the source, and set the circuit breaker of the robot controller to OFF.
(2) Connect the start box to the robot controller.
(3) Remove the cover plate on the top of the operation box that corresponds to each station number
concerned, and remove the corresponding connector (CNST2, 3, or 4) mounted on the printed circuit
board inside operation box. (This concerns only the connectors for mounting the start box.) Retain the
removed connectors in a safe place. Please keep carefully for the removed corresponding connector.
(4) After removing the short-circuit connector, connect the start box connector. The station No. and
connector No. correspond each other as follows. (See the table below.)
Station No. Connector No. inside operation box

2 CNST2
3 CNST3
4 CNST4
Station Station Station

No.2 No.3 No.4
Cover plate
To sequence printed
circuit board CNOP
Fig. 3.5.5 Mounting positions in the start box
3-26
3.5.5 Connection of TP interconnection board

The TP interconnection board (L20400T00) will broadcast I/O signals between the I/O sequence board
(L20400F00) and its teach pendant, operation box, starting box, and any of the other upper control boards.
Function
・ Suspension circuit of I/O operation signal
・ Emergency output circuit of welding power source
・ Warning lamp output circuit
1 15
B
1 15 A
CNOP
1
5
R1
6
8
C2
R2
9
10 11
C1
R3
5 6 7 8
4 3 2 1
2 1 D1
A
13
14
B
TBOP1 TBOP2
C D2
R4 LED
Fig. 3.5.1 Appearance of the TP interconnection board
Connection
Connector Signal Function

name
CNOP1 Control I/O Signal Input and output from the IO sequence board is connected.
CNOP2
CNTP1
CNOP Operation box Connects the operation box.
I/O signal (Short-circuit the A7-B14, B9-B10, B11-B12 when the operation
box is disconnected)
CNTP Teach pendant Connects the teach pendant.
I/O signal
3-27
1. TBOP1(User connection)
Be sure to make a redundant contact when applying the external emergency stop.
（<Example> When applying the external emergency stop : Pin 8-9 and Pin 10-11）
Pin No. Signal Function Common

1 M_ON IN Motors energized P1
2 M_ON OUT Motor ON lamp P1
3 MODE Teach/playback input P1
4 P1 Internal DC24V －
5 STOP IN+ Temporary stop input －
6 STOP IN- ※1 －
7 STOP OUT Stop lamp output P1
8 EMG IN1+ Emergency stop input 1 －
9 EMG IN1- ※1 －
10 EMG IN2+ Emergency stop input 2 －
11 EMG IN2- ※1 －
12 HPA+ Warning lamp output A －
contact +
14 HPA- Warning lamp output A －
contact -
※1．Short-circuit when not being used.
2. TBOP2(User connection)
Pin No. Signal Function Common

1 ST1 IN Station 1 P1
Starts playback
2 ST1 OUT ST1 IN lamp P1
Starts playback
Starts playback
Start playback
11 HPB+ Warning lamp output B －
contact +
12 M1 GND of internal DC24V －
13 HPB- Warning lamp output B －
contact -
3-28
3. Connection of TBOP 1,2
When temporary stop or emergency stop is not being used.
Fig. 3.5.2 Example of TP interconnection board connection
When temporary stop and emergency stop input is not going to be connected, short-circuit the areas that are disconnected
as shown in Fig. 3.5.7.
3-29
4. Warning lamp connections

While the robot can possibly start operating in a condition such as when it has
temporarily stopped or stopped, waiting for an external signal input, it is impossible for
an operator visually to judge the condition.
In order to maintain safety of the operators, install a warning lamp to make it stand out on
WARNING the guarding fence etc. so that operators can notice that the robot is ready to operate,
which prevents personnel from entering the guarding fence.
Warning lamp
Guarding fence
Fig. 3.5.3 Warning lamp
The HPA is interlocked to the magnet switch and is short-circuited during servo power ON.
Signal (Terminal block : TBOP 1）

HPA+ 12
HPA- 14
Signal (Terminal block : TBOP 2）
HPB+ 11
HPB- 13
3-30
3.5.6 Connecting Digital Welding Power Supply

This chapter describes how to connect the digital welding power supply.
As for the welding power supplies which are not written in this section, please refer to maintenance manual
“1L8800B”.
1. Types of Digital Welding Power Supply
Welding process Type Model

DM-350/500 Digital auto DM350/500
CO2/MAG welding DR-350 Digital auto DR350
DL-350 Digital inverter DL350
MAG/MIG welding DP-350/500 Digital pulse DM350/500
TIG welding DA-300P Inverter digital ELECON DA300P
MIG welding DW-300 Digital inverter DW300
2. Connection Cable for Welding Power Supply

To connect the robot dedicated welding power supply, the following external connection cables are required.
<DM-350, DP350, DR-350, DW-300, DL-350>

1) Control cable 4 ：Connection cable ( Robot - Robot controller )
For NB4,NB4L,NV6,NV6L,NV20
Component
Type Torch-side Workpiece-side Specifications
Gas hose Control cable4
welding cable welding cable
For A2RB-4105 L2527B L9155C L9155D L21050B Length: 5m
DM,DP, A2RB-4110 L3375T L9156C L9156D L21050C Length: 10m
DR,DW A2RB-4115 L3375V L9157C L9157D L21050D Length: 15m
A2RB-4605 L2527B L9155C L9155D L21060B Length: 5m
For
A2RB-4610 L3375T L9156C L9156D L21060C Length: 10m
DL
A2RB-4615 L3375V L9157C L9157D L21060D Length: 15m
2) Control cable 5 ：Connection cable ( Welding power supply - Robot controller )

Type Specifications
AXRB-5105 (Standard) Length: 5m
AXRB-5110 Length: 10m
Note. When connecting from back side of robot controller, the interconnection cables L21160E are separately required.
3) CAN I/F board : Communication board (Robot controller – Welding power supply)
Available power supply Type Specifications
For DM L9129C CAN I/F board
For DP, DL, DR, DW L9123C Robot I/F board
4) Voltage detection cable（workpiece-side）

L5666B (Standard) Length: 5m
For DP, DW (Note) L5666C Length: 10m
L5666D Length: 15m
For DL L9509C Length: 10m
L9509D Length: 15m
(Note) This cable is necessary when the to-and-fro length of welding cable is 30m or longer.
3-31
Fig. 3.5.6 Connecting the Digital Welding Power Supply (DM-350)
Fig. 3.5.7 Connecting the Digital Welding Power Supply (DP-350)
3-32
Fig. 3.5.8 Connecting the Digital Welding Power Supply (DL-350、DW-350)
3-33
<DM-500, DP500>
1) Control cable 4：Connection cable ( Robot - Robot controller )
①For NB4,NB4L,NV6,NV6L,NV20
Component
Type Torch-side Workpiece-side Specifications
Gas hose Control cable4
A2RB-4405 L2527B L2527D L3342B L21050B Length: 5m
A2RB-4410 L3375T L3375E L3375L L21050C Length: 10m
A2RB-4415 L3375V L3375G L3375N L21050D Length: 15m
2) Control cable 5：Connection cable ( Welding power supply - Robot controller )

Type Specifications
3) CAN I/F board：Communication board (Robot controller – Welding power supply)

For DM L9129C CAN I/F board
For DP L9123C Robot I/F board
4) Voltage detection cable（workpiece-side）

For DP, DW (Note) L5666C Length: 10m
L5666D Length: 15m
(Note) This cable is necessary when the to-and-fro length of welding cable is 30m or longer.
3-34
Fig. 3.5.9 Connecting the Digital Welding Power Supply (DM-500)
Fig. 3.5.10 Connecting the Digital Welding Power Supply (DP-500)
3-35
<DA-300P>
1) Power cable hose ：Connection cable ( Welding power supply – Robot )
Type Specifications
L-7623E Length: 6m
For 200A torch
L-7623J Length: 10m
L-7633E Length: 6m
For 350A torch
L-7633J Length: 10m
2) Torch adaptor：Connection cable ( Welding power supply – Power cable )

Type Specifications
BBAWD-1701 For 200A torch
BBAWD-1801 For 350A torch
3) Control cable 5：Connection cable ( Robot - Robot controller )

Type Specifications
4) Workpiece side welding cable

Type Specifications
L9155D Length: 5m
L9156D Length: 10m
L9157D Length: 15m
5) Robot I/F board：Communication board (Robot controller – Welding power supply)

Type Specifications
L9123C Robot I/F
6) CAN I/F board：Required with using Filler wire

Type Specifications
L9129C TIG filler controller – Welding power supply
Fig. 3.5.11 Connecting the Digital Welding Power Supply (DA-300P)
3-36
3. How to connect cables
Turn OFF the primary power and the breaker of robot controller.
Check that the voltage of primary power meets the voltage specification of controller.
The voltage of controller is indicated beside the breaker.
WARNING
(a) Control cable 5：Connection cable between the robot controller and welding power supply
For connection of control cable 5, an interconnection cable inside the controller, either L21160W00 (for
lateral-side leading-in) or L21160E00 (for rear-side leading-in), is necessary.
(1) Leading-in of the control cable 5 (AXRB-5105)
Lead the connector for the Control Cable 5 into the robot controller, from the lead-in opening at the lateral or
rear side.
(2) Connection of the Control Cable 5 (AXRB-5105) - 1

--In case of leading-in from the lateral side--
Connect the CNCAN of the connector pulled into the robot controller to the connector CNCAN of the storage
board, while connecting CNWEL to CNWEL of the interconnection cable (L21160W00)
--In case of leading-in from the rear side--

Connect the connector pulled into the robot controller to the connector of the interconnection cable
(L21160W00)
(3) Connection of the Control Cable 5 (AXRB-5105) - 2
Clamp the shield section of the Control Cable 5, and fix the flange.
In case of leading-in from the lateral

side, use this panel.
If you use the lateral side, an interconnection cable

inside the controller (L21160W00) is necessary.
In case of leading-in from the rear

side, use this panel.
If you use the rear side, an interconnection cable
inside the controller (L21160W00) is necessary.
Fig. 3.5.12 Connection of the Control Cable 5 (AXRB-5105)
3-37
(4) Connecting Control cable 5 (AXRB-5105) -- (3)

<For DM (S-1)>
・ Remove the top cover from the welding power supply.
・ Draw the control cable 5 into the welding power supply through its back, and then fix the cable flange using
the supplied tapping screws.
・ Joint the connector to the connector CN3 on PCB (L9129C), and the crimp-style terminal to the terminal
block (No.1&2) on PCB (P10260T). (SeeFig. 3.5.13)
・ After connecting the cables, connect the grounding and then fix the top cover.
(Refer to Fig. 3.5.6 for the location of PCB.)
Fig. 3.5.13 Terminal Block

＜For DL, DP, DR, DW, DM (S-2)＞
・ Remove the top cover from the welding power supply.
・ Draw the control cable 5 into the welding power supply through its back, and then fix the cable flange using
the supplied screws.
・ Joint the connector to the connector CN3 / CN57 on PCB (L9123C) , and connect the “EMG” terminal to
the terminal block on the side panel (for DL) or the chassis (for DP).
Fig. 3.5.14 Terminal Block

・ After connecting the cables, connect the grounding and then fix the top cover. (Refer to Fig. 3.5.8 for the
location of PCB.)
(b) Control cable 4 (L21050B : For DM, DP, DW L21060B : For DL) : Connection cable (Robot – Robot controller )
Joint the control cable 4 to the connector ICN4 in welding power supply and to the connector CN4 in
manipulator.
3-38
(c) Workpiece-side welding cable (L9155D) : Connection cable (Welding power supply – Workpiece)
Connect the workpiece-side welding cable to the (-) terminal of the welding power supply and secure it by
turning the connector.
(d) Torch-side welding cable(L9155C) : Connection cable (Welding power supply – Robot)
Connect the torch-side welding cable to the (+) terminal of the welding power supply and secure it by turning
the connector.
Installation of welding power supply

Welding power supply requires fixing on the firm and horizontal floor such as concrete.
Be sure to have enough space when installing welding cables to prevent connectors from being bent.
Forcibly installing the cables with the connectors bent may cause damage to the connectors.
CAUTION Good example Bad example
・ Installation on the floor ・ Forcibly installing the cables
Be sure to have enough space when installing the The connectors may result in bending when
welding cables to prevent the connectors from the cables are installed forcibly.
being bent.
・ Installation on the end of the pedestal ・ Installation by the pedestal corner

Be sure to have sufficient length between the The connectors may result in bending when
welding power supply and the pedestal corner to pulled by weight of the cables.
prevent the connectors from being bent.
3-39
(e) Voltage detection cable(workpiece-side)(L9509B)：Connection cable (Welding power supply – Workpiece) for DL
< Connection of voltage detection cable for DL-350 (on workpiece-side) >
Properly wire the voltage detection cable for DL-350 so that the Arc voltage can be accurately fed back.
1） Connection of voltage detection cable
Connect the voltage detection cable on both torch and workpiece sides. When wiring, the area of shaded part
as shown in the figure below shall be as small as possible to minimize the effects of inductive noise.
Fig. 3.5.15 Wiring of the voltage detection cable (1)
2） When provided with multiple welding stages
Connect the workpiece-side welding cable to each stage in series, and the voltage detection cable
(workpiece-side) to the stage last connected. (To avoid detecting the voltage drop occurred in the
workpiece-side welding cable.)
Workpiece-side CN28
welding cable
3-40
3） When installing the workpiece on rotary table
Connect the cable to minimize the voltage drop caused by the welding current.
Example)： When applying the rotary positioner, connect it directly to the table. It shall be connected under
the table or other positions where no interference each other occurred when the rotary table
rotates.
1. For the outline drawing, the internal structure and others about a welding power supply,
see the instruction manual attached to each welding power supply.
:Important
2. For the maintenance of welding power supply, see the instruction manual attached to
each welding power supply.
4. Modifying Parameters
After connecting cables, be sure to modify the setting of welding parameters.

For how to modify the parameters, refer to “APPLICATION MANUAL (ARC WELDING)”
1. Arc voltage detecting cable (torch side) is included in the control cable 4.
2. Arc voltage detecting cable (workpiece side) is required when the to-and-fro
length of welding cable is 30m or longer.
CAUTION 3. To use the arc voltage detecting cable (workpiece side), connect it away from the
workpiece cable.
4. Wire feed unit attached with encoder can be combined with a fixed bracket, but
not with a rotational bracket.
3-41
DM-350
Control Cable 5
TP Interconnection board
Control Cable 4
Robot Controller
Gas cylinder
Workpiece side Torch-side
Control Cable 1
Control Cable 2
Wire feed unit Manipulator
Robot Controller (In case of leading-in from the lateral side)

Robot dedicated welding power supply
DM-350
Interconnection connector
Terminal block Control Cable 5
Emergency stop
Storage board
AXRB-5105
Manipulator Wire feed unit

Control Cable 4
Wire feed Wire feed
motor motor
Encoder Phase A
Encoder line
Encoder Phase B
Gas
Gas valve
Arc voltage detection (torch)
Arc voltage detection
(workpiece)
Output Torch
Workpiece
3-42
DP-350 / DR-350 / DW-300
Control Cable 5
Control Cable 4
Robot Controller
Gas cylinder
Control Cable 1
Control Cable 2
Workpiece side Torch-side welding
welding cable cable

DP-350 / DR-350 / DW-300
Interconnection cable
Terminal block Control Cable 5 TP Interconnection
Robot I/F board
Emergency stop
board
Storage board
AXRB-5105

Control Cable 4
Wire feed Wire feed
motor motor
Encoder Phase A Encoder line

Encoder Phase B
Gas
Gas valve
(workpiece)
Output Torch
Workpiece
3-43
DL-350
Control Cable 5
Control Cable 4
Robot Controller
Gas cylinder
Control Cable 1
Control Cable 2
Workpiece-side Torch-side
Voltage detecting cable

DL-350 Interconnection cable
Robot I/F board Emergency stop
Storage board
AXRB-5105

Control Cable 4
Wire feed Wire feed

motor motor
Encoder Phase A
Encoder line
Encoder Phase B
Gas
Gas valve
(workpiece)
Voltage detecting cable

Output Voltage detecting cable
Torch (torch side)
(workpiece side)
Workpiece
3-44
DA-300P（With no Filler wire feeder）
Gas cylinder Control Cable 5
Robot Controller
Control Cable 1
Control Cable 2
Manipulator

DA-300P
Robot I/F board Emergency stop
Storage board
AXRB-5105
Manipulator
Output Torch
Workpiece
3-45
DA-300P (With Filler wire feeder)
Control Cable 5
Gas cylinder
Torch SW
Feed unit
CAN I/F board
CAN communication
cable Robot Controller
Control Cable 1
Control Cable 2
Control Cable 4
Robot Controller (In case of leading-in from lateral side)

Welding power supply
DA-300P
Emergency stop
Storage board
AXRB-5105
Robot I/F board
TIG filler feed controller
HC-71D
Feed unit Control Cable 4
Wire feed Wire feed
motor motor
Encoder Phase A
Encoder line
Encoder Phase B
Torch SW Torch SW
CAN I/F board
CAN
Communication
CAN I/F board
cable
Output
Torch
Workpiece
3-46
3.6 Power connections (AX21)
3.6.1 Primary power supply connections
position.
WARNING specification of the robot controller. The voltage of the robot controller is indicated
near the circuit breaker.
(1) The specifications of this robot controller's primary power supply are as follows.
Manipulator used in combination Rated voltage Power-handling capacity

3-phase AC200V
NB4/NV6 (+10%, -15%) 3 kVA
50/60 Hz
(2) Use a cable with a diameter of at least 3.5 mm2 for the primary power supply cable. Install an M5
round solderless terminal (R3.5-5) on the robot controller, and connect it to the circuit breaker.
Fig 3.6.1 Concerning the primary power supply cable
(3) Connect the primary cable to the circuit breaker on the robot controller through the cable bushing
accessory.
3-47
(4) Between the circuit breakers on the robot controller and power supply source and the welding power
supply source, install a no-fuse circuit breaker (3-phase AC 200 V) or leakage circuit breaker that
supports the current used by the model concerned.
Model Working current

NB4/NV6 30A
1. An inverter circuit for controlling the AC servo motor is used in this robot controller.
In order to prevent the leakage circuit breaker from being tripped in error by the
high-frequency leakage current generated from the inverter circuit, the leakage circuit
CAUTION breaker must be designated for inverter use when one is to be used.
2. When installing the leakage circuit breaker, use one with a medium current sensitivity
(100 mA or more). When installing a single leakage circuit breaker to cover a multiple
number of robot controllers, use one with a current sensitivity equivalent to 100 mA
multiplied by the number of robot controllers.
(5) In order to minimize the effect of noise due to current leakage, supply the primary power of the robot
controller and primary power of the welding power supply from separate power supplies.
(6) Connect the grounding terminals on the robot controller and welding power supply separately and
isolate the connections from each other.
To ensure safety, ground the equipment without fail.

Due to the risk of electric shocks, turn off the power source of the robot controller
DANGER before installing the unit.
Grounding must be
implemented inside the
casing.
Primary power supply cable
To primary power
View of detail A
Fig 3.6.2 Lead-in opening of the primary cable
3-48
3.6.2 Grounding
To ensure safety, use the grounding method (type D ground) described in Fig 3.6.3. (The user is responsible
for providing the grounding wires.)
Ground the manipulator separately using the M8 tap at the bottom part of the main unit and a grounding cable
with a diameter of at least 3.5 mm2.
• Ground the robot controller separately using a grounding cable with a diameter of at least 3.5 mm2. The
grounding terminals of the robot controller are located above the circuit breaker and on the bottom of the robot
controller.
• Ground the welding power supply separately using a grounding cable with a diameter of at least 14 mm2 for
the model 350A and at least 22 mm2 for the model 500A. For details, refer to the operating instructions of the
welding power supply concerned.
• Set the ground resistance to less than 100 ohms.
• As shown in Fig 3.6.3, connect the (1), (2), (3) and (4) grounds separately and isolate the connections from
each other, and do not allow under any circumstances whatsoever the grounding wires or grounding poles to
be shared with any other source of electrical or mechanical power.
• When using metal pipes, ducts or distributing frames to install grounding cables, ground the metal pipes, etc.
in compliance with the technical standards governing electrical apparatus.
Fig 3.6.3 Grounding
Note) The above is a rough diagram of CO2 welding. For TIG welding, do not place the robot controller
and welding workbench on the common base.
3-49
Fig 3.6.4 Welding current flow to the robot controller
As shown in Fig 3.6.4 Welding current flow to the robot controller, if the (B) workpiece
side cable connections have not been performed properly, the welding current will flow
through the motor frame to the robot controller, possibly damaging the robot controller:
CAUTION
this is very dangerous. Furthermore, similar care must be taken when using a separate
welding power supply for the tack welding of workpieces.
3-50
3.7.1 Connecting I/O signals to Relay board

This section describes how to connect the robot controller and peripheral equipment using the relay unit.
Refer to “3.4 Signal line connections (AX20) “, when connecting I/O signals to I/O board directly. In such case,
refer to “3.7.4 Input signal connections “for a pull-in opening of the wiring.
3.7.2 Specification of I/O signals
Relay unit
Right side of robot controller

(Inside)
Condition setting Directly setting the general physical I/O port in the task programs
Allocation setting Setting the allocation of logical I/O port to physical I/O port in the I/O conversion table
Extension of input and output in the relay unit is allowed respectively up to 64 points by
External control input
General physical I/O each 32 points (Option)

Max. 2 extension boards in the robot controller
ON/OFF by DC24V, 10mA
The input signals needs to be closed for 150ms or longer.
Connect the relay contact (Dry contact).
Electrical input
To avoid contact failure etc., select the relay to meet the above specification and
specification
conditions.
When connecting open-collector device, please use the one which leakage current is up
to 1mA.
Electrical output Relay contact (Dry contact) output : AC100V or DC30V, 1A
specification Note) Min. current 5V, 1mA
Note) This is the target value at the minimum load level.

Since this value depends on the switching frequency, environment conditions, and expected reliable level, be
sure to check with the actual load condition before operation.
3-51
3.7.3 Wiring
The relay unit can be mounted on the door side or the back side. As shown on” Fig 3.7.1” the pull-in opening of the wiring,
when mounting the relay unit on the door side, it is recommended that using the right side lower panel. When mounting on
the back side, it is recommended that using the middle of the lower right part panel.
Cable for Relay Unit
L20400M00
General-
Purpose I/O
Board
Enterance of
Wiring Lead-In
Relay Relay
Board 1 Board 2
Figure of Side
When mounting on the door side
Relay Cable for Relay Unit

Board 1 Relay Board 2
Relay Board
L20400M
General-
Purpose I/O
Board
Entrance of
Wiring Lead-In
Back Figure Side Figure
When mounting on the back side
Fig 3.7.1 Mounting position and wiring of relay unit
Fasten the wire tightly onto the terminal block with the binding band to prevent it from falling off after wiring. The
binding band is a provided attachment.
Tie band
3-52
3.7.4 Input signal connections

In the robot controller (Standard specification), it becomes available to use 32-point general-purpose input
signals by adding the relay unit (Option). Both type of NPN and PNP power suppies can be selected by switchig
CNSW.
Any of the signals can be allocated to serve as the general-purpose input signals or as the status input signals
(signals signifying "external start," etc.). For further details, refer to “Chapter 4 Setup.”
Table 3.7.1 List of input signals(TBIN1)

Terminal block Signal
Signal name Pin description
pin No. (I*)
1 IN1 I1 General-purpose input signals
5 IN COM1 COMMON Common for pins 1 to 4 (IN1～IN4)
21 24V Internal 24V 24V internal power supply
22 EX 24VA Input 24V External power supply input (24V)
23 EX 24VB Output 24V External power supply output (24V)
3-53
Table 3.7.2 List of input signals(TBIN2)

pin No. (I*)
1 EX 0VB Output 0V External power supply output (0V)
2 EX 0VA Input 0V External power supply input (0V)
3 0V Internal 0V 0V internal power supply
4 IN17 I17 Program selection bit 1
14 IN25 I25 Program strobe U1
17 IN28 I28 Welding ON/OFF
20 IN30 I30 Ext. play start.
External stop (keep an input signal supplied here
21 IN31 I31
when this pin is not used.)
22 IN32 I32 External motor power OFF
１，ＮＰＮ２，ＰＮＰ
CNSW
CNSW
１２３４５６７
24V 24V １２３４５６７
INCOM_A INCOM_B 0V
INCOM_A INCOM_B 0V
FCIO_A FCIO_A
CNIN CNIN
IN24V <-AX21 External Jigs -> IN24V <-AX21 External Jigs ->
45 45
46 35 TBIN1 46 35 TBIN1
36 21
24V 36 21
24V
47 47
INCOM_B
37 22
EX24VA 37 22
EX24VA
9 9 INCOM_A
23 EX24VB (NPN Type) 23 EX24VB (PNP Type)

IN1 IN1
IN1 IN1
1 1 1 1 1 1
IN2 IN2
IN2 IN2
2 3 2 2 3 2
IN3 IN3
IN3 IN3
3 5 3 3 5 3
IN4 IN4
IN4 IN4
4 7 4 4 7 4
INCOM1 INCOM1
5 5
18 38 18 38
IN5 IN5
IN5 IN5
5 9 6 5 9 6
IN6 IN6
IN6 IN6
6 11 7 6 11 7
IN7 IN7
IN7 IN7
7 13 8 7 13 8
IN8 IN8
IN8 IN8
8 15 9 8 15 9
INCOM2 INCOM2
10 10
27 39 27 39
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
TBIN2 TBIN2
36 40 36 40 INCOM_B
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
INCOM_A INCOM8 INCOM8

21 21
1 EX0VB 1 EX0VB
48 EX0VA 48 EX0VA
2 External Jigs 2 External Jigs
49 33 49 33
0V 0V
50 34 3 50 34 3
IN0V IN0V
<I/O Board> <Relay Board> <I/O Board> <Relay Board>
Fig 3.7.2 Basic configurations of Input circuit
3-54
~ Signal connection with external jigs ~

To input the relay unit, connect the output of relay dry contact and transistor as the diagram below.
IN1 IN1 IN1
IN2 IN2 IN2
COM
. COM COM
.
. .
. .
. .
.
.
.
.
.
Connection of relay dry Connection of transistor output Transistor (PNP) Output connections
.
.
contact (NPN). (Sink type (-) Common) (Sink type：(+) common)
~ External 24V power supply ~

1 2
TBIN2 TBIN1 TBIN2 TBIN1
3 21 3 21
2 22 2 22
1 23 1 23
TBIN2 TBIN1
3 21
2 22
External power 1 23 External power
supply input (0V) supply input (24V)
4
TBIN2 TBIN1
3 21
2 22
External power 1 23 External power
supply output (0V) supply output (24V)
Fig. 3.7.1 Method used to supply the 24V external power supply
(1) Check that shorting cables are connected to TBIN1 and TBIN2.
(2) Disconnect the two TBIN1 and TBIN2 shorting cables.
(3) Connect the external power supply input (24 V) and (0 V) pins to the pins shown in (3).
(4) When a multiple number of relay units are used or 24 V is to be supplied elsewhere, connect the 24 V
output pin to the pin shown in (4).
3-55
The DC 24V power can be supplied from the power supply inside the robot controller.
The capacity of the power which can be supplied is DC +24V (0.8A).
DC+24V output from relay unit

DC+24V TBIN1 Pin 23(EX24VB)
GND(0V) TBIN2 Pin 1(EX0VB)
It is also possible to use an external power supply instead of the internal power supply. Do not use power with
the wrong polarity.
DC+24V input to relay unit
External power supply DC+24V±10%
External input DC+24V TBIN1 Pin 22(EX24VA)
GND(0V) TBIN2 Pin 2(EX0VA)
Internal and external power supplies can be used together since there is a separate common for every four
input/ output circuits.
Example:
Output signal Power supply
O 1 to O 4 Controller
O 16 to O 19 External
The electrical specifications per input circuit are listed below.
Input impedance Approx. 3 k ohms

Input current 8mA
The electrical specifications per output circuit are listed below. Be absolutely sure to use the robot within these
ratings.
Rated switching capacity DC24V±3V,0.1A

Be absolutely sure to use a surge suppression diode for the load.
3-56
3.7.5 Output signal connections
In the robot controller (Standard specification), it becomes available to use 32-point general output signals by
adding the relay unit (Option).
A total of 32 DC 24 V output signals are provided with the AX controller (under the standard specifications).
Any of the signals can be allocated to serve as the general-purpose output signals or as the status output
signals (signals signifying "robot running," etc.). For further details, refer to “Chapter 4 Setup.”
The table below shows the statuses which have been allocated as the factory initial settings.
Table 3.7.3 List of output signals (TBOUT1)

pin No. (O*)
1 OUT1 O1 General-purpose output signals
5 OUT COM1 COMMON Common for pins 1 to 4 (OUT1～OUT4)
Table 3.7.4 List of output signals(TBOUT2)

pin No. (O*)
1 OUT17 O17 Wire stick check
2 OUT18 O18 Weld failure
3 OUT19 O19 Unit READY U1
4 OUT20 O20 Program end U1
6 OUT21 O21 Error U1
7 OUT22 O22 Interlock alarm U1
8 OUT23 O23 Alarm U1
9 OUT24 O24 Emergency stopped
11 OUT25 O25 In teach mode
12 OUT26 O26 Robot running U1
13 OUT27 O27 Ext. prg. sel enable
14 OUT28 O28 Ext. start enable
16 OUT29 O29 Motors energized
17 OUT30 O30 Status output 1
18 OUT31 O31 Work home position 1 U1
19 OUT32 O32 Information U1
3-57
EXP1
CNOUT
OUT1
.....
.....
.....
.....
.....
Signal output
OUT4
to external jigs etc.
.....
EXM1
.....
.....
COM1
I/O board
OUT5
.....
.....
.....
Signal output
OUT8
to external jigs etc.
.....
Relay board COM2
Fig. 3.7.2 Basic configuration of output circuitry
3-58
In this section, such safety-related signals as the emergency stop signal and safety plug signal will be
connected. These signals are absolutely indispensable as a safety measure for operators who perform teaching
work and as an emergency stop measure when a fault has occurred.
The AX controller comes with safety redundancy circuits as a standard feature. Connect a separate pair of
signals each for the external emergency stop input, safety plug input and enable switch input. The controller will
not work properly if any of the separate pairs of signal inputs are mismatched in the safety redundancy circuits.
A safety plug or enable switch is required to perform the teaching work inside the
safety fence. These connections must be performed without fail. If a safety plug is
not going to be used, install a "switch that permits automatic start" outside the
safety fence, ensure that it is constructed in such a way that it cannot easily be set
CAUTION to ON in case operators are working inside the safety fence, and connect its signal
to the safety plug input.
3.8.1 I/O sequence board
In the case of AX20, the terminals for the safety-related signals are located on TBEX1, TBEX2 on “I/O
sequence board (The type number in case of NACHI; UM301, in case of DAIHEN/OTC : L20400F00)”. The
position of the I/O sequence board is shown below.
CN1
A1A2B1B2 CN31
B1 A1
CN32
B1 A1
CN33
B1 A1
CN8
CN43
B2B1A2A1 CN42
B2B1A2A1 CN41
B2B1A2A1
2 1
CN7
1
CNPS CN9
32 1
CNSTR
1ABC
LED 配置位置
ISA bus slot (CN31) in which the I/O
sequence board (UM301, L20400F00) is CN10
inserted. 2 1
CN6
32
Fig. 3.8.1 Position of the I/O sequence board (UM301 / L20400F00)
3-59
3.8.2 Position of the terminal block

Position of the TBEX1 and TBEX2 are shown below.
Please use a blade-shape terminal (plate shape terminal) for the connections.
3mm
The width of the terminal should
be 3 mm or less.
CNWEL
CNP
CNTP
CNOP2
P1
CNOP
TBEX2
TBEX2
P2
TBEX1
TBEX1
CR2
CNSV
CNDE2
CNDE1
CR1
CR3
Fig. 3.8.2 TBEX1, TBEX2 on the I/O sequence board (UM301)
3-60
Electrical Input/Output specification of the terminal blocks

Electric input specification：ON/OFF (DC24V,10mA)
IMPORTANT The input signal must have been closed for 150ms or longer.
Connect the relay contact (dry contact) and the relay to satisfy the above specification to
avoid contact failure and other fault.
Electric output specification：Relay contact (dry contact) output AC100V or DC30V, 1A
To connect the coil circuit such as relay, be sure to install the surge absorb circuit in
advance.
The following value is a rough standard of the minimum load level. It may vary depending on
the switching frequency, the environment condition and the expecting reliability standard,
therefore, check with the actual load prior to use.
Rough standard of minimum load : Minimum current 5V, 1mA
TBEX1
Pin No Signal name Function Description
1 External emergency stop input 1+ This is an external emergency stop input
E.STOP1 terminal.
2 External emergency stop input 1- Jumper wires are connected between 1-2 and
3 External emergency stop input 2+ 3-4 terminals at default. Remove these jumper
E.STOP2 wires to use this terminal.
4 External emergency stop input 2-
5 Safety plug input 1+ This is a safety plug input terminal.
SFP1 Jumper wires are connected between 5-6 and
6 Safety plug input 1- 7-8 terminals at default. Remove these jumper
7 Safety plug input 2+ wires to use this terminal.
SFP2
8 Safety plug input 2-
9 Teaching enable switch input 1+ This is a teach enable switch input terminal.
MATSW1 Jumper wires are connected between 9-10
10 Teaching enable switch input 1- and 11-12 terminals at default. Remove these
11 Teaching enable switch input 2+ wires to use this terminal.
MATSW2
12 Teaching enable switch input 2-
3-61
TBEX2
Pin No Signal name Function Description
Emergency stop output 1+ Dry contact A output terminal to indicate the
1 status of the emergency stop signal.
(dry contact)
E.STOP.OUT1 When the emergency stop button on the
Emergency stop output 1- operation panel of the controller or the teach
2
(dry contact) pendant is pressed, or, when an emergency
Emergency stop output 2+ stop signal is input from the external
3 devices, this signal turns OFF(the contact is
(dry contact)
open).
E.STOP.OUT2
Emergency stop output 2- This output has been designed dual. (The
4 dry contact output has been provided in two
(dry contact)
individual systems.)
Dry contact A output terminal to indicate the
5 CPU error output + (dry contact) status of CPU in the robot controller. It turns
CPU.ERRR ON (the contact is closed) when the CPU
6 CPU error output - (dry contact) error occurs.
7 MONCOM Common *1 Common terminal for Pin No. 8,9, and 10.
Input terminal to externally input the Motors
ON signal. If this terminal is connected with
MONCOM, the motors are turned ON. In
External Motors ON (input)
8 E.MON order to enable this terminal input, specify [2
(X0055)
MotorsON/START sel source] to "External"
in [Service][1 Teach/Playback Condition]
setting screen.
Optional function. To use this function, an
External teach/ playback (input) optional product should be purchased.
9 E.MODE When RMD_EN is ON (connected with
(X0039)
MONCOM), the controller is switched to
“playback mode” if E.MODE is turned ON
(connected with MONCOM). Using this
External mode select (input) function, it is possible to select the teach
10 RMD_EN
(X0041) mode and the playback mode from the
external operation panel.
Terminal for DC24V - 0V power inside the
11 P1 24V robot controller. Do not use this terminal
outside the robot controller since this is for
the internal use only. Also, do not use this
12 M1 Ground terminal when other devices are to be
installed.
Supplying the external power (DC24V)
between the terminals P2-M2 makes the
power supply possible to the emergency
13 P2 External power 24V input stop circuit in the robot controller. Even the
primary power of robot controller has been
shut off, the emergency stop circuit
effectively works if the external power
(DC24V) is supplied with this function. Then,
the emergency stop output 1 and 2 switches
ON/OFF according to the condition of the
emergency stop button. (Normally,
14 M2 External power ground short-circuited)
Note: When using the external power,
specify the JP3 setting to 2-3 short circuit.
(The default setting is 1-2 short circuit.)
M2 terminal is connected with M1 terminal in
the controller.
*1: Because Pin7 is connected with Pin11 in the substrate, Pin11 can be used as MONCOM.
When using relays, ensure that the configuration has relays of less than DC 24 V. AC relays
cannot be used.
IMPORTANT
3-62
(14) M2
(13) P2
(12) M1
(11) P1
(10) RMD_EN
(9) E.MODE
(8) E.MON
(7) MONCOM (=P1)
(6) CPU.ERRR (－)
(5) CPU.ERRR (＋)
(4) E.STOP.OUT2 (－)
(3) E.STOP.OUT2 (＋)
TBEX2 (2) E.STOP.OUT1 (－)

(1) E.STOP.OUT1 (＋)
(12) MATSW2 (－)
TBEX1 (11) MATSW2 (＋)

(10) MATSW1 (－)
(9) MATSW1 (＋)
(8) SFP2 (－)
(7) SFP2 (＋)
(6) SFP1 (－)
(5) SFP1 (＋)
I/O sequence board
(4) E.STOP2 (－)
(UM301)
(3) E.STOP2 (＋)
(2) E.STOP1 (－)
(1) E.STOP1 (＋)
Fig. 3.8.3 Pin layout of TBEX1 and TBEX2
3-63
For details of each terminal connection, please refer to the following descriptions.
3.8.3 External emergency stop input (TBEX1 : 1-2, 3-4)

As soon as the external emergency stop input signal becomes open under any circumstances whatsoever, the
brake is quickly applied to the robot, and the motor power (servo power) is cut off by the hardware circuits.
Input the emergency stop command from the emergency stop button or host controller. The separate pairs of
signal inputs must perform the same operations. Connect single normally closed contact between terminals 1 and
2 and another one between terminals 3 and 4. Bear in mind that the connections given in Fig. 3.8.5 cannot be
performed.
Sequence I/O board Sequence I/O board

External
E.STOP External
TBEX1 TBEX1 E.STOP
1 1
ESTOP1 ESTOP1
2 2
3 3
ESTOP2 ESTOP2
4 4
Fig. 3.8.4 Connection diagram of external emergency stop inputs
Sequence I/O board
TBEX1 External E.STOP

1
ESTOP1
2
3
ESTOP2
4
Fig. 3.8.5 Example where the external emergency stop input cannot be performed
3-64
3.8.4 Safety plug input (TBEX1 : 5-6, 7-8)

The guard fence must have a door for allowing the operators to move in and out. Provide a safety plug to
ensure that the robot will be stopped automatically when the door is opened to ensure that operators will not enter
inside the guard fence without due reason while the robot is operating, and connect the signals of the plug to the
safety plug input on the robot controller. The separate pairs of signal inputs must perform the same operations.
Bear in mind that the connections given in Fig. 3.8.8 cannot be performed.
If the safety plug input signal is left open during auto operation, the brake is quickly applied to the robot as for
emergency stop, and the motor power (servo power) is cut off by the hardware circuits. In this case, by switching
to teach mode, operation preparation (servo power) can be supplied once again in safety plug input signal open
status. However, the operation speed is limited to low speed (speed of 250mm/sec or below at tool end).
Guard fence
Manipulator
Limit switch for turning off the servo

power when the door in the guard
Welding power fence is opened
supply
Robot controller
Fig. 3.8.6 Safety plug (Guard fence door)
[Condition of the safety plug input signals that is required for turning ON the motors power]
TEACH mode : When both in opened and closed, motor ON is available.(The speed is limited to 250mm/s)
(If the opened/closed status changes, the motors are turned OFF for the present.)
PLAYBACK mode : Available only in closed state. (The limit of 250mm/s is not applied.)
Sequence I/O board

Safety plug
TBEX1
5
SFP1
6
7
SFP2
8
Fig. 3.8.7 Connection diagram of the safety plug inputs
Sequence I/O board

Safety plug
TBEX1
5
SFP1
6
7
SFP2
8
Fig. 3.8.8 Example where the safety plug input cannot be connected
3-65
3.8.5 Enable switch inputs (TBEX1 : 9-10, 11-12)

For the enable switch inputs, input a condition allowing robot operation in the teach mode. A mat switch can be
connected, for instance. Short-circuit the terminal block when the enable switch is not going to be used.
Sequence I/O board Sequence I/O board

Safety plug Safety plug
TBEX1 TBEX1
5 5
SFP1 SFP1
6 6
7 7
SFP2 SFP2
8 8
9 Enable 9
MATSW1 MATSW1 Short-circuit he
10 switch 10 when the enab
11 11 switch is not go
MATSW2 MATSW2 be used.
12 12
Fig. 3.8.9 Connection diagram of enable switch inputs
3.8.6 Connections when the robot controller is used by itself

When the robot controller is not going to be connected to an external device but used by itself, perform the
connections shown below. The external emergency stop and teach enable switches are shorted, but connect the
safety plug for detecting that the door of the guard fence has been opened to the safety plug inputs.
Sequence I/O board

(UM301)
TBEX1
1
ESTOP1 External E.STOP 1
2
3 External E.STOP 2
ESTOP2
4 Safety plug
5
SFP1
6
7
SFP2
8
9
MATSW 1 Enable switch 1
10
11
MATSW 2 Enable switch 2
12
Fig. 3.8.10 Diagram of connections when the robot controller is to be used by itself
Jumper setting (Initial setting)
Terminal block terminal No. to be
jumperred
1-2 External emergency stop input 1
3-4 External emergency stop input 2
5-6 Safety plug input 1
TBEX1
7-8 Safety plug input 2
9-10 Enable switch input 1
11-12 Enable switch input 2
3-66
3.8.7 Emergency stop output connection (TBEX2 : 1-2, 3-4)

Sequence I/O
board (UM301)
EXP24V(P2
)
TP_EMG OP_EMG CREMG1
EMG2 EMG1
E.STOP.OUT1 1
OV(M1) 2
EMG2 EMG1
EXP24V(P2) E.STOP.OUT2 3
4
TP_EMG OP_EMG TBEX2
CREMG2
OV(M1)
Fig. 3.8.11 Emergency stop output internal circuit diagram
Sequence I/O board

(UM301)
P24V(P1) EXP24V(P2)
JP3
1
24V
24V +
2 13 External
Ground - power
3 14
TBEX2
0V(M1)
Fig. 3.8.12 Emergency stop circuit external power supply connection diagram
JP setting
Position Contents Setting
Power source selection
1-2 (INT) : Internal DC24V power supply is used (std.)
JP3 for the emergency stop circuit
2-3 (EXT) : External DC24V power supply is used
(NOTE 1)
(NOTE 1)
The emergency stop output circuit uses internal power supply of the controller, and when the power supply of the
controller becomes OFF, the emergency stop button output signal becomes OFF too. In the case to use the emergency
stop output even when the power supply of the controller is OFF, supply external power supply from TBEX2, and
change the setting of the above jumper (JP3)
3-67
3.8.8 Each External Input Signal Connection
I/O sequence board (UM301)
P1
PC23 P1(MONCOM)
7
E.MON External Motors ON
8
9
10
TBEX2
P1
M1
11
12
TBEX2
M1
Fig. 3.8.13 External operation on - external teach /playback - external mode selection connection diagram
3-68
Chapter 4 Setup
This chapter describes the preparations performed up to the stage where
teaching can be performed for the robot. Setting the tool length and weight and
allocating the I/O signals for connection with the peripheral devices are absolutely
essential when the robot is to be used. Acquire a thorough understanding of the
information contained in this chapter and proceed with the setup.
4.1 Power-on.......................................................................................................4-1
4.1.1 Power-on.................................................................................................4-1
4.2 Configuration.................................................................................................4-2
4.2.1 Performing encoder reset and encoder correction (For DAIHEN) .........4-2
4.2.2 Performing encoder reset and encoder correction (For NACHI) ...........4-7
4.3 Motor power (servo power) ON ....................................................................4-8
4.3.1 Motor power-on.......................................................................................4-8
4.3.2 Motor power-off .......................................................................................4-9
4.4 Installing a tool ............................................................................................4-10
4.4.1 Mounting the tools (for the ST-166-02).................................................4-10
4.4.2 Mounting the tools (for the NV6/NV6L/NV20) ...................................... 4-11
4.5 Tool constant settings .................................................................................4-12
4.5.1 Tool name..............................................................................................4-13
4.5.2 Tool length.............................................................................................4-15
4.5.3 Tool angle..............................................................................................4-20
4.5.4 Center of gravity (COG) and weight of tool ..........................................4-21
4.5.5 Tool’s moment of inertia ........................................................................4-26
4.5.6 Max, radius of tool.................................................................................4-37
4.5.7 Tool length and angles of Daihen’s arc welding torch ..........................4-38
4.5.8 Tool Exchange.......................................................................................4-42
4.6 Signal attribute settings ..............................................................................4-45
4.6.1 Standard signal attributes assignment .................................................4-47
4.6.2 Basic input signals ................................................................................4-48
4.6.3 Basic output signals ..............................................................................4-50
4.7 Concerning the qualifications of the operators...........................................4-56
4.7.1 Operation qualifications ........................................................................4-56
4.7.2 Procedure for changing the operator qualifications..............................4-57
4.7.3 How to change the passwords .............................................................4-58
4.7.4 How to set the operator qualifications class at power-on.....................4-59
4.8 I/O area mapping function ..........................................................................4-60
4.8.1 I/O are mapping ....................................................................................4-60
4.8.2 Relation with software PLC...................................................................4-63
4.8.3 Setting method......................................................................................4-64
4.8.4 Example 1 : Making only field bus as external input / output signal in PLC
cutoff...............................................................................................................4-67
4.8.5 Example 2: Using only standard IO board – field bus CH1 in PLC cutoff4-68
4.8.6 Example 3: Forcibly inputting / outputting signals of additional IO board 1
as 1-32 signals with PLC enabled .................................................................4-69
4.9 High Speed Interference Detection Function (Revised).............................4-70
4.9.1 Outline of High Speed Interference Detection Function.......................4-70
4.9.2 Objective machine types.......................................................................4-70
4.9.3 Setting at Robot Start............................................................................4-71
）
4.9.4 Setting Most Suitable Threshold Value for Work Program...................4-73

4.9.5 Switching Detection Level by Function.................................................4-76
4.10 Setting the application type ......................................................................4-77
4.11 Setting the [Clamp / Arc] key ....................................................................4-79
4.12 Setting the software limit (operating range) .............................................4-82
4.12.1 Outline.................................................................................................4-82
4.12.2 [Position record] screen settings ........................................................4-83
4.12.3 [Data input] screen settings ................................................................4-84
4.12.4 [Auto Set] screen settings...................................................................4-85
4.1 Power-on
4.1 Power-on
In order to operate the robot, first turn on the primary power supply (control power) of the controller. The servo
power (motor power) is not turned on simply by turning on the primary power supply (control power).
4.1.1 Power-on
To turn on the power, simply set the circuit breaker to the ON position. (The position of the
circuit breaker differs depending on the series and the specifications.)
Before turning on the power, ensure that the door of the controller is closed
without fail.
Receiving an electric shocks from touching any of the power supply areas may
DANGER result in death or serious injury.
POWER
ON
OFF
Power supply
電源ブレーカ
circuit breaker
Fig. 4.1.1 Power-on
Depending on the system configuration, restrictions may apply to the power-on sequence. In
some cases, the control power is turned ON and OFF by remote signals from the central
controller (option). For further details, refer to the instruction manual of the system.
The operating system (Windows) starts up, the AX system automatically starts, and the
selfcheck is commenced. When the self-check is completed normally, the mode, program
number, step number and other settings which were established before the power was last
turned off are automatically called (when power failure detection is operational), and a screen
resembling the one below appears on the teach pendant.
Fig. 4.1.3 Initial screen (example of teach mode) when the system has started up normally
If one of the error messages is displayed during the self-check, read what it says, take the
remedial action suggested in the message, and then turn off the power and turn it back on.
4-1
4.2 Configuration
4.2 Configuration
The mechanical system configuration (such as the mechanism model settings, unit configuration definition,
encoder correction settings, Encoder Battery replacing, and operating range settings) and operability
configuration (such as the display language settings, application settings, and function key layout) have been
shipped from the factory in the optimum condition for the status of the system purchased.
Since there is normally no need for the user to change these settings, simply proceed to the next section.
4.2.1 Performing encoder reset and encoder correction (For DAIHEN)

Encoder reset and encoder correction (previously referred to as the ABSO setting) are performed in order to
adjust the home positions of the robot's axes.
These tasks must be carried out when the robot is shipped from the factory and whenever a motor is replaced
(including when a mechanism main unit is replaced).
Upon completion of the encoder correction, the basic posture check program is prepared. This program
corresponds to the conventional P999 or P9999. Prepare the program using the same number of 9999 for the
AX20/AX21 control unit as well.
Don't perform encoder reset and encoder correction when not needed.
In the case not described below, please don't perform encoder reset and encoder
CAUTION correction.
・After the manipulator and the robot control unit have been installed properly, the task
program (9999) does not provide the position where all the origin adjustment
matchmarks are in alignment.
・When the encoder has been changed or when a connector has been disconnected
from the encoder.
・When a connector has been disconnected from the charging battery equipped inside
the manipulator.
・When the following errors have occurred:

・Ｅ００３０ Encoder absolute data failure
・Ｅ００３１ Motor rotation too fast when turning Motors ON
・Ｅ００５０ Encoder counter overflow/underflow
・Ｅ００５２ Encoder battery charge low
・Ｅ００５５ Motor rotation too fast when power off
・Ｅ００５７ Encoder count status failure
・Ｉ１０１６ Manipulator battery warning
・Ｉ４９０５ Playback was started in the state that the basic posture of any
axes is not setup.
Systems which are not available to perform encoder reset with the teach pendant.
In some robots and servo guns that apply the servo motors, encoder reset cannot be
executed on Teach pendant. With these models, special operation is required to
execute encoder reset.
For the details on how to execute encoder reset, refer to each instruction manual.
< Relevant models >

・MV50
・Servo guns driven by Panasonic MS152Q2D and MS252Q2D
4-2
4.2 Configuration
Moving to the basic posture and selecting the menu items

1 Select the teach mode.
2 Turn on the servo power supply.
3 Perform manual operations in such a way that all the robot's axes are aligned with
the mark-off lines on the castings.
* The encoder reset and encoder correction positions are not index mark
positions. (Index marks have been discontinued with the AX control unit.)
If an index mark is adhered at the home position of an axis, peel it off (and
adhere it elsewhere) to reveal the mark-off lines underneath, and then proceed
with the manual operations.
4 Press <Constant Setting>, and select [3 Machine Constants] and [4 Encoder

Correction].
≫ This has the effect of selecting the encoder correction & reset screen.
Now proceed with the encoder reset and encoder correction operations. (These are
described on the next and subsequent pages.)
The screen that appears when the menu is selected is the screen on which the
encoder correction is performed. The encoder correction or encoder reset operation is
selected on this screen.
4-3
4.2 Configuration
Resetting the encoder

1 To reset the encoder, press f9 <Encoder Reset>.
≫ The encoder reset screen is selected.
2 To reset all the axes at once, press f8 <All Select>.

≫ All the axes are selected, and check marks appear for them.
The selected status can be released by pressing f8 <All Release>.
ON 3 To reset a specific axis only for replacing a motor, for instance, select the axis, and
ENABLE ＋
1 press [ENABLE] + [1].
≫ A check mark appears for the selected axis.
To release the selected axis, press [ENABLE] + [2].
4 When the axis to be reset is selected, press f12 <Execute>.

If the robot axes are not equipped with a brake, press f12 <Execute> while keeping
the servo power on. (If all the axes of the robot are equipped with a brake, this
operation may be performed with the servo power off.)
4-4
4.2 Configuration
Correcting the encoder

1 Upon completion of the encoder resetting, proceed with the encoder correction.
Press f9 <Encoder Correct>.
≫ The screen which appeared immediately after [3 Machine Constants] and [4 Encoder
Correction] were selected is restored.
2 Either "Data Input" or "Position Record" can be used as the method for encoder
correction.
"Position Record" is normally used.
Compensation
Details
method
Position Select this method at a production process or when a motor or

Record mechanism is to be replaced.
Be absolutely sure to perform the operations with the robot placed in
a posture where the mark-off lines are aligned.
The correction value is input by pressing
[Enter] followed by [REC]. (These values
are input for each axis.)
Angle (deg.) of each axis
Encoder value (in hexadecimal

notation) after correction
Data Input Use this method when the encoder correction values are already
known.
An "encoder correction value which is already known" is a
post-mastering encoder correction value which is provided inside
the control unit when the robot is shipped from the factory. It
corresponds to what was referred to as the "manipulator adjustment
value" in the past.
Therefore, the times when the encoder correction values are input
after shipment are as follows:
• When the encoder battery has been replaced
• After the memory has been formatted
When these values are input, it is acceptable for the robot to be in
any position and any posture.
The encoder correction value is
input (in decimal notation) here.
Angle (deg.) of each axis
Encoder value (in decimal

notation) after correction
4-5
4.2 Configuration
3 The "Position Record" method is described here.

Press f8 <Record Position>.
≫ The screen now changes.
4 Align the cursor with the axis whose encoder is to be corrected, and press [Enter]
Enter O.WRITE
followed by [REC].
REC
If the robot axes are not equipped with a brake, press [REC] while keeping the
servo power on. (If all the axes of the robot are equipped with a brake, this
operation may be performed with the servo power off.)
* Encoder correction cannot be implemented for all the axes together so repeat these
operations for each axis in turn.
5 At this stage, the encoder correction values are still not saved in the memory.
To save them, first turn the motor power OFF (by pressing emergency stop).
Then press f12 <Complete>.
Axis 4 Matchmarks Axis 1 Matchmarks
Axis 3 Matchmarks Axis 6 Matchmarks
Axis 2 Matchmarks
Axis 5 Matchmarks
Fig. 4.2.1 Origin Adjusting Matchmark Positions (NV6/NV6L/NV20)
4-6
4.2 Configuration
4.2.2 Performing encoder reset and encoder correction (For NACHI)
The procedure depends on each Robot type.

Refer to the maintenance manual for each Robot.
4-7
4.3 Motor power (servo power) ON

Next, turn on the motor power (servo power). When the motor power (servo power) is turned on, current flows
to the motor installed on the robot.
4.3.1 Motor power-on
Before turning on the motor power (servo power), be absolutely to check that no
one is in the vicinity of the robot. If the robot should move without warning and
come into contact or sandwich a person, death or serious injury may result.
DANGER
Operating procedure for Motors ON

>>First, as a safety precaution, select the teach mode without fail. If the teach mode is
established, the motor power (servo power) will come on only while the deadman
switch on the teach pendant is grasped so the robot will not suddenly start moving.
The steps taken to change the mode differ depending on the type of controller
used.
How to select the Teach mode

1. Turn the [Mode selector switch] to the “Teach” side.
2. Turn the [TP enable switch] to the “Teach” side.
2 Push the [Motors ON] button.

>>The motor power ON button starts flashing. In this state, no power is yet supplied to
the motor.
3 Grasp the deadman switch on the teach pendant. The robot is now set for
manual operation.
>>The motor power ON button stops flashing and lights up, and power is supplied to
the motor.
Release(or tightly grasp) the [Enable switch]

>> The power to the motors is turned OFF when it is released or when it is grasped
tightly.
4 Set the robot to the tool installation posture.
Refer to the “Basic Operations Manual”, and try performing manual operation of the
axes.
4-8
Table 4.3.1 Overview of the switches / buttons
Switch / button Overview

AX20 (operation panel) AX21(Operation box)
Mode selector switch
TP enable switch
(at the top left of the
teach pendant)
AX20 (operation panel) AX21(Operation box)
運転準備
Motors ON button MOTER ON
Enable switch
(Dead man switch)
(Backside of the teach
pendant)
Once power is supplied to the motor, the robot can be operated.

When teaching, first check that no one and no obstacles are blocking the path to the
target position, and then operate the robot. If the robot should come into contact or
DANGER sandwich a person, death or serious injury may result.
What if the robot cannot be operated?

• Has the emergency stop button on the teach pendant been pressed?
Turn the emergency stop button clockwise to release it.
• Has an external emergency stop signal been input?
→The preparations for the units around the robot (system side) have not been
completed.
First, complete the preparations on the system side, and release the emergency stop
signal.
4.3.2 Motor power-off
Simply press the emergency stop button on the teach pendant. While the robot is not going to be operated,
press the emergency stop button to keep the motor power (servo power) in the OFF status as a safety
precaution.
4-9
4.4 Installing a tool

I In this section, a tool will be installed to the flange surface of the robot wrist. Depending on the intended
application, the tool may be a spot welding gun, arc welding torch, material handling gripper or sealing nozzle
gun.
For the other manipulators, please refer to the instruction manual “MANIPULATOR No. 1L7700A”.
4.4.1 Mounting the tools (for the ST-166-02)

When a tool is to be installed, it need not necessarily point straight up or straight down. However, confirm that,
by operating the J6 axis (tip axis), the tool reaches the proposed range.
The figure below shows a case where a spot welding gun serves as the tool.
Flange
surface
Spot welding gun
Fig. 4.4.1 Installing a tool (Spot welding gun)
For the layout of the installation bolt holes and other detailed specifications, refer to the figure below.
The installation area differs from one robot model to another. Details are provided in the Maintenance Manual
of the model concerned, and so refer to them.
Fig. 4.4.3 Detailed outline drawings of tool installation area
The depth to which the tool (end effector) installation bolts are to be screwed in
must be less than the depth of the threads in the tool installation surface. The
wrist may be damaged if the bolts are screwed in beyond the depth of the threads.
CAUTION
4-10
4.4.2 Mounting the tools (for the NV6/NV6L/NV20)

When a tool is to be installed, it need not necessarily point straight up or straight down. However, confirm that,
by operating the J6 axis (tip axis), the tool reaches the proposed range.
The figure below shows a case where an arc welding torch is used.
Welding torch
Fig. 4.4.5 Mounting the tools
For the layout of the installation bolt holes and other detailed specifications, refer to the figure below.
The mounting area may be different with some robot models. For further details, refer to the maintenance
manual of the manipulator concerned.
Fig. 4.4.7 Detailed outline drawings of tool installation area (NV6/NV6L/NV20)
Be absolutely sure to set the screw-in depth of the tool (end effector) mounting
bolts to a depth which is less than that of the threads in the mounting surface of
the tool.
The wrist may be damaged if the bolts are screwed in beyond the depth of the
CAUTION
threads.
4-11
4.5 Tool constant settings

The “tool constants” refer to a set of parameters including the length, angle, center of gravity, weight and
moment of inertia of the installed tool. These parameters are extremely important for ensuring precise linear
operations and appropriate acceleration/deceleration control. Before moving the robot, read carefully through
the instructions in this section and take the steps described without fail. Tool constants for up to 32 tools can be
stored in the AX20/AX21 controller’s memory. If an application involves the use of a multiple number of tools,
perform the settings for all the tools concerned.
Continued use under the wrong settings for the center of gravity, weight and tool’s
moment of inertia may fatally damage the machine. Perform the settings set forth
in this section without fail.
The settings must be performed even for small and/or lightweight tools. The same
CAUTION
settings used for a large tool cannot be used for a small tool.
Table 4.5.1 Tool constants

Tool
Explanation
constants
A name can be set for each of the tools. A tool name may consist of not more than 16
Tool Name
alphanumerics and symbols. (Japanese characters cannot be used.)
This constant is the length up to the tool tip in the TCP coordinate system (X, Y and Z
components of the tool tip). It is absolutely necessary in order to ensure precise linear
Length movements.
When the tool length automatic setting function is used, the tool length can be
ascertained automatically using the already created program.
This constant is for setting the inclination of the tool tip in the TCP coordinate system
using the X, Y and Z axis rotation components. It proves useful since, when teaching, the
Angle
tool can be operated manually in the direction in which it is pointing.
When the tool angle simple setting function is used, the tool angle can be set easily.
This constant is for setting the tool's center of gravity position in the TCP coordinate
system and its weight. It is required in order to ensure appropriate
C of G acceleration/deceleration control.
The constant is set using the tool center of gravity (COG) and weight automatic
setting function. (The weight of a tool cannot be input manually.)
This constant is for setting the moment of inertia around the center of gravity in the TCP
coordinate system using the X, Y and Z components. It must be set if the moment of
Inertia inertia has exceeded the allowable value.
When the tool moment of inertia simple setting function is used, the moment of
inertia can be set easily by designating the tool shape.
Max. radius This constant is the max. radius of the tool. It is used to check the territory, etc.
Tool name
Compulsive
Tool length Be sure to set this for precise straight line interpolation.
Compulsive
Tool angle In the case of servo gun, be sure to set this for correct bending correction control.
Compulsive Tool center of

gravity and weight Be sure to set this for appropriate acceleration and deceleration control.
If the tool is used without setting continuously, fatal damage may be made on the machine.
Set "Tool inertia moment" after setting "Tool center of gravity and weight".
Compulsive Tool inertia
moment
Tool maximum
rotation radius
Fig. 4.5.1 Tool constant setting
4-12
Common operating procedure for setting tool constants

(With the exception of the tool weight, all of the tool constants are set on the same screen shown below.)
2 ［Select [Constant Setting], and press [2 Machine constants] followed by [1 Tool

constants].
>>The tool constant input screen resembling the one shown below now appears.
3 Align the cursor with the desired position, input a number (such as 1), and then
ON Enter press the [Enter] key.
1
4 To change the tool number, press the page up or down key.
5 Upon completion of the settings, press the [Complete] key. The settings are
now saved in the constant file.
>>Operation returns to the machine constant menu screen.
4.5.1 Tool name

With an application which involves the use of a multiple number of tools, the parameters
become more comprehensible if the welding gun or torch name and model, for instance, are
registered here first.
It is not required to set the tool name. The initial setting may be used as is. (Initial setting:
TOOL* where “*” is the tool number)
The tool name does not appear on the programs display screen.
Registering the tool names

1 Following the common operating procedure outlined above: Align the cursor
with the tool name field, and press [ENABLE] + [EDIT].
>>The character input screen (Soft Keyboard) shown below now appears. Input a tool
name consisting of up to 16 characters using alphanumerics and symbols.
For details on the comment input operation procedure, refer to the Basic Operations
Manual.
4-13
2 Upon completion of the character input, press the [Complete] key.

>>Operation returns to the above tool constant setting screen.
4-14
4.5.2 Tool length
Coordinate system Wrist coordinate

defined on tool system
installation surface
+X
+Y
The point where the J5

and J6 rotary axes
intersect is not the home
point of the wrist
coordinate system.
+Z This differs from contollers
used in the
Ｌ１
Tool tip
Tool length
(X component)
+Z Tool length The operations involved will be facilitated if the
+Y (Z component) upward direction of the tool is set as the Z (up)
direction and its forward direction is set as the
X (forward) direction since these are the
directions used with the robot coordinates.
Tool coordinate Define the tool coordinate system by rotating
+X the wrist coordinate system in such a way that
the above is achieved.
Fig. 4.5.3 Illustration of tool length and angle
The tool length is the coordinates of the X, Y and Z component of the tool tip in the wrist
coordinate system. Similarly, the tool angle expresses the inclination of the tool tip in the wrist
coordinate system as the angle of rotation around the X, Y and Z axes. The coordinate system
defined by these parameters is called the tool coordinate.
In the wrist coordinate system, the center of the tool installation surface serves as the home
point, and the direction in which this surface is pointing serves as the Z direction as is shown in
the figure above. (In other words, dimension L1 in the above figure need not be included in the
tool constants.) It should be borne in mind that this differs from the coordinate system
(shown by the dotted lines in the above figure) used prior to Nachi's AW controller and
its home point position and direction.
Measure the tool length which was measured in accordance with the definition given above,
and input it.
However, if the tool dimensions are not known or high-accuracy interpolation operations are
required by a material handling application, for instance, use instead the method which
automatically measures the tool length.
For the tool length automatic setting function described next to be used, the basic teaching
and playback check jobs must be performed. Since these jobs cannot be done if the Basic
Operations Manual has not yet been read, do not set the tool length but use the initial setting as
is and continue until the end of the setup is reached.
After reading the Basic Operations Manual, proceed with this setting again.
4-15
Setting the toll length automatically

Although one program for calculating the tool length must be taught, the tool length can then be
set automatically simply by taking this preparatory step.
It does not matter whether the tool angle has already been set or not.
1 First, the programs for setting the tool length automatically must be taught.
Teach the kind of programs where the tip of the installed tool (install a tool with
a sharp tip here as well) is aimed in a number of different postures at a sharp
tip which has been secured to the ground. The required number of steps is at
least 10.
Tool
Sharp tip
secured to
ground
Ensure that the posture of the robot varies significantly with each of the steps, and
that its aim is as accurate as possible. This holds the key for ensuring a high
accuracy.
Record all the steps with linear interpolation ON. (Although it has nothing to do with
calculating the tool length, this comes in handy in when checking the results in 7.)
2 On the tool constant setting screen for the desired tool number, press the
[Easy Setting] key.
>>The tool length automatic setting screen such as the one shown below now
appears.
3 If any other screen has appeared, press the [Length Set] key.
4 Select the setting type. Select "Axis Constants & Length" or "Length only"
using the [ENABLE] and [Left/right cursor] keys.
Normally, "Length only" is selected. Select "Axis Constants&Length" only when a
more accurate length setting is required. In this case, the axis constants for the J2,
J3, J4 and J5 axes are also corrected automatically. (The axis constants of all the
other axes remain unaffected.)
(The axis to be compensated differs depending on the mechanism type.)
5 Align the cursor with the program No., input the program No. (such as 1) that
ON Enter was created previously in 1, and press the [Enter] key.
1
6 ［Press the [Execute] key.
4-16
7 The tool length is calculated, and the results appear as follows a few moments
later.
>>The maximum error expresses the accuracy of the tool length which has been
calculated. The lower the value here, the higher the resulting accuracy of the tool
length which has been calculated.
The errors at each step up to a maximum of 10 steps are displayed simultaneously.
If the results in 9 below are not satisfactory, simply proceed to modify the position in
sequence starting with the step with the highest value.
If satisfactory results have been obtained, select [Yes] on the pop-up window,
and press the [Enter] key.
>>At this stage, only the display is updated, and the data is not yet stored in the
constant file.
9 Upon completion of the settings, check them. Exit the constant menu and, in
the teach mode, try running the program taught in 1 using check go/back.
Tool tip
Sharp tip
secured to
ground
If, unlike the movements which resulted when the program was first taught, the tool
tip hardly moves at all from the sharp tip secured to the ground even during
operations between the steps, then the tool length has been set successfully.
4-17
Tool Length Automatic Setting (2-point tool length setting)

In order to easily set a new tool length when the shape of a tool is deformed, 2-point tool length
setting function is prepared. In the case where the torch interferes during operation, or the torch
is changed with a new one, be sure to use this function. By use of this function, the tool length
after deformation is automatically calculated. It is necessary to teach the task program before and
after tool deformation as a calculation program in advance.
1 First, it is necessary to teach the task program with the tool before deformation.
Carry out teaching (1 step) the task program which the attached tool tip (to
which a sharp end portion is attached too) is likely to target, to the sharp end
fixed to the ground.
Tool tip before

deformation
Sharp tip
secured to
ground
2 Next, it is necessary to teach the task program with the tool after deformation.
Carry out teaching (1 step) the task program in the same manner as in the
above 1.
>>Set the tool posture same as that taught in the above 1.
Tool tip before

deformation
Sharp tip
secured to
ground
3 In the tool constant setting screen of the desired tool number, press the [simple
setting] key.
>>The 2-point teaching tool length automatic setting screen is displayed as shown
below.
4 If a different screen is displayed, press the [2-point teaching length setting] key.
5 Move the cursor on the program of the reference point before conversion, and
ON Enter input the program number prepared in the above 1 (for example, No.1), and
1 press [Enter] key.
4-18
6 Move the cursor on the step of the reference point before conversion, and input
ON Enter the step number prepared in the above 1 (for example, No.1), and press [Enter]
1 key.
7 Input the program of the reference point after conversion, the program number
prepared in step 2, and the step number in the same manner as in the above 5
and 6.
8 Press [Execute] key.
9 The tool length is calculated, and after a while, the result is displayed as shown
below.
If it is all right, select [OK] on the popup window, and press [Enter] key.
>> At that time, only the display is updated, and the tool length is not stored in the
constant file yet.
10 After the setting, press [Complete] key. The set contents are stored into the
constant file.
>> The screen goes back to the machine constant menu screen.
11 When the tool constants are changed, following pop-up window will be displayed.
When the taught position for the robot in the taught program should be shifted
according to the modified tool constants, select [YES] and press [Enter] key.
>>It goes back to the tool shifting operation.
page4-42『4.1.1 』
When the program should not be shifted, select “NO” and press “Enter” key. >> The
screen goes back to the machine constant menu screen.
4-19
4.5.3 Tool angle

The operations involved will be facilitated if the upward direction of the tool is set as the Z (up)
direction and its forward direction is set as the X (forward) direction since these are the
directions used with the robot coordinates. The tool angle is what defines the tool coordinate so
that this is achieved. The tool angle is referenced only by the operation direction when manual
operations are performed with the tool coordinate and by [Service: Transform existing program:
Parallel shift]. Since all other operations and the path used during playback are not affected in
any way, the initial setting (0 degrees for all directions) may be used as is.
However, if a servo gun (servo-driven spot welding gun) requiring bending compensation
control for the gun arm (in the arm direction) is used, the tool angle directly determines the
direction of the bending compensation and so must be set.
Since it is often difficult to measure the tool angle, the following simple setting function has been
provided. Follow the setting procedure below.
Simply setting the tool angle

1 On the tool constant setting screen for the desired tool number, press the [Easy
Setting] key.
>>The tool angle simple setting screen such as the one shown below now appears.
2 If any other screen has appeared, press the [Angle Set] key.
3 As per the guide picture, visually align the upward direction of the tool with the
Z (up) direction of the robot and its forward direction with the X (forward)
direction of the robot.
4 Press the [Execute] key.
5 The tool angle is calculated form the posture, and the result is displayed.
The angle of rotation is now calculated so that the tool upward direction in the
tool coordinate system is set to the Z (up) direction and its forward direction is
set to the X (forward) direction.
If this is satisfactory, select [Yes] on the pop-up window, and press the [Enter]
key.
constant file.
≫>>Operation returns to the machine constant menu screen.
7 Upon completion of the settings, check them. Exit the constant menu and, in
the teach mode, select the tool coordinates and try performing manual
operations.
If the tool is now moved in the up/down direction by the Z key and in the front/back
direction by the X key, then the tool angle has been set successfully.
4-20
4.5.4 Center of gravity (COG) and weight of tool
The tool center of gravity and weight are parameters required to exercise the
appropriate acceleration/deceleration control.
After installing all the tools, arm loads, etc., it is absolutely necessary to set the tool
CAUTION center of gravity and weight.
The tool weight cannot be input manually on the tool constant setting screen. This is to avoid
the danger of seriously damaging the machine which would result if a weight which is
considerably different from the actual weight were to have been set by mistake. At the factory,
the value of the rated conveyable weight was set. (The tool center of gravity can be input.)
Therefore, the AX20/AX21 controller comes with a function that automatically calculates the
correct values for the center of gravity (COG) and weight of tool. Use this convenient function to
set the center of gravity (COG) and weight of tool.
For the tool center of gravity and weight setting function described next to be used, the
basic teaching and playback check jobs must be performed. Since these jobs cannot be done if
the Basic Operations Manual has not yet been read, do not set the center of gravity (COG) and
weight of tool but use the initial settings as is and continue until the end of the setup is reached.
After reading the Basic Operations Manual, proceed with these settings again without fail.
Setting the center of gravity (COG) and weight of tool automatically

Operate the robot in a predetermined manner, calculate the torque generated from the current
at this time, and use the measured value as a basis to calculate the center of gravity (COG) and
weight of tool. Although one program for sampling the current must be taught, the center of
gravity (COG) and weight of tool can then be set simply by playing back the program.
For this procedure, the operator must be qualified as an Expert or above.

page4-56『4.7 Concerning the qualifications of the operators』
(1) Create the program for measuring the center of gravity (COG) and weight of tool
2 First, the program for the center of gravity (COG) and weight of tool setting
function must be taught. Select [Automatic COG Setting] from [Service Utilities].
>>An automatic center of gravity setting screen such as the one shown below now
appears.
3 Select [Program creation] from the menu items.

>>The program creation screen for the auto tool load center setting such as the one
shown below now appears.
4-21
4 First, align the cursor with the program No., input here the number of a program
which is not currently being used, and press the [Enter] key.
>>This is the number of the program which will now be created for automatically
setting the center of gravity (COG) and weight of tool. An unused number must be
specified here without fail.
It is also possible to input a comment directly from this setting screen.
Align the cursor with the comment field, and press the [ENABLE] + [EDIT] keys.
The soft keyboard appears so that a comment can be registered.
5 Switch on the motor power, and use the axis operating keys to operate the robot
and set it to a posture in which an unbalanced torque (load resulting from the
effect of the gravity) is applied to the J3, J5 and J6 axes.
>>The posture shown in the figure below, for instance, is ideal. At this time, any
posture may be assumed for the J1 and J2 axes. The torque of each axis is displayed
as a bar graph on the torque monitor at the bottom right of the screen. A posture in
which the bar graph is the longest for the J3, J5 and J6 axes is the ideal one. However,
pay particular attention to the resulting movements of the cables since a posture in
which tension is applied to the application cable or which causes the cables to rub
against the robot body will adversely affect the accuracy.
The Torque monitor (bar graph) displays the torque as a ratio to the stalling current of
each axis motor. The higher is this ratio, the greater will be the unbalanced torque
which is applied and the better suited will be the posture to the automatic center of
gravity (COG) and weight of tool settings.
6 Align the cursor with the Pose 1 field, and press the [Enter] key and [O.WRITE/
REC] key.
>>The first posture (Pose 1) is now registered. The angle data loaded for the axes is
displayed as shown below.
7 Next, make a major change to the posture. As this is done, make as major a
change as possible to the wrist posture.
Pose 1
Pose 2
Point
・Shake the J5 axis up and down.
・Change the angle of the J6 axis too.
4-22
8 Align the cursor with the Pose 2 field, and press the [Enter] key and [O.WRITE/
REC] key.
>>The first posture (Pose 2) is now registered. The angle data loaded for the axes is
9 This completes the registration of two of the points required. Press the f12
[Execute] key.
>>Based on the two postures registered in this way, the program shown below
consisting of a multiple number of steps for initiating the automatic center of gravity
(COG) and weight of tool settings is now generated automatically. The program No.
which is automatically generated at this time is the one which was specified in 4.
1 Comment data
2 Pose 1 point
3 Point where J6 axis is positioned when it has moved by 10 degrees
4 Pose 1 point
6 Pose 1 point
8 Pose 1 point
9 Pose 2 point
11 Pose 2 point
13 Pose 2 point
15 Pose 2 point
16 END instruction
>>Upon completion of the automatic generation of the program, the following pop-up
message is displayed. Press any key.
The poses (robot positions) were recorded directly by following the instructions set forth above,
but an alternative to this is to teach a program in which these positions have been recorded
ahead of time, and then call that program.
Since a program can be used over and over again once it has been taught, this method is
preferable in cases such as a tool change application where the work involved in setting the
center of gravity and weight will be repeated for a number of different types of tools.
10 First, have recorded ahead of time the program in which two positions were
recorded.
The same precautions as the ones described above apply to the robot positions
and postures.
The interpolation type, speed, accuracy, tool numbers, etc. may be disregarded
at this point. Only the positions are referenced.
11 Press the f8 [Refer] key without recording poses 1 (or 2) in 5 to 8.

>>A dialog box such as the one shown below for inputting the number of the program
to be used now appears. Input the number of the program prepared several steps
before, and press the [Enter] key.
4-23
12 The move command for two movement steps are loaded from the head of the
program, and the angle data of each axis is displayed.
>>Even when comments or jump and other functions have been recorded in the
program, they will not be read but skipped instead, and only the move command will
be picked up.
13 The procedure is now the same as in 9.
(2) Executing the center of gravity (COG) and weight of tool settings
14 Finally, measure the center of gravity (COG) and weight of tool.

“The program for measuring the center of gravity (COG) and weight of tool”
which was created before must now be played back.
First, switch to the playback mode.
Check that the single cycle mode with 100% speed override is now established.
15 Select [Automatic COG setting] from [Service Utilities] as before, and then
select [Tool COG Measurement].
The screen for executing the automatic tool COG setting such as the one shown below
appears.
16 Input the number of the program for measuring the center of gravity (COG) and
weight of tool in the [Program] item.
Input the tool number (1 to 32) to be measured in the [Tool No.] item.
>>When the tool number is input, the center of gravity position (mm or inches) and
weight (kg) of that tool which are currently registered in the constants are displayed.
17 17 In some cases such as when a new spot welding gun is used, the tool weight
is already known. In such a case, align the [Tool weight setup] item with
<Specifies> and set the known tool weight in kilograms in the "Mass" input field.
Normally, the item is aligned with <Auto calculation>.
18 When the J3 axis carries a load such as a valve box and its center of gravity
position and weight are known, input up to two of these values in the [Service
load setup] field.
>>If the service load is not known, there is no need to set it. The center of gravity
(COG) and weight of tool setting function measures the tool and service load together
(as if the load were concentrated on the tool).
19 Press the f12 [Execute] key.

>>"Waiting" appears as the execution status. This indicates the status in which the
playback operation for collecting the current data is awaited.
4-24
20 Switch on the motor power, and press the start button in the single cycle to start
the playback operation.
>>The program whose number was specified in 16 now starts playing back. The
operating speed is the low safety speed. While the current data is being collected, the
"Collecting" appears as the execution status, and the progress made is indicated on
the progress bar.
>>The playback operation stops automatically after one cycle.
21 Upon completion of the playback operation, the tool center of gravity and weight
are obtained on the basis of the sampled current data, and the results are
22 Select [YES] using the cursor keys, and press the [Enter] key.
Enter >>As soon as the [Enter] key is pressed, the data is saved in the constant file.
>>If the "Tool is too heavy. Reduce its weight" message appears at the same time as
the measurement results, it means that the tool weight exceeds 100% of the rated
conveyable weight. Check the installed tool, and reduce the weight so that it becomes
less than the rated conveyable weight. (The data of the center of gravity (COG) and
weight of tool are registered irrespective of the alarm message.)
23 This now completes the measurement of the center of gravity (COG) and weight
of tool.
The results have been saved in the constant file.
Switch off the motor power.
4-25
4.5.5 Tool’s moment of inertia

The tool’s moment of inertia must be set without fail if it exceeds the allowable
level of the wrist.
Just as with the center of gravity (COG) and weight of tool, the machine may be
fatally damaged if the setting for the moment of inertia is different from the actual
CAUTION
value.
The moment of inertia, in short, corresponds to the weight which is brought to bear on the
rotational movement of an object. In the figure below, it is easy to visualize the fact that (b) has
a greater rotational force than (a). This is due to the fact that (b) has the greater moment of
inertia.
Rotational speed
Rotary axis Same Rotary axis
Load mass
Load
High moment of
Low moment of inertia
inertia
(a) (b)
Fig. 4.5.5 Conceptual view of moment of inertia

The following two elements are considered when calculating the moment of inertia.
Moment of inertia = Moment of inertia of the material point + Moment of inertia of the shape
The moment of inertia of a material point refers to the moment of inertia that is applied when an
object turns around an axis which is not at its center of gravity. It is expressed as MR2 where “R”
is the radius of the rotation and "M" is the mass. If, for instance, the moment of inertia when the
object rotates around the J6 axis is calculated, “R” would be the radius of the rotation from the
center of the rotation around the J6 axis to the center of gravity of the object.
On the other hand, the moment of inertia of a shape refers to the moment of inertia of the object
itself, and it is determined by the shape of that object. Refer to each of the following explanatory
diagrams.
Table 4.5.2 Moment of inertia of a material point

Illustration Moment of inertia of the material point around a rotary axis
2
I1=mR
Table 4.5.3 Moment of inertia of a shape

Shape Moment of inertia of the shape around each axis
Rectangular
column Ix=m×(Ly2+Lz2)/12
2 2
Iy=m×(Lx +Lz )/12
Iz=m×(Lx2+Ly2)/12
Cylindrical
column 2 2
Ix=Iz=m×(r /4+Ly /12)
Iy=(m×r2)/2
4-26
The AX20/AX21 controller comes with a function that automatically obtains the moment of
inertia simply by inputting the tool shape and size. Use of this function obviates the need for the
timeconsuming calculations like the one given above.
Execute the following procedure outlined below.
Simplified setting procedures for the tool moment of inertia (registration of shape)
1 On the tool constant setting screen for the desired tool number, press the [Easy
Setting] key.
>>The tool moment of inertia simple setting screen such as the one shown below now
appears.
2 If any other screen has appeared, press the [Inertia Set] key.
3 As per the guide picture, select the tool designation direction and tool shape, and
input the width, depth, height and sheet thickness.
>>Select from among the four patterns the shape that is thought to most closely
represent the shape of the installed tool.
End support End support Face support Face support

Box type Frame type Box type Frame type
4 Press the [Execute] key.

>>A message whether the tool center of gravity and weight setting has been completed
or not is displayed. If it has not completed yet, select "No" and exit this setting screen,
and first carry out the center of gravity and weight setting.
5 The results of the moment of inertia calculation are now displayed.
If this is satisfactory, select [Yes] on the pop-up window, and press the [Enter]
key. When the dimensions have been input incorrectly, select [No]. They can now
be input again from the start.
constant file.
6 Upon completion of the settings, press the [Complete] key. The settings are now
saved in the constant file.
4-27
Setting the tool moment of inertia automatically
A function for setting the tool moment of inertia automatically is provided in cases where the tool
shapes are complex and the above procedure yields significant errors or in order to minimize the
variations arising with different operators. A high error in the setting arising from a particularly high
moment of inertia may exert a considerably adverse effect on the performance and service life of
the robot. Use of this function is recommended when the moment of inertia is high. The robot is
made to perform a prescribed set of operations and, based on the torque generated as a result,
the precise tool moment of inertia is calculated automatically. Before using the function, three
programs must be taught.
Function Function for automatically Method used to register the Manual calculation
Item setting the tool moment of tool shape
inertia
Estimated • Not dependent upon the • High error with complex • Not dependent
accuracy tool shape. shapes. upon the shape or
• The variations arising with • Not affected by size. size.
different operators are • Variations in the values • The accuracy is
minimal because the calculated due to variations high but since it is
operation is done in the external dimensions dependent upon
automatically. arising with different the number of
• The accuracy is operators. divisions,
diminished with a low variations arise
moment of inertia which is with different
less than 40% of the operators.
specification.
Required 2 to 3 minutes 30 to 60 sec. 2 to 3 hours
Time
What to Tool External dimensions based Drawing
have ready Automatic measurement on tool or drawings
program
For this procedure, the operator must be qualified as an "Expert" or above. page 4-56 "4.7
Concerning the qualifications of the operators”
Before using this function, the tool weight and center of gravity position must be
set in the tool constants correctly. Inexact settings for the tool weight and center
of gravity position may drastically reduce the identification accuracy of the
moment of inertia and adversely affect the performance and service life of the
CAUTION
robot.
Before starting measurement of the tool moment of inertia, press the "Mechanism"
key on the teach pendant, and select the target mechanism for the system with
multiple manipulators.
CAUTION
(1) Flow of steps taken automatically to set the tool moment of inertia
Automatic measurement program preparation

Service Utilities — Automatic moment of inertia setting — Program creation
Moment of inertia measurement

Service Utilities — Automatic moment of inertia setting
— Tool moment of inertia measurement
(2) Prepare the program for automatically measuring the tool moment of inertia.
4-28
The first step taken to measure the tool moment of inertia is to prepare the automatic
measurement program. With the tool moment of inertia, there are components around the
coordinate axes, namely, the components around the X, Y and Z axes. Only one of the three X, Y
and Z components can be calculated using one automatic measurement program. This means
that three programs must be prepared in order to calculate all three X, Y and Z components.

>>Automatic measurement programs can be prepared only in the teach mode or
1-step playback mode.
2 Press [R], [3], [1], [4] and [Enter].

A dialog box on which to input the password is now opened. Input the password
for the qualifications level of or above, and press the [Enter] key.
>>The tool number selected here is recorded in the automatic measurement program.
3 Press [R], [3], [1], [4] and [Enter].

A dialog box on which to input the password is now opened. Input the password
for the qualifications level of or above, and press the [Enter] key.
>>The operator must have the qualifications level of or above to automatically set the
tool moment of inertia.
4 Press the [Service Utilities] key.

>>The [Service Utilities] menu now appears.
5 Move the cursor to the "Automatic moment of inertia" menu item using the
cursor keys, and press the [Enter] key.
>>The "Automatic moment of inertia setting" menu appears.
4-29
6 Move the cursor to the "Program creation" menu item using the cursor keys, and
press the [Enter] key.
>>The "Program creation" menu appears.
7 Move the cursor to the "Program," input the number of the program which is to
be used as the automatic measurement program, and press the [Enter] key.
>>The comment function is automatically recorded at the head of the automatic
measurement program, and this can be changed as required.
In order to identify whether the tool rotates around the X, Y or Z axis, the differentiation
between the X, Y and Z axes is automatically recognized from the poses at two
recorded points, and the letter "X," "Y" or "Z" is automatically added onto the end of the
comment which is recorded in the automatic measurement program.
8 Poses at two points are required in order for the automatic measurement
programs to be prepared.
Turn on the motor power and move the robot manually to the target poses while
taking care that the robot and tool will not interfere with the nearby equipment.
In order to obtain a satisfactorily accurate tool moment of inertia, bear in mind

the following points when deciding on the pose.
• Move the robot in such a way that one axis among the J4, J5 and
J6 axes will turn around the X, Y or Z axis of the tool. If possible,
use only the J5 or J6 axis.
• Ensure that a wide operating range is provided. (An angle of 60
degrees or more is recommended.)
• Minimize the effects of gravity.
Use a torque monitor to check the effects of gravity.

If the deflection of the torque monitor pointer is significant while the robot
is in the hold status, this indicates that gravity is exerting an effect so
move the robot to a pose where this effect is reduced.
By the phrase "while the robot is in the hold status" is meant the state in
which the motor power is ON but the robot is at a standstill. Take care
when the robot is operated since the torque monitor pointer will deflect
significantly due to the operation.
4-30
Described below is an example of the teaching for SH200-03 where the effect of gravity exerted is
minimal.
9 When preparing the program for the X component:

Rotate the J4 axis through +90 or –90 degrees from the basic pose.
Pose 1 Similarly, rotate the J6 axis through +90 or –90 degrees.
Since the pose shown in the figure is now established, align the cursor with
pose 1, and press the [REC] key.
Pose 2
+X
+Z
+Y
The wrist axis shall rotate

with minimal effect of the
gravity around the X
component on the tool
coordinate system. (In this
case, the rotational center of
the J5 axis shall be vertical
to the ground)
Next, move the J5 axis through an appropriate angle (60 or more degrees) to
align the cursor with pose 2, and press the [REC] key.
10 When preparing the program for the Y component:

Pose 1 Since the pose shown in the figure is now established, align the cursor with
+Y
Pose 2
+X
+Z

gravity around the Y
to the ground)
4-31
11 When preparing the program for the Z component (example 1)；

Pose 1 Since the pose shown in the figure is now established, align the cursor with
Pose 2
+X
+Y The wrist axis shall rotate

+Z gravity around the Z
to the ground.)
12 When preparing the program for the Z component (example 2)

Rotate the J2 axis through +45 degrees from the basic pose.
Pose 1 Rotate the J3 axis through +45 degrees.
Since the pose shown in the figure is now established, align the cursor with
Pose 2
+Z
+Y
+X

gravity around the Z
to the ground.)
Move the J4 axis or J6 axis through the appropriate angle to align the cursor
with pose 2, and press the [REC] key.
4-32
13 One way of specifying the poses is to perform the manual operations here in
steps 9 to 12. An alternative way is to specify a program in which the poses have
already been recorded.
In this case, press the f8 [Refer] key which causes a dialog box on which to
input the program number to appear. Input here the number of the program to be
referenced, and press the [Enter] key.
>>Reference another program in which two or more movement steps have been
recorded to specify the pose. The position of the movement step found first in the
referenced program is recorded as pose 1, and the position of the movement step
found next is recorded as pose 2.
14 Finally, press the f12 [Execute] key.

>>Based on the recorded poses, the program for automatically measuring the tool
moment of inertia is automatically generated. When the program is generated
properly, the following confirmation dialog box appears.
15 Press the [R] key to return to the service utilities menu.
(3) Measuring the tool moment of inertia
16 It is now time to measure the tool moment of inertia.

Set the mode selector switch on the operation panel to "Playback."
>>The "Moment of inertia measurement" menu can be opened only in the 1-step
playback mode.
Specify the number of the tool whose moment of inertia is to be measured by

proceeding as in step 2.
As with the procedure in step 3, the operator must have qualifications level of
Expert or above.
For the system with multiple manipulators, press the "Mechanism" key on the
teach pendant, and select the mechanism that you measure the tool moment of
inertia.
17 Select [Service Utilities] and [Automatic moment of inertia setting] followed by

"Tool moment of inertia."
4-33
>>The menu screen shown below now appears.
18 Move the cursor to "Program," input the number of the automatic measurement
program which has been prepared, and press the [Enter] key.
19 Press the f12 [Execute] key.

>>The execution status changes to "Waiting to gather data."
20 Press the [Motor power] button.
21 Press the [Playback] button.

>>The automatic measurement of the moment of inertia starts at the same time as the
robot playback starts.
Take sufficient care to ensure that the robot and tool do not interfere
with the nearby equipment.
If the robot overshoots during playback, reduce the speed override for
the playback.
>>When the automatic measurement of the moment of inertia is completed, a

confirmation dialog box appears.
22 A dialog box on which to check the calculation results now appears.

Select "Yes" to register the calculation results in the constants or "No" to
cancel.
23 Press the [R] key to return to the service utilities menu.
24 Finally, play back the movements where the tool rotates at high speed and
check that there is no overshooting, etc.
4-34
(4) Trouble which may occur while the tool moment of inertia is being measured and troubleshooting
procedures
Phenomena Troubleshoot
The robot overshoots If the automatic measurement program is played back while a tool having an
during playback. excessively high moment of inertia is installed on the robot, the robot may
overshoot (move beyond the recorded point and then return) or trouble may
simultaneously occur.
[Countermeasure]
Reduce the override for the playback. If the measurement is undertaken with
the override reduced, however, the accuracy with which the moment of
inertia is calculated will deteriorate.
The moment of inertia [Countermeasure]

cannot be measured
with the work gripped (1) Obtain the moment of inertia of the work by calculating it manually or
by the tool. registering the tool shape.
(2) Obtain the moment of inertia minus the value for the work using the
automatic setting of the tool moment of inertia. Now set a different tool
number from the tool number in (1) as the tool whose moment of inertia
is to be measured.
(3) Select [Constant Setting], [Machine Constants] and [Tool Settings], and
input the numerical values for the tool with work and without the work to
register the moment of inertia.
A2699 This trouble occurs when there is something wrong with the speed and
Something is wrong current data which were gathered in order to calculate the tool moment of
with the results inertia.
obtained by [Countermeasure]
measuring • Revise the teaching so that the movement amount will be greater.
for the automatic • Revise the teaching for the automatic measurement program so that effect
setting of the tool of gravity will be minimized.
moment of inertia. • Revise the teaching so that only one axis, either the J5 axis or J6 axis, will
move.
The pose used for the This message appears when the two designated poses fall into any of the
automatic setting of following categories:
the tool moment of • When the axis targeted for the measurement moves through less than 30
inertia is not degrees
appropriate. • When two or more axes move through 5 degrees or more
• When an axis other than the J4, J5 or J6 axis moves through 5 degrees or
more
[Countermeasure]
• Revise the teaching so that the movement amount will be greater.
• Revise the teaching so that only one axis—J4, J5 or J6—will move.
This program is not This message appears when an attempt has been made to measure the tool
used for the automatic moment of inertia by selecting a program which was prepared on a menu
setting of the tool screen other than the "Program creation" menu for the automatic setting of
moment of inertia. the tool moment of inertia.
[Countermeasure]
Select a program which was prepared using the "Program preparation" menu
item for the automatic settings of the tool moment of inertia.
The same filename This message appears when a program with the number which was
exists. designated in the "Program creation" menu item already exists.
[Countermeasure]
Designate the number of the program which is not yet used.
This step does not This message appears when the program referenced on the "Program
exist. creation" menu item does not have at least two movement steps.
[Countermeasure]
• Reference a program with at least two movement steps.
• Move the robot manually, and designate a pose.
4-35
Switch the designated This message appears when an attempt has been made to open the
mechanism to a "Program creation" menu and "Tool moment of inertia" menu in a situation
manipulator. where a multiple number of 6-axis multi-joint robots exist in one unit and the
current mechanism is not a 6-axis multi-joint robot.
[Countermeasure]
First return to the mode screen, press the "Mechanism" key on the teach
pendant, and switch the current mechanism to manipulator (6-axis multi-joint
robot).
The wrong axis or This message appears in the following cases:

mechanism has been • When the axis selected by the "Tool moment of inertia" menu to move in the
specified. program is not J4, J5 or J6
• When an attempt has been made to measure the moment of inertia on the
"Tool moment of inertia" menu in a situation where a multiple number of 6-
axis multi-joint robots exist in one unit and the current mechanism is not a 6-
axis multi-joint robot
[Countermeasure]
• Revise the teaching so that only one axis—J4, J5 or J6—will move.
• First return to the mode screen, press the "Mechanism" key on the teach
pendant, and switch the current mechanism to manipulator (6-axis multi-joint
robot).
The tool moment of This message appears when the results of automatically measuring the tool
inertia rating has been moment of inertia and the value input for the tool moment of inertia on the
exceeded. Tool Settings" menu selected from "Constant Setting" and "Machine
Constants" have exceeded the rating.
When a robot with a tool having an excessively high moment of inertia is
used, its performance and service life may be adversely affected.
Furthermore, during playback the robot may overshoot (move beyond the
recorded point and then return) or trouble may simultaneously occur.
[Countermeasure]
• Review the tool.
• If there is no alternative to using the current tool, take remedial action by
reducing the override or revising the teaching, for instance, and take
sufficient care to ensure that the robot will not overshoot or no other trouble
will occur.
4-36
4.5.6 Max, radius of tool

Set the maximum radius of tool rotation if the tool length (length up to the interpolation point) and
the tool shape are significantly different as they are in the figure below. Use the radius of a sphere
which encompasses all the space from the interpolation point as the center, up to the outermost
circumference of the tool (including the work piece which is gripped in the case of a material
handling tool) as the setting.
This radius has absolutely no effect on the operations and paths during manual operations and
playback. It is used to check interference territory and other purposes.
Tool tip
Gripper
●
Max. radius of tool
Fig. 4.5.7 Max. radius of tool
4-37
4.5.7 Tool length and angles of Daihen’s arc welding torch

Tool constant of an arc welding torch differs according to a torch type or a robot type which is
installed. When a representative arc welding torch made by Daihen is used, the tool constant
values are shown as following.
Tool constant of an arc welding torch which is not mentioned in this instruction manual is
described in the instruction manual for each arc welding torch. For further details, refer to the
instruction manual for that.
CO2/MAG Torch
Table 4.5.4 Daihen arc welding torch tool constant(New torch)
For N series Referential
Length Angle Center of gravity Weight Moment of inertia Radius
V type drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
RT3500S 127.0 2.1
118.0 0.050 0.030
RT5000S 128.0 2.2
140.0 0.0 385.0 180.0 0.0 0.0 0.0 0.090 Fig. 4.5.9
RTW5000S 119.0 129.0 2.3
0.060 0.040
RZ3500S 118.0 126.0 2.2
RT3500H 140.0
2.3 0.070 0.100
RT5000H 107.0
0.0
Fig.
0.0 0.0 400.0 180.0 -45.0 0.0 0.0 142.0 0.030
RTW5000H 2.4 0.080 4.5.10
0.110
RZ3500H 111.0 141.0 2.3 0.070
RT3500L 148.0
119.0 2.4 0.120 0.040
RT5000L 149.0
0.0 0.0 400.0 180.0 -45.0 0.0 0.0 0.080 Fig. 4.5.11
RTW5000L 121.0 146.0 2.6
0.130 0.050
RZ3500L 126.0 142.0 2.5
B type drawing
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 Kgm^2 mm
RT3500H -10.0 74.0 1.9 Fig.
310.0 0.030 0.030
RT5000H
-135.5
-11.0 76.0 2.0 4.5.12
0.0 180.0 -45.0 0.0 0.0 0.0 0.0 Fig.
RTW5000H 320.0 85.0 2.1 0.040
-12.0 0.040 4.5.13
RZ3500H -140.5 315.0 79.0 2.0 0.030 Fig. 4.5.14
RT3500L -5.0 69.0
310.0 1.9 0.030 0.030 Fig. 4.5.15
RT5000L -90.5 70.0
0.0 180.0 -31.0 0.0 -6.0 0.0 0.0 0.0
RTW5000L 82.0 0.040 0.040 Fig. 4.5.16
330.0 2.0
RZ3500L -95.5 -7.0 78.0 0.030 0.030 Fig. 4.5.17
Fig. 4.5.9 Fig. 4.5.10 Fig. 4.5.11 Fig. 4.5.12
Fig. 4.5.13 Fig. 4.5.14 Fig. 4.5.15 Fig. 4.5.16 Fig. 4.5.17
4-38
CO2/MIG/MAG Torch(Past Torch)

Table 4.5.5 Daihen arc welding torch tool constant (Past Torch)
V type drawing
MTXC-3531 2.0
MTXCB-3531 2.1
MTXCB-5031 2.3
MTXC-5031 0.0 0.0 400.0 180.0 -45.0 0.0 109.0 0.0 123.0 2.1 Fig. 4.5.18
MTXCW-5031 2.2
MTXCA-2531 2.1
MTXCAW-5031 2.2
MTX-3531 1.9
MTXB-3531 2.0
MTX-5031 2.0
MTXB-5031 140.0 0.0 385.0 180.0 0.0 0.0 116.0 0.0 107.0 2.2 0.0 0.0 0.0 0.0 Fig. 4.5.19
MTXW-5031 2.1
MTXA-2531 2.0
MTXAW-5031 2.1
MTX-3531 1.9
MTXB-3531 2.0
MTX-5031 2.0
MTXB-5031 0.0 0.0 350.0 180.0 -45.0 0.0 143.0 0.0 195.0 2.2 Fig. 4.5.20
MTXW-5031 2.2
MTXA-2531 1.9
MTXAW-5031 2.2
Fig. 4.5.18 Fig. 4.5.19 Fig. 4.5.20
4-39
TIG Torch
Table 4.5.6 Daihen arc welding torch tool constant (TIG Torch)
V type drawing
MWXC-2001 90.0 0.0 151.0 2.2
0.0 0.0 360.0 180.0 -45.0 0.0 Fig. 4.5.21
MWXC-3501 90.0 0.0 148.0 2.1
0.0 0.0 0.0 0.0
MWX-2001 114.0 0.0 148.0 2.2
170.0 0.0 385.0 180.0 0.0 0.0 Fig. 4.5.22
MWX-3501 111.0 0.0 146.0 2.1
Fig. 4.5.21 Fig. 4.5.22
Pull type servo torch (4 roll specifications) CO2/MIG/MAG

Table 4.5.7 Tool constants of DAIHEN pull type servo torch (4 roll specifications)
For N series Referentia
V type l drawing
MTXC-3534P 5.4
MTXCB-3534P 0.0 0.0 445.0 5.5 Fig. 4.5.23
MTXC-5034P 180.0 -45.0 0.0 107.0 0.0 212.0 5.4 0.0 0.0 0.0 0.0
MTXCW-5034P 5.6 Fig. 4.5.24
MTXCA-2534P 0.0 0.0 465.0 5.6 Fig. 4.5.25
MTXCAW-5034P 5.7 Fig. 4.5.26
Fig. 4.5.23 Fig. 4.5.24 Fig. 4.5.25 Fig. 4.5.26
4-40
Pull type servo torch (2 roll specifications) Aluminum MIG

Table 4.5.8 Tool constants of DAIHEN pull type servo torch (2 roll specifications)
l drawing
V type
MTXC-3541PS
0.0 0.0 375.0 3.3 Fig.4.5.27
MTXCA-3041PS
180.0 -45.0 0.0 110.0 0.0 80.0 0.0 0.0 0.0 0.0
MTXCW-5041PS 3.4
0.0 0.0 385.0 Fig.4.5.28
MTXCAW-4041PS 3.3
l drawing
B type
MTXC-3541PS
-137.0 0.0 440 3.2 Fig.4.5.29
MTXCA-3041PS
180.0 -45.0 0.0 -11.0 0.0 150.0 0.0 0.0 0.0 0.0
MTXCW-5041PS -127.0 0.0 460.0 3.3 Fig.4.5.30
MTXCAW-4041PS -123.0 0.0 455.0 3.2 Fig.4.5.31
Fig.4.5.27 Fig.4.5.28 Fig.4.5.29 Fig.4.5.30 Fig.4.5.31
4-41
4.5.8 Tool Exchange

In the case the tool shape deforms, an already taught task program will lose compatibility. It is
necessary to convert the already taught task program so that the tool tip position and the target
angle should be same as those before deformation.
When the settings of the tool length and the tool angle are changed, in order to keep the
compatibility of already taught task program, the following tool conversion function is prepared.
Convert the program according to the following procedures.
1 After the settings of the tool length and the tool angle, press [Complete] key.
The set contents are stored into the constant file.
2 When the tool set value is changed, the following popup window is displayed.
>> The change of the tool set value can be checked by either of the following
changes.
・When one of tool lengths x, y, and z has changed 0.05mm or more
・When one of tool angle length x, y, and z has changed 0.005deg or more
4-42
3 When to convert the program, select [OK] on the popup window, and press
[Enter] key.
>> The following tool conversion screen is displayed.
When the 2-point tool length is set, the conducted mechanism and the tool
number, and the program number and the step number showing referential
points before and after conversion are succeeded to.
4 Press [Execute] key.
5 The corrected value is calculated, and after a while, the result is displayed as
shown below.
>> At that time, only the corrected value is displayed, and the program
conversion is not carried out yet.
If it is all right, select [OK] on the popup window, and press [Enter] key.
6 The objective program is converted, and the result of the converted program is
7 After conversion of all the objective programs is completed, press [Enter] key.
>> The screen goes back to the machine constant menu screen.
4-43
8 After the conversion, carry out entire confirmation.

Exit the constant menu, and run the program converted in the above 6 by check
go/back in the teach mode.
The conversion is successful if the tool tip position and the target angle are same as
those before deformation.
4-44
4.6 Signal attribute settings

This section describes the method used to set the signal attributes of the AX20/AX21 controller. The signal
attributes can be classified differently as in the tables below.
Table 4.6.1 Types of signal attributes

Signal
Explanation
attributes
Signals which are input from external sources to the controller.
Input signal
Classification by They are also called "I" signals.
direction Output Signals which the controller outputs to external sources.
signal They are also called "O" signals.
Signal
Explanation
attributes
Signals with a predetermined significance such as the "start
command" input signal for starting the robot and the "robot
running" output signal which turns on during robot playback
Status
operations are called status signals. Many and varied signals are
signal
Classification by provided by the applications but those signals which are used as
application the standard signals and which are not dependent on applications
are called standard signal attributes.
General- These are signals which, for instance, can write ON/OFF
purpose commands freely in programs. Applications can be created freely
signals by putting together the external sequences in the manner desired.
Signal
Explanation
attributes
This is a blanket term for signals If a software PLC is not
Logical
which enable access from the going to be used, the logical
signals
software side. signals are directly
Classification by connected with physical
This is a blanket term for signal
construction signals in their original form.
Physical attributes which have been
In this case, therefore, this
signals connected with a DC 24V field bus
classification may be
or other external source.
ignored.
A total of 2,048 input signals and 2,048 output signals have been provided as the signal attributes of the
AX20/AX21 controller (total number of logical signals). On the other hand, the physical signals are restricted by
the I/O (Input/ Output) format provided. Under the standard specifications, for instance, there are up to 32 inputs
and 32 outputs whereas under the DeviceNet specifications (option), it is possible to use all 2,048 inputs and all
2,048 outputs.
With the AX20/AX21 controller, the numbers of the logical signals used as status signals can be set freely in order
to fit in with the physical I/O (Input/Output) capacity which is actually used. This is known as the signal attribute
assignment. At the factory, the standard assignment is used for the signals although this can easily be changed.
Set the alternative assignment in accordance with the system design.
4-45
AX20/AX21 controller
Output signal
Status
Logical signals
Physical signals
signal
Input signal Output signal
Software
PLC Outside
Input signal
General- Output signal
purpose
signals
Input signal
If a software PLC is not going to be used, the logical signals and physical signals are directly connected.
Fig. 4.6.1 Signal attributes
4-46
4.6.1 Standard signal attributes assignment

2 Select [Constant Setting], and press [3 Signal attributes] [2 Input signal

assignment] [1 Standard Inputs].
>>The basic input signal assignment setting screen such as the one shown below now
appears.
(For details on the spot welding signals and other special-purpose signals, refer to the
operating instructions of the application concerned.)
3 To switch the screen, press the page up or down key.
4 Align the cursor with the desired position, input the signal number (such as 1),
ON Enter and then press the [Enter] key.
1 >>"Ext. play start [30]" signifies that signal no. 30 among the 2,048 logical input signals
is treated as the start instruction. "Reduce speed [0]" signifies that this status signal is
not used.
5 When the [Refer] key is pressed, the following table appears listing the numbers
of the signals that serve as keys. This is useful for checking what has been set.
A signal indicated in gray is a status signal; a signal indicated with black characters (or
no characters) on a white background is a general-purpose signal.
After browsing, use the [RESET/R] key to exit.
Furthermore, it is possible to give names to the general-purpose signals on this
screen. When the cursor is aligned, and the [ENABLE] + [EDIT] keys are pressed, the
soft keyboard screen appears. Input the desired names on this screen.
>>It is not possible to assign a logical input signal to more than one status. When the
[Complete] key is pressed, the assignment of all the logical input signals is checked,
and if a signal has been assigned to more than one status, an error message is
displayed. (This duplication check is conducted not only for the basic input signals but
for all the input signals.)
>>After the signal assignment has been saved, operation returns to the input signal
assignment menu.
7 If the contents are not going to be rewritten, do not press the [Complete] key but
the [RESET/R] key instead to exit the setting screen.
8 Similarly:
The basic output signals can be assigned by pressing [6 Signal attributes] [2
Output signal assignment] [1 Standard Outputs].
Operation is the same as for the basic input signals.
4-47
When the input signal or output signal assignment has been changed, go to the trouble
of turning off the power of the controller and then turning it back on.
This step must be taken without fail in order to initialize the status signals.
If operation is continued without turning off the power, the status signals may not be input
CAUTION
or output properly.
4.6.2 Basic input signals

This section describes the basic input signals among the status signals which are used under the
standard specifications.
"U1" after the names of signals in the table denotes that the signals are used for unit 1. Ignore this
designation except when the multi-unit specifications have been provided. Under the multiunit
specifications, the signals are assigned on a unit by unit basis.
Table 4.6.2 Basic input signals

Basic input signal Factory-set
Functions
designation Input signal
Ext. play start. U1 I30 This is the signal to start a program from external
devices such as PLC and so forth.
In the case to use this, set <service> - "1
Teach/Playback conditions" - "2 start selection" to
"external".
Int. unit play stop U1 0 This signal individually stops units (programs) that have
been started with an internal start.
Remember that this signal, provided that it is allocated,
is always valid regardless of the start select (internal,
external or station start) signal setting.
All external stop 0 This signal stops the robot from an external source.
All the units stop together. Set to "0" if a multi-unit is not
being used.
Ext. unit play stop U1 I31(AX20) This signal stops the robot from an external source. It
0(AX21) takes effect at all times regardless of the motor
ON/START select setting.
The setting of "I31" is allocated for the AX20 controller
and "0" is allocated for the AX21 controller at the factory.
Motors off externa I32 This signal turns off the motor power from an external
source. It takes effect at all times regardless of the motor
ON/START select setting.
Program sel. bits U1 1 I17 These signals are for selecting programs in response to
Program sel. bits U1 2 I18 instructions not from the teach pendant but from an
Program sel. bits U1 3 I19 external controller.
Program sel. bits U1 4 I20 When these signals are to be used, it is necessary to
Program sel. bits U1 5 I21 select "1 Teach/Playback conditions" from "Service
Program sel. bits U1 6 I22 Utilities" and set "3 Playback mode program select" to
Program sel. bits U1 7 I23 "External."
Program sel. bits U1 8 I24 Programs 1 to 9999 are selected using the 16 signals
Program sel. bits U1 9 to 16 0 listed on the left. The input signal that determines the
timing at which signals are to be read in a binary format
Program strobe U1 I25
is the program strobe signal.
External reset 0 This signal is input when executing fault reset and
clearing the step No. from an external source at the
same time. It functions in the same way as short-cut R0 .
4-48
Basic input signal Factory-set

Functions
designation Input signal
Reduce speed 0 This establishes the "safety speed" as the speed during
playback.
The safety speed refers to the movement of the tool tip
at a speed of 250 mm/sec.
Reservation cancel 0 This signal is for canceling all the programs reserved in
the queue when "1 Teach/Playback conditions" from
"Service Utilities" has been selected and "4 Program
queue" is valid.
Ext. Machine Lock 0 This signal is input in order to switch the machine lock
status from an external source. When this signal is ON,
machine lock is enabled, and the robot will not work
even if the axis operation key is pressed or a program is
operated. However, even when machine lock is enabled,
servo power supply remains ON, which please note.
Interference area 1 to 16 0 If the work space of different robots overlaps, an

"interference area" is defined for each of the controllers
to ensure that the robots will not simultaneously enter
the area of overlap. The robot first confirms the input of
this signal, and it then enters into the "interference area."
Fault Reset 0 This signal is input when executing fault reset from an
external source.
Conveyor running 0 In the simultaneous conveyor state, the signal which is

set to ON while the conveyors are operating is input. For
further details, refer to the instructions for synchronizing
the conveyors (option).
Conv. normal 0 In the simultaneous conveyor state, this specifies the

Conv. simulation 0 conveyor synchronized operation mode. For further
Conv. test 0 details, refer to the instructions for synchronizing the
conveyors (option).
Conv. start LS 0 In the simultaneous conveyor state, this inputs the
trigger for starting the tracking operation. For further
details, refer to the instructions for synchronizing the
conveyors (option).
Mechanism isolation 0 It ensures that the designated mechanism will not move
by axis operations or manual open/close operations.
Since errors are also not checked, the robot can be
evacuated when, for instance, the servo gun fails to
operate.
The lock mode is established when this signal is input.
Speed override inputs 1 to 7 0 Speed override is exercised in accordance with the input
signal.
Setting can be made up to 4 ports (7 bits per port).
For details, refer to the instructions for the
input-dependent speed override function (option)
(analog inputs included).
Branch program No. (BCD) 0 This signal selects the program when the function
U1 command (JMPPBCD or CALLPBCD) is executed.
There are 16 points.
Branch program No. (BIN) U1 0 This signal selects the program when the function
command (JMPPBIN or CALLPBIN) is executed.
There are 16 points.
User check complete 1 to 8 0 This signal notifies the robot when the maintenance has
(M1 to M9) been completed,which the mechanism or the arc welder
(W1 to W4) 0 for the maintenance target.
Reset out. signal 0 This signal inputs when an out signal except the status
signal is put the state OFF mandatory.
4-49
4.6.3 Basic output signals

This section describes the basic output signals among the status signals which are used under
the standard specifications.
"U1" after the names of signals in the table denotes that the signals are used for unit 1.
Ignore this designation except when the multi-unit specifications have been provided.
Table 4.6.3 Basic output signals

Basic output signal Factory-set
Functions
designation Output signal
Stopped U1 0 This level signal is output at all times except during the
robot running and CHECK GO/BACK.
This signal is for outputting the stop status of each unit.
The "stopped" signal is used as the signal which
indicates the status in which all the units are stopped.
This signal remains unchanged even when the mode is
changed. (When it is ON in the playback mode, it will not
be set to OFF even when the playback mode is changed
to the teach mode.) The "temporarily stopped" signal is
used when the stop status is to be output to an external
device in the playback mode only. The "temporarily
stopped" signal is output only while automatic operation
is stopped. (It is not output in the teach mode.)
Program end U1 O20 This level signal is output at the end of a program during
playback.
By selecting "Constants Setting," "4 Signal attributes," "1
Signal conditions" and "4 End relay output time," the
minimum output time can be set, and it is reset at
startup.
Emergency stopped O24 This level signal is output while the emergency stop
button or external emergency stop button is held down.
Playback mode 0 This level signal is output while the playback mode is
selected.
In teach mode O25 This level signal is output when the teach mode has
been selected.
High Speed Teach mode 0 This level signal is output while the high-speed teach
mode is selected. (The high-speed teach mode is an
option.
Step-set alarm 0 This signal is output when a step which is two or more
steps ahead of the current step has been specified in the
teach or playback mode. It is a 200ms pulse signal.
It is not output when step 0 has been selected.
Interlock alarm O22 This level signal is output when the interlock wait status
has exceeded the specified time, and it is reset when
interlock wait is released.
The specified time is set using "Constants Setting," "6
Signal attributes," "1 Signal conditions" and "7 Interlock
alarm timer."
Standing-by unit numbers 0 While waiting for interlock, these output the numbers of
1 to 4 the units standing by in synchronization with the
"interlock trouble" output signal.
Standing by I signal numbers 0 During interlock wait and in synchronization with the
1 to 16 "interlock alarm" output signal, the numbers of the
waiting I signals are output.
Over run 0 These are turned ON during the operation of the limit
switches used to detect overrun and mounted on the
robot arm.
4-50

Functions
Program acknowledge U1 0 The specified program ACK signal can be output when a
1 to 16 program has been selected by setting "External" for
program selection. This is a 200ms pulse signal. (Refer
to the “Prg. sel. bits” among the basic input signals.)
External reset ackno. 0 This signal is output when the input of the "external reset
signal" has been acknowledged while the playback
mode is in single cycle or continuous and holding. It is a
200ms pulse signal.
Operation underway U1 0 During playback operation, this signal is output while the
robot is moving regardless of whether it is being
operated manually. (servo on and axis works actually)
Robot running U1 O26 This signal is output during the robot running or at the
time of check go/back. It is a level signal which coincides
with the lighting of the start lamp.
(In the case of a multi-station start system, the start lamp
remains lighted and the start underway signal remains
ON even during temporary stop.)
External program selection O27 「This level signal is output when "1 Teach/Playback
underway U1 conditions" from "Service Utilities" has been selected
and "3 Playback mode program select" has been set to
"External."
External program selection can be set per unit, and
there is signal per unit.
Ext. start enabled U1 O28 This level signal is output when "1 Teach/Playback
conditions" from "Service Utilities" has been selected
and "2 Motors ON/START select" has been set to
"External."
Common to all the units.
Speed reduced 0 This level signal is output while the robot is running at
the safety speed.
Motors energized O29 This level signal is output while the servo power (motor
power) is on.
Unit READY U1 O19 This level signal is output in a status in which the auto
operation (starting in playback mode) is acknowledged.
Starting cannot be initiated if the conditions have not
been satisfied. The signal can be set using a
combination of several conditions.
Status output 1 O30 It is possible to create this output signal using a

combination of various statuses such as the playback
mode and program selection status. The statuses to be
combined can be defined in 16 different ways, and the
2-16 0 first of these signals is assigned as the status output
signal. (It corresponds to the robot ready OK signal
which was used in the past by Nachi.)
Home position U1 1 O31 This level signal is output when the robot is at the
prescribed home position. Up to 32 positions per unit
can be registered by selecting "Constant Setting,"
Home position U1 2 to 32 0
"Range setting" and "Work home position."
Interference area 1 to 16 0 If the work space of different robots overlaps, an

"interference area" is defined for each of the controllers
to ensure that the robots will not simultaneously enter
the area of overlap.
This signal is set to ON while the robot is inside the
"interference area."
4-51

Functions
Program echo bit 1 to 16 0 These signals output the program No. reserved in the
queue.
Start program 1 to 16 0 This outputs the number of the task program executed
first after startup. This signal remains unchanged even
when the number of the program executed by a program
call or jump command changes.
Select [Constant Setting], [6 I/O Signals], [1 Condition
Settings] and [2 Program & Step No. Monitor Output
Format], and select binary or BCD as the output format.
The initial value is the binary format.
Controller READY 0 This level signal is output after the power has been
turned on when the operating system (Windows) and the
robot software have started up in sequence and normal
control is exercised.
It is only when this signal has been output that the status
in which I/O (Input/Output) control is enabled is
established.
Task program execution 0 This is set to ON in either of the following circumstances

underway regardless of the start system.
a) During automatic operation
b) While automatic operation is stopped
c) When, after automatic operation has stopped, the
mode has been transferred to the teach mode while the
"start return designation in the playback mode" is set to
"designated return."
Operation underway U1 0 This level signal is output during automatic operation in

the playback mode regardless of the start system.
It is not output in the check GO/BACK mode or in the
playback mode while operation is stopped.
Holding 0 This level signal is output at all times except during the
robot running and check go/back.
It turns ON while the robot is not in motion whether the
temporary stop, cycle end or other cases.
In the multi-unit control, it is output only after all the units
are stopped.
Temporarily stopped 0 This level signal is output when automatic operation has
been stopped at an interim point (stopped at an interim
point in the program) in the playback mode regardless of
the start system. It is not output when operation stops at
the cycle end.
The "holding" signal is output in any mode, but the
"temporarily stopped" signal is output only in the
playback mode.
Machine disabled 0 This level signal is output when "1 Teach/Playback

conditions" from "Service" has been selected and "6
Machine lock" has been set to "Valid."
Continuous cycles 0 This level signal is output when "1 Teach/Playback

and "1 Playback mode" has been set to "Continuous."
Single cycle 0 This level signal is output when "1 Teach/Playback

and "1 Playback mode" has been set to "Cycle."
Single step 0 This level signal is output when "1 Teach/Playback

and "1 Playback mode" has been set to "Step."
4-52

Functions
Check go underway 0 This level signal is output while check go is being
processed in the teach mode.
Check back underway 0 This level signal is output while check back is being
processed in the teach mode.
On searching U1 0 It is set to ON while a search command is being

executed by the search function. For details, refer to the
Handling Instructions or External shift.
Search basis write 0 This signal is set to ON during search basis writing by
the search function.
For details, refer to the Handling Instructions or External
shift.
Program number monitor U1 0 These signals output the currently selected program No.
1 to 16
Step number monitor U1 0 These signals output the currently selected step No.
1 to 16
Conveyer counter reset 0 In the simultaneous conveyor state, it is output to
1 0 acknowledge that the conveyor counter has been reset.
2 0 For further details, refer to the instructions for
synchronizing the conveyors (option).
Conv. normal 0 In the simultaneous conveyor state, it outputs the

Conv. simulation 0 current operation mode. For further details, refer to the
Conv.t est 0 instructions for synchronizing the conveyors (option).
Remote enable 0 This outputs the fact that the switching of the
teach/playback mode selection using input signals is
now enabled.
Battery warning 0 This signal is output when the voltage of the encoder
battery has dropped.
Fault 0 This level signal is output with the occurrence of an error

or alarm or with the generation of information.
Error O21 This level signal is output when an error (fault with a high
level of fatality) has occurred.
Alarm O23 This level signal is output when an alarm (warning level
fault) has occurred.
Information O32
Bundled cause classification 0 The causes of the detected fault are classified into
code 1 to 8 several categories, and these signals output the
corresponding classification code that applies.
Fault codes 1 to 16 0 These signals output the code number of the detected
Fault output select 0 fault.
Fault output STRB 0 The fault output select and STRB signals are output
signals which are used to arrange the timing.
The error numbers are output under the condition set by

"1 Failure code output" under [Constant Setting][6
Signals][1 Signal condition] screen.
Fault unit number 1 to 8 0 These signals output the number of the unit in which
fault has been detected.
Fault mechanism number 0 These signals output the number of the mechanism in
1 to 4 which fault has been detected.
Fault axis number 1 to 4 0 These signals output the number of the axis in which
4-53

Functions
Fault welder number 1 to 3 0 These signals output the number of the welder in which
Fault welding sensor number 0 These signals output the number of the sensor in which
1 to 3 fault has been detected.
Fault welding auxiliary code 0 These signals output the number of the auxiliary code
number 1 to 16 when fault has been detected.
Fault reset request 0 This signal is output when the kind of fault that requires
the fault reset operation has occurred.
Mechanism disconnect 0 This is set to ON while a mechanism is being

underway disconnected.
M1 One signal is provided for each of the mechanisms.
M2
Individual mechanism servo 0 This signal is for outputting the servo power status of
OFF each mechanism to the external devices.
M1 0 One signal is provided for each of the mechanisms.
For details, refer to the instructions for handling the
M2 0 function (option) which turns the servo power of each
mechanism ON or OFF.
Playback limited 0 This level signal is output when the playback limit (dry
run) of the function command has been established.
"Dry run" refers to playback operations for which no
specific function commands are executed. The robot
does move.
To set dry run, first select [Service Utilities] and
[Teach/Playback Conditions] followed by [8 Function
Command Playback Limit], and then select "Valid" or
"Input signal." If "Input signal" is selected as the
playback limit setting, the "Playback limit valid" basic
input signal is set to ON.
In the case of the multi-unit specifications, select the
playback limit target on the above menu to "By unit" or
"Input signal." If "Input signal" is selected, the "Playback
limit by unit" basic input signal is set to ON, and then the
signal is input to the unit targeted for the dry run by the
"Unit playback limit valid" signal provided for each unit.
Unit playback now limited U1 0 This level signal is output if the playback limit (dry run) of
the function command is set to "By unit" and the unit
concerned has been set to dry run.
TCP speed output ports 0 These enable signals proportionate to the linear speed
1 to 6 of the robot's tool center point (TCP) to be output. For
details, refer to the instructions for handling the TCP
speed data output function (analog outputs included)
(option).
Shock sensor operation 0 This signal is output while the shock sensor (option)
underway mounted on the robot is detecting a collision.
Sub mechanism number 0 This is the signal for confirming the sub mechanism
connection.
The sub mechanism number during connection is
output.
Encoder power OFF 0 Mechanism is electrically cut off, and then it becomes
ON.
This is the signal prepared for mechanism.
Mechanism cutoff permit 0 This becomes ON when mechanism may be cut off.
This is the signal prepared for mechanism.
4-54

Functions
Visual sensor connecting 0 This is the signal that is output when the visual sensor is
connected.
Visual sensor monitor off 0 This is the signal that turns off the monitor display of the
visual sensor when there is no key input.
User maintenance 1 to 8 0 This is the signal that is output when the maintenance
(M1 to M9) item which is set on the User maintenance function
(W1 to W4) 0 reaches at the time of maintenance,which the
mechanism or the arc welder for the maintenance target.
4-55
4.7 Concerning the qualifications of the operators
4.7.1 Operation qualifications

The qualifications of individual operators can be set in the AX20/AX21 controller.
Once the qualifications of the individual operator are set, special functions or menus can be
hidden from view or displayed depending on the expertise level of the operator who is operating
the robot.
When, for instance, Beginner (elementary level operators) has been set as the operator
qualifications, it is possible to place restrictions on the important menus and functions related to
robot control so that the operator will not be able to operate them by mistake or out of
carelessness.
Table 4.7.1 Classes of operator qualifications

Operator
Operators targeted Content
qualifications
This class is set for those operators who are beginning
Elementary level
Beginner to learn about operating the robot and who only perform
operators
the startup of the robot in the factory.
This class is set for those operators who are somewhat
User Regular operators
familiar with the operation of the robot.
This class is set for those operators who are in charge of
Expert Expert operators
maintaining the robot.
This class is set for a handful of the operators who are in
Specialist Senior expert operators
charge of maintaining the robot.
Table 4.7.2 Main functions whose access is restricted

Operator qualifications
Beginner User Expert Specialist
Main functions
Whose access is restricted
General operations ○ ○ ○ ○
Constants Setting × － ○ ○
Functions and maintenance work

× × ○ ○
requiring special expertise
Optional function settings × × × ○
○:Can be accessed; ×:cannot be accessed; –:not displayed in part.
4-56
4.7.2 Procedure for changing the operator qualifications

When the control power is turned on, either User or Beginner is set as the operator qualifications class. If an
operator has the qualifications of Expert or above, either class may be set. page 4-59 "4.7.4 How to set
the operator qualifications class at power-on”
To change the class of qualifications to Expert or above, use the short-cut code (R314) to make the switch
each and every time it is required. Once the class of qualifications is switched, the new class is held until the
operator qualifications class is switched again or the control power is turned off.
A password is required to change the operator qualifications class to Expert or above.

The initial passwords are listed below. The passwords can also be changed.
page 4-58 "4.7.3 How to change the passwords”
Table 4.7.3 Initial password

Operator
Password set at the factory Changing the password
qualifications
Beginner (No password provided)
(No password provided)
User
Expert None (simply press [Enter]) Password can be changed (using
Specialist 12345 short-cut code R313)
How the passwords work

* If the operator inputs the wrong password, Beginner or User is set as the
operator qualifications class.
* Since the initial passwords for Expert and Specialist are given in these
instructions and are open to anyone who reads the instructions, elementary level or
regular operators can easily change their own qualifications to the Expert or
Specialist class.
Since there is a danger that the constants and other settings required to operate the
robot may be changed in error by an elementary level or regular operator, the initial
passwords must be changed as soon as the robot is delivered.
How to change the operator qualifications class

1 Press [RESET/R].
>>A table of the short-cut codes now appears.
2 Input "314" using the numeric keys, and press [Enter].

Enter >>The password input screen now appears.
314
The current operator qualifications can be checked on this screen.
3 Input the password for "Expert" or "Specialist," and press [Enter].

Passwo Enter If, for instance, the initial password is to be used and "Expert" is the qualifications
rd class, press [Enter].
If "Specialist" is the qualifications class, press "12345" followed by [Enter].
>>The operator qualifications class is now changed.
Operation returns to the original screen by pressing any key.
4-57
4.7.3 How to change the passwords

It is possible to change the passwords (for Expert and Specialist).
Alphanumerics (a distinction is made between upper case and lower case letters) and symbols are used as the
characters which can be input for a password. All characters must be half-sized characters only. A password
must not be more than 10 characters long.
Expert or Specialist operators must make a note of the new password which they have
changed themselves without fail so that they will not forget it. If an operator has forgotten a
CAUTION password, the password cannot be set again insofar as he or she does not have a higher
class of operator qualifications.
How to change the passwords

1 Press [RESET/R].
>>A table of the short-cut codes now appears.
2 Input "313" using the numeric keys, and press [Enter].

Enter >>The password change screen now appears.
313
3 For a password that consists only of numerals, input the number using the
pass Enter numeric keys, and press [Enter].
word
If letters or symbols are to be included in the password, input them from the soft
keyboard by pressing [ENABLE] + [EDIT], and press [Enter].
>>A confirmation message is displayed.
4 To make the change, select [OK], and press [Enter].

Enter >>The password is now changed, and operation returns to the original screen.
To cancel the change, select [CANCEL], and press [Enter].
4-58
4.7.4 How to set the operator qualifications class at power-on

If the operator qualifications class is Expert or above, this class can be set to Beginner or User when the
control power is turned on. The class was set to User at the factory.
How to set the operator qualifications class at power-on
１ Select [Constant setting] followed by [1 Control environment] and [6 Protecting

level selection].
>>The setting screen now appears.
２ Select either User or Beginner.
３ Press the [Complete] key.

>>The setting is changed, and operation returns to the original screen.
4-59
4.8 I/O area mapping function
4.8.1 I/O are mapping

IO area mapping function is the function to freely change logic input / output signals and allotment of physical
media. By use of this function, it is possible to arrange IO directly without software PLC. (PLC through input /
output)
Mapping can be changed in unit of 8 points for IO board signals, and in unit of 512 points for field bus signals.
AX controller
IO mapping
Output signal
Status
Logical signals
Physical signals
signal
Allotment Outside
Input signal
purpose
signals
Input signal
Fig. 4.8.1 Concept of IO area mapping
At factory shipment, mapping is made as shown below. For example, the head signal output from the IO board
is fixed to 01 signal.
Table 4.8.1 Factory shipment setting of IO area mapping
Physical port Logic IO signal

1 to 8
Standard IO board 9 to 16
(8 points x 4) 17 to 24
25 to 32
33 to 40
Additional IO board 1 41 to 48
(8 points x 4) 49 to 56
57 to 64
65 to 72
Additional IO board 2 73 to 80
(8 points x 4) 81 to 88
89 to 96
Field bus CH1
161 to 672
(512 points)
Field bus CH2
673 to 1184
(512 points)
Field bus CH3
1185 to 1696
(512 points)
Field bus CH4 1697 to 2208
(512 points) (Actually, up to 2048)
4-60
By use of IO area mapping function, change is made for example as shown below.
Table 4.8.2 IO area mapping setting change example

Physical port Logic IO signal
1 to 8
Standard IO
9 to 16
board Same allotment as usual
17 to 24
(8 points x 4)
25 to 32
Additional IO
No input / output with additional IO board 1
board 1 -
(8 points x 4)
Additional IO
No input / output with additional IO board 2
board 2 -
(8 points x 4)
Field bus CH1 Field bus CH1 is used as signals of 33 ~ 544.
33 to 544
(512 points)
Field bus CH2 Field bus CH2 is used as signals of 545 ~
545 to 1056
(512 points) 1056.
Field bus CH3
- No input / output with field bus CH3.
(512 points)
Field bus CH4 Field bus CH4 is used as signals of 1057 ~
1057 to 1568
(512 points) 1568.
By designating the number of logic signal to be allotted to the physical port, mapping is set. At that time, the
number of logic signal is not written one by one, but it is designated by "port number" which is made into groups in
prior in unit of 8 points.
Table 4.8.3 "Port number" used in IO area mapping setting

Port Logic IO signal Port Logic IO signal Port Logic IO signal Port Logic IO signal
1 1-8 65 513 - 520 129 1025 - 1032 193 1537 - 1544
2 9 - 16 66 521 - 528 130 1033 - 1040 194 1545 - 1552
3 17 - 24 67 529 - 536 131 1041 - 1048 195 1553 - 1560
4 25 - 32 68 537 - 544 132 1049 - 1056 196 1561 - 1568
5 33 - 40 69 545 - 552 133 1057 - 1064 197 1569 - 1576
6 41 - 48 70 553 – 560 134 1065 - 1072 198 1577 - 1584
7 49 - 56 71 561 - 568 135 1073 - 1080 199 1585 - 1592
8 57 - 64 72 569 - 576 136 1081 - 1088 200 1593 - 1600
9 65 - 72 73 577 - 584 137 1089 - 1096 201 1601 - 1608
10 73 - 80 74 585 - 592 138 1097 - 1104 202 1609 - 1616
11 81 - 88 75 593 - 600 139 1105 - 1112 203 1617 - 1624
12 89 - 96 76 601 - 608 140 1113 - 1120 204 1625 - 1632
13 97 - 104 77 609 - 616 141 1121 - 1128 205 1633 - 1640
14 105 - 112 78 617 - 624 142 1129 - 1136 206 1637 - 1648
15 113 - 120 79 625 - 632 143 1137 - 1144 207 1649 - 1656
16 121 - 128 80 633 - 640 144 1145 - 1152 208 1657 - 1664
17 129 - 136 81 637 - 648 145 1153 - 1160 209 1665 - 1672
18 137 - 144 82 649 - 656 146 1161 - 1168 210 1673 - 1680
19 145 - 152 83 657 - 664 147 1169 - 1176 211 1681 - 1688
20 153 - 160 84 665 - 672 148 1177 - 1184 212 1869 - 1696
21 161 - 168 85 673 - 680 149 1185 - 1192 213 1697 - 1704
22 169 - 176 86 681 - 688 150 1193 - 1200 214 1705 - 1712
23 177 - 184 87 869 - 696 151 1201 - 1208 215 1713 - 1720
24 185 - 192 88 697 - 704 152 1209 - 1216 216 1721 - 1728
25 193 - 200 89 705 - 712 153 1217 - 1224 217 1729 - 1736
26 201 - 208 90 713 - 720 154 1225 - 1232 218 1737 - 1744
27 209 - 216 91 721 - 728 155 1233 - 1240 219 1745 - 1752
28 217 - 224 92 729 - 736 156 1237 - 1248 220 1753 - 1760
29 225 - 232 93 737 - 744 157 1249 - 1256 221 1761 - 1768
30 233 - 240 94 745 - 752 158 1257 - 1264 222 1769 - 1776
31 237 - 248 95 753 - 760 159 1265 - 1272 223 1777 - 1784
32 249 - 256 96 761 - 768 160 1273 - 1280 224 1785 - 1792
33 257 - 264 97 769 - 776 161 1281 - 1288 225 1793 - 1800
34 265 - 272 98 777 - 784 162 1289 - 1296 226 1801 - 1808
35 273 - 280 99 785 - 792 163 1297 - 1304 227 1809 - 1816
36 281 - 288 100 793 - 800 164 1305 - 1312 228 1817 - 1824
4-61
37 289 - 296 101 801 - 808 165 1313 - 1320 229 1825 - 1832
38 297 - 304 102 809 - 816 166 1321 - 1328 230 1833 - 1840
39 305 - 312 103 817 - 824 167 1329 - 1336 231 1837 - 1848
40 313 - 320 104 825 - 832 168 1337 - 1344 232 1849 - 1856
41 321 - 328 105 833 - 840 169 1345 - 1352 233 1857 - 1864
42 329 - 336 106 837 - 848 170 1353 - 1360 234 1865 - 1872
43 337 - 344 107 849 - 856 171 1361 - 1368 235 1873 - 1880
44 345 - 352 108 857 - 864 172 1369 - 1376 236 1881 - 1888
45 353 - 360 109 865 - 872 173 1377 - 1384 237 1889 - 1896
46 361 - 368 110 873 - 880 174 1385 - 1392 238 1897 - 1904
47 369 - 376 111 881 - 888 175 1393 - 1400 239 1905 - 1912
48 377 - 384 112 889 - 896 176 1401 - 1408 240 1913 - 1920
49 385 - 392 113 897 - 904 177 1409 - 1416 241 1921 - 1928
50 393 - 400 114 905 - 912 178 1417 - 1424 242 1929 - 1936
51 401 - 408 115 913 - 920 179 1425 - 1432 243 1937 - 1944
52 409 - 416 116 921 - 928 180 1433 - 1440 244 1945 - 1952
53 417 - 424 117 929 - 936 181 1437 - 1448 245 1953 - 1960
54 425 - 432 118 937 - 944 182 1449 - 1456 246 1961 - 1968
55 433 - 440 119 945 - 952 183 1457 - 1464 247 1969 - 1976
56 437 - 448 120 953 - 960 184 1465 - 1472 248 1977 - 1984
57 449 - 456 121 961 - 968 185 1473 - 1480 249 1985 - 1992
58 457 - 464 122 969 - 976 186 1481 - 1488 250 1993 - 2000
59 465 - 472 123 977 - 984 187 1489 - 1496 251 2001 - 2008
60 473 - 480 124 985 - 992 188 1497 - 1504 252 2009 - 2016
61 481 - 488 125 993 - 1000 189 1505 - 1512 253 2017 - 2024
62 489 - 496 126 1001 - 1008 190 1513 - 1520 254 2025 - 2032
63 497 - 504 127 1009 - 1016 191 1521 - 1528 255 2033 - 2040
64 505 - 512 128 1017 - 1024 192 1529 - 1536 256 2041 - 2048
In the case when physical port is IO board, mapping is made in unit of 8 points for logic input / output signal.
In the case when physical port is field bus (device net or the like), logic input / output signal is mapped in unit of
512 points. Namely, 64 ports (512 points) continuously are mapped from allotted port number as for field bus
channel.
4-62
4.8.2 Relation with software PLC

When software PLC is used, IO area mapping function does not work effectively. This is because the rudder
program on software PLC executes IO area mapping function. However, in mapping by software PLC, delay time
occurs in ON/OFF of signal only for scan time of software PLC in principle.
Therefore, in this function, when software PLC is used, a function to change not all the areas but only
designated area according to mapping information is prepared. This function is called "PLC through" herein. "PLC
through" is the function to directly input / output (through) only designated area to physical port without influence
of software PLC.
For example, in the case without "PLC through" function, even when to output an output O signal as an external
signal as it is, it is necessary to write such a rudder program. But, by use of "PLC through" function, without
writing such to PLC program, it is possible to output directly to the physical port, and PLC program can be
simplified, and scan time can be shortened.
PLC through
Output signal
Status
signal Logical signals
Physical signals
Software Outside
PLC Input signal
purpose
signals
Input signal
Fig. 4.8.3 Relation with PLC (PLC through IO)
By the way, this function causes no influence upon assembled PLC itself, even if a rudder to be operated to
signal of mapping change is written, it itself works normally. (However, actually, designated signals are input /
output made directly with physical port.)
4-63
4.8.3 Setting method

IO area mapping setting is carried out in the following procedures.
Set the operator qualification to Expert or higher. (User or below can only browse setting contents.)
1 Select teach mode.
2 From f key <constant setting>, select [6 Signals] → [15 Hardware setting].

>>The following setting screen is displayed.
When mapping information is not written in "S00SIGL.CON" file, the above value is
set as default.
In the case operator qualification is User or below, the following is displayed, and
data cannot be set.
Meanings of display items are as shown below.

Parameter Description
Number of This shows the number of signal points of each physical medium. 8
points points x 4 for one IO board. Field bus has 512 points of signals per
channel.
Port This designates the logic signal number of AX20/AX21 controller by
port number.
For example, when "1" is designated by IO board, the range of
corresponding input signal is I1 ~ I8, and output signal is O1 ~ O8.
When "12 is designated by field bus, the range of corresponding
input signal is I1 ~ I512, and output signal is O1 ~ O512.
4-64
Signal number The range of signal to input port number is automatically displayed.
PLC through When "input" is checked, the signal concerned is forcibly input
irrespective of the result of PLC program. In the same manner,
when "output" is checked, the signal concerned is forcibly output
irrespective of the result of PLC program. Data not checked is
dependent on the action result of PLC program.
On the contrary, at PLC cutoff, this setting makes no influence.
3 Press f8 <initialize> key, and the setting contents go back to default ones
(contents shown in 2).
4 Move the cursor to each logic port, and input numeric value of mapping
information by port number.
Number When "0" is input, no input / output with the physical medium.
5 At PLC execution, when to directly input / output only specified area without via
PLC, check the "process at PLC execution" of the area.
Move the cursor to desired "process at PLC execution", and press [Enable] and
[1] at the same time to check it. By pressing [Enable] [2], it is unchecked.
6 After completion of all the settings, press the f12 <Complete> key.
>>The software checks whether there is duplication in the set area. If duplication is
found, a popup message showing setting error is displayed. Press [Enter] and the
cursor moves onto the place of duplication, so correct setting data.
In the same manner, even when all the ports are set as 0, a popup message
showing setting error is displayed, so press [Enter] and carry out setting.
7 If there is contradiction in set data, a confirmation message whether to actually

execute or not is displayed.
When [Cancel] is selected, setting is not carried out. (Not exit from this screen) Select
[OK] and press [Enter], and the set data is written into "S00SIGL.CON" file, and you
can exit this screen.
8 According to the message, turn off the controller once and then turn it on
again.
You cannot exit the message unless you restart the controller.
After changing mapping, according to the message, turn off the controller once and
then turn it on again. This is necessary to initialize mapping information.
CAUTION
After changing mapping, all the output signals after power restart are cleared (OFF)
once, which please note.
As the result of setting, when signal number exceeds 2048, field bus signal is limited
to 2048 unconditionally.
For example, the signal range in the case where "251" is designated to the logic port
number of field bus is 2001 ~ 2048. (The number of signals is 48 points.)
4-65
As the number of signal points of field bus is 512 points, the logic port number of
each channel must be away at least "64" or more. If not away, press <Complete> key,
error message of area duplication is displayed, and setting cannot be made.
4-66
4.8.4 Example 1 : Making only field bus as external input / output signal in PLC
cutoff
For example, here are some mapping setting examples. (Shaded portions are items to be set.)
Even when only field bus is input / output with outside, normally 1888 points of 161 ~ 2048 are allotted to field
bus signal.
When this is set as shown below, input / output signals of field bus are mapped to 1 ~ 2048, all the 2048 points
can be used.
Table 4.8.4 Mapping example (making only field bus as external input / output signal in PLC cutoff)
Physical medium (number of Logic IO signal PLC through
Port
signal points) number Input Output
8 0 － Ignored Ignored
Standard IO board
Additional IO 8 0 － Ignored Ignored
board 1 8 0 － Ignored Ignored
Field bus CH1 512 1 1 to 512 Ignored Ignored
In the case of PLC cutoff, check mark in PLC through process has no meaning.
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4.8.5 Example 2: Using only standard IO board – field bus CH1 in PLC cutoff
When to use standard IO board 32 points and 512 points of field bus channel 1 as continuous signals, make
the setting as shown below.
Table 4.8.5 Mapping example (using only standard IO board - field bus CH1 in PLC cutoff )
Port
8 1 1 to 8 Ignored Ignored
Standard IO board
Field bus CH2 512 0 － Ignored Ignored
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4.8.6 Example 3: Forcibly inputting / outputting signals of additional IO board 1

as 1-32 signals with PLC enabled
When to forcibly input the input signals from standard IO board as I1 ~ I32, irrespective of PLC, and forcibly
output 033 ~ 064 to additional IO board 1, make the setting as shown below.
Table 4.8.6 Mapping example (forcibly inputting / outputting signals of additional IO board 1 as 1 ~ 32 signals with PLC
enabled)
Port
8 1 1 to 8 Checked
Standard IO
8 2 9 to 16 Checked
board
8 3 17 to 24 Checked
Additional IO
board 1
8 Ignored ？
Additional IO 8 Ignored ？
board 2
8 Ignored ？
8 Ignored ？
Field bus CH1
512 Ignored ？
Field bus CH2
512 Ignored ？
Field bus CH3
512 Ignored ？
Field bus CH4
512 Ignored ？
Even when mapping is changed by use of this function, there is no influence upon PLC
relay number of physical medium. Even if the setting is made as shown above, for
example, relay number of additional IO board remains X64 ~ X95 - Y64 ~ Y95.
And, their relay coil functions normally. (However, the status of coils Y64 ~ Y95 is not
output to additional IO board. Output is the status of 33 ~ 064.)
Only signals checked in PLC through process are forcibly input / output.
Other signals are dependent on assembled PLC.
In the table, logic ports of items not related to forcible input / output are ignored, however,
they must be set so that their signal area should not overlap.
At execution of PLC, logic port numbers of items not checked have no meaning, therefore,
it is an effective method to input "0" expressly and avoid duplicated check of area.
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4.10 Setting the application type
4.9 High Speed Interference Detection Function (Revised)
4.9.1 Outline of High Speed Interference Detection Function

The high speed interference detection function aims at protecting the tool by detecting and preventing collision of
the work tool and outside. In the case operation mistake, incomplete measurement, or unexpected interference
occurs during teaching work, error can be detected before the tool is broken, therefore, there is no need for
exchanging tools. System version AXV5.09 obtains easy operation, because device to improve sensitivity further
has been added.
The high speed interference detection function estimates contact force with outside world from the position,
speed and current of the robot motor, and when the contact force exceeds the set threshold value, the high speed
interference detection function regards it as a contact with outside world, and stops actions of the robot.
4.9.2 Objective machine types

The high speed interference detection function (revision) can be used at present in the following robot types.
MA15 series
MA30 series
SC350
SC500
SC700DL
SC80L
SG160P
SR15
SH133-03
SH166-03
SH200-03
NB4
NB4L
NV6
NV6L
NV20
NH5
NS3
In the robot types other than the above, the conventional high speed interference detection function can be
used, therefore, refer to the following section in the online manual available from TP.
Constants menu - 3 Machine constants 3. 16 Interference detection
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4.9.3 Setting at Robot Start

At factory shipment, the interference detection status is set to "low sensitivity". In this "low sensitivity", detection
level is set moderately so as to prevent mistake in detection in the case when the tool constant is not set
appropriately.
As for tool whose tool constant has been set according to the following procedures, set the sensitivity to "normal
sensitivity". When the tool constant setting is carried out, and sensitivity is changed to "normal sensitivity", highly
precise interference detection function is realized.
The high speed interference detection function requires precise tool weights and a
center of gravity.
If precise tool weights and a center of gravity are not set, the detection
CAUTION performance is extremely deteriorated, for example, the occurrence of a mistake in
detection of the interference condition, or the problem that it is not detected even
though interference happens. Be sure to carry out the section 4.5 Tool Constants
Setting in the Chapter 4 Setup of the Operating Manual "Installation".
Carry out the following operation only to the tool to which "4.5 Tool constant
settings" has been conducted.
If precise tool weight and center of gravity are not set, interference condition is
CAUTION mistakenly detected, or interference is not detected, and detection performance
will be deteriorated extremely, which is very dangerous.
1 First, read through this chapter, and carry out the initial setup such as tool
constant and the like. Especially, carry out the tool constant setting of section
4.5 precisely.
2 Input R314, and select operator level Expert.
3 Select [Constant Setting] and press [3 Machine Constants] → [1 Tool

Constants].
>>The following tool constant input screen is displayed.
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4 Select the tool whose tool constant has been set, and press f11 < interference
setting >.
>>The following interference setting screen is displayed.
Threshold values per axis are displayed in the order of teach, level 0, and level 1.
J1, J2, J3
J4, J5, J6
5 Change the mode. By the [enable] + [left and right cursor] key, change the
＋ mode from "low sensitivity" (at factory shipment) to "normal sensitivity".
Do not change the numeric values in teach, level 0 and level 1.
Setting method is shown in the next section.
6 Press f12 <Complete>.

>>The contents are saved, and the screen goes back to the previous one.
Table 4.9.1 Interference setting parameter

Item Description
"Low sensitivity"
This is used when toll constant setting is not completed, such as at line start or so.
The detection sensitivity is set moderately so as to prevent mistake in interference
Mode detection.
"Normal sensitivity"
This is set when precise setting of tool weight and center of gravity is completed.
Threshold values whose detection level is set lower than low sensitivity are used.
This sets the detection level [kgfm] in teach mode when the mode is set to "normal
Teach
sensitivity".
This sets the detection level [kgfm] in playback mode when the mode is set to "normal
Level 0
sensitivity".
This sets high sensitivity detection level [kgfm] in playbackmode when the mode is set to
"normal sensitivity". This level becomes enabled when 1 is set to the argument of Fn230
Level 1
(interference detection level selection function). As for details, refer to the interference
detection level selection function in the next section.
Threshold values (6 axes for each of teach, level 0 and level 1, 18 values) :
As for threshold values, by carrying out the work of "4.9.4 Setting Most Suitable Threshold Value for Work
Program", most suitable value is set automatically. There is no need for operator to manually input.
When 0 is set to the threshold value, interference detection for the objective axis of the detection level (teach,
level 0, level 1) becomes disabled.
When the value is made larger, the detection sensitivity becomes lower, and mistake in detection is not tend to
occur.
When the value is made smaller, the detection sensitivity becomes higher, and mistake in detection is tend to
occur, but collision condition is detected keenly, and it is possible to restrict damage due to interference to
minimum limit.
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4.9.4 Setting Most Suitable Threshold Value for Work Program

In this section, the method to automatically determine the threshold value of interference detection according to
work program is explained. Threshold values such as level 0 and level 1 and so forth are set at factory shipment,
so that there should be no mistake in detection on the basis of maximum speed actions with maximum load, and
their sensitivity is rather low. By this work, it is possible to easily set the detection threshold value to meet the
work program at the optimized sensitivity.
There are two methods available to automatically set up the threshold for interference detection; using the
dedicated interference torque sampling screen and using the R code on the normal screen.
Using the interference torque sampling screen
4.5 precisely.
3 Select [Service Utilities] and select [26 Torque sampling for Interference Det.].
4 Press f08 <Start Tracing>.
After trace start, playback the program that you want to measure for several
times. During running, the following screen is displayed.
The current interference force of each axis is displayed in bar graph.

The maximum value of current measurement is displayed in green line.
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At collection completion, press f08 <Finish Tracing>.
(100 + margin value)% of the value displayed here is set as the threshold value. For
example, when the margin value is 50%, J1 axis in the above figure becomes 99.9 x
150% = 149.85.
Kind
Teach This changes the teach threshold value.
Level 0 This changes the threshold value of only level 0.
All This changes the threshold values of both level 0 and level 1.
Normally, select all playback, and there is no problem.
The threshold value is updated.
As the interference detection function becomes ineffective during the

interference torque sampling, be sure to watch out for the robot in case that the
CAUTION
interference happens.
Using the R code on the normal screen
4.5 precisely.
3 Input R355, then the following dialog is displayed.
Press [YES] to start the torque sampling for interference detection.
4 The icon below appears on the status window while sampling the interference
detection torque.
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5 Play back the program for measurement.
6 At the end of torque sampling, input R356. Then, the following dialog is
displayed.
Press [YES] to end the torque sampling for interference detection.
7 The following screen appears.
(100 + margin value)% of the value displayed here is set as the threshold value. For
example, when the margin value is 50%, J1 axis in the above figure becomes 99.9 x
150% = 149.85.
Kind
Teach This changes the teach threshold value.
All This changes the threshold values of both level 0 and level 1.
Normally, select all playback, and there is no problem.

Note that as the interference detection function becomes ineffective while

sampling the interference torque, be sure to prevent the interference or others
CAUTION
from occurring.
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4.9.5 Switching Detection Level by Function

It is possible to switch the threshold value regarded as interference during playback.
For example, when to insert the end of the robot into a narrow portion, when to look strictly at interference, when
to decrease threshold value level and increase detection sensitivity, and when to carry out robot contact work, it is
used to decrease interference detection sensitivity, and prevent mistake in detection.
For switching, "interference detection level selection function" is used. Details are as shown below.
Pneumonic Number Japanese name

COLSEL FN230 Interference detection level selection function
Parameter
Data Contents, setting range
Parameter No.1 Level number This designates detection level number.
(0 to 3) 0: Normal use condition. The threshold value of level 0 is used
(default).
1: This switches to specification condition at high sensitivity. The
threshold value of level 1 is used.
2: This is designated when to get low sensitivity. The threshold
value of low sensitivity at factory shipment is used.
3: This is designated when to turn off detection. This can be set
only by Expert or higher.
Unless this function is used, the threshold value set to level 0 is used always at playback.
At teaching, this function is carried out, but in the case of 0 and 1, all detection level of teach are used.
In the case when this function is executed, designated detection level is used until this function is executed for the
next time.
Detection level automatically becomes 0 (level 0) at step 0 replay of program. However, in the case of program
call, even in step 0, it does not automatically become 0 (level 0).
Even if it is stopped halfway and restarted, level is not switched. However, if step is selected, level automatically
becomes 0, so when level is changed, use it with care.
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In the [Constant Setting], [12 Format and Configuration], and [7 Application] menus, you can enable various
related functions, optimize the f key layout, and configure other settings in accordance with the application of the
robot (application type). Although these settings are in most cases configured prior to shipment from the factory,
they can be configured as necessary while referring to this section.
Only configure these settings once prior to the first time of use. Inadvertently
changing them later may cause problems such as the initialization of various
CAUTION
settings and the inability to use functions that were used up until that time.
Up to two application types per unit can be set. For example, if the robot can be used for both spot welding and
handling, set "Usage1" to [Spot Welding] and "Usage2" to [Handling].
Configuration example
1 First, input R314 and select operator level Expert or above.
2 Select teach mode and select [12 Format and Configuration] from the
[Constant Setting] menu.
>>The following setting menu appears.
3 Select [7 Application] from the menu.

>>The following setting screen appears.
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4 Align the cursor with "Usage1" or "Usage2", press the [Enter] key, and select
Enter an item.
If, for example, the robot is also to be used for a spot welding application, select
[Spot Welding] for "Usage1" and [Handling] for "Usage2".
Enter >>A list of application selection candidates appears. Use the up or down cursor to
select [Handling] and press the [Enter] key again.
5 After completion of the settings, press the f12 [Complete] key.

The settings are written to the controller general constant file C00ctrl.con.
To stop configuring the settings, press the [RESET/R] key.
At present, the following application types can be selected.
Standard: The standard functions are enabled.

Spot Welding: For spot welding with a spot welding gun.
Handling: For using the robot for a handling application.
Arc Welding: For arc welding with an arc welding torch.
Sealing: For sealing with a sealing gun.
Glass Transfer: For handling glass substrates.
Table 4.10.1 Items settable by unit

Item Description
Specify the application (usage) for the unit. The function
Usage1 commands (FN) and shortcuts that can be used vary depending
the application that is set.
Set this when one unit is to be used for multiple applications.
Usage2
Normally set this to [Standard].
Specify the optimized control parameters to enable optimum
Tuning control for the application.
(Note that some mechanisms have no optimized parameters.)
Soft Key Set the optimum soft key (f key) layout for the application type.
Table 4.10.2 Items common to all units

Item Description
Initialize the input and output signals to a format suitable for the
Signal Format
application.
Function group Initialize the function group to a format suitable for the
initialization application. (This item is currently unavailable).
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4.11 Setting the [Clamp / Arc] key

Any one of the following functions can be set for the [Clamp/Arc] key of the hardware keys of the teach pendant.
(1) Function to turn a specific output signal ON/OFF manually

(2) Spot welding function
(3) Arc welding function
When the application is handling, an end effector such as a gripper is usually attached to the robot. This key can
be used to open and close the gripper if the signal to open and close the gripper is assigned to function 1 above.
Furthermore, this function is also compatible with grippers that use double solenoids because it is possible to
assign two output signals and configure them to switch the gripper ON and OFF alternatively.
Fig. 4.11.1 [Clamp/Arc] key of the teach pendant
The function of (1) and its usage are described hereinafter. Concerning (2) and (3), please refer to the
instruction manuals “Application : Spot welding” and “Application : Arc welding”.
When the application is spot welding or arc welding, the [Clamp/Arc] key is initially
set for using the corresponding welding function and the key cannot be used to
CAUTION
turn a signal ON/OFF manually.
Setting Procedure
1 First, input R314 and select operator level Expert or above.
2 Select teach mode and then select [7 f-Keys] from the [Constant Setting]
menu.
>>The following f-keys menu for the teach pendant appears.
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3 Select [5 Usage of Clamp Key] from the menu.

4 Align the cursor with "Clamp Key" and press the [ENABLE] and left or right
＋ cursor keys together to align the cursor to "Output Signal".
5 Next, align the cursor to "Alloc Signal," input the number of the output signal
Enter for opening and closing the gripper, and press the [Enter] key.
Number Two output signals can be registered. If just one signal is to be used, set "1"
only.
If two signals are to be used as is the case with double solenoids, set the two
signals you want to use to switch ON and OFF alternatively for "1" and "2."
• The same signal cannot be input for both signal 1 and signal 2.
• When you want to set a multiple-output signal, set it for signal 1 only.
Two multiple-output signals cannot be set.
• Signals that have already been assigned cannot be set.
• If 0 is set for the signal number, the key has no function.
• Even if the application differs depending on the unit, only one
application can be set for the clamp key for safety reasons.
6 After completion of the settings, press the f12 [Complete] key.

The settings are written to the controller general constant file C00ctrl.con.
To stop configuring the settings, press the [RESET/R] key.
Using the clamp key (normal operation)
1 Just pressing the [Clamp/Arc] key has no effect when the signal ON/OFF
function has been set for the key. Furthermore, a function command cannot be
registered.
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Using the clamp key (with the [ENABLE] key)
(1) When a general-purpose output signal is set
1 In teach mode, the set output signal can be turned ON/OFF manually.
＋ Using the signal assigned to signal 1 of the clamp key output as the reference
signal, output is performed by switching between ON and OFF alternatively.
The ON/OFF state of the output signal assigned to signal 2 is always the
opposite to that of signal 1.
>>Pressing the [ENABLE] and [Clamp/Arc] keys when signal 1 is OFF.

→Signal 1 is set to ON and signal 2 is set to OFF, regardless of the state of signal 2.
>>Pressing the [ENABLE] and [Clamp/Arc] keys when signal 1 is ON.
→Signal 1 is set to OFF and signal 2 is set to ON, regardless of the state of signal 2.
(2) When a multiple-output signal is set
1 In teach mode, the set multiple-output signal can be output manually.

＋ >>The following dialog box for inputting the output data appears.
２ Input decimal numbers for the data you want to output and press the [Enter]
Enter key.
Number
>>The registered output signal is turned ON/OFF in accordance with the specified
numerical value.
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4.12 Setting the software limit (operating range)
4.12.1 Outline
The software limit (operating range) is set to the maximum operating range prior to shipment from the factory. If
the positions of the "stopper" and "limit switch" are changed or the operating area is changed for operational
reasons, be sure to also change the software limit.
There are the following three ways of setting the software limit.
(1) Position Recording

The robot is actually operated to move each of its axes to the position you want to set as the software limit and
then the [Record] key is pressed.
(2) Data Input

The software limit can be set without having to move the robot by inputting hexadecimals for the encoder
values.
Because of the nature of inputting numeric values and the difficulty of predicting the operating area, be
extremely careful when configuring these settings.
(3) Auto Setting

The software limit range is calculated automatically from the posture data of programs registered in the
internal memory of the controller and then set.
The setting procedures are described on the following pages.
4.
！ The software limit function is not for defining the limit area*. To change the limit
area, use the "stopper" and "limit switch".
Unexpected robot motion leading to a person being hit or caught may result in
DANGER loss of life, serious injury, or an accident.
* Limit area: The area the robot cannot move out of even if there is a failure or
malfunction with the robot system.
The setting procedures are described on the following pages.
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4.12.2 [Position record] screen settings

Operate the robot to move each of its axes manually and set the software limit values.
The operator needs to have the Specialist or above qualification set to perform this operation.
1 Press the [Record Posi.] f key from the [Data input] screen.
>>The following [Position record] screen appears.
2 Align the cursor with the target axis and operate the robot manually to move
each axis to a position you want to set for the software limit.
3 Press the [Enter] key and then press the [WRITE/REC] key.
Enter >>The software limit values are overwritten.
4 Press the [Complete] f key.

>> The software limit values are written to the constant file and the [3 Machine
Constant] menu reappears.
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4.12.3 [Data input] screen settings

The software limit can be set by inputting hexadecimals for the encoder values of the moving tip of each axis.
The operator needs to have the Specialist or above qualification set to perform this operation.
Work out the software limit values (hexadecimals) to input beforehand.
1 Select [Constant Setting], [3 Machine Constant], and [5 Software Limit].

Enter >>The following [Data input] screen appears. (The same screen is also displayed by
pressing the [Input Value] f key from the [Position record] screen.
2 Align the cursor with the target axis, input hexadecimals for the software limit
ON Enter values, and press the [Enter] key.
1 >>The software limit values are overwritten.

>>The software limit values are written to the constant file and the [3 Machine
Table 4.12.1 Hexadecimal input method (A to F)

A B C D E F
ON OFF
＋＋＋＋ 4 ＋ 5 ＋ 6
1 2 3
4-84
4.12.4 [Auto Set] screen settings

The minimum and maximum values are calculated automatically from the recorded positions of the selected
program( s), and then those values are set as the software limit values.
The operator needs to have the Expert or above qualification set to perform this operation.
The following items are not supported for auto setting of the software limit.
(1) Servo gun axis*
(2) Endless axis*
CAUTION (3) Other than angle commands of robotic language for each axis angle (MOVE/
MOVEJ/MOVEX_J/MOVEX_E)
* Calculation is not performed automatically, but values can be input directly in the
data input area.
1 Press the [Constant Setting] f key, select [3 Machine Constant], align the cursor
Enter with [5 Software Limit], and press the [Enter] key.
2 Press the [Auto Set] f key.

>>The following [Auto Set] screen appears.
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Table 4.12.2 [Auto Set] screen items

Parameter Function
Display the list of the programs stored in the internal memory of the
controller.If the cursor is in the Program List box, a program (multiple
programs) can be selected.
To select a program To delete a program
Program List
Enter
BS
Display the program(s) selected in Program List.

If write processing is carried out, all selected programs are saved to the
Select Program LOG file (LGSEOPRO. LOG).
If there is any change to the minimum and maximum values after the
automatic calculation is executed, all selected programs are cleared.
Whether to perform the automatic calculation can be set for each axis
individually.
The automatic calculation is only performed for axes with checkmarks.
Checkmarks cannot be added for the servo gun axis and endless axis
because they are not applicable to automatic calculation.
Axis To perform the automatic To not perform the automatic
calculation calculation
ON OFF
＋＋
1 2
Set the margin value for the minimum value of the software limit.
-Margin Initial value: 5.00 (rotation axis: deg/translation axis: mm)
Input range: 0.00 to 90.00
Set the minimum value of the software limit.
The setting cannot be configured if the software limit setting range
exceeds "Minimum" - "-Margin"
Minimum
Initial value: software limit initial value* (rotation axis: deg/translation
axis: mm)
Input range: Minimum value to maximum value of the software limit
Set the maximum value of the software limit.
The setting cannot be configured if the software limit setting range
exceeds "Maximum" + "+Margin"
Maximum
Initial value: software limit initial value* (rotation axis: deg/translation
axis: mm)
Input range: Minimum value to maximum value of the software limit
Set the margin value for the maximum value of the software limit.
+Margin Initial value: 5.00 (rotation axis: deg/translation axis: mm)
Input range: 0.00 to 90.00
* The initial values of the software limit refer to the values set at the time of formatting.
When the software limit is set automatically, only the robot posture data included in
programs is used to calculate the software limit. Therefore, an error may be
generated if an interpolation operation results in the robot attempting a movement
that exceeds the software limit.
CAUTION After setting the software limit automatically, confirm that all programs move the
robot without a problem. Furthermore, if an error is generated, adjust the ±margin
values.
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Table 4.12.3 [Auto Setting] screen f keys

Key Function
[Back] f key
Redisplays the [Position record] screen or [Data input] screen.
The screen displayed prior to selecting [Auto Set] reappears.
[Select] f key
Moves the cursor to the Program List box and a program can be
selected.
[Execute] f key
Calculates the minimum and maximum values from the recorded
positions of the selected program(s). The minimum and maximum values
are not calculated for any axis not selected with a checkmark.
[Edit] f key
Moves the cursor to the data input area and the axes checkboxes,
margins, and minimum and maximum values can be set.
[Complete] f key Writes the software limit values that were calculated automatically or
input directly.
If the software limit range is exceeded, the values cannot be written.
After writing of the values is complete, the [Machine Constant] menu
reappears.
3 Press the [Select] f key.

>>The cursor moves to the Program List box.
4 Align the cursor with any program any press the [Enter] key.
Enter >>The program is copied to the Select Program box.
5 Align the cursor with any program any press the [BS] key.
BS >>The program in the Select Program box is cleared.
Repeat Steps 4 and 5 until all the programs for which to execute automatic
calculation are selected.
6 Press the [Execute] f key.

>>The minimum and maximum values are calculated automatically for all selected
programs.
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>>If the calculation results exceed the setting range of software limit, the following
message appears.
* Press any key to move the cursor to the axis that exceeds the setting range of the
software limit. Input values that are within the setting range.
7 Press the [Edit] f key.

>>The cursor moves to the data input area.
8 Set the margin.

>>The software limit values are written to the constant file and the [3 Machine
>>If the input data exceeds the setting range of the software limit, the following
message appears.
* Press any key to move the cursor to the axis that exceeds the setting range of the
software limit. Input values that are within the setting range and press the
[Complete] f key again.
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Chapter 5 Spot welding setup
This chapter is aimed at operators who intend to use the robot for spot welding
applications, and it describes the setup work specifically for these applications
5.1 Overview of setup work ................................................................................5-1

5.2 Assignment of spot welding input/output signals .........................................5-3
5.2.1 Spot welding input signals ......................................................................5-3
5.2.2 Spot welding output signals ....................................................................5-4
5.3 Settings inherent to a servo gun...................................................................5-5
5.3.1 Servo gun condition ................................................................................5-5
5.3.2 Tip consumption detection ......................................................................5-8
5.1 Overview of setup work

Depending on the drive system of the welding gun used, spot welding is classified into two kinds: "air gun" and
"servo gun." The air welding gun is driven pneumatically whereas the servo welding gun is driven by servo
control. Due to differences in the control method, the steps taken for setup differ between the two kinds of spot
welding.
Fig. 5.1.1 Air gun and servo gun

Many more steps need to be taken for the setup in the case of a servo gun compared with an air gun since a
servo gun involves the registration of machine constants—specifically the "mechanism constants" for exercising
servo control over the gun axes—and of the servo tuning parameters, the measurement of the bending
characteristics, and so on. Normally, however, this kind of servo drive mechanism is installed and set up
appropriately at the factory so that users do not have to take this action themselves. The items shaded in the
figure below correspond to these steps.
This section does not go into these steps, and it describes only the setup work (non-shaded area) which must be
carried out by the user after delivery.
Fig. 5.1.2 Overview of spot welding setup work
5-1
If the servo gun is to be installed and adjusted by the user, the work in the shaded section must be performed.
This work must be done by an operator who has the qualifications of an Expert or above, that is to say, who is
well versed in the operation of the controller. Refer to the spot welding instructions in the separate Applications
Manual. For details on the operator qualifications, refer to Chapter 4 "Setup".
5-2
5.2 Assignment of spot welding input/output signals

In this section, the signal attributes used specifically for spot welding applications will be described. These
signals include the gun pressure output signal and welding completed (WI) input signal. Whereas the basic
signal attributes are used as the standard signals with all applications, the signals described in this section are
used only for spot welding applications.
The operating procedure for assigning the signal attributes is exactly the same as for the basic signal attributes.
If the robot delivered has "spot welding" set as its application, some of the signals were already assigned at the
factory.
Among the signals are the ones used with air guns only, the ones used with servo guns only, and the ones used
for both types of guns. "○" in the table denotes a signal which is used. "–" denotes a signal which is not used
even if it has been assigned.
5.2.1 Spot welding input signals
Table 5.2.1 Spot welding input signals

Basic input signal Factory-set Air Servo
Function
designation Input signal Gun Gun
This signal requests that the fact that the welding
26 has been completed be input from the welder
Weld
(Connector (timer contactor). ○ ○
completed(WI)
pin#34) When this signal is input, the gun release is started
in order for the gun to move to the next step.
Welding ON, welding OFF or pressurizing OFF is
selected by means of external signals. The
27 combinations of these signals are presented
Weld ON (Connector below. For the individual statuses, refer to the ○ ○
pin#35) "Basic spot welding operations" in the Basic
Operations Manual.
Welding ON and welding OFF can be switched by
means of external signals only when the "Welding
ON/OFF" spot welding condition has been set to
"Input signal." The pressurizing OFF status,
however, is established simply as a result of the
input of the pressurizing OFF signal regardless of
this setting.
"Pressurizing
Pressurizing "Weld ON"
0 OFF" Status ○ ○
OFF Input signal
Input signal
ON ON →Pressurizing
OFF
ON OFF →Weld ON
OFF ON →Pressurizing
OFF
OFF OFF →Weld ON
5-3
5.2.2 Spot welding output signals

Table 5.2.2 Spot welding output signals
Basic Output signal Factory-set Air Servo
Funtion
designation Output signal Gun Gun
This is output when the step in which the spot
welding command (SPOT: FN119) has been
17
recorded is played back. It is also output during
Pressurizing (Connector ○ ○
manual pressurizing operations in the teach
pin#19)
mode.
Only welder 1 (W1) is initially assigned.
This is the signal for opening the air gun fully.
18
It is output when semi-open has been set with
Fully open (Connector ○ －
"Stroke" in the spot weld sequence.
pin#20)
Only welder 1 (W1) is initially assigned.
This is the signal for opening the air gun
Half open 0 halfway. It is output when semi-open has been ○ －
set with "Stroke" in the spot weld sequence.
This is output when the "Power-on signal" in
the spot welding sequence has been set to
Power-on 0 "Output provided" and the spot welding ○ ○
command is played back in the welding ON
status.
The "Welding condition output data" which has
Welding condition
0 been set as the spot welding conditions is ○ ○
output
output. The signal range from 1 to 16.
In the case of an air gun, the [Pressure control]
data specified by the spot welding conditions is
Welding force output discretely.
0 ○ －
control signal Use this when air guns that employ an
electropneumatic proportional valve, etc. to
control the welding force are used.
19
<This function is not supported at the present
Weld warning (Connector ○ ○
time.>
pin #21)
5-4
5.3 Settings inherent to a servo gun

When an air gun is used, there is no need to read through this section.
A number of technical terms relating to spot welding will appear in this section. To find out what these terms
mean, read through the section on basic spot welding operations in the Basic Operation Manual before
proceeding.
The "servo gun conditions" and "tip consumption detection" parameters that are concerned with how to
determine the position of the open stroke and other aspects of operating the servo gun are set here. Prior to
shipment from the factory, the general initial settings were already performed. Therefore, under normal
circumstances, no changes need to be made by the user. Outlined in this section are a number of terms and
parameters with which an operator must at the very least be familiar in order to proceed with the basic teaching
using the servo gun.
For an explanation of all the parameters displayed, refer to the spot welding section in the instruction manual.
5.3.1 Servo gun condition

The servo gun conditions are the general conditions that come into play when the servo gun is to
be used. There are two kinds of parameters, ones which are common to all spot welding tools and
ones which are for individual tools.
１ Select the teach mode.
２ Select the [Spot Constant] f key. The same menu can be selected by pressing
[8.Spot welding application] from the [Constant Setting] f key.
>>The constant setting menu used exclusively for spot welding such as the one
Menu items for title No.3 and following are displayed only when servo guns have
been set.
３ Align the cursor with "Working condition of Servo Gun," and press the [Enter]
key.
>>A setting screen such as the one shown below now appears.
(Screen showing the settings common to all guns)
5-5
４ The setting screen corresponding to the number of pre-defined spot welding

tools now appears. If a multiple number of spot welding tools have been
defined, input the number in the edit box at the very top of the screen and press
the [Enter] key or press the [Prev gun] or [Next gun] f key to switch the spot
welding tool number.
５ Some parameters are defined for each spot welding tools while others are
common to all spot welding tools.
"0" is set in the gun number field at the very top of the screen for the common
parameters. Set the number "1" or above for the parameters specific to
individual guns.
(Screen for performing settings for an individual gun)
６ If there is an edit box, input the appropriate number, and press the [Enter] key.
ON Enter
1
If the radio buttons (the horizontal rows of selector buttons) are used, press the
[ENABLE] and left or right cursor keys at the same time to select their settings.
If the combo box (box with the arrow at the far right) is used, align the cursor
Enter with it, and press the [Enter] key. A table with a list of selection candidates now
appears. Use the up or down cursor key to select the chosen candidate, and
press the [Enter] key again.
Enter
７ Upon completion of the settings, press the [Complete] f key.

The settings are written in the spot welding constant file.
(To stop editing at any time, press the [Reset] key.)
5-6
Only the basic parameters will be described below. For an explanation of all the parameters displayed, refer to
the spot welding section in the instruction manual.
Table 5.3.1 Servo gun conditions (common data)

Factory
Parameter Description of function
settings
Bend coef. at record Low rigid Low rigid work piece: The position is modified by the entire bending
work amount during step recording.
piece Select.: This depends on the setting for "work piece rigidity type"
among the spot teach/playback condition menu items.If "low
work piece rigidity" applies, the position is modified by the
entire bending amount; if "high work piece rigidity" applies, it
is modified by the bending amount on the movement side.
Table 5.3.2 Servo gun conditions (individual data)

Factory
settings
Wide release value 50mm This specifies the distance at which the
moving side electrode and fixed side
electrode have opened maximally
during manual opening/closing. This
distance must be set inside the soft limit.
In the case of a gun without a battery,
the gun is set to this position after
returning to its home point.
Stroke 1 40mm Since the gun axis is servo-controlled,
the gun can be stopped at any position
but, with a view to facilitating the
teaching process, the design enables
Stroke 2 35mm stroke switching by a single-action
operation. When the [Stroke select] f
key is pressed, stroke switching
Stroke 3 30mm operations can be performed in one go
for a total of four settings, namely,
stroke 1, stroke 2, stroke 3 and wide
release value.
Pressurizing stroke 20mm This parameter specifies the distance
when the moving side electrode and
fixed side electrode have closed
maximally during manual
opening/closing. A value lower than the
wide release end default value must be
set without fail.
Moving side 0mm This parameter specifies the distance between the moving (or fixed)
clearance side electrode and the work immediately prior to pressurizing when
the spot welding command (SPOT: FN119) is played back.
Fixed side clearance 0mm
5-7
5.3.2 Tip consumption detection

In this section, the operating conditions for determining how the gun tip consumption is to be
detected (gun search) are set. These settings must be performed for all the spot welding tools that
are to be used.
Fig. 5.3.1 Servo gun electrode wear
２ Select the [Spot Constant] f key. The same menu can be selected by pressing
[8.Spot Welding Application] from the [Constant Setting] f key.
>>The constant setting menu used exclusively for spot welding such as the one
Menu items for title No.3 and following are displayed only when servo guns have
been set.
３ Align the cursor with "Tip consumption detection." and press the [Enter] key.
>>A setting screen such as the one shown below appears.
４ The setting screen corresponding to the number of pre-defined spot welding

tools now appears.
If a multiple number of spot welding tools have been defined, input the number
in the edit box at the very top of the screen and press the [Enter] key or press
the [Prev gun] or [Next gun] f key to switch the spot welding tool number.
５ If there is an edit box, input the appropriate number, and press the [Enter] key.
ON Enter
1
5-8
If the radio buttons are used, press the [ENABLE] and left or right cursor keys
at the same time to select their settings.
If the combo box (box with the arrow at the far right) is used, align the cursor
Enter with it, and press the [Enter] key. A table with a list of selection candidates now
appears. Use the up or down cursor key to select the chosen candidate, and
press the [Enter] key again.
Enter
６ Upon completion of the settings, press the [Complete] f key.

The settings are saved in the spot welding constant file, and the editing screen
is closed.
(To stop editing at any time, press the [Reset] key.)
Only the basic parameters will be described below. For an explanation of all the parameters displayed, refer to
the spot welding section in the instruction manual.
Table 5.3.3 Tip consumption detection

Factory
settings
Move-tip consump. 0% If the tip consumption is to be detected using gun search 1 alone or
rate using gun searches 1 and 3 together, only the "total tip
consumption," which is obtained by adding the moving side electrode
tip consumption and fixed side electrode tip consumption, can be
detected. Using the value set here, the "total tip consumption" is
divided into two parts, the moving side electrode tip consumption and
the fixed side electrode tip consumption.
(This parameter cannot be used with gun search 2.)
5-9
5-10
Chapter6 Arc welding setup
This chapter describes the setup work procedure for operators who will be
operating the robot for the arc welding application.
6.1 Outline of setup work ....................................................................................6-1

6.1.1 Setup relating to welding power supply..................................................6-1
6.1.2 Setup relating to external input/output signals .......................................6-1
6.2 Checking the welding characteristics data and wire feed
characteristics data .......................................................................................6-2
6.3 Allocating the dedicated arc welding input/output signals............................6-4
6.3.1 Allocating the dedicated arc welding input/output signals......................6-4
6.3.2 Table of input signals ..............................................................................6-5
6.3.3 Table of output signals ............................................................................6-6
6.1 Outline of setup work
6.1 Outline of setup work

Follow the setup work procedure relating to arc welding set forth below when operating the robot for the arc
welding application.
6.1.1 Setup relating to welding power supply

If the robot and welding power supply were purchased at the same time and a request for the arc
welding setup has been made to Daihen, this setup is unnecessary.
At this point, simply check whether the welding characteristics data has been registered. See
page 6-2 "6.2 Checking the welding characteristics data and wire feed characteristics data".
The setup work must be done if operators aim to do the setup themselves or if the welding power
supply is to be changed after the robot was delivered. For further details, refer to the Application
(Arc Welding)
Manual.
6.1.2 Setup relating to external input/output signals

In addition to the basic input/output signals which were covered by "Setup" in Chapter 4, a
number of input/output signals which can be used only for the arc welding application have been
provided.
Set up these signals in line with the specifications of the user. See page 6-4 "6.3 Allocating the
dedicated arc welding input/output signals".
This work need not be done if the robot is not going to be connected to an external device.
6-1
6.2 Checking the welding characteristics data and wire feed characteristics data
6.2 Checking the welding characteristics data and wire feed

characteristics data
Upon request of the arc welding setup, the welding characteristic data and the wire feed characteristic data has
been setup in line with the purchased welding power supply.
At this point, simply check whether the welding characteristics data has been registered.
Do not change the registered welding characteristics data and wire feed
characteristics data without good reason.
If any changes have been made in the data, the welding characteristics and wire feed
characteristics will be changed. This means that they will be at variance from the
CAUTION actual operating environment. As a result, the welding results will be adversely
affected.
Checking the welding characteristics data and wire feed characteristics data
Before proceeding, switch the operator specifications level to Expert or above.
１ After pressing f5<Arc Constant> in the teach mode, select [4 Setting of weld data].
>>The screen for setting the characteristics data now appears. Check the data on this
screen.
Presented above is an example of a screen displayed with the DP350 (specifications

for Japan). (The display screen and maximum number of data registered depend on
the type of welding power supply connected.)
２ When a multiple number of welding power supplies have been connected, press
Enter [Enter] in the "welding power supply" field to select the welding power supply
whose data is to be set.
This operation need not be performed if only one welding power supply has been
connected.
３ After checking the data, press [RESET/R].

>>The screen is now closed.
To register new welding characteristics data, proceed as follows.
6-2
6.2 Checking the welding characteristics data and wire feed characteristics data
４ Move to the target location using [Up] or [Down], and press f8<Select>.
>>A list of the characteristics data now appears.
５ While reading the comments, select the desired characteristics data, and press
Enter [Enter].
>>The characteristics data is now selected. Repeat these steps for as many times as
necessary.
６ Upon completion, press f12<Complete>.

>>This completes the registration of the characteristics data.
6-3
6.3 Allocating the dedicated arc welding input/output signals
6.3 Allocating the dedicated arc welding input/output

signals
This section describes the input/output signals which are used exclusively for arc welding. Included among
these signals are the "welding underway" output signal and "welding ON/OFF" input signal.
Whereas the "basic input/output signals" are used as standard signals for all applications, the signals described
in this section are used for the arc welding application only.
If the application of the robot is set for "arc welding," a number of these signals were already allocated prior to
shipment.
6.3.1 Allocating the dedicated arc welding input/output signals

The method used to allocate the input/output signals is exactly the same as the one used to
allocate the "basic input/output signals".
Allocating the dedicated arc welding input/output signals

２ Select <Constant Setting>, and press [6 Signals] → [2 Input Signal Assignment]

→ [3 Arc inputs].
>>The screen for setting the allocation of the arc input signals as shown below now
appears.
For the output signals, select <Constant Setting> → [6 Signals] → [3 Output Signal
Assignment] → [3 Arc Outputs].
３ Allocate the output signals by performing the same operations as for the basic
input/output signals.
４ Upon completion of the settings, press <Complete (f12)>.

>>The settings are now saved in the constant file.
6-4
6.3.2 Table of input signals

The following input signals can be used with arc welding.
In the table, "MP1 to MP6" and "W1 to W4" refer to the numbers of the manipulators and the
numbers of the welding power supplies that serve as the target of the signal operations,
respectively.
For example, MP1 refers to the signal that operates manipulator 1, and W1 refers to the signal
that operates welding power supply 1. With a standard robot system which has one manipulator
and one welding power supply, perform settings for MP1 and W1 only. (MP2 to MP6 and W2 to
W4 can be ignored.)
Table 6.3.1 Dedicated arc welding input signals

Factory
Input signal name settings Description of function
Input signal
Weav ON (MP1 to MP6) 0 This signal controls the weaving ON and OFF
statuses from the external source.
W.P.S. failure (W1 to W4) 0 The trouble which is relayed from the welding power
supply is input to the robot by this signal.
Wire not fed (W1 to W4) 0 The out of wire status which is relayed from the
remaining wire detection unit (option) is input to the
robot by this signal.
Low gas pressure (W1 to W4) 0 The low gas pressure status which is relayed from
the gas pressure detection unit (option) is input to
the robot by this signal.
Cooling water (W1 to W4) 0 The out of cooling water status which is relayed from
the out of cooling water detection unit (option) is
input to the robot by this signal.
Not enough wire (W1 to W4) 0 The insufficient remaining wire status which is
relayed from the remaining wire detection unit
(option) is input to the robot by this signal.
Ope. preparation (W1 to W4) 0 Whether the is in the operable status is input to the
robot by this signal. When this signal is to be used,
the welding interface must be remodeled.
Gas ON/OFF (W1 to W4) 0 This signal controls the shielding gas ON and OFF
statuses during automatic operation.
Inching ON/OFF (W1 to W4) 0 This signal controls the wire inching.
Retract ON/OFF (W1 to W4) 0 This signal controls the wire retracting.
Wire speed change (W1 to W4) 0 This signal switches the inching or retracting speed
(to low speed or high speed).
Welding ON/OFF (W1 to W4) 27 This signal controls the welding ON and OFF
statuses from the external source.
Whole OFF cancel (W1 to W4) 0 If the robot is operating in the "Whole sect. W OFF"
status after an arc start failure, this signal releases
this status.
"Whole sect. W OFF" means that welding in all the
remaining welding sections is canceled.
Scratch start (W1 to W4) 0 This signal is used to perform scratch start.
"Scratch start" refers to the start method by which
welding is started without checking whether arc start
has been completed.
Abnorm. sect. OFF (W1 to W4) 0 This signal prevents welding from being performed
after welding trouble has occurred in the welding
section concerned.
Weld OFF cancel (W1 to W4) 0 If the robot is operating in the "Section weld OFF"
status after an arc start failure, this signal releases
this status.
"Section weld OFF" means that welding is canceled
only in the welding section concerned after trouble
has occurred.
WCR input twin AS (W1 to W4) 0 This defines the start check method when
performing simultaneous arc start using two
manipulators in a twin synchromotion system.
Wire short circu. (W1 to W4) 0 This checks for wire short-circuiting.
6-5
6.3.3 Table of output signals

The following output signals are used with arc welding.
In the table, "MP1 to MP6" and "W1 to W4" refer to the numbers of the manipulators and the
numbers of the welding power supplies that serve as the target of the signal operations,
respectively.
For example, MP1 refers to the signal that is output from manipulator 1, and W1 refers to the
signal that is output from welding power supply 1. With a standard robot system which has one
manipulator and one welding power supply, perform settings for MP1 and W1 only. (MP2 to MP6
and W2 to W4 can be ignored.)
Table 6.3.2 Dedicated arc welding output signals

Factory
Output signal name settings Description of function
Output signal
Weav ON (MP1 to MP4) 0 The weaving ON or OFF status is output.
Welding failure (W1 to W4) 18 This is output when welding trouble has occurred.
Wire stick check (W1 to W4) 17 This is output when wire stick has occurred.
Arc not generated (W1 to W4) 0 This is output when the arc has run out.
Wire not fed (W1 to W4) 0 This is output when the wire has run out.
Gas pressure (W1 to W4) 0 This is output when the gas pressure is low.
Cooling water (W1 to W4) 0 This is output when the cooling water has run out.
Arc start failure (W1 to W4) 0 This is output when an arc start failure has occurred.
W.P.S. unready (W1 to W4) 0 This is output when a welding power supply
not-ready trouble (no communication with welding
power supply) has occurred.
Not enough wire (W1 to W4) 0 This is output when the remaining wire has become
insufficient.
W.P.S. failure (W1 to W4) 0 This is output when welding power supply trouble
has occurred.
Ope. preparation (W1 to W4) 0 This is output while the "Ope. preparation" input
signal is input to the robot. When this signal is to be
used, the welding interface must be remodeled.
WCR short-circuit (W1 to W4) 0 This is output when WCR short-circuiting trouble
(when WCR is short-circuited even though no arc
has been generated) has occurred.
WI/F time out (W1 to W4) 0 This is output when WIF timeout trouble (no
response from the welding power supply) has
occurred.
Multi-pass weld (W1 to W4) 0 This is output during the execution of a multi-layer
sequence welding section.
In welding (W1 to W4) 0 This is output when welding is being performed. This
signal is not output when no arc has actually been
generated.
In welding sect. (W1 to W4) 0 This is output while a welding section is being
executed. This signal is output even when no arc has
actually been generated. One example of this would
be a case where check GO or BACK has been
initiated for the welding section.
Welding ON/OFF (W1 to W4) 0 The welding ON or OFF status is output.
Wire inching (W1 to W4) 0 This is output during inching.
Wire retracting (W1 to W4) 0 This is output during retracting.
Arc gas ON (W1 to W4) 0 This is output while the gas is output.
During AS cmd (W1 to W4) 0 This is output when the arc start command is issued
to the welding power supply.
W.P.S. pulse cmd (W1 to W4) 0 This is output when the pulsed welding conditions
are controlled by the welding power supply.
Scratch start set (W1 to W4) 0 This is output when scratch start has been selected.
Weld current fail (W1 to W4) 0 This is output when trouble with the welding current
(the current level has exceeded the rating) has
occurred.
6-6
Factory
Output signal name settings Description of function
Output signal
Weld voltage fail (W1 to W4) 0 This is output when trouble with the welding voltage
(the voltage level has exceeded the rating) has
occurred.
WCR input twin AS (W1 to W4) 0 This is output when the WCR check function is
enabled by the "WCR input twin AS" input signal.
Abnorm. sect. OFF (W1 to W4) 0 Section OFF has been set by the "Abnorm. sect.
OFF" input signal as the operation to be performed
after welding trouble has occurred.
Whole sect. WOFF (W1 to W4) 0 Automatic operation is continued by the "Whole sect.
WOFF" setting after an arc start failure has occurred.
Section weld OFF (W1 to W4) 0 Automatic operation is continued by the "Section
weld OFF" setting after an arc start failure has
occurred.
Current Cond. 0 This is output during the welding section when the
(W1 to W4) current condition type is set at the wire speed.
Voltage Adjustment Method 0 This is output during the welding section when the
(W1 to W4) voltage adjustment mode is individual (voltage
command).
6-7
NOTE
6-8
Chapter 7 Preparations for auto operation
This chapter describes the usual preparatory steps taken to operate the robot
automatically.
7.1 Specification of the operation method ..........................................................7-1

7.1.1 Controller operation ................................................................................7-1
7.1.2 External operation...................................................................................7-1
7.1.3 Multi-station operation.............................................................................7-5
7.2 Setting multi-station operation ......................................................................7-6
7.2.1 Connecting the operation boxes and start boxes...................................7-6
7.2.2 Registering the number of stations.........................................................7-6
7.2.3 Allocating the start signals (only when using stations 5,6).....................7-7
7.2.4 Allocating the input/output signals for multi-station use .........................7-7
7.2.5 Allocating the program to be started.......................................................7-8
7.3 Home position registration............................................................................7-9
7.3.1 Home position registration by referencing the program .........................7-9
7.3.2 Home position registration by manual recording..................................7-12
7.3.3 Home position registration by numeric input ........................................7-13
7.4 Registering Start Enable Area ....................................................................7-14
7.4.1 Registering the start enable area .........................................................7-14
7.4.2 Checking the unit if it is in the start enable area ..................................7-16
7.4.3 Checking which axis is out of the start enable area .............................7-17
7.5 READY status output signals .....................................................................7-18
7.5.1 Controller READY signals.....................................................................7-18
7.5.2 Unit READY signal................................................................................7-18
7.5.3 Status output signals.............................................................................7-21
This is dummy page.
7.1 Specification of the operation method

When the robot is operated under normal circumstances, it is operated not using the teach pendant but using
input signals from an external source.
The method of performing all the operations from the teach pendant is called "controller operation." On the other
hand, the method that is based on signals from an external source is called "external operation."
7.1.1 Controller operation

The series of operation-related commands such as start, program selection and stop are all executed on the
operation panel of the controller or teach pendant.
At the factory, the robot was set to the controller operation mode.
For further details on operation, refer to the Basic Operations Manual.
7.1.2 External operation

The series of operation-commands related to such operations as start, program selection and stop are input from
an external device such as a host controller or operator console.
If the robot could be started from both the teach pendant and external input signals, this would be extremely
dangerous.
Therefore, only one of these command input methods can be used for such commands as the start command and
program select command. (Conversely, commands from any sources are accepted at all times for the safety
commands such as the stop and emergency stop command.)
Host controller or
Teach pendant operating console, etc.
Start input,
program
number input
Controll External
AX
controller
Fig. 7.1.1 Controller/external operation for motors ON/START select and program selection command
The switching of the start command to controller (operation using teach pendant) or external (operation by input
signals) is known as "motors ON/START select." It is the same with the program selection command. Controller
or external can be set independently for these commands.
Setting controller or external for motors ON/START select, program select
1 Teach or playback may be set as the mode.
2 Press the [Teach/Play Condition] f key.

>>The Teach/Playback Conditions setting screen such as the one shown below now
appears.
The same menu also appears when [1 Teach/Playback Condition] are selected from
the [Service Utilities] f key.
7-1
3 Align the cursor with "Motors ON/START sel. source," and press the [ENABLE]
ENABLE ＋ and left or right cursor keys to select the settings of the radio buttons (the
horizontal rows of selector buttons).
Motors ON/
Description/Explanation
START select
Controller Automatic operation can be initiated using the start button on the
operation panel of the controller.
External Automatic operation can be initiated by an input signal (external
start signal) from an external device. A signal is assigned as a
standard signal for the external start signal.
4 In the same way, align the cursor with "Playback mode prog. sel.", and press
ENABLE ＋ the [ENABLE] and left or right cursor keys to select the settings of the radio
buttons (the horizontal rows of selector buttons).
Playback mode
Description/Explanation
program select
Controller Programs can be selected from the teach pendant.
External Programs can be selected by input signals (external program
selection signals) from an external device. A signal up to 8 bits is
assigned as a standard signal for the external program select
signal.
In the teach mode, programs cannot be selected using the external input signals.
"External" for program select is set only in the playback mode.
5 Upon completion of the settings, press the [Complete] f key.

The settings are saved in the file, and so their statuses are retained even when
the power is turned off.
== Switching both signals simultaneously in a single action ==
6 Press the [Start Ext·Prog Ext/Start Con·Prog Con] keys at the same time as the
[ENABLE] key.
ENABLE ＋
>>Each time these keys are pressed, "Controller" or "External" for the motors ON/
START select and program select signals is switched in synchronization.
This is useful when the motors ON/START select and program select settings are
ENABLE ＋
to be used in the same status.
When this key is used, there is no need to press the [Complete] key.
If the f key [Start selection/program selection] has not been assigned, it can be
assigned by selecting [Constant Setting], [7 T/P Keys] and [2–4 Soft Key Layout].
With "External" for the program select signal, the number of the program to be played back is determined by an
input signal from the external source. There are several ways to read the program numbers.
Read through the following, and proceed with operation using the settings tailored to the system.
Specification of the external program select method

For this procedure, the operator must be qualified as an Expert or above.
1 On the same setting screen as the one mentioned above, align the cursor with
"Selection type."
There are three ways to read the program select bits (16 signal lines): "binary,"
"discrete" and "BCD (Binary Coded Decimal)."
2 Press the [ENABLE] and left or right cursor keys to select the settings of the
ENABLE ＋ radio buttons (the horizontal rows of selector buttons) and select one of the
three methods.
7-2
External program selection method

Binary With this method, the signals are read out as binary numbers. If, for
instance, bits 3 and 5 are ON, program no.20 (22+24 = 4+16) will be
selected.
Discrete With this method, the number of the bit turned ON by the signal is used as
the program number. This means that only programs with numbers from 1
to 16 can be selected. If two or programs are input at the same time, the
one with the lower number is selected.
BCD With this method, the signal is read out as a BCD code. If, for instance,
(Binary bits 3 and 5 are ON, program no.24 will be selected since the 1's digit is
Coded 22=4 and the 10's digit is 21=2.
Decimal)
Program select bit U1

Signal 16 15 14 13 12 11 10 ９８７６５４３２１
Binary 215 214 213 212 211 210 29 28 27 26 25 24 23 22 21 20
Discrete 16 15 14 13 12 11 10 ９８７６５４３２１
BCD 1000's digit 100's digit 1's digit
Signals 1 to 16 are the numbers of the 16 "program select bit" input signals.
When "binary" or "BCD" is selected for the "selection system," a multiple number of
signal lines are read so that the program strobe signal for determining their read
timing is used. There is a special method that does not use the program strobe signal,
as set forth below.
3 On the same setting screen as the one mentioned above, align the cursor with
"Strobe signal."
There are two method: one uses the program strobe signal and the other does not
use it.
Strobe signal Description/Explanation

Effective When the robot is to be started from an external source, maintain a
pulse width of at least 0.2 sec. for the start signal. Input the strobe
signal when at least 0.01 sec. has elapsed after the program select
signal has stabilized. If the start status has already been established
by this time, program selection is executed at this time. If the start
status is not established, program selection is executed as soon as
the start signal has been input.
(Program selection range: 0 to 9999) (Note that even No.0 can be
selected.)
Ineffective When the robot is to be started from an external source, maintain a

pulse width of at least 0.2 sec. for the start signal. At the point when
no change has occurred for 0.10 sec. after the program select signal
was input, the input signal is considered to be a definite signal, and it
can be captured. If the start status has already been established by
this time, program selection is executed. If the start status is not
established, program selection is executed as soon as the start signal
has been input. (Program selection range: 0 to 9999) (Note that No.0
cannot be selected.)
4 Press the [ENABLE] and left or right cursor keys to select the settings of the
ENABLE ＋ radio buttons (the horizontal rows of selector buttons) and select one of these
two methods.
5 Upon completion of the settings, press the [Complete] f key.
7-3
While the program is

Time chart applied when the strobe signal is set to “Effective” stopped, it does not
matter whether the
start signal comes
At least 0.2 sec. At least 0.2 sec. earlier or later than
the program
selection signal.
Start signal
P1
Program selection
P2
Program selection signal input
signal P9
P10
Strobe signal
At least 0. sec.
ACK signal
At least 0.01 sec. Max. 0.15 sec. 0.2 sec.
Fig. 7.1.2 Strobe signal = Effective
While the program is

Time chart applied when the strobe signal is set to “Ineffective”
stopped, it does not
matter whether the
start signal comes
At least 0.2 sec. At least 0.2 sec. earlier or later than
the program
selection
Start signal
P1
Program selection
P2
Program selection signal input
signal
P9
P10
ACK signal
At least 0.10 sec. 0.2 sec.
Max. 0.15 sec.
In either case, be sure to turn OFF the program selection signal and the strobe signal
when the ACK signal (Program acknowledge output signal) is output.
(The strobe signal shall be effective to use the program reservation function although its
timing chart differs from the above.)
Fig. 7.1.3 Strobe signal = Ineffective
7-4
7.1.3 Multi-station operation

Under this operation system, the task programs are started and reserved by pressing the start button on the
operation box installed on each station. It is supported only by the AX21 controller.
Robot
Work bench 1
Work bench 3
Operation
Operation box 3
box 1
Task programs are started or

Work bench 2
reserved by pressing the start
Operation button on the operation box
box 2 installed at each station.
Fig. 7.1.4 Multi-station operation
7-5
7.2 Setting multi-station operation

The following connections must be made and settings selected in order to perform multi-station operation.
• Connecting the operation boxes and start boxes

• Registering the number of stations
• Allocating the start signals (only when using stations 5, 6)
• Allocating the input/output signals for multi-station use
• Allocating the program to be started
7.2.1 Connecting the operation boxes and start boxes

Up to four stations are supported under the standard specifications.
If there are four or fewer stations, connect the operation box (station 1) to the sequence board and the start
boxes (stations 2 to 4) to the connection ports of the operation box.
For details on the connections, refer to Chapter 3 "Connections".
If stations 5 and 6 are to be used, use the free input pins on the relay unit for the connections.
(Then allocate them by operating the robot in such a way that these input pins will be used as the start signal
inputs.)
7.2.2 Registering the number of stations

The number of stations must be registered when multi-station operations are to be performed.
(Normally, this need not be done since the number of stations that corresponds to the user's specifications
was already selected at the factory.)
An operator must have the qualifications class of Expert of above to change the number of stations.
Registering the number of stations
1 Press [Constant Setting] and then select [5 Operation Constants] — [6 The

number of stations].
>>The number of stations registration screen now appears.
2 Input the number of stations. A setting of "0" cancels multi-station operation.
3 Press f12 [Complete].

>>The number of stations is registered, and the display returns to the previous
screen.
7-6
7.2.3 Allocating the start signals (only when using stations 5,6)
If there are four or fewer stations, the start signal and stop signal are placed in the input enable status simply
by connecting the operation box and start boxes. (These signals are directly coupled to the fixed inputs on
the sequence board.)
If stations 5 and 6 are to be used, the signals must be allocated in such a way that the start signals are input
as the robot status input signals (station 5 start, station 6 start).
Allocating the start signals (only when using stations 5,6)
1 Press [Constant settings], and select [6 Signals] — [2 Input Signal Assignment]

— [9 Multi-station Inputs].
>>The input signal allocation screen now appears.
2 Input the numbers of the input signals to be used as the station 5 and station 6
start signals, and press [Enter].
3 Press f12 [Complete].

>>What has been allocated is stored in the memory, and the display returns to the
previous screen.
7.2.4 Allocating the input/output signals for multi-station use

The following signals have been provided as the input/output signals specifically used for multistation
operation.
Table 7.2.1 Input signals for multi-station use

Factory-set
Input signal name Description of function
input signal
Allotment reached reset 0 When multi-station operations are to be performed, any
program which is to be started by each station can be
allocated, and the allotment count (projected production
count) can also be set at the same time. When this
allotment count is set ahead of time, the allotment reached
signal will be output to an external device when the
production count (number of times the END command has
been executed) has reached the allotment count.
This signal is used to reset the allotment reached signal.
(At the same time, the production count is set to zero.)
7-7
Factory-set
Input signal name Description of function
input signal
Station 5 start 0 Since up to four stations are supported under the standard
specifications, settings must be performed in such a way
that the start signals are input from the start boxes as the
Station 6 start 0 "station 5 start" and "station 6 start" signals if stations 5
and 6 are to be used. (There is no need to allocate the
start signals for stations 1 to 4 since they are fixed input
signals.)
Table 7.2.2 Output signals for multi-station use

Factory-set
Output signal name Description of function
output signal
Station* 0 This outputs the number of the unit which is being
reservation unit, 1 to 4 reserved by station ∗.
(*: Station No.) Unit numbers 1 to 9 are indicated as follows using four
signals.
Signal 4 3 2 1
3 2 1 0
Binary 2 2 2 2
Station ∗ 0 This outputs the number of the program which is being

Reservation program1 to 16 reserved by station ∗. Program numbers 1 to 9999 are
(∗: Station No.) indicated as follows using 16 signals.
Signal 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Binary 215 214 213 212 211 210 29 28 27 26 25 24 23 22 21 20
BCD 1000’s digit 100’s digit 10’s digit 1’s digit
Whether a binary output or BCD output is used depends

on the what has been selected by [Constant Setting] — [6
Signals] — [1 Signal Condition] — [2 Output method of
program and step number].
Station ∗ allotment reached 0 This is output when the production count of station ∗ has
reached the allotment count. Similar signals are also
provided for stations 2 to 6.
Station ∗ start lamp 0 Allocate this signal when the start underway or reservation
underway signal for station ∗ is to be output to an external
device.
It is output as a level output for start underway and as a
pulse output for reservation underway.
Station ∗ start underway 0 This level signal indicates that station ∗ is now starting. It
is output during the automatic operation in the playback
mode of the program in which start has been assigned.
Station ∗ reserve 0 This level signal indicates that station ∗ is reserved.
Whereas "Reserved" indicated by the start button or
station start lamp signal is a pulse output signal, this is a
level output signal.
Station ∗ reservation 0 This level signal indicates the sequence of the station ∗ (*:
sequence 1 to 6) reservations.
Reservation sequence 1 to 6 is indicated by three signal
lines.
Bit： 3 2 1 For example, when bits 1 and 3
Output value： 4 2 1 are ON, the reservation
sequence No. is 5 (1+4).
7.2.5 Allocating the program to be started

The programs to be started are allocated ahead of time for each station. (The teach pendant is used for the
allocation.)
For details on the operation method, refer to the Basic Operations manual.
7-8
7.3 Home position registration

When a multiple number of robots are to be started up together from the host controller unless start is instructed
after it has been verified that the robots are at their prescribed positions (home positions), they may, in a worst
case scenario, interfere with one another.
To solve this problem, whether the robots are at their prescribed positions can be verified by means of an output
signal by registering the home positions of the robots.
In checking the home positions, the positions of each robot axis are directly monitored so that the operator can
know for sure that a robot is at its home position by the output signal.
Range in which work home

position is registered
While the robot is in this range, the

home position output signal is set to
ON; when it is outside this range, it
is automatically set to OFF.
Fig. 7.3.1 Home position
Up to 32 home positions can be registered per unit (the unit in which the programs is configured).
A number of methods for registering the home position are provided. First, the usual registration method will be
described.
7.3.1 Home position registration by referencing the program
1 First, teach the position that is to serve as the home position using the robot.
Select any program, and record the actual position as a step.
Any interpolation type, speed or tool number is acceptable.
>>Normally, this step should be the first step (move command) in the program which is
to be started from the work home position. Any program and any step with any
number will do. Make a note of them.
3 Select [9 Range] and [1 Home Position] from the [Constant Setting].

>>A screen such as the one shown below now appears.
7-9
4 Align the cursor with "Area Definition," and press the [ENABLE] and left or right
cursor keys together to set the radio button to "Defined."
>>The home position setting screen such as the one shown below now appears.
5 Leave the "Position" setting as "Program" and the "Range" setting as "TCP."
6 Align the cursor with "Program No.," input the number of the program prepared
ON Enter in 1, and press the [Enter] key.
1 In the same way, align the cursor with "Step No.," input the step number, and
press the [Enter] key. A step No. indicating a move command—not a comment
or other function command—must be input without fail.
>>The data recorded in the program and step which were input is now called, and the
positions recorded for the axes are displayed in the center.
7 Align the cursor with "TCP," input the home position range here, and press the
[Enter] key. The diameter of a spherical shape that can be visualized is input
here.
The home position signal is output when the tool tip is inside this spherical
shape.
Normally, a setting of about 20 mm is satisfactory.
>>The size of the spherical shape is broken down into the angles of the axes, and a
range is now displayed at the positions recorded for the axes in the center.

This now completes the settings.
If the position of the program and step which were input in 6 has been modified or if
interim steps have been deleted or inserted at any point after this, the setting for the
step number of the home position will be automatically updated in tandem with this
change.
By having the step in the registered program serve as the first step in the program
which is started, no further attention need be paid to the home position registration
even when the position in that step has been modified by teaching after home position
registration.
(However, in the event that the registered step itself has been deleted, the home
position registration will be deleted in tandem with this deletion.)
7-10
Registering a multiple number of work home positions
9 A multiple number of home positions can be recorded. (Up to 8 positions per

unit)
To switch the screen, press the [Prev No] or [Next No] key.
Alternatively, align the cursor with the "Territory No." in the edit box, input the
home position number directly, and press the [Enter] key.
Range No.1 is the only basic output signal which was allocated at the factory. To use
No.2 and up, the assignment of the basic output signals must be changed.
The numbers of the output signals currently assigned are displayed at the bottom of
the screen.
Specifying the range on an axis by axis basis
10 The range of the home position can be specified directly for each of the axes.
Set "Range" to "Angle" rather than to "TCP."
>>The range input field changes as shown below. Input the range directly in degrees
into the range field of each axis (the edit box on the right of + –).
When auxiliary mechanisms are present
11 If an auxiliary mechanism such as servo gun or travel unit is being used, "Aux.
mechanisms," which is a new item, is displayed. Depending on the
characteristics of the mechanism concerned, the home position may or may not
be monitored.
Select one or the other. In the case of a servo gun, select "Ignored."
7-11
7.3.2 Home position registration by manual recording

This method is used to record the home position directly without referencing the program. Operate the robot
to set it.
The home position registration is not changed in tandem with any modifications made by teaching, and the
absolute position is now registered. Unlike the program reference system, a programs need not be provided
ahead of time.
Only the differences from the program reference system will be described below.
1 Set "Position" to "Manual."

>>The setting screen changes as shown below.
2 Turn on the motor power (servo power), and move the robot by manual
operations to the position which is to serve as the home position.
Once the position has been determined, release the deadman switch.
(Alternatively, turn off the motor power.)
3 Press the [Current Record Posi.] f key.

>>The current position is read from the robot encoder, and the position data of each
axis is displayed in the center.
4 Set the "TCP" in the same way as with referencing the program. (The next steps
are the same.)
7-12
7.3.3 Home position registration by numeric input

This method is used to record the home position directly without referencing the program. Key in the position
data directly from the teach pendant.
The home position registration is not changed in tandem with any modifications made by teaching, and the
absolute position is now registered. Unlike the program reference system, a programs need not be provided
ahead of time.
Only the differences from the program reference system will be described below.
1 Set "Position" to "Numerical."

>>The setting screen changes as shown below.
2 Move the cursor to the "Territory" field, input the position of each of the axes
directly in degrees, and press the [Enter] key.
>>It is possible to input positions that significantly exceed the software limits
(operating ranges) of the axes. Some axes which have been excluded from being
the target of inspection for their home positions can be supported by setting a high
value.
The same result can be achieved by proceeding as follows: after "Position" has been
set to "Program," the program and step have been specified and the position data has
been read, switch the "Position" setting to "Numerical," and modify the position of each
axis.
3 Set the "TCP" in the same way as with referencing the program. (The next steps
are the same.)
7-13
7.4 Registering Start Enable Area

This function enables to register the safe position to start the robot (Start enable area), which restricts the start by
AX20/AX21 robot controller if the robot is not within the specified area. The difference from the home position
registration system is that the AX20/AX21 robot controller itself can confine the robot start.
To restrict the robot start by AX20/AX21 robot controller using the Start enable
area, the setting for “Start enable area” shall be specified as the condition of
IMPORTANT “Unit READY” in the section 7.5.2 Unit READY signal.
The start enable area can be registered to the mechanism one to one. When all the mechanisms included in a
unit are in the registered area, the unit is considered within the range of start enable area. For the management
unit, all the mechanisms in a system are to be checked.
7.4.1 Registering the start enable area

This section describes how to register the start enable area.
Note that the operator qualification of Expert or higher is required for this operation.
2 Proceed to <Constant Setting> - [9 Area] – [3 Start enable area].

≫The following screen appears.
3 Align the cursor with “Area Definition” and press [Enable] + [Right/Left] key at a
time to move the radio button to “defined”.
7-14
4 Move to the axis to set the area, and press [Enter] key.
Enter
≫Now, you can input the value. To restore the screen, press [Enter] key again.
5 When the value input is available, enter the area to set and press [Enter] key.
ON Enter
≫The input is now fixed. No more value input is available.
1
For the rotation axis, specify the area within the range of -999.0 ﾟ - 999.0 ﾟ. For
the slide axis, -9999.9mm - 9999.9mm.
The axis, of which both “Max.” and “Min.” have been set at 0.0, is not to be
checked whether it is in the start enable area or not.
6 When the value input is available, press f key <Record Current Position>.
≫The current position of the axis to input is recorded.
7-15
UNIT 7 Press [Mechanism] key to move to the next mechanism.

MECHA-
NISM ≫The cursor moves to the first axis of the following mechanism, renewing the
mechanism No. of f key <Manual speed>.
8 After inputting the start enable area, press f key <Write>.

Thus, the setting is complete.
7.4.2 Checking the unit if it is in the start enable area

This section describes how to check if the unit is in the start enable area.
UNIT 1 Switch the unit that checks if the robot is in the start enable area to the current
ENABLE ＋ MECHA- unit by pressing [Enable] + [Unit] key.
NISM
2 When the current unit is within the start enable area, the following icon appears
in the “Variable status display area”.
If not, this icon does not appear.
7-16
7.4.3 Checking which axis is out of the start enable area

When the current unit is out of the start enable area, it is enabled to check which axis is out of the range.
There is no requirement on the operator qualification to perform this operation.
2 Proceed to <Constant Setting> - [9 Area] - [3 Start enable area].

≫The following screen appears.
The axis out of the start enable area should be indicated in red.
On the other hand, the mechanism not included in the current unit should not be
indicated in red even if out of the area.
7-17
7.5 READY status output signals

If the robot is to be started from an external source, it is necessary to check beforehand whether the robot is
actually in a status in which it can be started. This job is done by the controller READY signal , Unit READY signal,
and status output signal.
Ensure that these output signals are used by the host controller as conditions of the start command for the robot.
7.5.1 Controller READY signals

This level signal is output after the power has been turned on when the operating system (Windows) and the
robot software have started up in sequence and normal control is exercised. It is only when this signal has
been output that the status in which I/O (Input/Output) control is enabled is established.
This signal has been assigned as a standard signal to serve as one of the basic output signals.
7.5.2 Unit READY signal

This level signal is output in a status in which the auto operation (starting in playback mode) is acknowledged.
The robot cannot be started unless the conditions are met. (The AX20/AX21 controller itself will not
acknowledge the start.) This signal has been assigned as a standard signal to serve as one of the basic
output signals.
The signal can be set using a combination of several conditions. Generate the "unit READY" signal by
combining each of the conditions in the sequence below.
Generating the unit READY signal
2 Select [6 Signal attributes] from [Constant Setting], and then select [4 Unit
Ready Signal].
The unit READY signal turns ON only when each of the conditions listed vertically has
been met. It remains OFF when even one condition has not been met.
3 Align the cursor with the item to be set.

ENABLE ＋ The check box can be moved by pressing the [ENABLE] and left or right cursor
keys.
7-18
ON 4 Align the cursor with the item serving as the ON condition of the output signal,
ENABLE ＋
1 and press the [ENABLE] + [ON] keys.
>>This will place a check mark in the box.
OFF
ENABLE ＋
2 If the item is not going to serve as an ON condition, press the [ENABLE] +
[OFF] keys.
>>This will remove the check mark from the box. It is acceptable to place more than
one check mark inside a horizontal row of boxes. It is also acceptable for no check
marks to be placed inside the boxes.
(No changes can be made in those boxes which have been set to the disable status.
Only a display appears in these boxes.)
In the following case, for example, the condition can be formed when the start
selection is set to “Internal” or “External”. If putting multiple checkmarks in a single
horizontal row like below, these items can be combined with the OR condition.
Even if not putting any checkmarks, on the other hand, it is still considered the same
as above. It means, in the following case, the condition is formed regardless of the
start selection, either “Internal” or “External” (= independent of the output signal).
With no checkmark, the condition will be independent of the output signal.

In the following example, the condition can be formed regardless of the start
selection, whether “Internal” or “External”.
For the details of each condition, see Table 7.5.1.
5 After all the items have been set, press the [Complete] f key.
>>This has the immediate effect of setting the output signals ON or OFF.
6 To clear all the check boxes at a time, press the [Initialize] f key.
>>The check marks in all the check boxes of the status output signals currently
displayed are now cleared.
ポイント
POINT Prior to shipment from the factory, no checkmark should be placed in any of the check
boxes.
This means that the unit READY output signal is always ON by the initial setting.
Table 7.5.1 Condition group used for Unit READY

Unit
Item Details
READY
Operation mode Playback: The condition is met when playback is set as the operation
×
mode.
TP selector SW AUTO: The condition is met when the teach pendant selector switch is
×
set to auto.
Operation ready ON: The condition is met when the motor power (servo power) is set to
×
ON.
Auto operation Stop: The condition is met when auto operation is not underway. ×
Temporary stop input No input: The condition is met without any temporary stop input signal. ○
Pose input No input: The condition is met without any pose input signal. ○
Hold input No input: The condition is met without any pose input signal. ○
7-19
Unit
Item Details
READY
Start enable area Within the area: The condition is met with the robot in the start enable
area.
However, it is unconditional in the following cases.

・When the start method is “Multi-station start”.
(1) At a temporary stop
(2) The task program selected in the unit has been allocated
as the start station and the current step is halfway with
“Restart method in Play mode” set to “Specified
○
restoration”.
・When the start method is “Internal/External start”.
(1) At a temporary stop
(2) The current step of the task program selected in the unit
is halfway.
The status “the current step is halfway” means that the current
step is at the level of step excluding “0 [START]” and “END
<FN92> function command with yellow color”.
Arbitrary logical input Input ON: The condition is met when any designated logical input signal
is set to ON.
Input OFF: The condition is met when any designated logical input
○
signal is set to OFF.
However, it is unconditional during a temporary stop and also with the
logical input signal of 0.
Start selection Controller: The condition is met when motors ON/START selection is
set to controller.
○
External: The condition is met when motors ON/START
selection is set to external.
Program selection Controller: The condition is met when program selection is set to
controller.
○
External: The condition is met when program selection is set to
external.
Soft Limit Inside range: The condition is met when the soft limit has not been
○
detected.
Link Soft Limit Inside range: The condition is met when the link soft limit has not been
○
detected.
Screen edit End: The condition is met excluding during screen edit. ○
○ Can be set as the condition.
× Does not serve as a condition.
To specify the start enable area as a condition of the unit READY, see 7.4
Registering Start Enable Area and follow the procedures to register the start
IMPORTANT enable area.
7-20
7.5.3 Status output signals

A signal known as a "status output" signal can be created by combining a number of statuses as desired.
Unlike the unit READY output signal described above, the AX20/AX21 controller itself will never fail to
acknowledge the start regardless of whether the "status output" signal is ON or OFF. This signal corresponds
to the robot ready OK signal which was used in the past by Nachi.
A multiple number of "status output" signals can be defined, and the signal with the first condition among
them has been assigned as a standard signal to serve as one of the basic output signals.
Follow the procedure below to create the "status output" signal by combining each of the conditions.
Generating a status output signal
2 Select [6 Signal attributes] from constant setting, and then select [5 State
output customization].
The status output signal turns ON only when each of the conditions listed vertically
has been met. It remains OFF when even one condition has not been met.
3 Press the [Prev No] or [Next No] f key or input a number in "Status output
signal" at the very top of the screen, and press the [Enter] key. This enables
one of the 16 status output numbers provided to be selected.
4 Align the cursor with the item to be set.

ENABLE ＋ The check box can be moved by pressing the [ENABLE] and left or right cursor
keys.
ON 5 Align the cursor with the item serving as the ON condition of the output signal,
ENABLE ＋
1 and press the [ENABLE] + [ON] keys.
>>This will place a check mark in the box.
OFF
ENABLE ＋
2 If the item is not going to serve as an ON condition, press the [ENABLE] +
[OFF] keys.
>>This will remove the check mark from the box. It is acceptable to place more than
one check mark inside a horizontal row of boxes. It is also acceptable for no check
marks to be placed inside the boxes.
(No changes can be made in those boxes which have been set to the disable status.
Only a display appears in these boxes.)
7-21
In the following case, for instance, the condition is met when the Playback mode is "1
cycle" or "Continuous." If, as in this case, a check mark has been placed in more than
one box in a horizontal row, the settings are combined by an OR condition.
Conversely, a case where none of the boxes has a check mark is handled in the
same way as a case where check marks have been placed in all of the boxes. In the
example given below, the condition is set whether the Playback mode is set to 1 step,
1 cycle or continuous, which means that it has nothing to do with the output signal.
For the details of each condition, see Table 7.5.2.
6 After all the items have been set, press the [Complete] f key.
>>This has the immediate effect of setting the output signals ON or OFF.
7 To clear all the check boxes together, press the [Initialize] f key.
>>The check marks in all the check boxes of the status output signals currently
displayed are now cleared.
Prior to shipment from the factory, no check marks were placed in any of the check
boxes.
This means that the status output signal is always ON with the initial setting.
Table 7.5.2 Condition group used for the status output

Item Details
Unit This specifies the number of the unit that serves as a condition. (1 to 9)
Either the same unit or various different units can be specified for all 16 status
output signals. With a single unit, only one signal is involved so no attention need
be paid to this operation.
Operation mode Playback: The condition is met when playback is set as the operation mode.
Teach: The condition is met when teach is set as the operation mode.
High-speed teach: The condition is met when high-speed teach is set as the
operation mode (option).
TP selector SW The teach pendant selector switch is not installed as a standard specification.
Normally, do not place a check mark for either mode.
AUTO: The condition is met when the teach pendant selector switch is set to auto.
Manual: The condition is met when the teach pendant selector switch is set to
manual.
Playback Mode 1 step: The condition is met when the operating mode is set to single step.
1 cycle: The condition is met when the operating mode is set to single cycle.
Continue: The condition is met when the operating mode is set to
continuous.
Step single Continue: The condition is met when step feed is set to continuous.
Single: The condition is met when step feed is set to single.
Operation ready ON: The condition is met when the motor power (servo power) is set to ON.
OFF: The condition is met when the motor power (servo power) is set to OFF.
Auto operation Start: The condition is met when auto operation is underway.
Stop: The condition is met when auto operation is not underway.
Temporary stop input Input ON: The condition is met when the stop input signal is set to ON.
Input OFF: The condition is met when the temporary stop input signal is set to
OFF.
Arbitrary logical input Input ON: The condition is met when any designated logical input signal is set to
ON.
Input OFF: The condition is met when any designated logical input signal is set to
OFF.
Start selection Controller: The condition is met when motors ON/START selection is set to
controller.
External: The condition is met when motors ON/START selection is set to
external.
Program selection Controller: The condition is met when program selection is set to controller.
External: The condition is met when program selection is set to external.
7-22
Item Details
Machine lock Enabled: The condition is met while machine lock is established.
Disabled: The condition is met while machine lock is not established.
Soft Limit Inside range: The condition is met when the soft limit has not been detected.
Outside range: The condition is met when the soft limit is being detected.
Link Soft Limit Inside range: The condition is met when the link soft limit has not been detected.
Outside range: The condition is met when the link soft limit is being detected.
Encoder battery Normal: The status is established when no fault in the encoder battery is
detected.
Fault: The condition is met when fault has occurred in the encoder battery.
Spot weld Welding ON: The condition is met when spot welding is set to pressure ON.
Welding OFF: The condition is met when spot welding is set to pressure ON.
Pressure OFF: The condition is met when spot welding is set to pressure OFF.
User level User or below: The condition is met when the current operator classification class
is User or below.
Expert or above: The condition is met when the current operator classification
class is Expert or above.
Speed override Under 100%: The condition is met when the speed override ratio is lower than
100%.
100%: The condition is met only when the speed override ratio is 100%.
Over 100%: The condition is met when the speed override ratio is higher than
100%.
Mechanism servo OFF Output ON: The condition is met when there is at least one mechanism of the
individual mechanism OFF.
Output OFF: The condition is met when there is no mechanism of the individual
mechanism OFF.
7-23
This is dummy page.
http://www.nachi-fujikoshi.co.jp/
Shiodome Sumitomo Bldg. 17F,

Phone: Fax:
JAPAN MAIN OFFICE 1-9-2 Higashi-Shinbashi
+81-3-5568-5245 +81-3-5568-5236
Minato-ku, TOKYO, 105-0021 JAPAN
NACHI NORTH AMERICA http://www.nachirobotics.com/
North America Headquarters Phone: 248-305-6545 Fax: 248-305-6542 22285 Roethel Drive, Novi, Michigan 48375 U.S.A.
Greenville Service Office Use 248-305-6545 Use 248-305-6542 South Carolina, U.S.A.
San Antonio Service Office Use 248-305-6545 Use 248-305-6542 Texas, U.S.A.
Kentucky Branch Office Phone: 502-695-4816 Fax: 502-695-4818 116 Collision Center Drive, Suite A, Frankfort, KY 40601 U.S.A
Training Office Phone: 248-334-8250 Fax: 248-334-8270 22213 Roethel Drive, Novi, Michigan 48375 U.S.A.
89 Courtland Avenue, Unit 2, Vaughan,

Toronto Branch Office Phone: 905-760-9542 Fax: 905-760-9477
Ontario L4K3T4 CANADA
Mexico Branch Office Phone : Fax: Urbina # 54, Parque Industrial Naucalpan,
+52-555312-6556 +52-55-5312-7248 Naucalpan de Juarez, 53370, Estado de México, MEXICO
Saltillo Service Office Phone : Fax: Canada 544 Privada Luxemburgo
+52-844416-8053 +52-844416-8053 C. P. 25230, Saltillo, Coahuila, MEXICO
NACHI ROBOTIC EUROPE

Germany http://www.nachi.de/
Nachi Europe GmbH Phone: Fax:
Bischofstrasse 99, 47809, Krefeld,GERMANY
+49-(0)2151-65046-0 +49-(0)2151-65046-90
United Kingdom http://www.nachi.co.uk/
Nachi U.K. LTD. Phone: Fax: Unit 7, Junction Six Industrial Estate, Electric Avenue,
+44-(0)121-250-1895 +44-(0)121-250-1899 Birmingham B6 7JJ, U.K.
Czech Republic
Nachi Europe Phone / Fax :
Mostni 73, Kolin 4, 28002 CZECH
+420-321-710-200
NACHI ROBOTIC ASIA
Korea http://www.nachi-korea.co.kr/
Korea Phone: Fax: 2F Dongsan Bldg.
+82-(0)2-469-2254 +82-(0)2-469-2264 276-4, Sungsu 2GA-3DONG, Sungdong-ku,
Seoul 133-123, KOREA
Copyright NACHI-FUJIKOSHI CORP.

Robot Division
1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511
Phone +81-76-423-5137
Fax +81-76-493-5252
NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or
reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document may
be modified without notice. Any missing page or erratic pagination in this document will be replaced.
In case that an end user uses this product for military purpose or production of weapon, this product may be liable for
the subject of export restriction stipulated in the Foreign Exchange and Foreign Trade Control Law. Please go
through careful investigation and necessary formalities for export.

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AX CONTROLLER

0812, TAXEN-053-017, 001

Chapter 1 Point on Safety

Chapter 2 Transportation and Installation

3.2 Cable connections (AX20)......................................................................................................... 3-2

3.3.2 Primary power supply connections.................................................................................... 3-3

4.11 Setting the [Clamp / Arc] key ................................................................................................. 4-89

4.12 Setting the software limit (operating range)........................................................................... 4-92

Chapter 5 Spot welding setup

5.2 Assignment of spot welding input/output signals....................................................................... 5-3

Chapter6 Arc welding setup

6.3 Allocating the dedicated arc welding input/output signals......................................................... 6-4

6.3.2 Table of input signals ......................................................................................................... 6-5

Chapter 7 Preparations for auto operation

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

1.1 For safe use of the robot

Cases where a mistake made in handling is likely to cause the user to be

The following symbol is also used for particularly important checkpoints:。

This is a particularly important checkpoint.

Precautions when performing adjustment, operation or maintenance

Carelessness common to the above accidents are:

Do not get near the robot.

If it is necessary to observe the robot's behavior, have another person (watcher)

LOCKOUT AND TAG OUT EQUIPMENT, Door lock

1.1.1 Safety Measures on manipulator

The manipulator is of such design that no unnecessary protrusions or sharp corners

When the motor is removed The arm will drop.

Never remove or disassemble a balance spring as it is compressed under great

It is not possible to eliminate electromagnetic interference completely using the

1.1.2 Safety measures in teaching and inspection

LOCKOUT AND TAG OUT EQUIPMENT, Door lock

1.1.3 Safety measures in test run

1.1.4 Auto operation

Make an emergency stop immediately if any abnormal behavior is observed and

1.1.5 Movement, alienation and selling of robot

1.1.6 Storage of robot

For storing a robot, following ambient conditions shall be met.

1.1.7 Disposition of Robot

Cautions about Batteries

Discard scrapped items safely to avoid injury.

1.1.8 Labels and marks on robot and controller

This mark indicates danger of an electric shock.

In the controller, a primary power voltage (AC

This label indicates a high voltage. Use caution when

This mark indicates hot parts on the robot.

This mark indicates an area operators may get caught by

Places bearing this mark should never be touched.

This label warns of stored electrical energy. Therefore use

1.2 To ensure the safety of arc welding

1.2.1 Preventing electric shock accidents

Do not touch any of the electrically charged areas.

(2) Do not touch any of the electrically charged areas.

・Do not inhale the fumes.

(2) Use a forced exhaust pipe during welding.

(3) To avoid a build-up of fumes and gases, provide adequate ventilation.

1.2.3 Protection from the arc light generated during welding

• Install a light-shielding wall in the area where arcs occur.

(4) Where there is loud noise, use ear protectors.

• Install a light-shielding wall in the area where arcs occur.

(6) Do not expose gas cylinders to high temperatures.

This chapter describes the procedures to be followed in terms of transportation,

2.1 Transportation ...............................................................................................2-1

As a basic rule, use a crane to transport the robot body.