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Mitsubishi Electric Melfa CR800-05VD Instruction Manual

Industrial robot
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Mitsubishi Electric Industrial Robot
CR800-05VD Controller
Instruction Manual
Controller Setup and Maintenance
BFP-A3731-B

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Summary of Contents for Mitsubishi Electric Melfa CR800-05VD

  • Page 1 Mitsubishi Electric Industrial Robot CR800-05VD Controller Instruction Manual Controller Setup and Maintenance BFP-A3731-B...
  • Page 3 Safety Precautions Always read the following precautions and the separate "Collaborative Robot Safety Manual" before starting use of the robot to learn the required measures to be taken. ■Basic precautions and important points when using collaborative robots Collaborative robots have a variety of safety functions, so unlike conventional industrial robots, they can work in the same space as humans without being separated by a machine guard.
  • Page 4 Recommended specifications: Electric). ・ Rated current: 10A Make sure to attach the TCS-05FA2 terminal cover ・ Rated sensed current: 30mA (manufactured by Mitsubishi Electric). ・ Rated breaking capacity: 2.5kA Cable for primary power supply Prepared by customer. AWG14 (2mm ) or above Tightening torque for terminal fixing screw is 2 ～...
  • Page 5 Revision history Date of print Specifications No. Details of revisions 2020-04-10 BFP-A3731 ・ First print 2020-10-09 BFP-A3731-A ・ Revised information on the parts included in the Easy-setup kit. 2020-12-25 BFP-A3731-B ・ Added an example of a protective circuit. (Fig. 2-5) ・...
  • Page 6 ・ This is the original document. ・ Company names and production names in this document are the trademarks or registered trade - marks of their respective owners. ・ Illustrations in this Instruction Manual may differ from the actual products. Copyright(C) 2020 MITSUBISHI ELECTRIC CORPORATION...
  • Page 7 For users who operate the robot using external signals Operation of robot programs such as start-up and shutdown are carried out using external signals (exclusive input/output signals). This instruction manual is based on key operations on the teaching pendant and operation in the operation screen of the teaching pendant. Using the parameter set- tings, please assign exclusive input/output signals that correspond with each operation to general purpose input/output signals, and operate the robot using signal operations.

  • Page 8: Table Of Contents

    Contents Page 1 Before starting use .......................... 1-1 1.1 Using the instruction manuals ....................1-1 1.1.1 The details of each instruction manuals ................1-1 1.1.2 Symbols used in this manual ....................1-2 2 Unpacking to installation ................................2-3 2.1 Confirming the products ............................... 2-3 2.2 Installation ....................................
  • Page 9 Contents Page 4.3.1 Turning the control power ON ..........................4-49 4.3.2 Input the serial number ............................... 4-50 (1) Setting the serial number using RT VisualBox ..................... 4-50 (2) Setting the serial number using the teaching pendant ................4-54 4.3.3 Shutting OFF the control power ..........................4-55 4.4 Changing the power supply voltage settings ......................

  • Page 10: Before Starting Use

    1Before starting use 1 Before starting use This chapter explains how to use this manual. It also contains information on safety and the basic symbols used in this manual. Moreover, handling and operation of a teaching pendant (T/B) are described based on R32TB in instruction manuals.

  • Page 11: Symbols Used In This Manual

    1Before starting use 1.1.2 Symbols used in this manual Symbols used in this manual are explained in Table 1-1. Learn the meaning of these symbols before reading this instruction manual. Table 1-1:Symbols in instruction manual Terminology Symbol Meaning Precaution indicating cases where there is a risk of operator fatality or DANGER serious injury if handling is mistaken.

  • Page 12: Unpacking To Installation

    2Unpacking to installation 2 Unpacking to installation 2.1 Confirming the products Confirm that the parts shown in the standard configuration of the controller shown in Table 2-1 are enclosed with the purchased product. Users who have purchased optional products should refer to the separate volume, "Standard Specifications Manual".

  • Page 13: Installation

    2Unpacking to installation 2.2 Installation 2.2.1 Unpacking procedures The controller is shipped from the factory packaged in cardboard.Open the cardboard package and take out the controller. CAUTION Slowly pull the controller box straight up. Be careful not to let the controller slip out of the box.

  • Page 14: Installation Procedures

    2Unpacking to installation 2.2.3 Installation procedures (1) CR800-05VD controller The installed size is shown as follows. When installing the controller horizontally, only one controller can be stacked on top of another controller. Fig.2-2 ： Installation dimensions CAUTION When installing the controller vertically, ensure that the air intake is at the bottom as illustrated in Fig.
  • Page 15 2Unpacking to installation CAUTION Fixing installation section sure for prevention from the fall, when using the controller placing vertically. The reference figure of the metal plate for fixing is shown in Fig. 2-3. You should install the metal plate for fixation to the controller with M4 x 8 or the shorter screw.

  • Page 16: Safety Extension Unit

    2Unpacking to installation (2) Safety extension unit To fix the safety extension unit in place, use the holes indicated by "*1" in the figure below or a DIN rail. Fix the unit in a place where it will not be subject to vibration. 3-M5 screw hole (*1) Fig.2-4 ：...

  • Page 17: Connection

    Recommended specifications: Electric). ・ Rated current: 10A Make sure to attach the TCS-05FA2 terminal cover ・ Rated sensed current: 30mA (manufactured by Mitsubishi Electric). ・ Rated breaking capacity: 2.5kA Cable for primary power supply Prepared by customer. AWG14 (2mm ) or above Tightening torque for terminal fixing screw is 2 ～...

  • Page 18: Emergency Stop Input And Output Etc

    2Unpacking to installation 2.3.2 Emergency stop input and output etc. Do wiring of the external emergency stop, the special stop input, the door switch, and the mode selector switch from the "special input/output" terminal connector. Connection of the external emergency stop is explained in "2.3.3 Connecting the external emergency stop and mode selector switch".

  • Page 19: Connecting The External Emergency Stop And Mode Selector Switch

    2Unpacking to installation [Note] If a stop signal or servo OFF signal is input simultaneously with a door switch open/emergency stop input, the error, H056n “Servo sys. error (A/D)” may occur. When a door switch open/emergency stop is input, the robot turns off the servo after it stops. It is unnecessary to input a stop signal or servo OFF signal.
  • Page 20 2Unpacking to installation Fig. 2-6 ： Emergency stop cable and mode selector switch connection Refer to the following for details on the example of external emergency stop connection, arrangement of connectors for exclusive input/output signals, and pin assignment. Item Reference Example of external emergency stop connection Fig.
  • Page 21 2Unpacking to installation Internal circuit structure (Customer) (Customer) (Controller side) T/B emergency stop +24V +24V +3.3V CNUSR11 +3.3V External emergency stop input +3.3V +3.3V Control circuit 1 +3.3V +24V Door switch input CNUSR11 Mode output +3.3V +24V Mode selector Emergency stop switch input output Robot error output...
  • Page 22 2Unpacking to installation Arrangement of connectors for exclusive input/output signals are shown in Fig. 2-8. The pin assignments of the connectors for exclusive input/output signals are shown in Table 2-3 Table 2-4. Fig. 2-8 ： Arrangement of connectors for exclusive input/output signals Table 2-3: Pin assignment (CNUSR11) Name Function...
  • Page 23 2Unpacking to installation Name Function Remarks Name Function Remarks OPKEY1COM(2 Mode selector Switching an operation OPKEY1 Mode selector Switching an operation switch input mode of a controller. switch input mode of a controller. This pin and pin 28 is a This pin and pin 12 is a pair.
  • Page 24 2Unpacking to installation Connection procedure Wire cables to the CNUSR11 and CNUSR12 user wiring connectors (attachment), and fit them into the corresponding connectors (ports) located on the rear side of the controller. The customer needs to prepare the following items. 　...

  • Page 25: Examples Of Safety Measures

    2Unpacking to installation 2.3.4 Examples of safety measures Two emergency-stop input circuits are prepared on the user wiring terminal block of the controller. A Safety extension unit must be connected to the robot. This section provides examples of safety measures. Refer to these figures when creating safety measures. The figures represent systems which are operating normally (i.e., systems not in an emergency stop state).
  • Page 26 2Unpacking to installation <Wiring example 1>: Not using a machine guard and running the robot in collaborative operation mode only Connect the emergency stop switch of peripheral equipment to the controller. The power supply for emergency stop input uses the power supply in the controller. <Operation of the emergency stop>...
  • Page 27 2Unpacking to installation <Wiring example 2>: Using a safety sensor (such as an area sensor) to switch between collaborative operation mode and high- speed operation mode Connect the emergency stop switch of peripheral equipment to the controller. The power supply for emergency stop input uses the power supply in the controller.
  • Page 28 2Unpacking to installation <Wiring example 3>: Using a machine guard and running the robot in high-speed operation mode only Connect the emergency stop switch of peripheral equipment to the controller. The power supply for emergency stop input uses the power supply in the controller. <Operation of the emergency stop>...
  • Page 29 2Unpacking to installation <Wiring example 4>: Connecting an emergency stop switch of a peripheral device when using collaborative operation mode The power supply for emergency stop input uses the power supply in the controller. Monitor the emergency stop state by the peripheral equipment side. <Operation of the emergency stop>...
  • Page 30 2Unpacking to installation <Wiring example 5>: Connecting an emergency stop switch of a peripheral device to two robot controllers when using collaborative operation mode The power supply for emergency stop input uses the power supply of peripheral equipment. Monitor the emergency stop state by the peripheral equipment side.
  • Page 31 (Example: QS90SR2SP (manufactured by Mitsubishi Electric)) 2) When connecting the output of the emergency stop switch to an external safety relay, set the polarity so that the electric current flows in the direction as indicated by the dotted arrows in the wiring diagram above.

  • Page 32: External Emergency Stop Connection [Supplementary Explanation]

    2Unpacking to installation (1) External emergency stop connection [supplementary explanation] (1) Use a 2-contact type switch for all switches. (2) Install a limit switch on the doors of the machine guards. Wire the switch to the Door switch input terminal so that the NO contact turns on (continuity state) when the door is closed and the NO contact turns off (non- continuity state) when the door is opened.

  • Page 33: Connecting To The Robot Arm

    2Unpacking to installation 2.3.5 Connecting to the robot arm Use a machine cable to connect a robot arm with a controller. (1) Connecting a machine cable Refer to the separate manual "Robot Arm Setup and Maintenance", and connect the controller and robot arm with machine cables.

  • Page 34: Connecting The Safety Extension Unit To The Controller

    2Unpacking to installation 2.3.6 Connecting the safety extension unit to the controller (1) Equipment supplied by customer Supply the following equipment. Part name Specifications Remarks Choose a product that meets the following specifica - 24V power supply A power supply for the safety extension unit tions: Voltage: 24 VDC ±5% Max.

  • Page 35: Connectors And Pin Assignment

    2Unpacking to installation (3) Connectors and pin assignment Create cables from the included DCIN/DCOUT, SDI1/SDI2, and SDO1/SDO2 connector sets. DCIN/DCOUT SDI1/SDI2 SDO1/SDO2 Table 2-5: DCIN/DCOUT pin assignment Terminal name Signal name Signal description Remarks Not used 24VDC +24 V power supply (input) Not used Not used Frame ground...
  • Page 36 2Unpacking to installation Table 2-6: SDI1、 SDI2 pin assignment SDI1 SDI2 Terminal name Signal name Signal description Terminal name Signal name Signal description DSI1A Safety input 1A DSI6A Safety input 6A COM+ +24 V output COM+ +24 V output DSI1B Safety input 1B DSI6B Safety input 6B...
  • Page 37 2Unpacking to installation Table 2-7: SDO1、 SDO2 pin assignment SDO1 SDO2 Terminal name Signal name Signal description Terminal name Signal name Signal description DSO1A Safety relay output 1A DSO1B Safety relay output 1B DSO1A Safety relay output 1A DSO1B Safety relay output 1B DSO2A Safety relay output 2A DSO2B...

  • Page 38: Electrical Specifications

    2Unpacking to installation (4) Electrical specifications Table 2-8: Safety DI electrical specifications Item Specifications Remarks Input type 0 V common Input point 8 points 16 points for duplication Input voltage at external contact ON 18 V or more Minimum current at external contact ON 6 mA or more Input voltage at external contact OFF 3.8 V max.
  • Page 39 2Unpacking to installation Table 2-9: Safety DO electrical specifications Item Specifications Remarks Output type Non-voltage contact output Relay contact Output point 4 points 8 points for duplication Maximum allowable contact voltage 250 V AC, 125 V DC Maximum allowable contact current Response time 8 ms max.
  • Page 40 2Unpacking to installation ■ Input wiring example The figure below is a signal connection example. Connected devices differ depending on the system configuration. Safety extension unit Connector pin numbers DC24V SDI1 DSI1A Control circuit Photocoupler DSI1B 5kΩ COM+ COM+ Photocoupler 5kΩ...
  • Page 41 2Unpacking to installation Safety extension unit Connector pin numbers DC24V SDI2 DSI6A Control circuit Photocoupler DSI6B 5kΩ COM+ COM+ Photocoupler 5kΩ DSI7A Photocoupler DSI7B 5kΩ COM+ COM+ DSI8A DSI8B Control circuit COM+ Photocoupler 5kΩ COM+ Photocoupler 5kΩ Photocoupler 5kΩ 0V(RG) Fig.
  • Page 42 2Unpacking to installation ■ Output wiring example Connector pin numbers Safety extension unit SDO1 DSO1A Control Load circuit DSO1A Control SDO2 circuit DSO1B Load DSO1B Connector pin numbers Safety extension unit SDO1 DSO2A Control Load circuit DSO2A Control SDO2 circuit DSO2B Load DSO2B...

  • Page 43: Station Number

    2Unpacking to installation (5) Station number Set the station number setting switch to "2". If not, an error (H2261) will occur. Station number setting switch Station number Station number setting 1 setting 2 Fig. 2-24 ： Station number setting switch Installation and connectionInstallation 2-34...

  • Page 44: Installing The Option Devices

    3Installing the option devices 3 Installing the option devices Refer to Page 47, "4.2.1 Installing and removing the T/B" for installing method of T/B. Refer to the separate "Standard Specifications Manual" or each option's manual for the optional devices other than those described in this manual.

  • Page 45: Removing The Option Card

    3Installing the option devices 3.1.2 Removing the Option Card The following describes how to remove the interface card. Fig. 3-2 ： Removing of the interface card 1) Turn off the power. 2) Remove the interface card with the removal lever pushed up. Hold the handle of the interface card and pull out the interface card in parallel with the controller.

  • Page 46: Installing And Connecting The Easy-Setup Kit

    3Installing the option devices 3.2 Installing and connecting the Easy-setup kit Installation and connection steps for users who have purchased the Easy-setup kit are shown below. Users who have not purchased the Easy-setup kit should refer to Page 8, "2.3 Connection".

  • Page 47: Installing The Safety Extension Unit

    3Installing the option devices 3) Fix the other side of the EMG / Mode selector switch box in place using an M5 × 8 fixing screw. (3) Installing the safety extension unit Install the safety extension unit in the Earth leakage breaker / safety extension unit power supply box.

  • Page 48: Connecting The Robot Controller And The Earth Leakage Breaker / Safety Extension Unit Power Supply Box

    3Installing the option devices (2) Connecting the robot controller and the Earth leakage breaker / safety extension unit power supply box Earth leakage breaker / safety extension unit power supply box Ground terminal FG terminal Cable gland Lock nut 2), 5) N terminal ACIN cable ACIN cable connection...

  • Page 49: Connecting Sdio Cables To The Safety Extension Unit

    3Installing the option devices (3) Connecting SDIO cables to the safety extension unit SDIO cables are used to connect safety sensors (area sensors, light curtains, etc.) and status indicator lights to the safety extension unit. Eight SDI cables and two SDO cables are included with the Easy-setup kit. The SDI cables connect to the SDI1 and SDI2 ports and the SDO cables connect to the SDO1 and SDO2 ports.

  • Page 50: Connecting The Safety Extension Unit To The Robot Controller

    3Installing the option devices (4) Connecting the safety extension unit to the robot controller RIO1 port RIO2 port Grommet RIO cable Cable clamp Terminator cap RIO port 1) Cut an opening in the grommet to allow the cable through. 2) Connect the RIO cable to the RIO port of the robot controller. 3) Pull the RIO cable through the grommet into the Earth leakage breaker / safety extension unit power supply box.

  • Page 51: Connecting The Emg / Mode Selector Switch Box To The Robot Controller

    3Installing the option devices (5) Connecting the EMG / Mode selector switch box to the robot controller 1) Connect CNUSR11 connector of the EMG / Mode selector switch box to the CNUSR11 port on the robot controller. Check that the levers on both sides of the CNUSR11 connector are up. CNUSR11 port Levers Installing and connecting the Easy-setup kit 3-42...

  • Page 52: Basic Operations

    4Basic operations 4 Basic operations In this chapter, the following items will be explained regarding the basic operations for handling the robot. Handling the controller The functions of the various keys on the controller are explained. Handling the teaching pendant The methods of installing/removing the T/B, and the functions of the various keys are explained.

  • Page 53: Handling The Controller

    4Basic operations 4.1 Handling the controller 4.1.1 Names of each parts 4.1.2 CR800-05VD controller Controller front Air intake for fan <18> <19> <20> <6> <21> <7> <8> <9> <10> <11> <12> <13> <14> <15> <16> <17> Controller rear Air exhaust <1>...
  • Page 54 4Basic operations Details AUTO Indicates the controller mode. On: AUTOMATIC mode Off: MANUAL mode ERROR Indicates the error status. On: Error occurred. Rapid flashing: High-level error occurred. Off: Normal operation READY Indicates the operation status. On: ON (ready) Slow flashing: During operation Rapid flashing: Operation suspended.

  • Page 55: Safety Extension Unit

    4Basic operations 4.1.3 Safety extension unit <9> <10> <16> <3> <4> <1> <5> <6> <15> <13> <2> <12> <7> <11> <8> <14> Fig. 4-2 ： Names of each part of the safety extension unit <1> DCIN connector........Socket used to connect the supplied DCIN cable (input voltage: 24 VDC) <2>...

  • Page 56: Handling The T/B

    4Basic operations 4.2 Handling the T/B 4.2.1 Installing and removing the T/B Installing and removing the T/B, with turning off the controller power. If T/B is installed and removed in the state of control source ON, emergency stop alarm will be occurred. However, it allows you to remove the T/B from the controller without occurrence of alarm by pulling out the T/ B connector within five seconds while the 3-position enable switch of the T/B is being pulled up lightly (in the position 2).

  • Page 57: Functions Of Each Key

    4Basic operations 4.2.2 Functions of each key ② ④ ① ③ ⑤ ⑤ ⑥ ⑥ ⑧ ⑦ ⑨ ⑩ ⑪ ⑰ ⑫ ⑱ ⑬ ⑭ ⑲ ⑮ ⑯ ⑳ Fig. 4-4 ： Teaching pendant ① [Emergency stop] switch ....The robot servo turns OFF and the operation stops immediately. The release of the emergency stop turns the switch to the right, or pulls it.

  • Page 58: Turning The Power On And Off

    4Basic operations 4.3 Turning the power ON and OFF 4.3.1 Turning the control power ON CAUTION Always confirm the following items before turning the controller power ON. 1) Make sure that there are no operators in the robot operation range. 2) Make sure that the controller and robot arm are securely connected with the machine cable.

  • Page 59: Input The Serial Number

    4Basic operations 4.3.2 Input the serial number If error C0152 (unmatched robot serial number) occurs after purchasing the robot, please input the serial number of the robot arm into parameter RBSERIAL. The serial number is printed to the rating name board on base section of the robot arm. This section describes how to set the serial number using RT VisualBox or the teaching pendant.
  • Page 60 4Basic operations 3) Click [Maintenance] to display the Maintenance window. 4) Click [Parameter Setting] to display the Parameter Setting window. 5) Enter "RBSERIAL" in the Parameter name field, and click the [Read] button. 4-51 Turning the power ON and OFF...
  • Page 61 4Basic operations 6) Enter the serial number of the robot arm in field "1". The serial number of the robot arm used is automatically displayed. 7) Click the [Write] button. The write confirmation dialog will appear. Click the [OK] button. 8) The dialog will appear after the serial number has been written.
  • Page 62 4Basic operations a) Click the [Restart now] button. b) Click the [Restart later] button, and then restart the robot controller. 4-53 Turning the power ON and OFF...

  • Page 63: Setting The Serial Number Using The Teaching Pendant

    4Basic operations (2) Setting the serial number using the teaching pendant 1) Press the [RESET] key of T/B and cancel the error of T/B. 2) Press the [EXE] key of T/B and display the menu panel. MELFA CR800-D Ver. S3 <MENU>　　...

  • Page 64: Shutting Off The Control Power

    4Basic operations 4.3.3 Shutting OFF the control power 1) If the robot is operating, stop the robot. 2) After the robot has stopped, turn the servo OFF. 3) Turn OFF the switch of the earth leakage breaker installed outside. 4-55 Turning the power ON and OFF...

  • Page 65: Changing The Power Supply Voltage Settings

    4Basic operations 4.4 Changing the power supply voltage settings The RV-5AS will automatically detect the power supply voltage and change the voltage settings. The flow chart below shows how the power supply voltage settings are changed. Start 1. The robot controller is connected to either a 100V or 200V power supply.

  • Page 66: Maintenance And Inspection

    5Maintenance and Inspection 5 Maintenance and Inspection The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are described in this chapter. The types and replacement methods of consumable parts are also explained. 5.1 Maintenance and inspection interval Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carry out at set intervals.

  • Page 67: Inspection Items

    5Maintenance and Inspection 5.2 Inspection items The controller inspection items are shown below. Refer to section "Maintenance and Inspection" in the separate manual "Robot Arm Setup and Maintenance", and inspect the robot arm at the same time. 5.2.1 Daily inspection items Carry out daily inspections following the procedures given in Table 5-1.

  • Page 68: Maintenance And Inspection Procedures

    5Maintenance and Inspection 5.3 Maintenance and inspection procedures The procedures for carrying out periodic maintenance and inspection are described below. Thoroughly comprehend the procedures, and follow the instructions. This work can be commissioned to the Mitsubishi Service Dept. for a fee. (Never disassemble, etc., any of the parts not described in this section.) The maintenance parts required for the maintenance and inspection are shown in Page 60, "5.4 Maintenance parts".

  • Page 69: Maintenance Parts

    Filter BKOFA0773H42 Inside the filter cover Mitsubishi Electric Co. Note1) Confirm the robot arm serial No., and contact the dealer or service branch of Mitsubishi Electric Co., for the type. Table 5-4 ： Controller spare parts list Note1) Part name Qty.
  • Page 70 5Maintenance and Inspection 5-61 Maintenance parts...
  • Page 72 HEAD OFFICE: TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS: 5-1-14, YADA-MINAMI, HIGASHI-KU NAGOYA 461-8670, JAPAN Authorised representative: Mitsubishi Electric Europe B.V. FA - European Business Group Mitsubishi-Electric-Platz 1, D-40882 Ratingen, Germany Tel: +49(0)2102-4860 Dec. 2020 MEE Printed in Japan on recycled paper.

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